Mtab Maps Teacher Workbook

Index
Table of Contents
HRC Fuse ........................................................................................................................................... 4
Basic concept of HRC fuse ........................................................................................................... 4
Construction and operations of HRC fuse .................................................................................... 5
HRC fuse with tripping device ...................................................................................................... 8
Different types of HRC fuse ......................................................................................................... 9
Fuses characteristic ................................................................................................................... 10
Typical uses and applications of fuses ....................................................................................... 14
Moulded Case Circuit Breaker ......................................................................................................... 15
Basic concept of MCCB .............................................................................................................. 15
Types of MCCB .......................................................................................................................... 16
Characteristic & Design of MCCB ............................................................................................... 17
Application of MCCB ................................................................................................................. 18
SENTRON VL series MCCB.......................................................................................................... 19
Internal Accessories of MCCB .............................................................................................. 20
Switch Disconnector (Super Switch) ................................................................................................. 21
Basic concept of super switch .................................................................................................... 21
Features.............................................................................................................................. 22
Types of super switch ................................................................................................................ 22
Selection of different types of super switch ............................................................................... 23
Application of super switch ....................................................................................................... 26
Benefits .............................................................................................................................. 26
Maintenance of Super Switch .................................................................................................... 26
Overload Relay ................................................................................................................................ 28
Basic concept of overload relay ................................................................................................. 28
Overload relay principle of operation ........................................................................................ 29
Connection methods ........................................................................................................... 30
Types of overload relay ............................................................................................................. 32
Thermal overload relays...................................................................................................... 32
Electronic overload relays (Microprocessor based).............................................................. 32
Siemens SIRUS series OLR ................................................................................................... 33
Characteristics of MCCB ............................................................................................................ 33
Sensitivity to phase failure .................................................................................................. 35
Basics of LVSG 1
1. HRC Fuse
Motor Protection Circuit Breaker ..................................................................................................... 36

Basic concept of MPCB .............................................................................................................. 36
Construction of MPCB ............................................................................................................... 37
Application of MPCB ................................................................................................................. 38
Characteristic of MPCB .............................................................................................................. 39
Selections of MPCB ................................................................................................................... 40
Miniature Circuit Breaker ................................................................................................................ 42
Basic Concept of MCB ............................................................................................................... 42
Design of MCB........................................................................................................................... 42
Characteristics of MCB .............................................................................................................. 45
Types of MCB ............................................................................................................................ 46
MCB As per Fault Tripping ................................................................................................... 46
MCB As per Pole ................................................................................................................. 47
Selection of MCB ....................................................................................................................... 48
Applications of MCB .................................................................................................................. 48
Residual Current Circuit Breaker ...................................................................................................... 50
Basic concept of RCCB ............................................................................................................... 50
Principle of operation and Design of RCCB................................................................................. 51
Types of RCCB ........................................................................................................................... 53
RCCB as per Fault Tripping .................................................................................................. 53
RCCB as per Pole ................................................................................................................. 53
Selection factors as per requirements of RCCB .......................................................................... 54
Applications of RCCB ................................................................................................................. 55
Soft Starter ...................................................................................................................................... 56
Basic concept of soft starter ...................................................................................................... 56
Operating principle of soft starter ....................................................................................... 56
Characteristic and Design of soft starter .................................................................................... 57
Operation and working of soft starter ....................................................................................... 60
Applications of soft starter ........................................................................................................ 60
Requirements of soft starter ..................................................................................................... 61
Technical Features .................................................................................................................... 62
SIRIUS 3RW30 ..................................................................................................................... 62
SIRIUS 3RW40 ..................................................................................................................... 63
SIRIUS 3RW44 ..................................................................................................................... 64
Basics of LVSG 2
1. HRC Fuse
Relay 65
Basic Concept of Relay .............................................................................................................. 65
Characteristic and Design of Relay ............................................................................................. 66
Types of Relay ........................................................................................................................... 67
Latching relay ..................................................................................................................... 67
Machine tool relay .............................................................................................................. 68
Time delay relay.................................................................................................................. 68
Contactor relay ................................................................................................................... 69
Solid-state relay .................................................................................................................. 70
Solid state contactor relay .................................................................................................. 70
Buchholz relay .................................................................................................................... 71
Overload protection relay ................................................................................................... 71
Multi-voltage relays ............................................................................................................ 72
Applications of Relays ............................................................................................................... 72
PAC Meter ....................................................................................................................................... 73
Basic Concept of PAC Meter ...................................................................................................... 73
Characteristic and Design of PAC Meter .................................................................................... 74
PAC4200 ............................................................................................................................. 74
PAC 3200 ............................................................................................................................ 76
PAC3100 ............................................................................................................................. 77
Applications of PAC meter ......................................................................................................... 78
Requirements of PAC meter ...................................................................................................... 79
Networking of PAC Meter ......................................................................................................... 80
Configuration of PAC Meter ...................................................................................................... 81
Parameter Configuration..................................................................................................... 84
Analysis using PAC Meter .......................................................................................................... 90
Basics of LVSG 3
1. HRC Fuse
HRC Fuse
Basic concept of HRC fuse
High Rupturing Capacity Fuse: This type of fuse contains a fuse wire in it, which carries the
short circuit current safely for a given time period. During this period, if fault is removed, then
it does not blow off otherwise it will melt and remove the circuit from electrical supply hence,
the circuit remains safe.
The common material, which is used to make an HRC fuse is glass, but this is not always the
case. Other chemical compounds are also used in HRC fuse manufacturing and construction
based on different factors. Its external enclosure is made fully airtight in order to avoid the
effect of atmosphere on the fuse materials. The major objection on HRC fuse is low and
uncertain breaking capacity of semi-enclosed fuse.
Indicator not Released - Healthy fuse Indicator Released - Blown fuse

The red coloured strip can be seen The red coloured strip is pulled high
after fuse operation- revealing the white
background
Purpose of fuses:
Circuit protection is critical, and in many cases required, in electrical and electronic products.
Fuses are an inexpensive and effective way to protect your device from damage due to
overcurrent conditions. Fuses can prevent safety hazards to the end user such as fire and
catastrophic failure of the product.
Basics of LVSG 4
1. HRC Fuse
Construction and operations of HRC fuse

HRC Fuse consists of highly heat resistant material (such as ceramic) body having metal-end
caps, which is welded by silver current carrying element. The fuse body internal space is
completely packed with a filling powder. The material, which has filled the insider space, may
be plaster of Paris, quartz, chalk, marble, dust and cooling mediums etc. That’s why it carries
normal current without overheating. The heat being produced vaporizes the silver melted
element. Chemical reaction taking place between silver vapour and filling powder results in
high resistance substance, which helps in quenching the arc in fuse.
A cutaway of the construction of the HRC is shown below.
Basics of LVSG 5
1. HRC Fuse
Operation:
Under normal operating conditions the current flowing through the fuse element does not
provide enough energy to melt the element. The heat produced is absorbed by the surrounding
silica sand.
If a large current flows the energy produced melts and vaporises the element.
The time taken to reach this point is known as the pre arcing time. The high prospective fault
current is ‘cut off’ although an arc will still be formed. The heat produced by the arc causes the
fuse element to fuse with the silica sand and for the silica sand to absorb the energy. This has
the effect of extinguishing the arc and stopping further current flow. The time taken to reach
this point is known as the total clearance time.
Overload condition:
Modern HRC fuse elements incorporate a tin alloy section. This is known as a eutectic material.
It is used to give the fuse specific operating characteristics. Under overload conditions the
material heats up and if the overload is prolonged, it will melt and break the fuse element.
Basics of LVSG 6
1. HRC Fuse
Short circuit condition:

Under high current short circuit conditions the smaller area constricted parts of the element
will melt rapidly and vaporise. These will break before the eutectic material.
The quartz silica sand surrounding the element is also heated and changes into a glass material
called fugurite. This quenches the arc and prevents any restriking across the element gaps.
A high fault clearance graph is shown below.
The pre-arcing time (shown by A) is the time given by fuse characteristic charts. The figures
given by the graphs are reliable for all conditions. This is the time taken for the fault current to
melt and break the element. However it is at this time that an arc will form and the current will
continue to flow. The quenching qualities of the silica sand will extinguish the arc and stop the
current flow. The time taken for this is less predictable (shown by B) as there are many factors
to vary its duration.
The total operating time (or clearance time) is the combination of the two and is shown by C.
The cut off current is shown by D and indicates the maximum fault current flowing in the
circuit. Quick clearance of the fault ensures that the cut off current does not reach prospective
fault current level.
Basics of LVSG 7
1. HRC Fuse
HRC fuse with tripping device

When a fuse blows out the tripping device during the fault condition, it will cause the circuit
breaker to operate. The body of fuse is made of ceramic material with a metallic cap fixed at
each end. They are connected by series of silver fuse elements. There is a plunger at one end,
which hits the tripping mechanism of circuit breaker under fault conditions, which leads it to
operate the circuit. The plunger is connected through a fusible link and a tungsten wire to the
other end of the cap. As fault occurs, the first element to be blown out is silver fuse and current
is transferred to tungsten wire. The travel of the plunger is set such a way that is not ejected
from the fuse body during fault conditions.
Advantages of HRC fuse with tripping device:

 During single-phase fault on a three-phase system, the plunger trips the circuit breaker,
which opens all the three phases, i.e. it prevents single-phase supply as well.
 The effects of the short circuit need to be considered in circuit breaker, which allow the
use of an inexpensive circuit breaker.
 The fuse-tripped breaker is capable of dealing with small currents, which avoids the
necessity of replacing the fuse (except high current).
 Low voltage H.R.C fuses are also available in a capacity of 16000A to 30,000A at 400V
(Also available in range of 80kA to 120kA). HRC Fuses are also used for protection on
low voltage distribution systems against overload and short circuit conditions .
Basics of LVSG 8
1. HRC Fuse
Different types of HRC fuse

1. NH type H.R.C fuse:
NH fuse provides overload and short circuit protection for low and medium voltage. They
provide backup protection to motor starters and other equipment against short circuit and
overload. They are light in weight with compact dimension.
2. Din type HRC fuse:
Din type fuses are available in wide range of rated currents. DIN fuse are used for different
purposes with their characteristic at different temperature condition. They types of fuses are
available for different voltages level and can be used in transformer protection even where
there is no LV (Low-Voltage) Secondary or backup protection. They have excellent clearing
capability of ideal low over current with short-circuit performance. Other uses and application
of DIN fuses are in air and gas insulated switchgear, mining, transformers and Feeder
sectionalizing.
3. Blade type HRC fuse:
This type of fuses (also known as spade or plug-in fuses) comes in plastic body and two metal
caps to fit in the socket. Mostly, they used in automobiles for wiring and short circuit
protection. They are light in weight. It contains low cut-off current. They are also used for short
circuit and backup protection of motors. They are available in different sizes and shapes with
different current rating capacity, which print on the top.
Basics of LVSG 9
1. HRC Fuse
Fuses characteristic
Time-current characteristic:
If a fuse is subjected to a current greater than the minimum current required to produce melting,
the fuse element will melt. The higher the current, the shorter the melting time will be. This
inverse relationship is shown graphically by the time-current characteristic (TCC). Figure
1 shows a typical time-current characteristic for a semiconductor fuse with a nominal current
rating of 450A. The time it takes for a fuse element to melt is often referred to as the pre-arcing
time, since melting is followed by a period of arcing. Melting of a fuse element is due to the
heating effect of the current, which depends on the r.m.s. value of the current actually flowing
through the fuse before melting occurs.
Figure: TCC for typical 450 A semiconductor fuse
For operation in times less than one a.c. cycle, the melting time of the element is greatly
affected by the wave shape of the current. In this case it is necessary to use I²t values for
checking the system protection. The standard time current curve shown in figure 1 is for a
symmetrical sine wave. The boundary C-C' shown on figure 1 indicates that the fuse will safely
interrupt currents at times below this limit. The fuse must not be applied to interrupt current
levels which produce melting times longer than this limiting boundary. Sustained overloads
which persist for longer times may result in failure of the fuse, and must be cleared by other
means. There is a limit to how long a temporary overload can be tolerated by the fuse. This
limit is shown by sloping part of the C-C' boundary.
Basics of LVSG 10
1. HRC Fuse
New style gR class fuses do not have a C-C' limit and can be used for overload protection.
They are defined in the IEC 60269 standards. They must melt for a 160% overload but should
not melt for a 125% overload.
Current limiting effect of the fuse and peak let-through current curve (cut off current):
An important advantage of the current-limiting fuse is its ability to break high fault currents
rapidly, which limits the peak current flowing in the circuit, and consequently limits the let-
through I²t. For current-limiting fuses the peak let-through current (or cut-off current) is a very
important parameter. Fuse data is presented in the form of peak let-through (cut-off)
characteristics. These characteristics are published for specified test conditions, typically AC
voltage, frequency and power-factor. Figure 2 shows a peak let-through characteristic for a
typical semiconductor fuse with a current rating of about 30A.
Figure: Peak-let through (cut-off) characteristic
For low prospective (available) currents, the fuse takes several a.c. cycles to melt, and the
highest value of current is equal to the peak current in the first half-cycle. This is 1.414⋅IRMS
for a symmetric wave and about 2.3-2.5⋅IRMS for an asymmetric wave, depending upon the
circuit power factor. These limits are shown by the faint lines in figure 2. However, above a
certain level of prospective current (threshold current), melting occurs within the first half-
cycle, and current-limiting action occurs. At high prospective currents, the peak current is much
lower than the peak prospective value.
For a given r.m.s. prospective current, the peak let-through current varies, depending on the
angle of the source voltage wave at which the short-circuit occurs. At the 100kA level, the
highest value of let-through current is obtained with a symmetrical short-circuit wave, while in
the region just above the threshold current the asymmetrical wave gives the highest value.
Published data always shows the highest possible (i.e. worst-case) value.
Basics of LVSG 11
1. HRC Fuse
Maintenance of fuse:
 HRC fuses should be used of approved makes only.
 Ensure that the breaking capacity of the fuse is lower than the prospective fault current.
 Fuses should be so selected as to achieve discrimination with other protective devices
in the system.
 The terminating wires at fuse holders should be tightened properly otherwise it causes
the burning of cable and damage of fuses.
 Fuse should be of rated capacity. If it is overrated at the time of system overloading it
may not break, causes the fire and failure of the systems. If it is underrated always
breakdown of fuses causes interruption of system working.
 In case of HRC fuse the healthiness of fuse to be checked periodically, otherwise it
causes overheating, damage of fuse holder terminating wires and system working.
Advantages of HRC fuse:

