ELECTRICAL

MAINTENANCE AND
TROUBLE SHOOTING OF
MACHINES AND
EQUIPMENT
 PREVENTIVE MAINTENANCE:

It is the orderly and routine checking, cleaning,

drying, tightening of bolts, re-greasing, testing,
monitoring, etc. of electrical equipment, machines
and devices, to ascertain their normal operations.
Every date and activity done must be properly
recorded.
PREDICTIVE MAINTENANCE:

It is the use of computer simulation on the

operation of certain electrical equipment or
machine and to predetermined the operating time
before any of its component or part fails to
perform its function. (Avery good computer
program is needed here).
 3 Circuits Comprising Electrical
Machines and Equipment
1. Electric circuit – electron flow
2. Magnetic circuit – magnetic lines
3. Dielectric circuit – insulation system

Of these 3 circuits, the most critical is the

dielectric, it has the lowest melting point
temperature being only hundreds of degrees
centigrade compared to the thousands of degrees
centigrade for the other two.

CLASSES OF INSULATION:
For ordinary building wiring based on 30°C or 80°F
ambient.
60°C – RUW, T, TW, UF etc.
75°C – FEPW, RH, RHW, RUH, THW, THWN, XHHW,
ZW
 CLASSES OF INSULATION FOR
MACHINES/EQUIPMENT:

Class “O” - 90°C thermal limit

Class “A” - 105°C thermal limit
Class “E” - 120°C thermal limit
Class “B” - 130°C thermal limit
Class “F” - 155°C thermal limit
Class “H” - 180°C thermal limit
Class “220°C” - 220°C thermal limit
Class “C” – Above 220°C thermal limit
Knowing the surface temperature of any insulation
using highly accurate thermometers like the
infrared thermal scanner, you will know if
overheating either due to high current or
accumulation of dirt is the primary cause.

To get the value of the hottest spot use,

T H.S = surface temperature + ambient temp. +
15°C

Example
The surface temp. is 40°C
The ambient temp. is 40°C
Therefore T H.S = 40 + 40 15 = 95°C
MEASURING INSULATION RESISTANCE:
The instrument used to measure insulation
resistance for low voltage system is the “megger”,
and for the high voltage it is the “hi-pot”.
SPOT TEST- This is the one minute reading of the
insulation tester.
Another test that can be done on an insulation tester
is the determination of the insulation’s
Polarization Index (P.I.)

Megger Reading 10 min.

Polarization Index (P.I.) =
----------------------------------
Megger Reading 1
min.

If P.I. is 1.4 or lower – insulation is unsafe to use.

If P.I. is 1.5 – insulation can be use with caution
If P.I. is 1.6 and up – insulation is very safe to use
What “megger” voltage rating is to be used?
(megger voltage ranges from 100 to7500volts)

12 – 24 volt system - 100 V megger

110 – 120 volt system - 250 V megger
230 – 480 volt system - 500 V megger
660 – 1000 volt system - 1000 V
megger
1200 – 2400 volt system - 2500 V
megger
3300 – 4800 volt system - 5000 V
megger
5000 – 7200 volt system - 7500 V
megger
MINIMUM ACCEPTABLE INSULATION
RESISTANCES USING SPOT TEST:

Conductors and Bus bars – kV rating + 1

Rotating machine – kV rating + 1
For dry type transformers – 2 MΩ / kV rating

To be able to get the correct insulation resistance,

the ambient temperature must be considered. For
correction factors (k) to be used, the following
values are given:
k = 4@ 60°C
k = 2@ 50°C
k = 1@ 40°C
k = 0.5@ 30°C
k = for other temp., use ratio and proportion
(k @ 0°C is
All resistance if insulation must be correct and
recorded at 40°C, the internationally accepted
ambient temperature. If megger is not available to
measure insulation resistance of machines/
equipment or even devices, and alternate method
called the voltmeter can be used.
(25% to 50% of the rated AC or DC voltage rating of
machine)

R1 = R2 (V1-V2) / V2
where:
R1 = insulation resistance
R2 = voltmeter resistance (voltmeter
sensitivity times full deflection)
V1 = voltmeter reading with switch closed
V2 = voltmeter reading with switch open
Using high Potential tester (hi-pot) to evaluate
insulation resistance of high voltage machines or
system.

