<br>

Page 1 of 24
(341570T
fta)
3T-T G5T
1 A (Ohm's Law)

34180T :
V
Ix R

af V= 220 V
R= 44 N

V=
=
ae (atre)
= V 220
I gRT (zeer) I =5
A

R 44
R = ufRTer (3=)
=
3R 5 qfr
2.
fdg 2i a (Electric Power Formula)

P= Vx I 3418UT:
V = 10 A

GHE, P = uf 230 V
I=
21f (are)
=
P= Vx I 230 x 10 2300 \W

=
I eRT (qeftar) 31R = 2300 aIC

3. yht hot 2Tt Ha (Single Phase Power Formula)

x x cos
P= V
I 341&RUT:
, , =
Gai, P =
f (are)
utz V= 230 V
I= 20 A cos 0.8

P= 230 x 20 x
0.8 = 3680 W
=
I eRT (efR) =
cos =
qjar hRR 3R 3.68 fbcilaIC

4. -ht 1fT qa (Three Phase Power Formula)

3 x cos 3415RUT:
P= Vx Ix , cos
GE, P =
rfat (aTE) tt V= 415 V, I 15A =
0.8

P = 1.732 x 415 x 15 x 0.8

V= IS alccu (aoe)
= = W
I ST SRT (yrr) 8625
cos =
ylr er 3GR = 8.6 fehcilaTe (4T)
5.
0f qIT {I (Energy Consumption Formala)
3418RUT:
E= Px t ,

E =
afe P =
2kW t= 5
GTB, huf (brare -ter) =
E= 2 x 5 10 kWh
=
t HHY (eT)
 Page 2 of 24
<br>

:
Date 01/05/24
:
Page No. 92

P (9)
=
220V 220V/ 230V
(ar) (Hr)
N (a).

VA
R

R, Y, B
str 120

(A) ER (Y) I 120 120* 120

R

. hor z bur arur (VL) 415V (rr)

3. arreat ddu (Voltage Relation)

(B) tocT (a) eT VL = V3 x Vp

4. UT (Calculation)
VL V3 x Vp
- 1.732 x240V (uTr)
= 415.68V 415V
5. 3416UT (Exampe)
hotçT (Vp)
=
hu Gr attot (R-N, Y-N, B-N)= 230v (a) R- N = 230V R-YAS
• bof bot atet (R-Y, Y-B, B-R) 445V (T) ?-
N
230V Y- B 415V
HENqUf
fg (Important Point) B- N
230V B- R
415

5
• 415V,
ft irg (Simple Addition) à ft freaT, g àR (Phasor) sitg frar

FoltowN 285
<br>

Page 3 of 24
* CABLE SIZE fsHIg GLAND SIZE LIST *
1. 2 CORE/3 CORE CABLE GLAND SIZE
2. 3.5 CORE
/4 cORE CABLE GLAND SIZE
CABLE SIZE APPROX. GLAND SIZE APPROX. GLAND SIZE
CABLE SIZE
1.5 sq mm 16 mm 2.5 sq mm 20 mm
2.5 sq mm 16 mm mn
4 sq mm 20
+ sq mm 20 mm 6 sq mm 25 mm
6 Sq mm 20 mm
10 sq mm 95 mm
10 sq mm 25 mm 16 sq mm 32 mum

16 sq mm 25 mm 25 sq mm 32 mm 40 mm
25 sq mm 32 mm 35 sq mm 40 mm
35 Sq mm 32 mm
50 sq mm 40 mm / 50 mm
50 sq mm 40 mm
70 sq mm 50 mm
70 sq mm 40 mm50 mm 95 sq mm 63 mm
95 sq mm 50 mm 120 sq mm 63 mm
120 sq mm 50 mm mm 150 sq mm
/63 75 mm
150 sq mm 63 mm 185 sq mm 75 mm
185 sq mm 63 mm / 75 mm 240 sq mm 90 mm
240 sq mm 75 mm 300 sq mm 90 mm / 100 mm
300 sq mm 75 mmn
/ 90 mm 400 sq mm 100 mm / 110 mm

3. SINGLE CORE CABLE GLAND SIZE 4. GLAND SELECT HT

Ht aT
t
:
CABLE SIZE APPROX. GLAND SIZE Step 1 Cable OD check
10 sq mm 20 mm Cable T outer diameter vernier YT

scale measure
16 sq mm 20 mmn
25 mm
Gland range check
25 sq mm 25 mm Step 2:
Gland aft packing
tI
35 sq mm 25 mm 32 mm seal range
50 sq mm 32 mm
cable OD match &t aftyi
F0 sq mm 32 mm / 40 mm Step 3: Cable type 1

95 sq mm 40 mm Armoured cable - Brass double

compression gland
mmn mm
120 sq mm 40 / 50
150 sq mm mm • Unarmoured cable Single compression /
50
PVC gland
185 sq mm 50 mm /63 mm
• Outdoor area Weatherproof gland
240 sq mm 63 mmn
300 sq mm 63 mm / 75 mm • Hazardous area Flameprof gland

400 sq mm 75 mm

5. IMPORTANT POINTS
,
• Gland cable OD
•
fg select
a sq mn
867
use srar
tI
Armoured cable double compression brass gland
G I
Gland ser sT a cable fit t tTsuft i
I

at sealing proper
Gland agT
tT MT I SINGLE DOUBLE
• Outdoor panel rubber seal 3itr shroud
COMPRESSION COMPRESSI
armour properly
• Earthing continuity fu gland tight
ti GLAND GLAND