The HRC fuse has many advantages over the rewire able fuse.
These include:
 The ability to safely interrupt short circuit currents of much higher values (higher
rupturing capacity). They are specifically designed to operate under these short circuit
conditions.
 The elimination of arcing because the fuse element is sealed
 It is obtainable in a range of fusing factors
 The current rating is clearly marked
 It has a reliable operation
 It can be used to provide good discrimination because it provides close protection and
operates at a ‘known’ value.
 It has constant fusing characteristics
 It operates ‘fast’
 Doesn’t deteriorate over time
 It clears high fault current as well as low fault current.
 Do not deteriorate with age.
 Having high-speed operation.
 Provides reliable discrimination.
 Require no maintenance.
 Cheaper than other circuit interrupting devices with same rating.
 Permit consistent performance
 Fusing operation is fast without Noise and Smoke
Disadvantages of HRC fuse:

 After each operation, they have to be replaced.
 Heat being produced by the arc may affect the associated switches.
Basics of LVSG 12
1. HRC Fuse
Some important terms need for fuse

 Minimum Fusing Current: It is minimum value of current due to which fuse melts.
 Current Rating of Fuse: It is maximum value of current due to which fuse does not get
melt.
 Fusing Factor: This is the ratio of minimum fusing current and current rating of fuse.
Therefore, fusing factor = Minimum fusing current / current rating of fuse. The value of
fusing factor is always more than 1.
 Prospective Current in Fuse: Before melting, the fuse element has to carry the short
circuit current through it. The prospective current is defined as the value of current which
would flow through the fuse immediately after a short circuit occurs in the network.
 Melting Time of Fuse or Pre-arcing Time of Fuse: This is the time taken by a fuse wire
to be broken by melting. It is counted from the instant, the over current starts to flow
through fuse, to the instant when fuse wire is just broken by melting.
 Arcing Time of Fuse: After breaking of fuse wire there will be an arcing between both
melted tips of the wire which will be extinguished at the current zero. The time accounted
from the instant of arc initiated to the instant of arc being extinguished is known as arcing
time of fuse.
 Operating Time of Fuse: Whenever over rated current starts to flow through a fuse wire,
it takes a time to be melted and disconnected, and just after that the arcing stars between
the melted tips of the fuse wire, which is finally extinguished. The operating time of fuse
is the time gap between the instant when the over rated current just starts to flow through
the fuse and the instant when the arc in fuse finally extinguished. That means operating
time of fuse = melting time + arcing time of fuse.
 Fuse current carrying capacity: Current carrying capacity is the amount of current
which a fuse can easily conduct without interrupting the circuit.
 Breaking capacity: The value of maximum current that can safely be interrupted by the
Fuse is called Breaking Capacity and should be higher than the prospective short circuit
current.
 I2t value of fuse: The I2t terms related to fuse normally used in short circuit condition. It
is the amount of energy which carry the fuse element when the electrical fault is cleared
by fuse element.
 Response characteristic: The speed at which fuse blows, depend on the amount of
current flowing through its wire. The higher the current flowing through the wire, faster
Basics of LVSG 13
1. HRC Fuse
will be the response time. Response characteristic shows the response time for over
current event. Fuses which respond rapidly to the over current situation is called ultrafast
fuses or Fast fuses. They are used in many semiconductor devices because semiconductor
devices damaged by over current very rapidly.
There is another fuse which is called Slow burn fuse, switch fuses do not respond rapidly
to the over current event, but blow after several seconds of over current occurrence. Such
fuses found their application in motor control electronics systems because motor takes a
lot more current at starting than running.
 Rated voltage of fuse: Each fuse has maximum allowed voltage rating, for example, if a
fuse is designed for 32 volts it cannot be used with 220 volts, different amount of isolation
is required in different fuses working on different voltage levels .
Typical uses and applications of fuses

Application of H.R.C fuses:
 Used for protection of Transformers, Motors and automobile, etc.
 It is also used in motor stators
 Backup protection
Electronic Fuses can be used in all types of electrical and electronic applications including
 Air-conditions
 Motors
 Home distribution boards
 General electrical appliances and devices
 Laptops
 Cell phones
 Game systems
 Printers
 Digital cameras
 DVD players
 Portable Electronics
 LCD monitors
 Scanners
 Battery packs
 Hard disk drives
 Power convertors
 Fuse characteristic, design
Basics of LVSG 14
2. Moulded Case Circuit Breaker
Moulded Case Circuit Breaker

Basic concept of MCCB
The standard range of Moulded Case Circuit Breakers (MCCBs) are designed for circuit
protection of low voltage distribution system. They are suitable for application as main
breakers and for protection of branch and feeder circuit & connected equipment / load. These
MCCBs provide overload and short circuit protection for all circuit elements. They are
designed for use in Switchboards, Control Panels, Combination Starters, in separate enclosures
and meet the requirements of lighting, distribution and power circuits. Standard offers a
comprehensive range of MCCBs employing world class technology and fully conform to the
latest IS /IEC-60947-2.
Moulded case circuit breakers:

Moulded Case Circuit Breakers are electromechanical devices which protect a circuit from
Overcurrent and Short Circuit. They provide Overcurrent and Short Circuit Protection for
circuits ranging from 63 Amps up to 3000 Amps.
Their primary functions are to provide a means to manually open a circuit and automatically
open a circuit under overload or short circuit conditions. The overcurrent, in an electrical
circuit, may result from short circuit, overload or faulty design.
Basics of LVSG 15
MCCB is an alternative to a fuse since it does not require replacement once an overload is
detected. Unlike fuse, an MCCB can be easily reset after a fault and offers improved
operational safety and convenience without incurring operating cost.
Moulded case circuit breakers generally have a Thermal element for overcurrent
and Magnetic element for short circuit release which has to operate faster.
MCCBs are manufactured such that end user will not have access to internal workings of the
over-current protection device. Generally constructed of two pieces of heavy-duty electrically
insulated plastic, these two halves are riveted together to form the whole. Inside the plastic
shell is a series of thermal elements and a Spring-loaded trigger.
When the thermal element gets too warm, from an overcurrent situation, the spring trips, which
in turn will shut off the electrical circuit.
Types of MCCB
Larger moulded case circuit breakers have adjustable range setting on the face of the device.
Moulded case circuit breakers can range in size from 32amperes up to 3000 amperes.
Moulded Case Circuit Breakers have the following Specifications
Current Rating - Amperes
Current Setting Range - Amperes
Short Circuit Rating - Kilo Amperes (KA)
Operating Characteristics - Normal / Current Limiting
Type MCCBs are now available with a variety of Releases or Operating Mechanisms these are
given below:
1. Thermal Magnetic Release
2. Electronic Release
3. Microprocessor Release
1) Thermal Magnetic Release MCCB

Thermal-magnetic circuit breakers use bimetals and electromagnetic assemblies to provide
overcurrent protection. Their characteristic inverse time tripping under overload conditions is
ideally suited for many applications varying from residential to heavy industrial loads. For
higher level (short circuit) over currents, instantaneous trip characteristics allow moulded case
circuit breakers to interrupt with no intentional delay.
The adjustable overload protection is from 70% to 100% of the nominal current and short
circuit setting from 5 to 10 times of the rated current is possible.
The minor disadvantage of the release is that operating characteristics of the breaker may vary
depending on the ambient temperature.
Basics of LVSG 16
2) Electronic Release MCCB

Electronic or Static Release Moulded Case circuit breakers use power electronic circuitry to
provide overcurrent protection. The Continuous adjustable overload protection from 60% to
100% of the nominal current and short circuit setting from 2 to 10 times of the rated current is
possible.
The advantage of the release is that operating characteristics of the breaker is independent of
the ambient temperature.
This wide flexibility takes care of future increases in load capacity of an installation and ensures
better planning at an optimum cost.
3) Microprocessor release MCCB

Microprocessor release Moulded Case circuit breakers use microprocessors to provide
overcurrent protection. The Microprocessor release works on monitoring of current True
R.M.S value. It is simulated and calculated from peak values, which installed microprocessor,
can detect. There is high Flexibility through multiple adjustments of protection settings, High
repeat accuracy and High reliability.
Time delays can be provided for Short Circuit Release better discrimination and co-ordination
using LCD display. System Diagnosis is possible as it stores the Trip history within the internal
memory. Trip current indication is also available for understanding of type of fault and set-up
programming at site.
Characteristic & Design of MCCB

Trip Curve for a Thermal Magnetic MCCB The most commonly selected form of thermal
protection is the bimetallic version. This works similarly to a traditional overload relay in which
a bimetallic element is heated, causing a deflection, which then exerts pressure on a trip bar
and causes the circuit breaker to trip.
Trip Curve for an Electronic MCCB
Basics of LVSG 17
An alternative to using fixed-thermal protection is to use electronic overcurrent protection,

which can electronically replicate the function of the mechanical overcurrent device. One of
the benefits of using electronic trip units is their ability to tailor the tripping characteristics of
the circuit breaker for the application. The electronic trip unit has the ability to provide
advanced protection in the form of additional trip functionality such as adjustable: Long Time
– Allows the long time between 1.05 and ~1.3 x the thermal rating to be delayed, similar to
how an adjustable relay changes classes Short Time – Adjustable short time between thermal
and short-circuit Instantaneous Trip – Adjustable instantaneous short-circuit trip time Ground
Fault – Adjustable time and value of ground fault tripping
Application of MCCB
Transformer Protection:-
Primary side:-
For the protection of transformer with air circuit breaker connected to the primary side (LT
primary) then unload inrush current of the transformer must be considered. The peak value
of the first current wave often reaches 10-15 times the rated current and may sometimes
reaches 20-25 times. However, the transient decays very quickly (in a few msec). Thus the
MCCB selected should have a magnetic setting which will not be actuated by the momentary
inrush current.
Secondary Side:-
STANDARDMCCBs can be used for protection of transformer on the LT side (secondary
side) as an outgoing protective device.
The rated current of the transformer is calculated as follows:
Basics of LVSG 18
Motor Control:
STANDARDMCCBs can be used for motor protection. Selection of MCCBs has to be done
taking into consideration the starting inrush current, and the system fault levels. Further the
selection is also based on type of starting, i.e. DOL or Star Delta.
DOL Starting:
Care is to be taken to avoid nuisance tripping during starting of Squirrel Cage Motors since
the inrush current will be in the order of 600 to 800% of the full load current of the motor.
The overload setting is chosen such that it does not trip during starting.
Star-Delta Starting:
In Star Delta starting of motors, since there is a reduction in the starting current due to reduced
voltage, the MCCBs do not have a problem in the overload setting. But the transient
currents can go upto12 times the rated current during changeover from star to delta which
will cause the instantaneous magnetic release to trip the breaker. So proper selection of
magnetic pickup level is important for prevention of nuisance tripping during change over
from Star to Delta.
It is always recommended to select an MCCB in co-ordination with Contactor and Over

Load Relay so as to have the best and optimum benefit of all the devices.
SENTRON VL series MCCB

 One series with complete range from 16A to 1600A
 3 breaking capacities : N / H /L
 Available for AC/DC applications
 Type 2 tested charts are available
 Trip units available for various applications (TM/ ETU)
 Current Limiting
 Thermal Memory
 Line Load Reversibility
 Positive isolation
 Continuous rated Shunt Coils
 Flexibility in Mounting (fixed /plug in / withdraw able )
 RoHS complied environment friendly
Basics of LVSG 19
Internal Accessories of MCCB
Basics of LVSG 20
3. Switch Disconnector (Super Switch)
Switch Disconnector (Super Switch)