Kinds of Hi- pot Tester:

1. AC Hi- Pot
2. DC Hi- Pot

When using Hi- Pot tester, the voltage to be

injected must be the non destructive value, that
is, it should not destroy the di-electric strength of
the insulation.

The safe values to be used are:

1. for AC = 1.5 x V rating of machine
2. for DC = 1.7 x 1.5 x V rating of machine
The correct connection of the tester into the
machine is as shown.

When using AC Hi- Pot, bring the non-destructive

test voltage right away into the machine as
shown above, for one minute. If no breakdown
(indicate by lamp or steady test current) occurs,
the insulation is considered safe for use. AC Hi-
pot is used therefore just to answer the question,
can we use this machine or not. A preliminary
test using megger 500V is needed. 1MΩ/KV is the
minimum acceptable test result before Hi-Pot
testing is allowed.
The DC Hi-pot is better because the
polarization index of the insulation can be
established. When using the test, one third of
the non destructive test voltage will be
injected and maintained for ten (10) minutes.
After which the test current recorded, the
remaining 2/3 of the non destructive test
voltage will be injected in ten (10) uniform
steps at one minute interval. In every interval
test voltage and current are as well recorded.
When the 100% of the NDTV has been
injected, the test current is to be taken and
recorded after one minute and also after ten
(10) minutes. P.I. being one (1) minute
reading divided by ten (10) minutes reading.
For the interpretation of P.I., it is the same as
earlier presented.

I 1 minute
Other insulation resistance test that are being
used well-financial companies are:
1. insulation power factor test
2. slot- discharge test
3. surge- comparison test
4. corona probe test
5. inter- laminar insulation test

These are highly specialized and are covered

separately.
INSULATING LIQUIDS
Used for oil immersed transformer for cooling
and insulation and also used for breakers and
switches as insulation, coolant and as arc
quencher.

Three kinds of insulating oil are available.

• Mineral Oil
• Insert Synthetic insulating oil, popularly known
as askarel. Askarel are sold with such trade
names as, Pyranol, Chlorextol, Inertene,
WEMCO-C etc.
• High temperature insulating liquids like silicon.

Mineral oil is expensive being a by-product of the

fossil-hydrocarbon being mined by petroleum
companies, plus the fact that it is flammable,
hence the production of “askarel”
 ADVANTAGES OF INERT SYNTHETIC
INSULATING OIL
1. Non – inflammable
2. Chemically stable
3. Non – sludging (can not corrode, sludge
means oxidized oil).

DISADVANTAGES OF INERT SYNTHETIC

OIL
1. It is toxic to humans and other living things (causes
different illnesses to respiratory system)

2. It affects the reproductive system of humans,

animals and also fishes. Offspring's of persons and
animals are often mutants (mutants are living
things with deformities).
 TESTING AND SAMPLING OF
INSULATING LIQUIDS

Bottles or glass container for oil samples taken

from Transformer or Oil Circuit Breakers tanks
must PROPERLY CLEANED in this manner to
avoid contamination with impurities.

1. First, it is cleaned with white gasoline.

2. After drying, it is washed with soapsuds.
3. It is rinsed with distilled water.
4. It is baked in an oven for at least 8 hrs. at 105°C
to 110°C.
 In getting oil samples, care and cautions must be
observe at all cost. If oil is askarel and it is
accidentally came in contact with the skin, castor
oil is used to wash the oil from the skin.

Gap between electrodes =

0.1”
Diameter of electrodes =
1”
(ANSI Standard)
Rate of voltage rise = 3 KVP
Minimum Acceptable
DBV
For mineral oil = 22 KV
For askarel = 25 KV

Five test on five samples to be used

 DBV AVE = DBV1+DBV2+DBV3+DBV4+DBV5
5

DBV-Di- Electric Breakdown Voltage

If the DBV is less than the acceptable minimum, oil
filtering is to be done.