6. IMPORTANT NOTE
abElectricalawifible
a AGO T selection
fI Select
outer diameker, core size, core quantity
s
ELECTRICAL
[Link]
qland chart |
approxuate,
jnal cable OD
3
 Page 4 of 24
<br>

YoT . :
102
1. qr :
zffao aaRUT (6 zffror)

3itr 6 zff t thuT R V Wi

ft HTA
zA ER (Y) T toer (A) VI
Wi huT B t RATT
Wa
huT R T 3 V2

Va O
We huT B T 3a
2. ER htNT (Y) : 3. toer AA (A) :

• U1 Wa
Gs
Ua, Va 3ik Wa
V WA
Wi V ua

HreIf R, Y, B
HIŠ R, Y, B

R Ut
Us, V, WI R
V2 We (IH)
(ftom)
R U1 (AleT)
Y V
V2 We Y VI(tter)
B W1 (-AteT)
B W (Ao)
:
4. T
HIRUÍt

ftfhaT
U2, Va, Wa 3HT À Ferfter fere /
eR (Y) R Ut, Y V, B Wi

Y
U1 - W2, Vi- U2,
Žoer (A)
Wi- Va
R Ua,
Y V, BWi
V4 Wi

IGT
3T
<br>
Page 5 of 24

HP
Ae
(zfAur)
(zfrur)
1 80W - 120W 0.4A - 0.7A 0.10A - 0.15A
1 18W
2 0.8A- 1.1A
150W- 200W
2. 25W 0.15A - 0.20A
3 200W- 300W 1.1A - 1.6A -
3
40W 0.20A 0.30A
4. 300W- 450W 1.6A - 2.3A
4 60W 0.30A - 0.45A
5. 450W - 600W 2.3A - 3.2A
6. 750W - 1000W 4A - 5.5A
4.
iT

(HP) (yfyerr)
1. 1/20 HP 40W 0.25A - 0.35A
2. 1/12 HP 60W 0.35A - 0.50A
200W I e + 230V = 0.87 ygr (au

3. 1/8 HP 90W 0.50A - 0.70A

5. HEALut te
4. 1/6 HP 120W 0.70A - 0.90A
5
1/4 HP 180W 1A - 1.3A
6 1/2 HP 370W 2A - 2.8A

ar
HECAYof
6.
34y
HIHT alecu = 220V - 240V (fJGI hur)
qR
<br>

Page 6 of 24
fabda r (aa) foce z a5T AC THTGTg ?

1. v faT AC
c
2. fkas
AC &HGT (ca) iieT
80 - 100 qt c 0.8 CoH

100- 120 qutbc

120 - 160 ut c
1

1.2 Co
C grr (aaf e) + 120 = AC
c (GTHr)

150 - 180 qot pc 1.5 C 3q18RUT:

180 - 220 t c 1.8 C
220 - 260 qut c
2 co
FH TAUT =

+
180
=
qu e
180 120 1.5 AC
260 - 320 auT c
2.5 c
320 - 400 qt c 3 Co

5. flfciu aISC 10 pc GGT E

6. ast T
fAst

4. bT 5H HIG 3GIERUT

AC cot

10 x 10 100 1

10 x 12 120 1 A
A 1.2
12 x 12 144 1.2 / 1.5 ct
12 x 15 180 1.5 a
14 X 16 224 2 Co

16 x 20 320 2.5/ 3 c
5. gte 3rTT (HAT À)
: 1 Cot
• 150 - 180 ut c 1.5 C
• 220 - 260 auT :
2 c at sT aGT AC TJIAIGT

322,cal 3ATHY:
wifi 2.5 T 3
Co
<br>

Page 7 of 24

Rte Cool Mode ON i

d,a zs High
ZrgHR
/ ofy is OFF

5.
gofazat t5

PCB
R/ eR 3HI3ZYT
t6
3. 33ZSR yAe ds 6. YIT AIT tE

h frer, er, PCB

/R

8. ata ( ar Fe) d
5. ftr
2. 33CEr A5
3.
oe t5
ts
4. 3413CSr
b/

EL ECTRICAL
<br>

Page 8 of 24
CABLE SIZE LIST (APPROX.) *
1. COPPER CABLE CURRENT CAPACITY
2. ALUMINIUM CABLE CURRENT CAPACITY

Cable Size Approx Current Cable Size Approx Current

mm)
(s (Ampere) (sq mm) (Ampere)
1 sq mm 10A 14A 2.5 sq mm 14A - 18A
1.5 sq mm 14A 18A 4 sq mm 18A - 24A
2.5 s mm 18A - 24A -
6 s mm 24A 32A
4 sq mm 24A 32A 10 s mm 32A - 42A
6 sq mm 32A 40A 16 sq mm 45A - 60A
10 sq mm 45A - 55A 25 sq mm 60A - 75A
16 sq mm 60A 75A 35 sq mm 75A - 95A
25 sq mm -
80A 100A 50 s mm 95A 120A
35 sq mm 100A 125A 70 s mm 120A 150A
-
50 sq mm 125A 150A 95 s mm 150A
-
190A
95 sq mm 160A 200A 120 sq mm 190A 220A
120 sq mm 240A 280A 150 s mm 220A 260A
150 sq mm 280A 320A 185 sq mm 260A 300A
- -
185 sq mm 320A 360A 240 s mm 300A 360A
240 sq mm 380A 430A 300 sq mm 360A - 420A
300 sq mm 430A - 500A