Basic concept of super switch
Super switches take the industry standards of low voltage power distribution to next higher
plane.
The SDF combinations are type tested and cost effective methods of switching resistive,
inductive and capacitive loads. In industry, most of the feeders can be fitted with SDFs except
few very critical feeders in process plants where switching equipment has to be reinstated
immediately to avoid loss of production. In such applications some users prefer fuse less
feeders over fused feeders.
Siemens offers both fused and fuse less solutions in duly tested type 2 coordinated
combinations. Some of the typical advantages of fused motor feeders are.
 Fuse being fastest short circuit protection device as compared to even current limiting
MPCB & MCCB, offers optimum sizing of contactors & overload relays. This results in
cost saving in equipment selection in motor feeders.
 Proper selection of fuses offer lower I2t and cut off current corresponding to equivalent
ratings of MCCBs and thus ensure lesser thermal and dynamic stresses and longer life of
cables and downstream equipment.
 Replacement cost of fuse is insignificant vis-a-vis MPCB and MCCB.
 Breaking capacity of fuses is very high i.e. up to 120kA, hence system can be made
suitable for higher fault level at substantially lower cost.
 Proper discrimination can be achieved in fuse system and in the event of a fault, only the
fuse nearest to the fault blows. This helps in increasing uptime of the overall system.
As Siemens also offers type 2 coordinated fuse less combinations for motor feeders too, it may
be worthwhile making an optimum choice depending on the criticality of applications.
Basics of LVSG 21
Features
Wide Range
SDF = 20 A - 800 A
SD = 63 A - 1600 A
2Pole, 3Pole+N, 4 Pole (Switched Neutral) versions
Super switches are available in 2 Pole, 3 Pole + Neutral and 4 Pole (Switched Neutral) version.
User can select SDF as per his application and requirements. If the application is of 2 Phase
switching such as rectifiers, he doesn’t have to incur extra cost by selecting 3P+N SDF. This
offers a great degree of flexibility and cost advantage to the user.
Types of super switch

The Switch Dis-connector Fuse and Switch Dis-connectors conform to IEC60947-3 and IS
13947-3. Super switches are environmentally friendly switches, which predominantly consist
of recyclable materials conforming to Siemens norms (SN36350). Super switches also carry
CE mark. These switches are suitable for NFC, BS and DIN fuses.
Basics of LVSG 22
Selection of different types of super switch

Fuse protected selection type 2, lq = 50kA, IS13947
The selection is valid only for complete Siemens combinations.
i.e. SDF + DIN Fuse + Contactor + Birelay (+ timer).
In case this combination is changed to accommodate another brand/rating of SDF/DIN

Fuse/Contactor/BMR, it shall be the responsibility of the person making such a change to
assure type 2 performance. Selection is for normal starting conditions with starting time £ 6
seconds. For heavy starting applications, please consult Siemens. At 60°C service temperature
the bi-relay has to be derated. The bi-relay can be used up to the maximum current setting
indicated. For example-A bi-relay with setting 32-50A, at 60°C can be used only upto 47A.
This however does not mean that at 60°C, the 50A setting corresponds to 47A. It means that,
the bi-relay should not be set beyond 47A. The electronic star-delta timer type 3RP should be
Basics of LVSG 23
used in star-delta feeders. SDF: Switch Disconnector Fuse. All contactors are with 2NO + 2NC.
All fuses are proper DIN HRC type.
Truly tested Type 2 combinations & Low LCC = Low Life Cycle Cost
Direct-on-line Feeder, for Low LCC
Basics of LVSG 24
Star-Delta Feeder, for Low LCC:-
Basics of LVSG 25
Application of super switch

3KL8 super switches are suitable for diverse applications up to 690 Vac, 50/60 Hz in motor
feeders with Direct-on- line, Star-Delta, Soft starters and VVVF drive applications. They are
suitable for wind mill generators, capacitor switching feeders, motor control centres and power
control centres.
3KL8 is also available in special executions for operations in corrosive atmosphere. 3KL8
switches are specially designed for high ambient temperature applications and do not need any
deration right upto 60°C.
Benefits
 Versatile - suitable for all applications

 2 Pole, 3 Pole+N, 4 Pole executions suitable for BS, DIN and cylindrical fuses.
 New intermediate ratings.
 Rugged - lasts long, low maintenance.
 No deration up to 60°C ambient.
 Operational voltage-690V, Insulation voltage-1000V
 Low life cycle cost – higher return on investment.
 Very high life (up to 25000 switching cycles)
 A unique moving contacts with roller.
 Type 2 co-ordinated combination for complete range.
 User friendly - designed for Indian conditions.
 DIN-rail mounting up to 63A
 Wider terminals and higher ground clearance.
 Superior ergonomics and improved aesthetics.
 Front Drive (Handle) is suitable for padlock, door interlock and castle lock.
 Safe - safety to plant and personnel.
 Fully shrouded.
 A unique positive off indication.
 100% rated isolable neutral.
Maintenance of Super Switch

Be sure to follow the instructions on all safety labels and instruction sheets included with the
equipment before servicing.
Inspection is one of the most important parts of a good preventive.
 Maintenance program. Careful observation of the super switch will usually uncover
evidence of a problem before it causes down time. In most cases, time can be saved if
problems are corrected before they lead to major breakdowns. Inspection consists of
Basics of LVSG 26
observation for signs of overheating, dirt, loose parts, noise and any other signs of
abnormalities.
 Keeping the super switch clean, both inside and outside, is important for good
operation. Keeping the contactor clean will help eliminate overheating, high voltage
leakage and breakdowns. Clean by blowing the dust and dirt away with a low pressure
dry air stream.
 Vibration may result in loose connections that will eventually cause problems. Verify
the screws mounting the super switch to the panel are tight.
 Check for proper torque on all terminal connections. Discoloration of wire and/or
terminals may be an indication of a loose connection. Brittle or discolored wire
insulation may be an indication of a loose connection as well.
 Remove the arc cover and inspect the contacts. Replace all 3 contacts if one or more
of the following conditions exists:
 Silver cadmium tips are unevenly worn,
 Silver cadmium tips are nearly worn down to the copper material of the contact,
 Copper material of moveable contact is discolored indicating over-heating.
Note: It is normal for the Silver cadmium tips to be discolored.
 Use a clean dry rag or a low pressure dry air stream to remove dust and debris from
contact housing.
 Remove coil and magnet. Use a clean dry rag or a low pressure dry air stream to remove
dust and debris from face of both magnet and armature. Use care not to drop magnet or
scratch the pole faces of either magnet or armature.
 If maintaining a super switch, while to be used :
 Check for proper torque on all terminal connections.
 Verify that the full load amps dial is properly set to the full load amps of the motor
nameplate. The optional anti-tamper cover will help to prevent unauthorized adjustment
of the dial.
 Manually trip the super switch to verify proper operation of the trip mechanism. This
is done by shifting the trip lever to the right using a pointed object. The trip lever is
located on the bottom side of the super switch where the load wire exist the device.
Upon successfully tripping the super switch don’t forget to reset it by pressing the reset
button.
 If maintaining a super switch with a bimetal overload relay:
 Check for proper torque on all terminal connections including the heater elements.
 Manually trip the overload relay to verify proper operation of the trip mechanism. This
is done by pressing the Man Trip button. The Auto/Man Reset dial must be in the Man
position to perform this test. Upon successfully tripping the overload relay don’t forget
to reset it by pressing the reset button.
Basics of LVSG 27
4. Overload Relay
Overload Relay
Basic concept of overload relay
Overload relay is a protective device that senses when motors will overload.
SIRIUS overload relays with screw-type, spring-loaded or ring cable lug connections reliably
protect loads as well as other switching and protective devices in the respective load feeder
against overload, phase asymmetry and phase failure. Thanks to ATEX certification, they can
be used in many different applications and are even suitable for protecting motors designed for
use in explosive environments. The overload relays can easily be used with the contactors of
the SIRIUS module kit.
For demanding applications, the modular variants of the 3RB22, 3RB23 or 3RB24 electronic
overload relays even offer full motor protection using connected thermistors to sense the motor
temperature, as well as comprehensive display and signaling functions, and a communication
link using IO-Link.
Optimized, standard accessories are available for 3RU2 and 3RB3. This helps to reduce costs
for ordering and maintaining stocks.
Basics of LVSG 28
4. Overload Relay
Overload relay principle of operation

Thermal motor protection relays contain three bimetal strips together with a trip mechanism in
a housing made of insulating material. The bimetal strips are heated by the motor current,
causing them to bend and activating the trip mechanism after a certain travel which depends
on the current-setting of the relay.
The release mechanism actuates an auxiliary switch that breaks the coil circuit of the motor
contactor. A switching position indicator signals the condition “tripped”.
Bimetal relays work on the bimetallic principle. Every Overload relay has a strip that is made
of two dissimilar metals bonded together. The two metals have different thermal expansion
characteristics, so the bimetal bends at a given rate when heated because of the current it carries.
Under a normal current, heat generated by this bi-metal is insufficient to cause the strip to bend.
As the current rises, heat increases as well, and the hotter the bimetal becomes, the more it
bends. In an overload condition, the heat generated from the heater will cause the bimetal strip
to bend until the mechanism is tripped, thus stopping the motor. Also, the heating is faster for
higher currents and hence the relay trips faster for higher overloads.
The bimetal strips may be heated directly or indirectly. In the first case, the current flows
directly through the bimetal, in the second through an insulated heating winding around the
strip.
The insulation causes some delay of the heat-flow so that the inertia of indirectly heated thermal
relays is greater at higher currents than with their directly heated counterparts. Often both
principles are combined.
Basics of LVSG 29
4. Overload Relay
For motor rated currents over approx. 100 A, the motor current is conducted via current
transformers. The thermal overload relay is then heated by the secondary current of the current
transformer.
The tripping current of bimetal relays can be set on a current scale, by displacement of the trip
mechanism relative to the bimetal strips, so that the protection characteristic can be matched to
the protected object in the key area of continuous duty.
Connection methods
1) Connection for mounting onto contactors:

Optimally adapted in electrical, mechanical and design terms to the contactors and soft
starters, these connecting pins can be used for direct mounting of the overload relays.
Stand-alone installation is possible as an alternative (in some cases in conjunction with
a stand-alone installation module).
2) Selector switch for manual/automatic RESET and RESET button:

With this switch you can choose between manual and automatic RESET. A device set
to manual RESET can be reset locally by pressing the RESET button. A remote RESET
is possible using the RESET modules (accessories), which are independent of size.
3) Switch position indicator and TEST function of the wiring:

Indicates a trip and enables the wiring test.
4) Motor current setting:

Setting the device to the rated motor current is easy with the large rotary knob.
5) STOP button:
If the STOP button is pressed, the NC contact is opened. This switches off the contactor
downstream. The NC contact is closed again when the button is released.
Basics of LVSG 30
4. Overload Relay
6) Transparent sealable cover:

Secures the motor current setting and the TEST function against adjustment.
7) Supply terminals:
The generously sized terminals permit connection of two conductors with different
cross-sections for the main and auxiliary circuits. The auxiliary circuit can be connected
with screw terminals and alternatively with spring-type terminals.
Wye-delta starting:
When overload relays are used in combination with contactor assemblies for wye-delta starting it must
be noted that only 0.58 times the motor current flows through the line contactor. An overload relay
mounted onto the line contactor must be set to 0.58 times the motor current.
Basics of LVSG 31
4. Overload Relay
Types of overload relay

Thermal overload relays
In the main circuit, the thermal overload relays are responsible for current-dependent overload
protection of electrical loads (e.g. motors). The overload relays are available with spring-
loaded, screw-type and ring cable lug connections - for a particularly flexible and cost-effective
implementation.
Electronic overload relays (Microprocessor based)
The SIRIUS 3RB electronic overload relays ensure real commercial added value: in the main
circuit, the 3RB30 electronic overload relays for standard applications are responsible for
current-dependent overload protection of electrical loads (e.g. motors). Due to the wide current
setting ranges and various tripping characteristics, complete series of motors are covered with
just a few types. The 3RB31 version offers enhanced functions, such as an integrated, electrical
remote reset or ground fault detection to name but a few.
Basics of LVSG 32
4. Overload Relay
Siemens SIRUS series OLR
Characteristics of MCCB
The tripping characteristics show the relationship between the tripping time and tripping
current as multiples of the current setting Ie and are given for symmetrical three-pole and two-
pole loads from the cold state.
The smallest current used for tripping is called the minimum tripping current. According to
IEC 60947-4-1, this current must be within specified limits. The limits of the total tripping
current for the 3RB20/3RB21 solid-state overload relays for symmetrical three-pole loads are
between 105 and 120 % of the current setting.
The tripping characteristic starts with the minimum tripping current and continues with higher
tripping currents based on the characteristics of the so-called trip classes (CLASS 10, CLASS
20, CLASS 30 etc.). The trip classes describe time intervals within which the overload relays
have to trip with 7.2 times the current setting Ie from the cold state for symmetrical three-pole
loads.
Basics of LVSG 33
4. Overload Relay
The tripping times according to IEC 60947-4-1, tolerance band E, are as follows for: The
tripping characteristic for a three-pole overload relay from the cold state (see illustration 1)
only apply if all three phases are simultaneously loaded with the same current. In the event of
a phase failure the 3RB20 / 3RB21 solid-state overload relays switch off the contactor more
quickly in order to minimize heating of the load in accordance with the tripping characteristic
for two pole loads from the cold state (see illustration 2). With phase unbalance the devices
switch off depending on the degree of the unbalance between the two characteristic curves.
Compared with a cold load, a load at operating temperature obviously has a lower temperature
reserve. The tripping time of the 3RB20/3RB21 solid-state overload relays is reduced therefore
to about 20 % when loaded with the current setting Ie for an extended period.
Tripping characteristics for 3-pole loads:
The tripping characteristic of a three-pole 3RU11 thermal overload relay is valid when all three
bimetal strips are loaded with the same current simultaneously. If, however, only two bimetal
strips are heated as a result of phase failure, these two strips would have to provide the force
necessary for operating the release mechanism and, if no additional measures were implemented,
they would require a longer tripping time or a higher current.
These increased current levels over long periods usually result in damage to the consumer. To
prevent damage, the 3RU11 thermal overload relay features phase failure sensitivity which,
thanks to an appropriate mechanical mechanism, results in accelerated tripping according to
the characteristic for two-pole loading from cold.
In contrast to a load in the cold state, a load at operating temperature has a lower heat reserve. This
fact affects the 3RU11 thermal overload relay in that following an extended period of loading at
operational current Ie, the tripping time reduces by about a quarter.
Basics of LVSG 34
4. Overload Relay
Sensitivity to phase failure
The tripping characteristic of three-pole motor protection relays applies subject to the
condition that all three bimetal strips are loaded with the same current at the same time.
If, when one pole conductor is interrupted, only two bimetal strips are heated then these two
strips must alone produce the force required to actuate the trip mechanism. This requires a
higher current or results in a longer tripping time (characteristic curve c in Figure below).
Typical trip characteristics of a motor protection relay