TYPE OF FILTERING

• Filter Press
• Centrifugal Purifier
• de- gasifying method.
 WHEN IS CLEANING OF ELECTRICAL
APPARATUS NECESSARY?

3. Visual determination of accumulated dirt on the

windings.
4. The operating temperature is 10°C to 15°C
above its normal operating temperature.
5. Insulation – evaluation measurements indicate
the presence of dirt or moisture as indicated by
low value of P.I.
 METHODS OF CLEANING

 For large machines where a person can enter it,

like propulsion motor of a ships, or big HP ball mill
motors, all pockets of a person doing cleaning
should be emptied. This can cause serious
damage to the machines if they accidentally fall.

 Loose dry dust is best accomplished with vacuum

cleaner.

 Encrusted dirt that blocks air passages should be

removed carefully with hardwood or fiber scraper,
don’t use metal scraper, it can damage the
insulation.

 Insulation coated with oily film should be cleaned

by wiping or rubbing with cheesecloth or lint less
rag
 CLEANING SUBMERGE OR FLOODED
ELECTRICAL APPARATUS
Fresh warm water not hotter than 80°C (176°F) is
used to wash flooded electrical apparatus until
(water pressure at no more than 25 psi) shows no
sign of salt and other impurities, after which, it is
blown with compressed air (not more than 30 psi).
DRYING ELECTRICAL INSULATION
• By external heat like oven, on top of boilers,
electric heater or radiant lamps, steam heaters
and also hot air furnaces, provided the
temperature do not exceed the thermal limit of
the insulation (for machines the lowest value is
90°C).

• Baking with internal heat, If the insulation

resistance using megger is 50,000Ω or higher,
current fed at low voltage until current is about 50
to 80 % of its rated current (voltage controlled by
 CARE OF ELECTRICAL APPARATUS
DURING PERIODS OF INACTIVITY

Make sure that the apparatus temperature is

several degrees higher than the surroundings,
this is to prevent oxidation. This can be done by
application of space heaters or heating lamps.
For large rotating machines it must be rotated by
small motor to prevent the motor from sagging.
 BATTERY

To be sure of performance, when recommending

dry cell (primary battery) specify only those with
expiry dates marked on the battery itself.

LEAD ACID BATTERY

 Should never be left in a discharged condition for

a very long time (more than a month) because
the plates will be hardened (Lead Sulfate)

 To determined the state of charged of the lead

acid battery, a voltmeter is never used. It is the
hydrometer that is to be used.
 HYDROMETER

CONDITION OF LEAD ACID BATTERY

As indicated by specific gravity of electrolyte:

Sp. Gravity (80°F) %

charge
1.285
100%
1.245
75%
1.225
66%
Correction factors if temperature is not 80°F(30°C)

130°F - +0.020
120°F - +0.016
110°F - +0.012
100°F - +0.008
90°F - +0.004
80°F - 0.000
70°F - -0.004
60°F - -0.008
50°F - -0.012
When the level of lead acid battery electrolyte is
lowered due to its evaporation. It must be top-up
with distilled water. Ordinary water has lots of
impurities that can damage the active materials.

When mixing Sulfuric Acid and water to form

electrolyte for lead acid battery it is the acid that
is poured to the water and not the water into the
acid. This will cause violent splashing and may
cause serious burns. If burns occurs due to
splashing it must be neutralized with baking soda
or diluted ammonia solution. If it splashes on the
eye, it should be wash with large quantity of
water and medical treatment must be
administered.
I. BATTERY CHARGING
The current to charge the battery must not be
higher than the ampere-hour (AH) rating of the
battery. Example, If the battery has a rating of
100AH, the current must not exceed 100amps.