3. COMMON HOUSE WIRING CABLE SIZE 4. IMPORTANT POINTS

Load Cable Size (sq mm)

Cable size load current fIA select

Light circuit 1 sq mm / 1.5 s mm Long distance voltage drop check

ti
Fan circuit 1.5 sq mm Copper cable aluminium eT
6A socket 1.5 sq mm current carry tdT I
16A socket 2.5 sq mm Cable HT HEt MCB rating
PI I
Geyser 2.5 sq mm
/4 sq mm • Cable heating at a load str
1 Ton AC 2.5 sq mm Connection check t|

Ton AC
1.5 4 sq mm

2 Ton AC 4 sq /6 s mm
mm Phase (Red)
Neutral (Black)
Water pump 2.5 s mm / 4 sq mm
Earth (Green)
Main suppy 6 sq mm / 10 sq mm

:
IMPORTANT NOTE
,
Cable size gAT Load current cable length, installation method

ar voltage drop ra select 6raT anfty |

EleCtriCa WAU, final selection site condition 4qHTR EŽ I
ELECTRICAL
4HOURS AGO S
<br>

Page 9 of 24
MCB
* MCB aR- aT trip tà v 3 aR-AIR ON T |qET fault find t|
1. OVERLOAD CHECK 6. WRONG MCB RATING
GRUT : UT:
MCB Brer
• Load IGT TT ET
Load fea Tetd &

• MCB rating hH & Cable size ferT rating

current calculate
Load
• Load current clamp meter t check • Cable size 341 MCB I
• Extra load Ee faT cable size check tby high rating
• MCB rating 3ite cable size match MCB
N

2. SHORT CIRCUIT CHECK

h 7. MCB WEAK/ FAULTY

RUT :
• Phase Neutral 3794T
sir touch
MCB RIAT YT weak &t TIT
Wire insulation damage
•
• Internal mechanism A
fabeft equipment internal short

• Load side wiring disconnect r6 check

Same rating
ttestgood quality MCB

replace hG
• Faulty
Damaged
wire
wire
r equipment identify
replace t
ar- AR trip history & ar MCB replace

3. EARTH FAULT
/ LEAKAGE CHECK
HRUT :
QUICK CHECKING SEQUENCE
Phase wire body / earth touch
OFF
Moisture 4T yft
T 1.
Ht load
• Motor /heater leakage 2. MCB ON 6
Hr
&t
T :
3. 31R fbr sft trip wiring fault
Megger test 311R ON EAT load one by one ON 5

4
Earthing eakage check t 5. frer oad trip &t
3 check
• Faulty equipment epair /replace t 6. Clamp meter current check
4. LOOSE CONNECTION CHECK
insulation test
7 Megger
6RUT:
•
• Termánal loose
Wire heating
8. Loose connection
3r heating check t
• Carbon deposit

• Supply OFF s terminal tight a •

IMPORTANT SAFETY
Supply OFF r 514
•
Burnt wire
Proper lug 3tr
/lug replace
ferrule use
t • Insulated tools use
• Wet area
5. FAULTY APPLIANCE CHECK # HTAUTAt
Fault clear fsy MCB ON
GRUT: faT
Motor, heater, AC, pump, geyser # fault MCB rating agt yg
Compressor short
Heating element leakage cable size Gt check
. OFF
ft load
load ON 5 check
5-5
•

•
forT load MCB trip &t
9 at faulty &t vadt

IMPORTANT NOTE
, MCB
MCB aTR- AR trip t+ T main reason overload short circuit,
faulty load aar &|
ear
lectricawifiction 1-ON

Fault clear r aTE MCB ON |

ELECTRICAL
WIFL SUNAT359AM
 Page 10 of 24
<br>

Date
:
O1/05/24
ACB Breaker ON gt à TEPosible Problems & Solutions
Page No.: 142

step- by- step checking t|

S.N. Problem Check Solution
1. Spring Charge Spring charge indicator Spring charge
• Manual charging handle Motorized ACB # charging
charge motor supply check

2. Under Voltage • UV coil supply fArT restore

Release (UVR)
Ê UVR supply
h
replace
Supply Missing
Control fuse
/ MCB check
at Faulty UV coil

3. Shunt Trip • Trip signal 3T TET t Trip command remove h

Coil Active check Faulty trip crcuit check h
4. Protection Relay
Trip Active •
•
Relay display
Trip
fault tt Fault remove
Relay reset
h
indication check
5
•
Interlock Door interlock / mechanical Proper service position #
Problem interlock active Interlock release h
ACB rack-in/rack-out position
check h
Door properly closed
t T t
,
6 Closing Coil Close command 4 coil voltage Control supply push button
Supply Mising check 3itr wiring check
,
7 ACB Trip Trip reset button press qE reset fs ON
h
Position
h
8 Fault in Closing Manual ON attempt Mechanism service / maintenance
Mechanism • Mechanism movement check
9 Load Side Fault Outgoing feeder isolate Faulty feeder remove h
Megger test fth ACB ON

• continuity check Fuse replace h

10. Control Fuse Fuse h at
Blown Fuse IR- TR blown t
short circuit check h
Quick Checking Sequence : Important Safety :
1. Spring charge check 6. Interlock check
reset 7. Relay fault reset h
PPE 8 a
2. Trip
Authorized person t work
3. UVR supply check t 8. Load side fault check
b • Live panel HAU-t z
4. Control fuse check h LOTO procedure follow
5. Closing coil voltage check h
Important Note : ACB ON # E R Ht YEt Spring Charge, UVR Supply, Trip Reset
I
3itr Interlock check het anfet
<br>