Ie= Rated current set on the scale
t = Tripping time
 From a cold state:
a = 3-pole load, symmetrical
b = 2-pole load with differential release
c = 2-pole load without differential release
 From the warm state:
d = 3-pole load, symmetrical
If larger motors (≥10 kW) are subjected to these higher currents for a longer time,
damage should be expected.
In order to also ensure the thermal overload protection of the motor in the cases of supply
asymmetry and loss of a phase, high quality motor protection relays have mechanisms with
phase failure sensitivity (differential release).
Basics of LVSG 35
5. Motor Protection Circuit Breaker
Motor Protection Circuit Breaker

Basic concept of MPCB
Designed to protect and control low tension motors from damage caused due to excess passage
of current. MPCBs combine the function of a switch, short circuit protective device and an
overload relay.
Siemens MPCB with thermal range 0.6-1.00A and with 1NO + 1NC. Can be reset immediately
after overload is removed. Accessories like handle, under voltage release available separately.
Adjustable thermal magnetic releases.
An MPCB combines the function of an overload relay and a switch. Siemens MPCB can be
used to protect low tension motors from damage if current is more than 1.00A. Similar MPCBs
can be found in other brands like L&T, ABB, GE, BCH, Havel’s, and Schneider etc.
Robust and compact, designed and developed by SIEMENS Germany for the world market, now
available in India. 3VU* circuit breakers set the standard in protection of motors and other loads.
These MPCB can be used in Machine Tools, textile machinery, automobile, food and many other
process industries where robust and compact devices are required for disconnection and protection of
plants and individual loads.
Benefits:
1. Space saving compact modular design.
2. Finger touch proof and open terminals with SIGUT connection technique.
3. Optional integrated auxiliary contacts save space and time.
4. Phase failure protection.
Basics of LVSG 36
Construction of MPCB
SIRIUS 3RV Compact, Robust and High-Performance
Just like all SIRIUS devices, the circuit-breakers are suitable for side-by-side mounting up to
60°C. In addition to the usual CLOSED/OPEN circuit-breaker positions the TRIPPED position
is also indicated. SIRIUS circuit-breakers can be connected easily and without any wiring to
the SIRIUS contactors and soft starters through a link module. The clear, structured range is
electrically, mechanically and optically harmonized to the other families of SIRIUS devices –
contactors, soft starters and overload relays. Furthermore, the four sizes cover a current range
up to 100 A. This corresponds to a power range up to 45 kW at 400 V AC.
The MPCBs are supplied with factory-fitted over current release.

There are five possible options:
1. MPCB with standard release
2. MPCB with relay function
3. MPCB with “MAG only” release
4. MPCB with Class 20 release
5. MPCB for Transformer protection
Basics of LVSG 37
Application of MPCB
• Motor Protection
Circuit breakers type 3VU13 & 3VU16 offer overload, short circuit and phase loss protection
for 3 phase motors up to 11kW and 22 kW respectively. The breaker has a toggle switch for
ease of operation and can be offered with auxiliary contacts, trip indicating contacts, U/V or
Shunt release. High breaking capacity of 100kA is available in 3VU13 up to 6A and in 3VU16
up to 25 A.
• Distribution Feeder Protection

Standard version of 3VU13 and 3VU16 has adjustable O/L and fixed S/C release. Main
application is for disconnection and protection of the distribution feeders, up to 25A and 63A
respectively. A large number of overlapping ranges are available for offering closer protection
to various loads.
• Transformer protection
A separate 3VU13 range can be offered to protect the primary side of the transformers. The
range is available up to 20A. To take care of the inrush current due to transformer switching,
the S/C release is set at 19 times the rated current unlike 12 times of the rated current available
in standard range.
• Fuse Monitoring
3VU1340-1MS00 is offered for Fuse Monitoring application. This device is connected in
parallel to the fuses. In case one of the fuses blows, the rated current will flow through the
corresponding phase of this MPCB. MPCB, through its auxiliary contacts, provides a tripping
signal to the contactor and thus the motor will be switched off. Hence, the motor will be
protected from single phasing. (Refer page 51 for connection diagram)
Basics of LVSG 38
Characteristic of MPCB
This is a typical characteristic curve of 3RV MPCBs. Part (A) is the inverse time delay curves
of MPCB. The part is followed in case of an overload fault. The higher the current, the less
time the MPCB takes to trip, and vise versa. Part (B) of the curve is followed in the case of a
short circuit fault. It is fixed to 13 times of the MPCB’s rated current. MPCB trips in a few
milliseconds once the short circuit is detected.
MPCB is a current limiting device, which means that in the event of a short circuit, the MPCB
limits (by tripping faster) the actual current to a value lesser than the prospective short circuit
current that has a high value. We can see in the current limiting curves of MPCB the actual
short circuit current or let through current in the system and the prospective short circuit
current. So the MPCB not only limits the short circuit value but also trips within a few
milliseconds. Therefore it reduces the let through energy I2t value. This let through energy is
seen by downstream products such as contactors and relays, and thus these products need to
withstand the let through energy. Thus MPCB avoids the possible damage to the downstream
products of the feeder and protects them.
Basics of LVSG 39
Selections of MPCB
MPCB are used to protect the motor from overloads and short circuit faults. The 3RV MPCB
range is up to 100A. There are 4 sizes: S00, S0, S2 and size S3. The current rating and class
of the three sizes is shown here. In addition, three types of 3RV MPCBs are available. The
3RV10 / 20 is an MPCB with standard release, the 3RV13 / 23 is an MPCB with Mag only
release, and the 3RV11/21 is a relay function MPCB.
Range- 3RV (up to 100A)

3RV20/10 - MPCB standard release
3RV23/13 - MPCB with ‘MAG only’ release
3RV21/11 - MPCB with ‘Relay Function’ release
MPCB with class 10 / 20 tripping
MPCB with 100kA breaking capacity
Size, current rating and class:
S00 0.16 - 16A (3RV2.1) class10
S0 16 - 40A (3RV2.2) class 10
S2 25 - 50A (3RV1.3) class 10, class 20
S3 50 - 100A (3RV1.4) class 10, class 20
S00 S0 S2 S3
Max. rated current 16 A 40 A 63 A 100 A

For 3-phase motor
7.5 kW 11 kW 22 kW 45 kW
up to (400 V)
Width 45 mm 45 mm 55 mm 70 mm
Short-circuit-proof 50/100 kA
55/100 kA 55/100 kA 50 kA
up to 555 (selectable)
Class 10 10 10/20 10/20
Basics of LVSG 40
We have already seen that the 3RV MPCBs are having 4 sizes – S00 to S3 with current ratings
up to 0.16 to100A. The S00 size MPCB can be used for the protection of motors up to 7.5kW,
S0 size MPCB can be used up to 18.5kW, S2 size MPCB can be used for the protection of
motors up to 22kW and S3 size MPCB can be used up to 45kW. Complete range is available
in 45mm / 55mm / 70mm width. Additionally, we can have the breaking capacity of 55 or
100kA for 3RV MPCBs. Only in case of 36A and 40A MPCBs in size S0 the breaking capacity
is 20kA. The MPCBs available in size S0 and S00 are from the newly launched SIRIUS
innovation devices which is the upgraded version of SIRIUS.
Basics of LVSG 41
6. Miniature Circuit Breaker
Miniature Circuit Breaker

Basic Concept of MCB
MCBs or Miniature Circuit Breakers are electromechanical devices which protect an
electrical circuit from an overcurrent. The overcurrent, in an electrical circuit, may result from
short circuit, overload or faulty design. The principal of operation is simple. An MCB functions
by interrupting the continuity of electrical flow through the circuit once a fault is detected. In
simple terms MCB is a switch which automatically turns off when the current flowing through
it passes the maximum allowable limit. Generally MCB are designed to protect against over
current and over temperature faults (over heating).
Design of MCB
There are two contacts one is fixed and the other moveable. When the current exceeds the
predefined limit a solenoid forces the moveable contact to open (i.e., disconnect from the fixed
contact) and the MCB turns off thereby stopping the current to flow in the circuit. In order to
restart the flow of current the MCB is manually turned on. This mechanism is used to protect
from the faults arising due to over current or over load.
To protect against fault arising due to over heating or increase in temperature a bi-metallic strip
is used. MCBs are generally designed to trip within 2.5 millisecond when an over current fault
arises. In case of temperature rise or over heating it may take 2 seconds to 2 minutes for the
MCB to trip.
Basics of LVSG 42
This section covers the insight of a single pole MCB commonly used in the house hold. The
following image (Fig. 6.1) shows the different internal parts of an MCB with top casing
removed. The subsequent sections will examine each part and its function.
(Figure: Internal Design of a MCB)
Basics of LVSG 43
1) Actuator lever: Used to manually trip and reset the circuit breaker. Also indicates the
status of the circuit breaker (On or Off/tripped). Most breakers are designed so they can
still trip even if the lever is held or locked in the "on" position. This is sometimes
referred to as "free trip" or "positive trip" operation.
2) Actuator mechanism: Forces the contacts together or apart.
3) Contacts: Allow current when touching and break the current when moved apart.
4) Terminals
5) Bimetallic strip: Separates contacts in response to smaller, longer-term overcurrent
6) Calibration screw: Allows the manufacturer to precisely adjust the trip current of the
device after assembly.
7) Electromagnetic Protection:
Thermal / Magnetic trip units definition
Current Limiting Breakers use an electromechanical (Thermal /Magnetic) trip unit to
open the breaker contacts during an overcurrent event. The thermal trip unit is
temperature sensitive and the magnetic trip unit is current sensitive. Both units act
independently and mechanically with the breaker’s trip mechanism to open the
breaker’s contacts.
Overload protection
The thermal trip unit protects against a continuous overload. The thermal unit is
comprised of a bimetal element located behind the circuit breaker trip bar and is part of
the breaker’s current carrying path.
When there is an overload, the increased current flow heats the bimetal causing it to
bends. As the bimetal bends it pulls the trip bar which opens the breaker’s contacts. The
time required for the bimetal to bend and trip the breaker varies inversely with the
current. Because of this, the tripping time becomes quicker as current increases in
magnitude. Overload protection is applicable to any installation, conductor, or
component which can be subjected to low-magnitude but longtime overcurrent. Low-
magnitude, long-time overcurrent can be dangerous because they reduce the life of the
electrical installation, conductor, and components and if left unchecked could result in
fire.
8) Arc runners / Arc chutes:
The arc runner and arc chute limit and dissipate the arc energy during the interruption
of an overload or short circuit event. During an overload or short circuit event, the
contacts of the breaker separate and an electrical arc is formed between the contacts
through air. The arc is moved into the arch chute by “running” the arc down the interior
of the breaker along the arc runner. When the arc reaches the arc chute it is broken into
small segmented arcs. The segmented arcs split the overall energy level into segments
less than 25V. Each 25V segment does not have a high enough energy level to maintain
an arc and all energy is naturally dissipated.
Basics of LVSG 44
Characteristics of MCB
Characteristic curve is the curve between release current and tripping time.
MCB have:
Type B characteristic curves.
Type C characteristic curves.
Type D characteristic curves.
MCB Characteristic Curves
The classification of Type B, C or D is based on fault current rating at which magnetic operation
occurs to provide short time protection (typically less than 100ms) against short circuits. It is
important that equipment having high inrush currents should not cause the circuit-breaker to
trip unnecessarily, and yet the device should trip in the event of a short-circuit current that
could damage the circuit cables.
Type B devices are generally suitable for domestic applications. They may also be used in light
commercial applications where switching surges are low or non-existent. Type B devices are
designed to trip at fault currents of 3-5 tomes rated current. For example a 10A device will trip
at 30-50A.
Type C devices are the normal choice for commercial and industrial applications
where fluorescent lighting, motors etc. are in use. Type C devices are designed to trip at 5-10
times in (50-100A for a 10A device).
Type D devices have more limited applications, normally in Industrial use where high inrush
currents may be expected. Examples include large battery charging systems, winding
motors, transformers, X-ray machines and some types of discharge lighting. Type D devices
are designed to trip at 10-20 times (100-200A for a 10A device).
Basics of LVSG 45
Normal cable ratings relate to continuous service under specified installation conditions.
Cables will, of course, carry higher currents for a short time without suffering permanent
damage. Type B and C circuit breakers can generally be selected to achieve tripping times that
will protect the circuit conductors against normal surge currents in accordance with BS 7671.
This is more difficult to achieve with Type D devices, which may require a lower earth loop
impedance (Zs) to achieve tile operating times required by Regulation 413-02-08.
Types of MCB
MCB As per Fault Tripping
MCBs are classified according to tripping over range of fault current as follows:
Type B MCB
Type C MCB
Type D MCB
Type B:
This type of MCB trips between 3 and 5 times full load current. Type B devices are mainly
used in residential applications or light commercial applications where connected loads are
primarily lighting fixtures, domestic appliances with mainly resistive elements. The surge
current levels in such cases are relatively low.
Type C:
This type of MCB trips between 5 and 10 times full load current. This is used in commercial
or industrial type of applications where there could be chances of higher values of short circuit
currents in the circuit. The connected loads are mainly inductive in nature (e.g. induction
motors) or fluorescent lighting.
Type D:
This type of MCB trips between 10 and 20 times full load current. These MCBs are use in
specialty industrial / commercial uses where current inrush can be very high. Examples include
transformers or X-ray machines, large winding motors etc.
All the above three types of MCBs provide tripping protection within one tenth of a second.
Basics of LVSG 46
MCB As per Pole