• TRICKLE CHARGING
Because of some impurities of the active
materials of the battery, a certain degree of
local discharging occurs. To neutralize this, a
small amount of charging current is needed,
this is called trickle charging.
I. SAFEST PRECAUTION WHEN
CHARGING
Do not smoke and sufficient ventilation be
provided.

IV. BATTERY MAINTENANCE

6. Corroded poles should be brushed using steel

brush while washing with water.
7. To avoid oxidation on the poles, it must be
treated with petroleum jelly.
 AC GENERATOR

BRUSHLESS GENERATOR
 ALTERNATOR MOTORIZATION

In the parallel operation of the alternators, if one

of them draws power from the bus rather that
supplying power to it, this is called motorization.
The synchronous generator will run as a
synchronous motor. The possible causes of
motorization are ; Low speed and low voltage,
although no mechanical damage will be done to
that motoring unit. Since the direction of rotation
is the same yet the harm is on the fact that the
remaining unit will be overloaded and eventually
trip causing total power failure.
 SYNCHRONIZING PROBLEM

If two alternators are to be operated in parallel,

synchronizing is a very critical condition- when
only synchroscope is installed, a possibility of
deliberate wrong reconnection for the purpose of
sabotage or to destroy the credibility of
operations Engineer and is very common
occurrence. To make sure of proper
synchronization, synchronizing lamps are installed
to confirm synchroscope indications.
A.

* Relation between synchronizing lamp and

synchroscope, when lamps are dark the pointer of
the synchroscope must be at zero, otherwise, the
scope is defective or its connection altered.
 SINGLE GENERATOR OPERATION
PROCEDURE

 Make sure that the generator breaker is open.

 Bolt or close disconnect links to the connection
bar.
 Switch the voltage regulator to “automatic”.
 Start prime mover and bring it to speed.
 Adjust the frequency to its rating using the
governor switch.
 Adjust the voltage regulator to obtain rated
voltage.
 Close alternator breaker.
PARALLEL OPERATION PROCEDURE

1) Secure the incoming alternator breaker is

OPEN.
2) Close the disconnecting switch of the
incoming to the connection bar.
3) Switch the voltage regulator to automatic.
4) Start the prime mover and bring it to speed.
5) Adjust the frequency of the incoming machine
to one-tenth (1/10) higher using the governor.
6) Adjust the voltage regulator of the incoming
machine so that its voltage is slightly higher
than the bus.
1. Switch the synchroscope to the in-coming
machine, adjust the frequency until the
synchroscope revolves slowly in the “FAST”
direction.
2. Close the in-coming breaker when the
synchroscope pointer is 2 to 1 degrees before 12
o’clock position. (This is to provide time to
breaker moving contact to travel).
3. Turn the synchroscope switch to “OFF” position.
4. Turn the governor switch of the in-coming to
“RAISE” and to one running to “LOWER” until the
KW load is proportionally shared.
5. If the KVAR of the two machine is not equal,
lower the voltage regulator setting of the one
higher and raise the one with lower value until
both have same power factor.
REMOVING THE ALTERNATOR FROM
THE BUS

Lower the governor switch of the machine to be

removed and simultaneously raising the one to
stay until the KVA load of outgoing is zero, after
which the breaker of the outgoing is turned “OFF”
 Maintenance of a generator,
particularly stand by generators

 Dripping liquids on the generator must be

prevented at all cost.
 Using the combination of compressed air (about
20 PSI) on one end of the generator, and a
vacuum cleaner of the opposite end, removal of
build-up dust must be conducted at least every
six months
 Every after five (5) years, the alternator must be
detached from its prime mover, disassembled,
steam washed, re-varnished with at least class
“F” insulating varnish and its both end bearings
replaced with new one
MINIMUM INSTUMENTATION AND
CONTROL OF
AC GENERATOR IN PARALLEL
PHASE SEQUENCE INDICATOR ( PSI)
 VOLTAGE FAILURE OF AC GENERATOR