Page 11 of 24
* MCB SIZE LIST *
1. SINGLE POLE MCB RATING LIST MCB POLE TYPE
2.
MCB Rating
Use Type Full Form Use
2A Bell, indicator, small control circuit Single phase phase
SP Single Pole
4A Control wiring , small load wire protection
6A Light circuit +
Double Pole Phase Neutral
10A Light + small fan circuit
DP
protection
16A Socket, small appliance
Power socket, small geyser/load TP Triple Pole Three phase protection
20A
25A AC, motor, medium load Triple Pole +
TPN 3 phase neutral
32A AC, geyser, pump, sub-main + Neutral
40A Sub-main distribution
Four Pole phase + neutral
3
50A Heavy load FP
full isolation
63A Main supply / heavy load

3. MCB CURVE TYPE 4. CABLE SIZE VS MCB (APPROX.)

Curve Trip Range Use Cable Size (sq mn) Approx MCB Rating

Light, heater, sq mm 6A - 1OA

B Curve
3- 5 times current 1
domestic load 10A - 16A
1.5 sq mm
Motor, AC, pump, 16A - 20A
C
Curve 5- 10 times current 2.5 sq mm
commercial load
4 Sq mm 25A - 32A
Transformer, welding, sq mm 32A - 40A
D Curve times current 6
10- 20 - 63A
high starting current load 50A
10 sq mm
16 sq mm 63A - 80A

5. LOAD vs MCB (APPROx.)

6. IMPORTANT POINTS
Load MCB Rating
1. MCB rating must be selected according to
Light point 6A
load current and cable size.
Fan + light circuit 6A - 1OA
2. Always select proper MCB rating. Do not use
6A socket 6A
16A socket 16A
higher rating only to avoid tripping.
1 Ton AC 16A 20A 3. Before installation, ensure proper cable size
1.5 Ton AC 20A - 25A and tight connections.
2 Ton AC 25A - 32A 4. For motor load, use C or D curve MCB.
Geyser 16A - 25A 5. MCB protects from Overload and Short Circuit.
Water pump 16A - 32A 6. Check manufacturer's data sheet for
Main single phase 32A - 63A detailed information.

NOTE : 0
CNC
* Always install MCB according to load current and cable size. C32
230/400V
SOH2

* Using higher MCB rating can damage the cable and cause fire.

Proper earthing and tight connection are very important. |-ON

Regularly check MCB for proper working

<br>

: Page
o4/o5/24 12 of 24
VFD(Variable Frequency Drive) fties
Y
. :
107

1. y :
VFD qT Terminals
VFD T gRT
A Variable Terminal Terminal
Frequency Drive str ti R/L1 Input Phase W Motor Output

S/ La Input Phase PE/E Earthing

Start/ Stop Command
T/ L3 Input Phase DI/ X1

Motor Output AI Speod Raference

Motor Output COM Common

2. Power Supply Connection (Input) 3. Motor Cornection (Output)

Three Phase Supply
R (Red) VFD
R/ L1
Y (Yellouw)
S/L2 V Vi
Motor
B (Blue) W
T/L3 Wi

Earth (Green) PE /E PE/E

Motor Body

4. Start / Stop Control Connection 5. Speed Control Connection

(Using Push Button (Using Potentiometer)
/ Saitch)

VED COM VFD DI1

VED +10V
e 1 Potentiometer yart
VFD AI 2 (Wiper) Frequency
/ Speed
TA DI! 3ir COM Short &ar
VFD COM 3

6. Basic Parameter Setting (3418U) 7. Important Checks Before ON

Parameter Setting •
Input suppy voltage check atI
Motor Voltage Nameplate gerr
Motor Current Nameplate rqerR
Motor cornection U-V-
t |
Motor Frequency 50 Hz Earthing proper
Motor RPM Nameplate rqr •
Motor nameplate data parameter sret I

Acceleration Time 5- 10 sec Output side ye Contactor direct suitching I

Deceleration Time 5- 10 sec
Rur Command
Frequency Comnand
Terminal
Potentiometer
/ Keypad

/ Keypad
• VFD output Capacitor bank 7 oI
8. Common Problems 9. Important Safety
Problem Possible Cause
VED ON a
ET Fuse blown
Supply OFF R* wiring |
Input supply missing
/
Run command missing / Parameter wrong
Capacitor discharge
i aT
šR |
Motor Jedt feem aT t Proper PPE Et|
Over Current Fault Load seTqT Acceleration time sH • VFD manual qR terminal
Earth Fault Motor T cable insulation weak connection |
Over Voltage Fault Deceleration time H/ Brake issue
Earthing

Note : VED connection Input R-S-T, Output U-V-W, Earthing

3itr Parameter Setting
VED Motor damage
a important
& Haft
ar eTT connection

Electrical wifi
<br>

a Page 13 of 24
VFD Start t 7ET
fris
:
o1/05/24
RIT IT Check o .: 115

1. Input Supply Check 2. VFD Display ON

- R, Y, B input supply
r Ht
t
T TET Problem
Possible Cause
Display
:
OFF

Input voltage
•
Fuse/ MCB / MCCB ON ZT T Irput supply missing
• Control fuse blown
Soluution :
.
- SMPS fault
Supply restore # .
VED internal fault
• Fuse blown ET
a replace Solution:
Loose connection tight •
Input voltage check
• Fuse check
• VFD control supply check t
3. Fault Code Check
4. Run Command Check 5. Emergency Stop/ Interlock Check
#
RT Check : Display
* R
fault Possible Cause Possible Cause i
f T
r •
Start command HÊ er ZET Emergency stop pressed &