Another practical way of distinguishing MCBs is by way of the number of poles supported by
the circuit breaker. Based on that, following types exist:
Single Pole (SP) MCB

A single pole MCB provides switching and protection only for one single phase of a circuit.
Double Pole (DP) MCB

A two Pole MCB provides switching and protection both for a phase and the neutral.
Triple Pole (TP) MCB

A triple/three phase MCB provides switching and protection only to three phases of the circuit
and not to the neutral.
Pole with Neutral [TPN (3P+N) MCB]

A TPN MCB, has switching and protection to all three phases of circuit and additionally
Neutral is also part of the MCB as a separate pole. However, Neutral pole is without any
protection and can only be switched.
Pole (4P) MCB

A 4 pole MCB is similar to TPN but additionally it also has protective release for the neutral
pole. This MCB should be used in cases where there is possibility of high neutral current flow
through the circuit as in cases of an unbalanced circuit
Figure: Types of MCB as per pole
Basics of LVSG 47
Selection of MCB
The first characteristic is the overload which is intended to prevent the accidental overloading
of the cable in a no fault situation. The speed of the MCB tripping will vary with the degree of
the overload. This is usually achieved by the use of a thermal device in the MCB.
The second characteristic is the magnetic fault protection, which is intended to operate when
the fault reaches a predetermined level and to trip the MCB within one tenth of a second. The
level of this magnetic trip gives the MCB its type characteristic as follows:
Type Tripping Current Operating Time
Type B 3 To 5 time full load current 0.04 To 13 Sec
Type C 5 To 10 times full load current 0.04 To 5 Sec
Type D 10 To 20 times full load current 0.04 To 3 Sec
The third characteristic is the short circuit protection, which is intended to protect against heavy
faults maybe in thousands of amps caused by short circuit faults.
The capability of the MCB to operate under these conditions gives its short circuit rating in
Kilo amps (KA). In general for consumer units a 6KA fault level is adequate whereas for
industrial boards 10KA fault capabilities or above may be required.
Applications of MCB
1. Domestic Electrical Panels/Distribution Boards
As with all breakers, the miniature circuit breaker is designed to protect the house from circuit
overload. They are much safer than the typical fuses, because they can be reset manually and
because they handle much larger amounts of power. The breaker can manage the flow of
energy, distributing properly the voltage even when many devices run off the same power
circuit.
2. Ground Fault Trip Mechanism

In some cases, you can use a miniature circuit breaker with ground fault, or arc fault
mechanisms, because the breakers consist of a system that opens the contacts if a line to ground
fault occurs.
3. Lights
Using miniature circuit breakers in the lighting system of the house, because they can deal with
the amount of power needed to light a house, especially if using specific types of lamps, such
as fluorescent lights. When switching on the lights, there is a need for additional power which
might cause problems to the circuit, especially when lights are used extensively in the entire
house.
Basics of LVSG 48
4. Industrial Applications
There are many small scale industrial buildings that use the miniature circuit breakers instead
of the old fuses. These installations require up to 30 kA capacity, therefore the miniature
breakers are ideal for this type of applications and devices. Same with commercial installations
and applications. Some industrial applications that use miniature breakers are large stoves, and
appliances used in restaurants, bakeries and food commercial stores.
5. Heaters
When using heaters at home or the office, the miniature circuit breaker can prove beneficial. It
is known in general that heaters can be problematic some times, especially with distribution of
electrical power. The miniature circuit breaker can prevent possible problems, cutting off
electricity in the case of overload or flaw. In this case, though, you need to choose the proper
type of miniature breaker, enabling it to handle the load of power when needed.
Miniature circuit breakers are used in small scale premises and domestic dwellings and
anywhere needed to control the distribution and supply of electrical power. They offer an
efficient way to manage the electrical circuit of a house or of an entire building. They are
commonly used these last few years and they come in a refined design, able to provide reliable
and effective protection of the circuit. They are a safe and dependable solution for the proper
management of the electrical circuit.
Basics of LVSG 49
7. Residual Current Circuit Breaker
Residual Current Circuit Breaker

Basic concept of RCCB
A Residual Current Circuit Breaker (RCCB), is a device to quickly disconnect current to
prevent serious harm from an ongoing electric shock, the device is more commonly known as
a Ground Fault Circuit Interrupter (GFCI), Ground Fault Interrupter (GFI).
In some places, these are better known by their initials RCCB, and a combined RCCB & MCB
is known as a RCBO (Residual-Current Circuit Breaker with Overcurrent Protection). An Earth
Leakage Circuit Breaker (ELCB) may be a residual-current device, although an older type of
voltage-operated earth leakage circuit breaker also exists.
These electrical wiring devices disconnect a circuit when it detects that the electric current is
not balanced between the energized (line) conductor(s) and the return (neutral) conductor. In
normal circumstances, these two wires are expected to carry matching currents, and any
difference usually indicates that a short circuit or other electrical anomaly is present. Even a
small leakage current can mean a risk of harm or death due to electric shock if the leaking
electric current passes through a human; a current of around 30 mA (0.030 amperes) is
potentially sufficient to cause cardiac arrest or serious harm if it persists for more than a small
fraction of a second. RCCBs are designed to disconnect the conducting wires quickly enough
to prevent serious injury from such shocks. (This is commonly described as the RCCB being
"tripped".)
Basics of LVSG 50
A RCCB does not provide protection against unexpected or dangerously high current when
current is flowing in the usual wires in the circuit, therefore it cannot replace a fuse or protect
against overheating or fire risk due to overcurrent (overload) or short circuits if the fault does
not lead to leakage current. Therefore RCCBs are often used or integrated as a single product
along with some kind of circuit breaker, such as a fuse or MCB, which adds protection in the
event of excessive current in the circuit. RCCBs also can’t detect the situation where a human
accidentally touches both conductors at the same time, since the flow of current through an
expected device, an unexpected route, or a human, are indistinguishable if the current returns
through the expected conductor.
RCCBs are usually testable and resettable devices. Commonly they include a button that when
pressed, safely creates a small leakage condition, and a switch that reconnects the conductors
when a fault condition has been cleared. Depending upon their design, some RCCBs disconnect
both the energized and return conductors upon a fault, while others only disconnect the
energized conductor and rely upon the return conductor being at ground (earth) potential. The
former are commonly known as "double-pole" designs; the latter as "single-pole" designs. If
the fault has left the return wire "floating" or not at its expected ground potential for any reason,
then a single-pole RCCB will leave this conductor still connected to the circuit when it detects
the fault.
Principle of operation and Design of RCCB
The Diagram depicts the internal mechanism of a residual-current device (RCD) or Residual
Current Circuit Breaker (RCCB). The device is designed to be wired in-line in an appliance
power cord. It is rated to carry a maximal current of 13 Amp and is designed to trip on a leakage
current of 30 mA. This is an active RCCB; that is, it latches electrically and therefore trips on
power failure, a useful feature for equipment that could be dangerous on unexpected re-
energisation.
Basics of LVSG 51
The incoming supply and the neutral conductors are connected to the terminals at (1), and the
outgoing load conductors are connected to the terminals at (2). The earth conductor (not shown)
is connected through from supply to load uninterrupted. When the reset button (3) is pressed,
the contacts ((4) and another, hidden behind (5)) close, allowing current to pass.
The solenoid (5) keeps the contacts closed when the reset button is released.
The sense coil (6) is a differential current transformer which surrounds (but is not electrically
connected to) the live and neutral conductors. In normal operation, all the current down the live
conductor returns up the neutral conductor. The currents in the two conductors are therefore
equal and opposite and cancel each other out.
Any fault to earth (for example caused by a person touching a live component in the attached
appliance) causes some of the current to take a different return path, which means that there is
an unbalance (difference) in the current in the two conductors (single-phase case), or, more
generally, a nonzero sum of currents among various conductors (for example, three phase
conductors and one neutral conductor). This difference causes a current in the sense coil (6),
which is picked up by the sense circuitry (7). The sense circuitry then removes power from the
solenoid (5), and the contacts (4) are forced apart by a spring, cutting off the electricity supply
to the appliance.
The device is designed so that the current is interrupted in milliseconds, greatly reducing the
chances of a dangerous shock being received.
The test button (8) allows the correct operation of the device to be verified by passing a small
current through the orange test wire (9). This simulates a fault by creating an imbalance in the
sense coil. If the RCCB does not trip when this button is pressed, then the device must be
replaced.
Basics of LVSG 52
Types of RCCB
RCCB as per Fault Tripping
Type, or mode (types of current leakage issue detected)
Standard IEC 60755 (General requirements for residual current operated protective devices)
defines three types of RCCB depending on the characteristics of the fault current.
Type AC: RCCB for which tripping is ensured for residual sinusoidal alternating currents.
Type A: RCCB for which tripping is ensured as for type AC,
For residual pulsating direct currents,

For residual pulsating direct currents superimposed by a smooth direct current of 6 mA, with
or without phase-angle control, independent of the polarity.
Type B: RCCB for which tripping is ensured as for type A.
For residual sinusoidal currents up to 1 KHz.

For residual sinusoidal currents superposed by a pure direct current,
For pulsating direct currents superposed by a pure direct current,
For residual currents that may result from rectifying circuits three-pulse star connection or six-
pulse bridge connection, two-pulse bridge connection line-to-line with or without phase-angle
monitoring, independently of the polarity.
RCCB as per Pole
The number of poles represents the number of conductors that are interrupted when a fault
condition occurs. RCCBs used on single-phase AC supplies (two current paths), such as
domestic power, are usually one- or two-pole designs, also known as single- and double-pole.
 A single-pole RCCB interrupts only the energized conductor, (In a single-pole RCCB,
the return conductor is usually anticipated to be at ground potential at all times and
therefore safe on its own).
 A double-pole RCCB interrupts both the energized and return conductors.
 A three poles RCCBs can be used on three-phase AC supplies (three current paths).
 To disconnect an earth conductor as well, with four-pole RCCBs used to interrupt
three-phase + neutral supplies.
Specially designed RCCBs can also be used with both AC and DC power distribution systems.
The following terms are sometimes used to describe the manner in which conductors are
connected and disconnected by an RCCB:
Single-pole / SP: RCCB will disconnect the energized wire only.
Double-pole / DP: RCCB will disconnect both the energized and return wires.
1+N and 1P+N: Non-standard terms used in the context of RCBOs, at times used differently
by different manufacturers. Typically these terms may signify that the return (neutral)
conductor is an isolating pole only, without a protective element (an unprotected but switched
Basics of LVSG 53
neutral), or that the RCBO provides a conducting path and connectors for the return (neutral)
conductor but this path remains uninterrupted when a fault occurs (sometimes known as "solid
neutral"), or that both conductors are disconnected for some faults (such as RCCB detected
leakage) but only one conductor is disconnected for other faults (such as overload).
Selection factors as per requirements of RCCB