3 Open in the field circuit

5 Open in the field rheostat

7 Failure of the exciter generator

9 Absence of residual magnetism on the poles of

exciter for the self excited type system.
 AC MOTOR

Before operating any electric motor, the

following information must be checked:

5. Service – AC or DC
6. Kind for AC, squirrel-cage, wound rotor,
induction motor or synchronous motor.
7. Operating voltage and frequency
8. Type of enclosure- ODP, TEFC, weather proof,
explosion proof, etc.
9. Class of insulation
10. Service factor
11. Number of terminal leads
12. NEMA code letter classification
 Maintenance for motors

3. Once in a year, it must be disassembled, cleaned

using steam washer with the proper solvents to
remove encrusted dirt, bake to dry and replace
both end bearings. Re-varnishing /baking is also
done prior to its assembly.

2. Test the winding using the following: spot

testing, determine P.I., conduct surge
comparison testing, and finally at no load test,
measure no load current, power drawn, and
speed.
 CLASSIFICATIONS OF MOTORS
ACCORDING TO NUMBER OF LEADS
A.
A. STANDARD CONNECTION FOR MULTI
SPEED
INDUCTION MOTORS
A.
A.
CHECKING MOTOR PERFORMANCE
( USING HOOK ON VOLT AMMETER )
A.
RECOMMENDED REGREASING
SCHEDULE
HORSEPOWER
TYPE OF SERVICE TYPICAL EXAMPLE ½-7.5
10-40 50-200
EASY OPERATING 1 HR/DAY 10YRS. 7 YRS. 5 YRS.
STANDARD MACHINE TOOLS, FANS 7 YRS. 5YRS. 3 YRS.
PUMPS, TEXTILE MACHINERY
SEVERE CONTINOUS OPERATION, 4 YRS. 2 YRS. 1 YRS.
SEVERE VIBRATION, POWER
PLANTS, COAL MINING
VERY SEVERE DIRTY, VIBRATING,SHAFT END 9 MOS. 4 MOS.
4 MOS.
HOT AND HIGH AMBIENT
 TROUBLE SHOOTING CHART FOR
MOTORS

TROUBLE POSSIBLECAUSE

A.SYNCHRONOUS MOTORS
Fail to start 1. blown fuse/
tripped breaker
2. open in one phase
3. over load
4. low voltage
Runs hot 1. overload
2. clogged
ventilating
ducts
3. shorted stator
coils
4. open stator coils
5. high voltage
6. grounded stator
7. field current set
low
8. field current too
high
9. un-even air gap
10. rotor rubbing on

stator
Runs fast 1. high frequency

Runs slow 1. low frequency

Pulls out of 1. over load

synchronization 2. open in field coils
3. no exciter
voltage
4. open in the field
5. rheostat set too
high
Will not synchronize 1. field current set too low
2. open in field
circuit
3. no exciter
voltage
4. open rheostat

Vibrates severely 1. out of

synchronism
2. open armature
coil
3. open phase
4. misaligned
A. 3Ø SQUIRREL-CAGE INDUCTION
MOTOR

Fails to start 1. tripped breaker / blown

fuse 2. open in one
phase
3. shorted stator coils
4. low voltage
5. high voltage
6. low frequency
7. open stator coils
8. one phase open
9. grounded stator
10. uneven air gaps
11. rotor rubbing on
stator
Runs slow 1. over load
2. low voltage
3. low frequency
4. broken rotor bars
5. shorted stator
coils
6. open stator coils
7. one phase open
A. WOUND-ROTOR INDUCTION MOTOR

Fails to start 1. breaker tripped / blown fuse

2. open one phase
3. overload
4. open in rheostat
5. inadequate brush
tension
6. brushes do not
touch
collector ring
7. open in rotor
circuit
Runs hot 1. overload
2. clogged ventilating
ducts
3. low voltage
4. high voltage
5. uneven air gap
6. shorted stator coils
7. open stator coils
8. one phase open
9. low frequency
10. grounded stator
11. rotor rubbing or stator
Runs slow 1. overload
2. low voltage
3. low frequency
4. too much resistance in
rheostat
5. shorted stator
coils
6. open stator coils
7. one phase open
8. open in rotor
circuit
A. SINGLE-PHASE INDUCTION MOTOR