• / Terminal mode opern &

Fault Code Meaning
Keypad
Tef • Safety interlock
• Door Limit Switch open &
OC Over Current (3tfs e) Check :
• start t
Over Voltage (9tfds ttar) VFD keypad ET

Solution :
• Terminal DI input active t ET
Under Voltage (27 acor) • Emergency stop release
OH Over Heat (TET ft)
Start push button / selector suwiteh Interlock wiring check #
EF Earth Fault (3f itoc) check Safety circuit complete h
Solution Solution:
Code note Run command parameter Ét
•
•
Fault clear
Reset button press
•

•
Keypad
DI
r Terminal mode select
t
3t cOM wiring check
ht
6. Motor Connection Check 7. Parameter Setting Check 8. Frequency Reference Check
IT Check
Important Parameters : Possible Cause i
VFD output u, V, W motor •Motor voltage * Frequency comumand O Hz &

.Motor currert . TA
Potentiometer
a • Motor frequency
Motor cable loose Analog input signal t 3T TET

• Motor winding • Motor RPM

at
short / earth . Rurn
comunand source
Check i
fault
• Frequency command source
• Display frequency reference tt
: Potentiometer wiring check
Solution • Acceleration time
AI cOM voltage check
u-v-W connection tight t Solution:
3iÌ

Motor megger test • Motor nameplate gHrR

Solution
set
Cable insulation check parameter srt • Frequerncy
• command source Hét
Run 5 • Potentiometer replace
• Frequency reference rt t • Analog signal correct

9. Control Wiring Check 10. Output Contactor / Load Check Quick Checking Sequence
RIT Check : Possible Cause_ :
1. Input supply R-Y-B check
• DI
3tr
cOM wiring loose
Start push button working
r T
r
• Output side contactor
Motor jam
open
2. VFD display ON check #
3. Fault code check
• • Pump / fan load jam
Selector switch Auto / Manual H 4. Fault reset
position à t Check : 5. Run command source check R
Motor shaft free rotate & zET t ft
Solution
- Wiring tight
:
Load jam t
a 6. DI- COM start signal check
7. Frequency reference check
t
a* Contactor coil supply check
Push button continuity check Solution 8. Motor U-V-W connection check 6
Selector switch check Mechanical jam emove 9. Motor megger test
•
h 40. Parameter setting verify
Contactor wiring check
• Bearing / coupling check

Important Safety Note :

Supply OFF wiring

- Capacitor discharge
at
check
srrR
VFD start at ,
HEGT
Frequency
Input
Supply, Fault
Reference str Parameter
Proper PPE VE Code, Run Command
Setting check i wiring T TG parameter
Electrical wifi
VED
ib2|rfe
motor
ed &
t
3gTR terminal check sir damage
ELECTRICAL
WIFI n9SUN AT 6:39 AMO
<br>

Page 14 of 24

HetigTH lr a 34T atta, te, eft, qar het, kw, kVA, kWh

1. fter H4 tfrer 2. atetr NT (3 tor 4 araR frea)

1R/L1 ur R aeu yc

|2 Y/L2 Y
adr FAye R (erer)
3
B/ L3 hor B ateeor ye R/ L1 R
Y (ten) Y / L2
4N
5
I1 (S1) R z
Hye (S1) B (Ater)
B/ L3 B
6
I1 (S2) r R ye (S2)
N (5Te1)
7 12 (S1) ar e Y Aye (S1)
MULTIFUNCTION

METER
N
8
I2 (S2) r Y
t Ag ($2)
9 I3 (S1) hor B e sAye (S1)
te: hr R zftrer 1 (R/L1)
|10 I3 (s2) tr B e
Hye (S2)
hut Y zffrer 2 (Y/L2)
|11 AUX L HT (L)
hot B
12 AUXN eT (N) zfter 3 (B/L3)
13 A (+) RS485 (A) zffte 4 (N)
B
14 (-) RS485 (B)

3. CT (4te gisf) tgT 4. AUXILIARY SUPPLY

4TA
CT CT2
R CT3
(arer)
Y (Aten)
P1 P2 P1 P2 P1P2 AUX L (11)
B (Aten) AUX N (12)

10
. AUX L
I2 I2 I3 zfer 11 (HIE L)
(S1) (s2) (S1) (S2) (S1) (S2) 12 AUX N N)
. after a
(4ef
HAE Aer rqR ( 85-265V AC/DC)
CT1 P1 eIÉ HS, , P2
saffrerHEs
CT2
S1
P1
zfer
HATÉ HTE,
5 S2
P2
ts
6
HIgS
5. RS485 zftkrr a
S1 zfir 7. , S2
afftE 8 PLC / SCADA / BMS
CT3 P1 HGTIE
IEs P2
>
As HIS A (+) (13) A (+)
S1 afer 9, S2
sffer 10
B (-) (14) B (-)
. CT P1 (K) AISS sÀT ât RS | •
zfie 13 (A) RS485 A
(+)
• CT 6T P2 (L) ES gÀT ts t aRs TI •
zffrr 14 (B) RS485 B(