Maximal rated current:
The rated current of an RCCB is chosen according to the maximal sustained load current it is
expected to carry, so generally if the RCCB is connected in series with a single fuse or circuit-
breaker, the rated current of the RCCB shall be at least the same as the fuse or circuit breaker,
though in the case of an RCCB feeding many circuit breakers, an allowance for load diversity
may or may not be permissible depending on the type of load expected.
Sensitivity:
RCCB sensitivity is expressed as the rated residual operating current, noted IΔn. Preferred
values have been defined by the IEC, thus making it possible to divide RCCBs into three groups
according to their IΔn value:
High sensitivity (HS): 6 – 10 – 30 mA (for direct-contact / life injury protection),
Medium sensitivity (MS): 100 – 300 – 500 – 1000 mA (for fire protection),
Low sensitivity (LS): 3 – 10 – 30 A (typically for protection of machine).
Note that the nominal value of residual current indicated above is not an absolute value. More
information is presented below.
Break time (response speed):
There are two groups of devices:
G (general use) for instantaneous RCCBs (i.e., without a time delay);
Minimal break time: immediate,
Maximal break time: 200 ms for 1× IΔn, 150 ms for 2× IΔn, and 40 ms for 5× IΔn.
S (selective) or T (time-delayed) for RCCBs with a short time delay (typically used in circuits
containing surge suppressors);
minimal break time: 130 ms for 1× IΔn, 60 ms for 2× IΔn, and 50 ms for 5× IΔn,
maximal break time: 500 ms for 1× IΔn, 200 ms for 2× IΔn, and 150 ms for 5× IΔn.
Surge current resistance:

The surge current refers to the peak current an RCCB is designed to withstand using a test
impulse of specified characteristics (an 8/20 µs[clarify] impulse, named after the time
constants of the rise and fall of current).
The IEC 61008 and IEC 61009 standards impose the use of a 0.5 µs of 100 kHz damped
oscillator wave (ring wave) to test the ability of residual-current protection devices to withstand
operational discharges with a peak current equal to 200 A. With regard to atmospheric
Basics of LVSG 54
discharges, IEC 61008 and 61009 standards establish the 8/20 µs[clarify] surge current test
with 3 kA peak current but limit the requirement to RCCBs classified as "selective".
Form factor (physical format):

A ground fault circuit interrupter circuit breaker (GFCI breaker in USA and Canada) and
residual-current breaker with overload (RCBO in Europe) are devices that combine the
functions of a residual-current device with a circuit breaker. They detect both supply unbalance
and overload current.
RCCBs can fit on the same DIN rail as the MCBs, however the busbar arrangements
in consumer units and distribution boards can make it awkward to use them in this way. If it is
desired to protect an individual circuit, an RCBO (residual-current circuit breaker with
overcurrent protection) can be used. This incorporates an RCCB and a miniature circuit
breaker in one device.
Applications of RCCB
There are two types of electrical faults that are quite dangerous:
High current fault arising due to short current or low resistance fault and is protected by MCB.
Earth leakage arising due to cable insulation failure, accidental touch by human, etc.
Such faults cannot be detected by MCB. It can only be detected by RCCB.
The underlying fundamental principle behind the functioning of RCCBs is that the current
flowing in to the equipment shall return back in full. If there is a difference of even few mill-
ampere, it will detect and trip the power supply. The current that leaks out of the system is
called residual current. The RCCBs are designed in such a way that, they are capable to
continuously sense and compare the difference i.e. the residual current values between the live
and neutral wires. Any small change in the current value on account of such event would trigger
the RCCB to trip off the circuit. Thus, we can say the RCCBs sense the difference between
current values in phase and neutral and breaks the circuit in case of an imbalance and hence
provides -complete electrical protection along with MCB to human beings and the equipment.
In an RCCB, the ON and OFF Positions are clearly visible with the help of window provided
at the top of housing or the chamber. The ‘Green’ color indicates the ‘OFF’ position, while the
‘Red’ color indicates the ‘ON’ Position
.
With advanced technology, some of the manufacturers have come out with integrated
protection for short circuit as well as earth fault, and the device is called RCBO. In such a
situation, MCB is not required.
Basics of LVSG 55
8. Soft Starter
Soft Starter
Basic concept of soft starter
Across-the line starting of induction motors is accompanied by inrush currents up to 7 times
higher than running current, and starting torque up to 3 times higher than running torque. The
increased torque results in sudden mechanical stress on the machine which leads to a reduced
service life. Moreover, the high inrush current stresses the power supply, which may lead to
voltage dips. As a result, the operability of sensitive consumers may be impaired.
Note: - An Induction motor has the ability to self-start owing to the interaction between the
rotating magnetic field flux and the rotor winding flux, causing a high rotor current as torque
is increased. As a result the stator draws high current and by the time the motor reaches to full
speed, a large amount of current (greater than the rated current) is drawn and this can cause
heating up of the motor, eventually damaging it. To prevent this, motor starters are needed.
Operating principle of soft starter

Soft starter limit the starting current and starting torque. This reliably prevents both mechanical
stress as well as line voltage dips. The motor voltage is reduced through phase angle control
and increased from an adjustable starting voltage up to the line voltage within the ramp time.
Thanks to the step-free control of the supply voltage, the motor is adjusted to the driven
machine’s load behavior. Mechanical operating equipment is accelerated in a particularly
gentle manner, which positively influences its operating behavior and prolongs its service life.
In short: Soft starting and stopping protects the connected devices and ensures a smooth
production flow.
A motor soft starter is a device used with AC electrical motors to temporarily reduce the load
and torque in the power train and electric current surge of the motor during start-up. This
reduces the mechanical stress on the motor and shaft, as well as the electrodynamics stresses
on the attached power cables and electrical distribution network, extending the lifespan of the
system.
Basics of LVSG 56
8. Soft Starter
A soft start-up eliminates the undesired side effects. Several types based on control of the
supply voltage or mechanical devices such as slip clutches were developed. The list provides
an overview of the various electric start-up types. The current and torque characteristic curves
show the behaviour of the respective starter solution. Torque surges entail high mechanical
stress on the machine, which results in higher service costs and increased wear. High currents
and current peaks lead to high fixed costs charged by the power supply companies (peak current
calculation) and to increased mains and generator loads.
Electrical soft starters can use solid state devices to control the current flow and therefore the
voltage applied to the motor. They can be connected in series with the line voltage applied to
the motor, or can be connected inside the delta (Δ) loop of a delta-connected motor, controlling
the voltage applied to each winding. Solid state soft starters can control one or more phases of
the voltage applied to the induction motor with the best results achieved by three-phase control.
Typically, the voltage is controlled by reverse parallel connected silicon controlled
rectifiers (Thyristors), but in some circumstances with three-phase control, the control elements
can be a reverse-parallel-connected SCR and diode.
Another way to limit motor starting current is a series reactor. If an air core is used for the
series reactor then a very efficient and reliable soft starter can be designed which is suitable for
all types of 3 phase induction motor [ synchronous / asynchronous ] ranging from 25 kW 415
V to 30 MW 11 kV. Using an air core series reactor soft starter is very common practice for
applications like pump, compressor, fan etc. Usually high starting torque applications do not
use this method.
Characteristic and Design of soft starter

The soft starter can be configured to operate in 6 wire mode. 6 wire mode may be the preferred
method due to:
 Possible reduction in the size of starter required, saving on space and /or cost.
 Wiring may already be present if a star/delta type starter was previously used.
 Reduced motor cable size.
The major advantage is that the current in the SCR is 58% less than it would be for the same
motor connected in 3 wire. The diagram below illustrates how the motor is connected in 6 wire,
also known as inside delta.
Basics of LVSG 57
8. Soft Starter
3Wire / 6wire connection: The standard connection of an electronic soft starter is 3 wire. An
alternative connection is 6 wire or inside delta connection. This is commonly used when
replacing a star/delta type motor starter.
The following illustrates the difference between soft starter in 3 wire & 6 wire connection:
Figure: 3-Wire & 6 Wire connection
The soft starter provides advanced motor protection with user selectable overload classes, over
& under current protection, phase imbalance and thermistor protection. It is important that the
power wiring is followed correctly to ensure proper protection and starter performance.
The soft starter comes standard with internal Current Transformers for monitoring the current
during acceleration, deceleration and when in bypass.
It is important that the soft starter be wired in a manner to ensure the Current Transformers are
always monitoring the motor current. For this reason 9 terminals are provided. This is important
to ensure continual protection of the soft starter, the motor and the load. The correct installation
of the Current Transformers is crucial for optimum performance of the soft starter torque
control system. In some situations such as 6 wire operation, it may be necessary to relocate the
Current Transformers external to the soft starter. For 6 wire operation the Current Transformers
are to be installed on the incoming line supply cables so that the line current is monitored (not
the phase currents).
Basics of LVSG 58
8. Soft Starter
Figure: Characteristics Comparison of Delta Start and Soft Starter
Figure: Characteristics of Soft Starter
Basics of LVSG 59
8. Soft Starter
Operation and working of soft starter

The Flux compensated magnetic amplifier (FCMA) Soft starter essentially consists of
predominantly inductive impedance in series with the motor windings to control the motor
current through a potential divider.
Inductive impedance in series with the motor windings finally when the motor has reached full
speed and the motor terminal voltage has reached around 90-96% a shorting device cuts the
Mag Amps out of the motor circuit and the motor runs under normal operating conditions.
Inductive impedance in series with the motor windings with shorting device Constructionally
the Flux compensated magnetic amplifier is an extremely rugged device comprising of
magnetic core and amply sized power windings. It should be emphasized that there is no
external control loop on the system and impedance variation is the natural characteristic of the
system achieved through suitable winding design and geometry.
This leads to 100% reliability of the operation.
Applications of soft starter

Soft starters can be set up to the requirements of the individual application. In pump
applications, a soft start can avoid pressure surges. Conveyor belt systems can be smoothly
started, avoiding jerk and stress on drive components. Fans or other systems with belt drives
can be started slowly to avoid belt slipping. Soft starts are seen in electrical R/C helicopters,
and allow the rotor blades to spool-up in a smooth, controlled manner rather than a sudden
surge. In all systems, a soft start limits the inrush current and so improves stability of the power
supply and reduces transient voltage drops that may affect other loads.
Areas of Soft Starter application

These are main applications of Soft starter:
 Steel industries (Rolling mills and processing lines)
 Cement industries
 Sugar plants
 Paper and pulp
 Rubber and plastic
 Textile industries
Basics of LVSG 60
8. Soft Starter
 Machine tool applications

 Power sector
 Water supply scheme
 And various process control applications
Requirements of soft starter

Soft starters have properties that are more suited to specific applications.
To make the proper selection, the following is needed:
 Motor nameplate full load amps,
 Blocked rotor amps,
 HP rating,
 Motor torque/speed curve if available.
Starting and stopping requirements:
 Longer start and stop times allow for smoother operation.
 Pulse start and/or jog option is useful for dough mixers, coal handlers or plastic
extruders.
 Pump applications require smooth stops to prevent water hammer damage.
Torque requirements of machinery driven and load inertia.
 Number of starts required per hour - Heat dissipation could pose a problem if the
number of starts is excessively high.
Overload protection requirement: Overload protection is based on class.
 Class 10 starter’s trip of the current draw is 6 times the motor's fill load amps for more
than 10 continuous seconds.
 A Class 20 starter trips in 20 seconds.
Electrical service range (line voltage)
Enclosure type
There are wide assortments of soft starters available including:
 200-690 VAC input, up to 700 HP at 230V and up to 1600 normal duty amps.
Basics of LVSG 61
8. Soft Starter
Technical Features
SIRIUS 3RW30
The products in the 3RW30 range feature a compact design and an integrated bridging
contact system. The innovative two phase control technology makes it compact. After the
starting time, the bridging contact system closes, thereby removing the thyristors from the
main circuit. Hence it is only during the start time that the thyristors are in the main circuit.
3RW30 offers a soft start feature. The patented technology of two phase polarity balancing
is used in these soft starters.
Basics of LVSG 62
8. Soft Starter
SIRIUS 3RW40
The features of SIRIUS 3RW40 soft starters are given in the slide. 3RW40 has a very compact
design. It has an integrated bridging contact system. After the starting time which is the time
taken for the motor to reach the rated speed, the bridging contact system closes thereby
removing the thyristors from the main circuit. Hence it is only during the start time that the
thyristors are in the main circuit. 3RW40 offers soft start, soft stop, integrated motor overload
and integrated device protection features. Due to this, separate overload protection relays are
not required.
The current limit can be adjusted. SIRIUS 3RW soft starters inherently limits the starting
current to a maximum of about 5.5 times. Using this adjustable current limiting feature, the
current can be limited to lower values based on the torque requirement for the motor to drive
the load at the rated speed. However it should be noted that when the current is reduced, the
resulting starting torque also reduces. Hence the value of the current should be so set that
sufficient torque is available to drive the load. The innovative two phase control technology is
used in SIRIUS 3RW40 soft starters which makes it compact and also price effective. The
patented technology of two phase polarity balancing is used in these soft starters. This
technology is explained later.
Basics of LVSG 63
8. Soft Starter
SIRIUS 3RW44
 Integrated bridging contact system.