Fails to start 1. tripped breaker/blown

fuse
2. defective starting
mechanism
3. open in auxiliary
winding
4. open in main
winding
5. shorted capacitor
6. open capacitor
7. over load
Runs hot 1. over load
2. starting
mechanism
does not open
3. low voltage
4. high voltage
5. clogged
ventilating
ducts
6. shorted stator
coils
7. worn bearings
8. low frequency
9. rotor rubbing on stator

Runs slow 1. over load

2. low voltage
3. low frequency
 MOTOR CONTROLLER / STARTER

Function of the protective – to protect the

controller and motor against shunt fault.

Function of the controller / starter

1. to provide stop / start control for the motor
2. to reduce in rush current (except DOL or
ATL starters)
3. to protect the motor against series fault
For PLC, the auxiliary contacts like that of the
timer contacts are replaced with a programmed
contacts that closes or opens when needed.

Among the components of the conventional

motor controllers are, start/stop buttons, seal in
contacts, contactors, NO/NC auxiliary, OL relays,
timers, indicating lamps and depending on the
type, we can have also, resistors, reactors or
even auto-transformers.
 TYPES OF MAGNETIC STARTERS
AVAILABLE COMMERCIALLY IN THE
PHILIPPINE MARKET

1. Direct on line of across the line starter – all leads

2. Part winding starter – 9 and 12 leads
3. Primary resistors starter – all leads
4. Primary reactor starter – all leads
5. Auto transformer starter – all leas
6. Wye- Delta starter – 6 and 12 leads
 SCHEMATIC DIAGRAMS OF THE
DIFFERENT TYPES OF STARTER
B.
A.
A.
A.
A.
 TROUBLE SHOOTING CHART FOR
MAGNETIC STARTERS

TROUBLE POSSIBLE CAUSE

Contact buzz (loud buzzing noise) 1. broken

shading coil
2. misaligned
magnetic
faces
3. dirt on magnetic faces
4. low voltage

Contact charter 1. poor contact in

the operating
coil
2. fluttering of a relay in
Excessive burning of contacts 1. excessive current
2. weak spring pressure
3. oxidized contacts
4. poorly bolted
connections
5. defective arcing horn

Welding of contacts 1. excessive and rapid

jogging
2. low spring
pressure
3. excessive current
4. low voltage on
operating coils
5. bouncing of contacts
Failure of contactor 1. low voltage
or relay to pick up 2. open coil
3. excessive magnet
binding
4. mechanical binding
5. open circuit in series
with operating coil

Failure of contactor or 1. welded contacts

relay to drop out 2. improper adjustment
3. accumulation of gum
and other foreign
matter
4. misalignment
5. voltage maintained at
coil because of
failure of contacts
in series with
 TRANSFORMER

Transformer to be highlighted in this seminar is

the substation type transformer, both outdoor
and the indoor type.
 Outdoor Type Substation Transformer
Breathes

How is its breathing done?

At the peak load, the current flowing on the

windings dissipate large value of heat, aggravated
by the radiant heat from the sun. The result is
high temperature within the tank, which causes
the expansion of oil (rise in elevation). This in turn
will push the air above the oil surface, making the
air to escape thru the provided breather (exhale)
and during base load, normally during the wee
hours of the early morning, the oil is cooled hence
it will contract (lower oil level). The negative
pressure created due to the lowering of the oil
causes the atmospheric air to rush-in, thru the
breather (inhale).
 What is the damaging effect of the transformer
breathing and how is it correct?

 The “inhaling” of atmospheric air into the

transformer tank will surely subject the insulating
oil to “slugging” due to the presence of moisture
in the air. Slugged is oxidize on corroded oil and
causes the DBV of the oil to lower. To eliminate
sludging brought about by the transformer
breathing, a filter is attached to the breather.