6. RT h1T SAUTH 7.
HETt GiT (Power ON qE)
•
CT1 CT2 CT3
• CT
atrtt N R, Y, B, N
t T
PL P2
P1P2 PLP2 taT S1, $2 t T t
N • AUX HenE
tt
• RS485 A, B
t t
• CT
8t gr (0pen) ft

23|4|s|67||8|9|1|12||13||4 8. HIAToy HHRI 3t HATUT

I3 13 AUX AUX
RY B N I1 I1 I2 I2 A B HHTETT
S1 S2 S1 S2 S1 S2 N AUX
Her
s
CT e/3qr CT
t
CT
AUX SUPPLYTO PLC/sCADA
eftt sett P1, P2 t
N A B
CT fra rer e
RS485 A, B
3e A, B
t

Electrical wifi
 Page 15 of 24

<br>

feis o1/05/24
: 101

1 A astT (Main Winding) aiHT (Common)

FIÉ anfftg (Auxiliary Winding) R zfer argftT (Running Winding)

tžr sfr (Starting Winding)

huT (L)
2.
e (N) aR 5t R
(f) zff R PI |
3.
hfer R
(zftr) 3tz s (efr) zftrT

c
thuT (L) (aHA)
(N) R
(zfir)
R S fa srftr (Earthing)
<br>

Page 16 of 24
LT PANEL (LOw TENSION PANEL) Date :
01/05/24
Page No. : 137

LT Panel is also known as Low Tension Panel. power

It is used for
distribution,, protection and control of electrical equipment at Low
voltage level (up to 415V AC).

Functions of LT Panel LT PANEL

Power distribution. R Y

Protection of
electrical equipment.
3) Control of motors and other Loads.
Protection from overload and short circuit.

5 Measurement and monitoring of parameters.

:
Main Components in LT Panel
:

- Types of LT Panel
1. ACB
/ MCCB Main incoming protection breaker

2. Bus Bar - Power distribution PCC Panel - Power Control Center

3. Contactor - Motor ON/OFF control - Motor Control Center
MCC Panel
4. Overload Relay Motor protection - Automatic Power Factor
3 APFC Panel
5. MCB Small circuit protectior. Control
6. Indicator Lamp - R, Y, B Phase indication Distribution Panel - Power Distribution
7. Meter Voltage, Current,, Frequency
LT Panel Voltage :
measurement
8. Capacitor Bank
- Power factor improvement Normally 415V AC
Three Phase, 4 Wire System
Frequency 50 Hz
:
Common Uses :
Important Safety Common. Problems :

• Factory Proper Earthing is must. Problem Possible Cause

. Commercial Keep panel door always locked. Breaker Trip
Building Overload / Short Circuit
• Hospital • Do not keep loose connection.
Heating Loose Connection
Reqular maintenance and
Mall Phase Failure Fuse Fault
inspection.
Industrial Plant Only authorized person Low Voltage Supply Problem

should access. Indicator Off Lamp Fault

/ Connection

:
Important Note
* LT Panel is a
Regular
very important part of electrical distribution system.

checking and maintenance

and trouble free.
keep the system safe, reliable A
SAFETY FIRST
Electrical wifi
<br>

Date :
01/o5/24
Page 17 of 24
LT PANEL - COMMON PROBLEMS AND SOLUTIONS
Page No.
:
138

LT Panel (Low Tension Panel) $ yR

arg
HI I

f Common Problems
ir 3 Solutions fey

[Link]. Problem Possible Causes Solution

1 Breaker Trip Overload Load current check h|

Problem Short circuit Faulty cable check |
Megger test I
•Earth fault

Bus Bar Heating I

Loose connection ft connections tighten
I
Overload current Thermography check
• Dust accumulation Panel cleaning arI
3 Phase Failure • Fuse blown
• Incoming supply mising
RYB

Fuse
phase voltage check
ontinuity check
a| I

4. Low Voltage Suply voltage low Incoming voltage check a|

Problem Loose terminals Terminal tightening I

Contactor Not Coil fauty Coil oltage check |

5
L
Working Control supply missing Control MCB check

6. MCCB/ ACB Protection trip Fault reset |l

Not ON Spring charge issue Spring charging check |
UW Relay check I
relay fault

Indicator Lamp • Lamp fused Ihdicator replace I

7.
• Loose wiring
OFF Wiring tighten
aI
8 Capacitor Bank Capacitor damage Capacitor value check |
Fault Contactor faulty APFC relay check I

Panel Burning Loose connection Supply OFF

9.
Smell
Overheating oft terminals check |
Burnt parts replace |
CT polarity check I
10. Meter Not PT/CT fault
• Meter supply issue
howing Reading Meter supply voltage check
rI
Important Maintenance Tips Important Safety :
OFF work
• Regular panel cleaning | • Earthing check I Supply
d |
• PPE kit gyaiT
I • Ventilation proper
Thermagraphy testing
it • All terminals tight
I
Authorized person tt work
t |
Loose corunection tighten
t T| • LOTO Procedure follow |