 Soft starting with breakaway pulse, torque control or voltage ramp, adjustable torque
or current limiting as well as any combination of these, depending on load type.
 Inside-delta circuit for savings in terms of size and equipment costs.
 Solid-state motor overload and intrinsic device protection.
 Thermistor motor protection.
 Keypad with a menu-prompted, multi-line graphic display with background lighting.
 Interface for communication with the PC for more accurate setting of the parameters
as well as for control and monitoring.
 Display of operating states and fault messages.
 Connection to PROFIBUS with optional PROFIBUS DP module.
 External display and operator module.
Basics of LVSG 64
9. Relay
Relay
Basic Concept of Relay
A relay is an electrically operated switch. Many relays use an electromagnet to mechanically
operate a switch, but other operating principles are also used, such as solid-state relays. Relays
are used where it is necessary to control a circuit by a low-power signal (with complete
electrical isolation between control and controlled circuits), or where several circuits must be
controlled by one signal.
A type of relay that can handle the high power required to directly control an electric motor or
other loads is called a contactor. Solid-state relays control power circuits with no moving parts,
instead using a semiconductor device to perform switching. Relays with calibrated operating
characteristics and sometimes multiple operating coils are used to protect electrical circuits
from overload or faults; in modern electric power systems these functions are performed by
digital instruments still called "protective relays".
This diagram shows the basic parts of an electromechanical relay: a spring, moveable
armature, electromagnet, moveable contact, and stationary contact. The spring keeps the two
contacts separated until the electromagnet is energized, pulling the two contacts together.
A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron core, an
iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature,
and one or more sets of contacts (there are two in the relay pictured).
The armature is hinged to the yoke and mechanically linked to one or more sets of moving
contacts. It is held in place by a spring so that when the relay is de-energized there is an air gap
in the magnetic circuit.
In this condition, one of the two sets of contacts in the relay pictured is closed, and the other
set is open. Other relays may have more or fewer sets of contacts depending on their function.
The relay in the picture also has a wire connecting the armature to the yoke. This ensures
continuity of the circuit between the moving contacts on the armature, and the circuit track on
the printed circuit board (PCB) via the yoke, which is soldered to the PCB.
Basics of LVSG 65
9. Relay
Characteristic and Design of Relay

A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron core, an
iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature,
and one or more sets of contacts (there are two in the relay pictured). The armature is hinged
to the yoke and mechanically linked to one or more sets of moving contacts. It is held in place
by a spring so that when the relay is de-energized there is an air gap in the magnetic circuit. In
this condition, one of the two sets of contacts in the relay pictured is closed, and the other set
is open. Other relays may have more or fewer sets of contacts depending on their function. The
relay in the picture also has a wire connecting the armature to the yoke. This ensures continuity
of the circuit between the moving contacts on the armature, and the circuit track on the printed
circuit board (PCB) via the yoke, which is soldered to the PCB.
When an electric current is passed through the coil it generates a magnetic field that activates
the armature, and the consequent movement of the movable contact(s) either makes or breaks
(depending upon construction) a connection with a fixed contact. If the set of contacts was
closed when the relay was de-energized, then the movement opens the contacts and breaks the
connection, and vice versa if the contacts were open. When the current to the coil is switched
off, the armature is returned by a force, approximately half as strong as the magnetic force, to
its relaxed position. Usually this force is provided by a spring, but gravity is also used
commonly in industrial motor starters. Most relays are manufactured to operate quickly. In a
low-voltage application this reduces noise; in a high voltage or current application it
reduces arcing.
When the coil is energized with direct current, a diode is often placed across the coil to dissipate
the energy from the collapsing magnetic field at deactivation, which would otherwise generate
a voltage spike dangerous to semiconductor circuit components. Such diodes were not widely
used before the application of transistors as relay drivers, but soon became ubiquitous as
early germanium transistors were easily destroyed by this surge. Some automotive relays
include a diode inside the relay case.
If the relay is driving a large, or especially a reactive load, there may be a similar problem of
surge currents around the relay output contacts. In this case a snubber circuit (a capacitor and
resistor in series) across the contacts may absorb the surge. Suitably rated capacitors and the
associated resistor are sold as a single packaged component for this commonplace use.
If the coil is designed to be energized with alternating current (AC), some method is used to
split the flux into two out-of-phase components which add together, increasing the minimum
pull on the armature during the AC cycle. Typically this is done with a small copper "shading
ring" crimped around a portion of the core that creates the delayed, out-of-phase
component, which holds the contacts during the zero crossings of the control voltage.
Basics of LVSG 66
9. Relay
Types of Relay
1. Latching relay
2. Reed relay
3. Mercury-wetted relay
4. Mercury relay
5. Polarized relay
6. Machine tool relay
7. Coaxial relay
8. Time delay relay
9. Contactor relay
10. Solid-state relay
11. Solid state contactor relay
12. Buchholz relay
13. Force-guided contacts relay
14. Overload protection relay
15. Vacuum relays
16. Safety relays
17. Multi voltage relays
18. Digital Relays
19. Line Monitoring Relays
Latching relay
Latching relay with permanent magnet
A latching relay (also called "impulse", "keep", or "stay" relays) maintains either contact
position indefinitely without power applied to the coil. The advantage is that one coil consumes
power only for an instant while the relay is being switched, and the relay contacts retain this
setting across a power outage. A latching relay allows remote control of building lighting
without the hum that may be produced from a continuously (AC) energized coil.
In one mechanism, two opposing coils with an over-center spring or permanent magnet hold
the contacts in position after the coil is de-energized. A pulse to one coil turns the relay on and
a pulse to the opposite coil turns the relay off. This type is widely used where control is from
simple switches or single-ended outputs of a control system, and such relays are found
in avionics and numerous industrial applications.
Another latching type has a remanent core that retains the contacts in the operated position by
the remanent magnetism in the core. This type requires a current pulse of opposite polarity to
release the contacts. A variation uses a permanent magnet that produces part of the force
required to close the contact; the coil supplies sufficient force to move the contact open or
closed by aiding or opposing the field of the permanent magnet. A polarity controlled relay
Basics of LVSG 67
9. Relay
needs changeover switches or an H bridge drive circuit to control it. The relay may be less
expensive than other types, but this is partly offset by the increased costs in the external circuit.
In another type, a ratchet relay has a ratchet mechanism that holds the contacts closed after the
coil is momentarily energized. A second impulse, in the same or a separate coil, releases the
contacts. This type may be found in certain cars, for headlamp dipping and other functions
where alternating operation on each switch actuation is needed.
A stepping relay is a specialized kind of multi-way latching relay designed for early
automatic telephone exchanges.
An earth leakage circuit breaker includes a specialized latching relay.
Machine tool relay

A machine tool relay is a type standardized for industrial control of machine tools, transfer
machines, and other sequential control. They are characterized by a large number of contacts
(sometimes extendable in the field) which are easily converted from normally open to normally
closed status, easily replaceable coils, and a form factor that allows compactly installing many
relays in a control panel. Although such relays once were the backbone of automation in such
industries as automobile assembly, the programmable logic controller (PLC) mostly displaced
the machine tool relay from sequential control applications.
A relay allows circuits to be switched by electrical equipment: for example, a timer circuit with
a relay could switch power at a preset time. For many years relays were the standard method
of controlling industrial electronic systems. A number of relays could be used together to carry
out complex functions (relay logic). The principle of relay logic is based on relays which
energize and de-energize associated contacts. Relay logic is the predecessor of ladder logic,
which is commonly used in programmable logic controllers.
Time delay relay

Timing relays are arranged for an intentional delay in operating their contacts. A very short (a
fraction of a second) delay would use a copper disk between the armature and moving blade
assembly. Current flowing in the disk maintains magnetic field for a short time, lengthening
release time. For a slightly longer (up to a minute) delay, a dashpot is used. A dashpot is a
piston filled with fluid that is allowed to escape slowly; both air-filled and oil-filled dashpots
are used. The time period can be varied by increasing or decreasing the flow rate. For longer
time periods, a mechanical clockwork timer is installed. Relays may be arranged for a fixed
timing period, or may be field adjustable, or remotely set from a control panel. Modern
microprocessor-based timing relays provide precision timing over a great range.
Some relays are constructed with a kind of "shock absorber" mechanism attached to the
armature which prevents immediate, full motion when the coil is either energized or de-
Basics of LVSG 68
9. Relay
energized. This addition gives the relay the property of time-delay actuation. Time-delay relays
can be constructed to delay armature motion on coil energisation, de-energisation, or both.
Time-delay relay contacts must be specified not only as either normally open or normally
closed, but whether the delay operates in the direction of closing or in the direction of opening.
The following is a description of the four basic types of time-delay relay contacts.
First we have the normally open, timed-closed (NOTC) contact. This type of contact is
normally open when the coil is unpowered (de-energized). The contact is closed by the
application of power to the relay coil, but only after the coil has been continuously powered
for the specified amount of time. In other words, the direction of the contact's motion (either to
close or to open) is identical to a regular NO contact, but there is a delay in closing direction.
Because the delay occurs in the direction of coil energisation, this type of contact is
alternatively known as a normally open, on-delay:
Contactor relay
A contactor is a heavy-duty relay used for switching electric motors and lighting loads, but
contactors are not generally called relays. Continuous current ratings for common contactors
range from 10 amps to several hundred amps. High-current contacts are made with alloys
containing silver. The unavoidable arcing causes the contacts to oxidize; however, silver
oxide is still a good conductor. Contactors with overload protection devices are often used to
start motors. Contactors can make loud sounds when they operate, so they may be unfit for use
where noise is a chief concern.
A contactor is an electrically controlled switch used for switching a power circuit, similar to a
relay except with higher current ratings. A contactor is controlled by a circuit which has a much
lower power level than the switched circuit.
Basics of LVSG 69
9. Relay
Contactors come in many forms with varying capacities and features. Unlike a circuit breaker,
a contactor is not intended to interrupt a short circuit current. Contactors range from those
having a breaking current of several amperes to thousands of amperes and 24 V DC to many
kilovolts. The physical size of contactors ranges from a device small enough to pick up with
one hand, to large devices approximately a meter (yard) on a side.
Solid-state relay
A solid state relay or SSR is a solid state electronic component that provides a function similar
to an electromechanical relay but does not have any moving components, increasing long-term
reliability. A solid-state relay uses a thyristor, TRIAC or other solid-state switching device,
activated by the control signal, to switch the controlled load, instead of a solenoid. An Opto-
coupler (a light-emitting diode (LED) coupled with a photo transistor) can be used to isolate
control and controlled circuits.
As every solid-state device has a small voltage drop across it, this voltage drop limits the
amount of current a given SSR can handle. The minimum voltage drop for such a relay is a
function of the material used to make the device. Solid-state relays rated to handle as much as
1,200 amperes have become commercially available. Compared to electromagnetic relays, they
may be falsely triggered by transients and in general may be susceptible to damage by
extreme cosmic ray and EMP episodes.
Solid state contactor relay

A solid state contactor is a heavy-duty solid state relay, including the necessary heat sink, used
where frequent on/off cycles are required, such as with electric heaters, small electric motors,
and lighting loads. There are no moving parts to wear out and there is no contact bounce due
to vibration. They are activated by AC control signals or DC control signals
from Programmable logic controller (PLCs), PCs, Transistor-transistor logic (TTL) sources, or
other microprocessor and microcontroller controls.
Basics of LVSG 70
9. Relay
Buchholz relay
A Buchholz relay is a safety device sensing the accumulation of gas in large oil-
filled transformers, which will alarm on slow accumulation of gas or shut down the transformer
if gas is produced rapidly in the transformer oil. The contacts are not operated by an electric
current but by the pressure of accumulated gas or oil flow.
Overload protection relay

Electric motors need overcurrent protection to prevent damage from over-loading the motor,
or to protect against short circuits in connecting cables or internal faults in the motor windings.
The overload sensing devices are a form of heat operated relay where a coil heats a bimetallic
strip, or where a solder pot melts, releasing a spring to operate auxiliary contacts. These
auxiliary contacts are in series with the coil. If the overload senses excess current in the load,
the coil is de-energized.
This thermal protection operates relatively slowly allowing the motor to draw higher starting
currents before the protection relay will trip. Where the overload relay is exposed to the same
environment as the motor, a useful though crude compensation for motor ambient temperature
is provided.
The other common overload protection system uses an electromagnet coil in series with the
motor circuit that directly operates contacts. This is similar to a control relay but requires a
rather high fault current to operate the contacts. To prevent short over current spikes from
causing nuisance triggering the armature movement is damped with a dashpot. The thermal
and magnetic overload detections are typically used together in a motor protection relay.
Electronic overload protection relays measure motor current and can estimate motor winding
temperature using a "thermal model" of the motor armature system that can be set to provide
more accurate motor protection. Some motor protection relays include temperature detector
inputs for direct measurement from a thermocouple or resistance thermometer sensor
embedded in the winding.
Basics of LVSG 71
9. Relay
Multi-voltage relays
Multi-voltage relays are devices designed to work for wide voltage ranges such as 24 to 240
VAC/VDC and wide frequency ranges such as 0 to 300Hz. They are indicated forto use in
installations that do not have stable supply voltages.
Applications of Relays
These are main applications of Relays:
 Electrical Panel Applications
 Instrumentation
 Alarm output for Devices
 Controlling
 Automation
 Starters
 Interfacing Panels
 Timer based Devices and Relays
 Protection Relay Devices
 Electronic PCBs and Devices
Basics of LVSG 72
10. PAC METER
PAC Meter
Basic Concept of PAC Meter
The SENTRON PAC4200 is a feature packed power monitoring device that is suitable for use
in industrial, government and commercial applications where basic to advanced metering,
logging, and I/O is required. The meter may be used as a standalone device monitoring over
200 parameters or as part of an industrial control, building automation or global enterprise wide
monitoring system. Advanced power quality monitoring and logging applications range from
single low voltage breaker / building metering to sub-station main feeder monitoring, sub-
billing or cost allocation installations with multiple tariffs. The SENTRON PAC4200 can also
be used to support LEED certification and provide the needed energy metering data for
federal/local government EPACT 2005 energy reduction programs. Whether your goal is to
reduce operation cost, reduce your carbon footprint or to maintain your power assets, the PAC
4200 meter should be an important part of your power monitoring system. The SENTRON
PAC4200 provides open communication using the standard built-in Ethernet Modbus TCP,
Optional Modbus RTU or PROFIBUS-DP protocols for easy integration into any local or
remote monitoring system. The gateway functionality of this device reduces installation cost
by replacing other gateway devices and simplifying wiring. Simple configuration of the meter
can be done from the front display or by using a PC with SENTRON power config setup
software, supplied with the meter.
Figure: SENTRON Power Monitoring Devices
Basics of LVSG 73 | P a g e
10. PAC METER
Power monitoring system with the SENTRON product family The SENTRON product family
offers the user power monitoring software in the form of the power manager and the
corresponding hardware in the form of 7KT/7KM PAC measuring devices and 3WL/3VL/3VA
circuit breakers for implementing a complete power monitoring system.
The TÜV-certified power monitoring system consists of the 7KT/7KM PAC measuring
devices, the 3WL/3VL circuit breakers and the power manager power monitoring software.
This forms the technical basis for supporting an operational power management system as
specified by ISO 500001.
The hardware and software components are optimally coordinated with each other. For
example, special drivers for the SENTRON devices are integrated in the power manager power
monitoring software. They enable energy data to be captured without any great configuration
effort and they indicate the key measured values or the status by means of predefined views,
thus reducing the engineering overhead. The device functions are optimally supported in the
software.
Characteristic and Design of PAC Meter