 To minimize the volume of the air to be breath by

the transformer, hence minimizing sludging, an
extension tank called “conservator” tank is
installed.
 INDOOR TYPE SUB-STATION
TRANSFORMER (sealed type)
 If leak is suspected due to negative pressure, bur
no oozing of oil is visible, the leak is most likely
above the oil level. If this is so, de-energized the
transformer and apply soap suds after purging
with nitrogen gas, bubbles will indicate leak
indicative. To repair this, electric welding sporting
is allowed directly on the crack even with the oil
on the tank. ( This is so because insulating oil is
non flammable). But if the leak crack is above the
oil surface (99%) Nitrogen gas), with the
transformer de-energized, drill the crack and pen
it with hardwood and covered with “duvan”
cement.

 The underneath of the transformer cover must be

checked every 10 years with the core sufficiently
exposed.
 The oil of transformer must be treated for DBV,
color and viscosity once a year.

 Dry type transformer must be “dusted” regularly

and properly ventilated (natural or by fan)
 Never use step down autotransformer as power
supply for continuous operation (more than 3 hrs).
An accidental opening on the common winding
will surely burn the load.

 Never open the secondary of current transformer

when its primary is energized. It will destroy the
insulation due to high-induced voltage in the
secondary windings and its magnetic circuit made
biased. Before removing the “burden” of a loaded
CT (primary energized). Make sure to short its
secondary terminal first.
INDOOR TYPE POWER TRANSFORMER
INDOOR TYPE
 Maintenance for power transformers

3. Once a year, test the insulation liquids for DBV,

viscosity, color and have it undergo dissolve gas
analysis.
4. Once a year, conduct insulation power factor
test.
5. Once a year, conduct hot collar test in the
bushings.
6. If IPF is no available, conduct DC hi-pot testing
or determine the P.I. if its small dry by
transformer.
7. For insulating liquids with low DBV, de- should
be done
Circuit Breakers
 Circuit breakers can be classified according to the
following;
 * Service- AC or DC
 * Mounting- Outdoor or Indoor
 * Enclosure- Bakelite, metal,etc
 * Voltage- Low, medium, high and extra high
 * Medium of interruption- air, vacuum, SF6, oil etc
 * Contacts- bayonet, explosion chamber, de-ion etc.
 * Operation- gravity open, gravity close etc.
 * Control- manual, electrically, remote etc
 * Trip unit- thermal and magnetic
 * Charging mechanism- spring, motor etc
Maintenance of a Circuit breaker
a) MCCB b) VCB c) GCB d) OCB

 In the past, to check the contact pressure and

surface area of contact, the cover of the breaker is
remove and spring balance is hooked up to the
moving contact and its reading recorded for the
value just enough to cause that contact to start
being lifted up.
 For the surface area of contact, a union skin and a
very thin carbon paper is placed in between the
open contacts and then closed later. Opening the
contacts and getting the union skin with carbon
imprinted on it. The area of the imprint is then
measured and if is 50% or higher as compared to the
actual surface area of the two contacts, then the
breaker is said to be okay as far as area of contact is
concerned.
In our present time, the maintenance practice is now
different and more scientific in its approach.

 The breaker cover is no longer remove, but just like

in the past, the breaker is taken out from its panel
or switch board.
 The beaker is phantom loaded with its current rating
using the SOLGEN’S circuit breaker and relay tester
(CBRT) and the surface temperature near its line and
load side terminals are measured using
thermographic or infrared scanners and considering
the relationship between, surface temperature,
ambient and hottest spot temperature, Ths= Tsurf +
Tamb + 15.
 For the surface area of contact and pressure
between contacts to be considered normally
operating, Ths which is the hottest spot temperature
must not be more than 50 deg. Centigrade.
 For the characteristic testing of the breaker, see
drawing below
Connection of CBRT to MCCB
This is the control board of a CBRT
 THANK YOU!!
“END OF
SEMINAR”
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