Note : LT Panel it l$ ft fault

system check
e HAT VEG supply, breaker status,

Electricalwifiection raT anftr i

ELECTRICAL
SAT AT 6:47 AM
<br>

VCB BREAKER BAR-BAR TRIP HO RAHA HAI Date : Page 18

01/05/24 of 24
:
KYA KYA CHECK KARE Page No. 144

VCB breaker bar- bar trip hone par sabse pehle fault indication relay code
dekhna chahiye.
1. PROTECTION RELAY FAULT CHECK KARE
2 OVER CURRENT FAULT
Check Relay display par kaunsa fault aa raha current reading check kare.
• 0C = Over Current
hai Check : Ammeter
/ relay
Load current rated current se compare kare.
EF Earth Fault • Outgong feeder one by one isolate
UV = Under Voltage
OV = Over Voltage karke check kare.
• Dferential REF fault
Solution : Fault code note kare.
/ Solution : Overload remove kare.
Faulty feeder identify kare
• Fault reset se pehle actual
fault clear kare. • Relay pickup setting check kare.
• Relay seting galat ho to seting verify kare

3 EARTH FAULT
4 HT CABLE FAULT
Check : • HT cable insulation weak Check • Cable insulation resistance
• Transformer winding leakage Cable jointend termination
• Moisture/water entry Cable heating mark
Cable termination problem • Burning smell
. Moisture
Solution :• HT cable megger test kare entry
• Transformer insulation test kare. Solution
:•• Cable megger
/ hipot test karaye.
kit termination inspect kare.
Cable end
/
• Earthing connection check kare.
Faulty cable joint replace kare.
•End terminatiorn proper kare
5. TRANSFORMER SIDE FAULT 6 TRIP CIRCUIT PROBLEM
Check • Transformer oil level Check : • Trip coil continuously supply le rahi hai.
• Ol temperature Trip relay contact stuck
Winding temperature Wiring short
Buchholz relay indication Protection relay output stuck
PRV/ OTI/WTI trip contact
Transformer megger value
Solution
:• Trip coil voltage check kare.
Trip relay contact check kare.
Solution Transformer protection fault clear kare.
Trip command kaha se aa raha hai
Ou leakage /overhinating issue sole kare.
trace kare.
Transformer testing karwaye.

7. UNDER VOLTAGE
/ oVER VOLTAGE FAULT 8 VCB MECHANICAL PROBLEM
Check • Ircoming HT voltage Check : • Spring charge indicator
PT fuse condition • Manual closing / tripping operation
PT secondary voltage Mechanical counter
Relay voltage reading Breaker service position
Solution: PT fuse replace kare. Solution: VCB mechanism servicing kare.
Voltage problem supply side se Lubrication/ alignment check kare.
confurm kare.
Relay voltage setting check
Vacun bottle test karwaye.
kare.
9 PROTECTION SETTING WRONG 10. CT/ PT PROBLEM

Check • CT ratio setting Check

:
• CT secondary loose to nahi
• Over current pickup setting CT polarity sahi hai ya nahi
Earth fault pickup seting CT ratio correct hai ya nahi
Time delay setting PT fuse blown to nahi
Relay curve settin Solution CT /PT wiring tight kare.
Solution • Relay setting ko approved setting sheet CT shorting link condition check kare.
se match kare. Faulty CT/ PT replace kare.
• Galat setting ho to correct kare.

QUICK CHECKING SEQUENCE : IMPORTANT SAFETY:

HT kaam keval
fault indication dekhe.
1. Relay
2. Trip history note kare.
6.
7.
Transformer protection check kare.
PT fuse voltage check kare. ukhPar
person kare.
Proper PPE pehne
3. Load current check kare. 8. Trip circuit voltage check kare.
LOTO procedure follow kare
4. Earth fault indication check kare. 9. Relay setting verify kare.
Earthing discharge rod use kare.
5. HT cable megger kare. 10. VCB mechanism check kare. Bina faut clear kiye VCB bar-bar
ON na kare

IMPORTANT NOTE : VCB bar-bar trip hone par sabse pehle relay fault code, HT cable insulation,
prokection aur trip circuit chedk kana chahiye.
Electrical'wifi Fault clear kiye bina breaker ON karne se bada damage ho sakta hai.
ELECTRICAL
WIFI
SAT AT 9:58 AM
<br>

Page 19 of 24
Date
:
01/05/24
Page No.
:
126

3T4IUG 34chUT (Tools) i STUYTH (Diagram)

1. Megger

2. Insulated Test Leads

3. Safety Gloves
Red Lead to
M2 Winding Terminal

MEGGER
OFF

TEST R
LoTO (Lockout- Tagout)
ic |

Black Lead
to Body
(Frame)

LT eR 500V / 1000V
HT AeR 5kV HEAqut HT (Inportant Safety)

tIT tes (Winding to Body Test)

(5) TEST CT SH
5 10 ths 16 TEST &CA GAlGR
TII
HEGyot aT (Important Points)

AfŠr (Insulation Resistance)

Above 1 M2 Good (sogoNT Ss t)

Below 1 M2
Weak Irsulation (37ur g

Near 0 MA
Short /Fault (9f& / ioe)

• Y to Body
. B to Body
• R to Body

•R-Y
• Y-B •
B-R

Electrical wifi
ELECTRICAL
WIF
FRI AT :32 PM O
<br>

Page 20 of 24

.
:
VFD (aRvaT At gIga) fzis 04/o5/24
quT :
129

6.
1.3itar atreur tve (ov)

2.3isT aveu ioe (UV)

At arafraT

3.3tar e stoe (oc)

4 3itar fr sloe (OH)•

8 VED Br OFF

• SMPS oc
9. saeft 3ATR-TG

10.