PAC4200
Figure: Exterior Dimension of PAC 4200 meter
The Siemens SENTRON PAC4200 is a feature packed Multifunctional Meter that is suitable
for use in industrial, government and commercial applications where basic to advanced
metering, logging, and I/O is required. The meter may be used as a standalone device
monitoring over 200 parameters or as part of an industrial control, building automation or
global enterprise wide monitoring system.
10. PAC METER
Advanced power quality monitoring and logging applications range from single low voltage
breaker/building metering to sub-station main feeder monitoring, sub-billing or cost allocation
installations with multiple tariffs. Whether your goal is to reduce operation cost, reduce your
carbon footprint or to maintain your power assets, thePAC4200 meter should be an important
part of your power monitoring system.
The PAC4200 provides open communication using the standard built-in Ethernet Modbus TCP
and has the capability of communicating through Optional Modbus RTU, PROFIBUSDP, and
PROFINET protocol modules simultaneously. This allows for easy integration into any local
or remote monitoring system. The gateway functionality of this device reduces installation cost
by replacing other gateway devices and simplifying wiring.
PAC4200 Power Meter Features Communications

Basic to advanced metering up to 200 Ethernet integrated (10 /100 Mbit/sec)
parameters Modbus TCP integrated RJ45
Load profile and event logging port (10/100 Mbit/sec) - STANDARD
Automation integration PROFIBUS DP expansion module
Modbus gateway for downstream serial - OPTIONAL
devices Modbus RTU expansion module
Harmonics measuring Volt/Amp - OPTIONAL
3...31st Digital Inputs and Outputs
Phase angle / Phase chart Digital input 24 Vdc / 0.7 mA…(2)
Option Expension module for 4DI/2DO Digital output 12-24 Vdc / 10-27
Operating hours counter mA……(2)
Limit monitoring function
Logic function
Event log more than 4000 event
Gate way function.
10. PAC METER
Figure: Wiring Diagram of PAC 4200
PAC 3200
The SENTRON PAC3200 is a powerful compact power monitoring device that is suitable for
use in industrial, government and commercial applications where basic metering and energy
monitoring are required. The meter may be used as a standalone device monitoring over 50
parameters or as part of an industrial control, building automation or global power monitoring
system

Ethernet Integrated 10 Base-T (10 Mbit/sec)
Replace Multiple Analog Meters Modbus TCP Integrated RJ45 port 10 Base-T
Basic Metering -Up to 50 parameters (10 Mbit/sec) - STANDARD
Cost Allocation / Energy Monitoring PROFIBUS DP expansion module
Automation Integration - OPTIONAL
Sub-Metering Modbus RTU expansion module - OPTIONAL
Digital Inputs and Outputs
Digital input 24 Vdc / 0.7 mA……(1)
Digital Output 12-24 VDC / 10-27 mA….(1)
10. PAC METER
PAC3100
SENTRON PAC3100 it’s quick and easy to get started with digital measuring systems. Our
entry model supplies you with more than 30 measured values on energy consumption and basic
electrical variables, dispensing with the need for a multitude of individual analog measuring
instruments. Thanks to its integrated communication interface and its digital inputs and outputs,
flexible system integration and adjustments in the plant are always possible with SENTRON
PAC3100.

Replace Multiple Analog Meters Modbus RTU STANDARD
Basic Metering -Up to 50 parameters Digital Inputs and Outputs
Cost Allocation / Energy Monitoring 2 Digital input 24 Vdc / 0.7 mA
Automation Integration 2 Digital Output 12-24 Vdc / 10-27 mA
Sub-Metering
7KM PAC PROFIBUS DP expansion module

The 7KM PAC PROFIBUS DP expansion module has the following features:
• Plug-in communication module for measuring devices for connection to PROFIBUS DPV1
• 7KM PAC3200 and 7KM PAC4200
• Configurable from the front of the device or using parameterization software
• Using PROFIBUS DPV1, data can be transferred in both cyclic and acyclic modes
• Easy engineering thanks to integration in SIMATIC STEP 7 and/or simple integration via
GSD file for other programming Systems
• Optimum use of process image of a control system for selection of individual measured
quantities for cyclical Transfer
• All baud rates from 9.6 kbit/s up to 12 Mbit/s are supported
• Connection through 9-pole D-sub connector according to IEC 61158
• No external auxiliary power necessary
• Additional display via the device display and via LEDs on the module
7KM PAC RS485 expansion module

The 7KM PAC RS485 expansion module has the following features:
• Plug-in 7KM PAC RS485 communication module for 7KM PAC3200 and 7KM PAC4200
measuring devices
• Configurable from the front of the device or using parameterization software.
• Support for the Modbus RTU protocol
• Plug and play
• Baud rates 4.8/9.6/19.2 and 38.4 kbit/s are supported
• Connection by means of 6-pole screw terminals
• No external auxiliary power necessary
• Status indication by LED on the module
10. PAC METER
• The 7KM PAC RS485 expansion module is required for the gateway function of the 7KM
PAC4200 for communication with simple devices with RS485 interface, such as the 7KM
PAC3100, via Ethernet (Modbus TCP).
Applications of PAC meter

Ideal for replacing multiple analog meters. Use it for external (enclosure) or embedded
automatic meter reading in panels, switchboards, switchgear, transformers, and more, to
allocate energy costs on a building by building basis.
Basic Metering the PAC4200 offers high-accuracy power, energy and demand measurements.
These revenue-accurate values can be used for bill verification, monitoring backup power on
critical systems and offering cost effective energy solutions.
Cost Allocation / Energy Monitoring Perfect for monitoring right down to the tool level, the
meter can help monitor cost centers, identify opportunities for demand control and check
energy consumption patterns. The acquisition of power or energy can be based on a certain
time frame (15 min. time interval) or controlled by a signal.
Automation integration monitors critical equipment processes and ties directly to the Siemens
family of PLCs and automation networks. Full integration into the Simatic system is made easy
using one of several methods. One method is power rate a premium add-on for WinCC and
PCS7. It can be used for energy management and control. Another is pre-engineered faceplates
integrated into the Simatic library or by simply using the GSD fi les available for the meter.
Sub-Metering Low cost, high accuracy and simple retrofit installation enables economical
measurement of commercial and residential tenant space. Integrate the PAC4200 with existing
energy management systems and RTUs. Reduce energy consumption by eliminating
previously uncontrolled expenses.
Large graphic LCD display provides:
• Display title or designation of the displayed measurements
• Phase angles and measurements
• Measured real-time and min/max values
• All reading with appropriate units
• Custom labelling for function keys
• Bar charts showing up to the 31st harmonic
• Four user defined custom screens with numeric or bar chart values
10. PAC METER
Requirements of PAC meter

 Basic to advanced metering up to 200 parameters
 Load profile and event logging
 Automation integration
 Modbus gateway for downstream serial devices
 Harmonics measuring Volt/Amp 3...31st
 Phase angle / Phase chart
 Option Expansion module for 4DI/2DO
 Operating hours counter
 Limit monitoring function
 Logic function
 Event log more than 4000 event
 Gate way function Ethernet integrated (10 /100 Mbit/sec)
 Modbus TCP integrated RJ45 port (10/100 Mbit/sec) - STANDARD
 PROFIBUS DP expansion module - OPTIONAL
 Modbus RTU expansion module - OPTIONAL
 Digital input 24 Vdc / 0.7 mA
 Digital output 12-24 Vdc / 10-27 mA
10. PAC METER
Networking of PAC Meter

At the same time the SENTRON PAC Meter helps to monitor the operating state of the
installation. Measured values, limit value violations, operating hours of a connected load or
power flows are supplied by the device quickly and reliably.
Configuring with SENTRON powerconfig is user-friendly. The scope of supply of the PAC
meter includes the SENTRON powerconfig software for the user-friendly configuring of the
PAC Meter from the PC.
The software runs on the following operating systems:

 Windows 2000 Professional SP4 and higher
 Windows XP Professional SP2 and higher
 Window 7 professional
10. PAC METER
Configuration of PAC Meter

 With the project manager in SENTRON powerconfig it is possible to save device
configurations and also to copy them if required.
 With project Manager it is possible to expand from the simple standard application to a
fully flexible customer solution.
 With project Manager it is possible to do fully scalable with regard to the number of
devices and to the software's functions.
 Creating the offline device configurations: All available devices and expansion modules
are grouped in a library. The required PAC3200 units are selected from the library and
moved into the device tree by means of Drag & Drop.
10. PAC METER
 Expansion modules can be added to the device tree in the same way. However, they can
only be entered under a device.
10. PAC METER
10. PAC METER
Parameter Configuration
10. PAC METER
Connection examples
You can operate the device up to the maximum permissible voltages with or without voltage
measuring transformers. It is only possible to measure the current with current transformers. Enter
the wiring method for the device in the device settings.
All input or output terminals not required for measuring remain free.
In the connection examples, the secondary side of the transformer is grounded at the "l" terminal. It
can be grounded at either the "k" or the "l" terminal. The grounding has no impact on the
measurement.
10. PAC METER
10. PAC METER
10. PAC METER
10. PAC METER
10. PAC METER
Analysis using PAC Meter
10. PAC METER

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Index

Motor Protection Circuit Breaker ..................................................................................................... 36

Indicator not Released - Healthy fuse Indicator Released - Blown fuse

Construction and operations of HRC fuse

A cutaway of the construction of the HRC is shown below.

Short circuit condition:

HRC fuse with tripping device

Advantages of HRC fuse with tripping device:

Different types of HRC fuse

2. Din type HRC fuse:

3. Blade type HRC fuse:

Figure: TCC for typical 450 A semiconductor fuse

Figure: Peak-let through (cut-off) characteristic

Advantages of HRC fuse:

Disadvantages of HRC fuse:

Some important terms need for fuse

Typical uses and applications of fuses

Moulded Case Circuit Breaker

Moulded case circuit breakers:

1) Thermal Magnetic Release MCCB

2) Electronic Release MCCB

3) Microprocessor release MCCB

Characteristic & Design of MCCB

An alternative to using fixed-thermal protection is to use electronic overcurrent protection,

It is always recommended to select an MCCB in co-ordination with Contactor and Over

SENTRON VL series MCCB

 Available for AC/DC applications

 Type 2 tested charts are available

 Trip units available for various applications (TM/ ETU)

 Line Load Reversibility

 Continuous rated Shunt Coils

 Flexibility in Mounting (fixed /plug in / withdraw able )

 RoHS complied environment friendly

Internal Accessories of MCCB

Switch Disconnector (Super Switch)

Types of super switch

Selection of different types of super switch

In case this combination is changed to accommodate another brand/rating of SDF/DIN

Star-Delta Feeder, for Low LCC:-

Application of super switch

 Versatile - suitable for all applications

Maintenance of Super Switch

Overload relay principle of operation

1) Connection for mounting onto contactors:

2) Selector switch for manual/automatic RESET and RESET button:

3) Switch position indicator and TEST function of the wiring:

4) Motor current setting:

6) Transparent sealable cover:

Types of overload relay

Electronic overload relays (Microprocessor based)

Siemens SIRUS series OLR

Tripping characteristics for 3-pole loads:

Sensitivity to phase failure

Typical trip characteristics of a motor protection relay

Motor Protection Circuit Breaker

The MPCBs are supplied with factory-fitted over current release.

• Distribution Feeder Protection

Range- 3RV (up to 100A)

Max. rated current 16 A 40 A 63 A 100 A

Miniature Circuit Breaker

(Figure: Internal Design of a MCB)

MCB Characteristic Curves

MCB As per Pole