* sfaa PPE (7A1, gà sf) qE|

ELECTRICAL
WIFI
FRLAT :32 PM
<br>

Page 21 of 24
:
feats 04/o5/24
to .: 131

311GA4G 346UT:

zft a a s Shutdown | Insulated Gloves

(sos q)
UPS Bypass Mode Spanner Set (tr t)
• UPS Bypass Mode sT
itr gAfRua • Multimeter (Hotfter)
• Safety Shoes
(eT qt)
UPS Output OFF

• UPS
T Output Breaker OFF |
Battery Breaker OFF Battery Connection (Example)
• Battery Bank MCB/ MCCB
à OFF

+Ve
5) Old Battery Voltage Check
• Multimeter Battery Voltage t *| + +
6 Battery Connections Remove
t 12V 12V 12V 12V
VE Negative (-) Terminal Eery
7Ah 7Ah 7Ah
•Metal ools Short
7Ah
• fr Positive (+) Terminal Eer I

• Ring, Watch
Old Battery Remove
-Ve
• yereft Battery Carefully argT Aart 1

8 New Battery Install a A: Ht UPS System 4qT Cornection

t |
• 75 Battery (Same Voltage
sit AH Rating ar)
t TI
r
UPS

Battery Connections Tight r

Replacement
t :

•Ha VE
Positive (+) Connection t| Check Point Status
• fhr (-) *
1
Negative Connection
1 Battery Votage OK
Battery Polarity Check t
• Positive (+) 2 Charging Current OK
*t Positive (+) Connect |
• Negative
(-) a Negative (-) Connect |
3. Alarm No Alarm
) Battery Breaker ON
4 Backup Time Check
Battery Breaker ON |
UPS ON
12)
UPS Normal

Charging Status 3itre Display

Mode

à Check |
HEGyot
e :

Battery GGt HHY Polarity

t ret
Loose Connection UPS qeTA
PPE Ì
* (IA, gA 3ft ) 8I
* Battery ve sH rA VE ft Supply OFF

* Battery 3HTGT-TrT HEG

Ventilation | RE Tight sir Check
at I
Eleotriol R
ELECTRICAL
WIFI
FRI AT 814 PM
 Page 22 of 24
<br>

:
T CHECK R Date O1/05/24
THREE PHASE MOTOR
Page No.
:
119

Three phase motor

T check heet * fee multimeter, clamp meter, megger

1. VISUAL INSPECTION: 6. CURRENT CHECK :

• Motor body damage check I Clamp meter R, Y, 8 current

• Burning smell check I measwre
• Loose terminals check I
IMPORTANT POINT:
Cooling fan frealy ET
E
tet phase current balanced

2. SUPPLY VOLTAGE CHECK:

7. BEARING CHECK :
• R, Y, B phase voltage measure h
I
Shaft manually gHTË
Normally 415V AC supply check
:
I Noise T tighbness check
*I
IMPORTANT POINT
• Phase imbalance Ht lT fTI 8. ROTATION CHECK :

• Motor rotation direction check

3. CONTINUITY CHECK:
hI
Multimeter continuity mode # TI WRONG ROTATION SOLUTION :

RESULT :
wft winding continuity check t I •
fart sft
à phases interchange
t |
Continuity present = winding OK COMMON PROBLEMS :
• No continuity = winding oper
PROBLEM POSSIBLE CAUSE
:
4. WINDING RESISTANCE CHECK Motor not starting Supply missing
•R-Y, Y-B, B-R resistance Single phasing Fuse blownopen phase
measure
Overheating Overload
:
IMPORTANT POINT
High current Winding short
ft resistance
Noise Bearing damage
:
5. INSULATION RESISTANCE TEST
Megger winding to body
IMPORTANT SAFETY:
insulation check h |

GOOD VALUE :
Supply OFF 6726 checking at 1

t
Generally above 1 Mega Ohm.
Proper insulated tools J44
• Lockout-Tagout (LOTO) follow
#I
IMPORTANT NOTE:
motor
Three phase checking
tT oinding resistance, insulation
3itr phase current balance HAT important checks aà ti
<br>

1 HP -H er- e eis
G
:

.:
Page 23 of 24
01/05/24
121

ateeur (Ac)
h
415V, 50Hz, 1.5A # 2.0A
440V, 50Hz, A h HJTHT 1.5A

ae (Ampere)
P= qIaR (Watt)
P
I= x V x V= aeco (Volt)
V3 PF x m
=
PF ydR haRR
yfbeftdft (z#ar)
3. 341RUT
=
1 HP 746 Watt (GUTYT)
= =
H1 dà V
415V, PF =
0.8, ) 0.85
746
I=
1.732 x
746
415 x 0.8 x O.85 31A: 1 HP
ut c
489.5
1.5A 2.0A 8ldI È|
I 1.52 Ampere (GHT)

4. HETquf ar
per its a#T GIIT 1.5A 2.0A Blar

(3 # 6 qT T6)I

Full Load Current (FLC) à s #RAT Tfty I

Electrical wifi
<br>

Page 24 of 24
Date :
o1/05/24
orfaT gGR (Earthing Type)
Page No.
:
122

(1) YIgY 31f (2)

e 3ftr (3)
Ís 31fT (4) fRzu / arr sfe
Cover
M.S. Strip
BM.S. Funnel
Charcoal
+
- GI Strip
Salt GI/Cu GI/Cu
or
Plate Rod
Cu Wire

• GI YISY aT 34qu

(5) fc fefT 2. 344T 3TEIR 3tfT

Compound

3. H8TqUf art

5 3H h

0.5 3iTH FH

Electrical wifi