Fapj 310-Takraf Dolvi o &M Manual PDF

FAPJ 310-PHASE-II-10MTPA EXPANSION PROJECT
OPERATION & MAINTENANCE MANUAL
PHASE-II-10MTPA EXPANSION
PROJECT
Project Name : - PHASE-II-10MTPA EXPANSION PROJECT

Customer : - Tenova India private limited
Location : - Maharashtra
Doc. Rev : - 00
Developed by Focaal Automation (P) Ltd Page 1 of 197

TABLE OF CONTENT:
Sl. No Title Page No
1 Introduction 5
2 Purpose of this Document 5
3 Safety Instructions/ Warnings Symbols 5
4 System Configuration 11
General Description For Reclaimer
5 12
a) Modes of Control
Operation Of Machine - Reclaiming
a) Reclaiming in Auto Mode
6 15
b) Checks To Start Auto ReClaiming Sequence
c)Manual Reclaiming
7 HMI Screens 19
8 Bill-Of-Material for PLC 65
9 Technical data of components 67
a) CompactLogix L33 Controller User Manual 67
b) Compact Logix Power Supply User Manual 70
c) CompactLogix SM2 User Manual 72
d) Compact Logix AENTR User Manual 73
e) Compact Logix Digital Input IA16 User Manual 75
f) Compact Logix Digital output OB16l User
76
Manual
g) Compact Logix Analog Input IF8 User Manual 77
h) Compact Logix Analog Input OF8C User
79
Manual
i) Power Supply Unit 80
j) Managed Ethernet Switch 82
k)Thermostats 86
l) Space Heater 87


10 Bill-Of-Material for MCC 88
a) Air Circuit Breaker User Manual 106
b) MCCB Working 115
c) MCB Working 118
d) Digital Ammeter 122
e) Digital Voltmeter 123
f) MFM 124
g) MPCB Working 128
h) Vaccum Contactor Manual 133
i) Earth Fault Relay Manual 135
j) timer 138
k)Control Transformer 142
l) Voltage Frequency Drive 143
i) Power Flex Drive 755 146
ii) Power Flex Drive 753 150
m)Over Load Relay 153
n)Semi Conductor Fuse 155
o) Current Transformer 157
p) Motor Protection Relay 158
q)CBCT 160
r)Current Transducers 162
s)Omron Rely 165


12 Bill-Of-Material for LDB 167
a)Contactor Working 169
b)Inverter 172
c)RCCB Working 173
14 Bill-Of-Material for CD 176
a)Power Supply Unit 180
b) HMI 183
c) Hooter 185
16 Bill-Of-Material for JBs 187
17 Software Details 192
18 Annexure-I&II 196

FAPJ 310-PHASE-II-10MTPA
10MTPA EXPANSION PROJECT
1. INTRODUCTION
The scope of this document is to provide the basic information for
operating portal scraper reclaimer which is to be installed at 10 MTPA
PHASE II EXPANSION PROJECT, Dolvi Dolvi.. Portal scraper reclaimer reclaims
the material from Jetty Yard
Yard-A
A and transfer the material to upstream through
Reclaiming yard conveyor.
2. PURPOSE OF THIS DOCUMENTATION

This
his document is prepared as Operation and Maintenance manual for
the use of operator to carry out regular operational activities and planned
maintenance.
3. SAFTY INSTRUCTIONS/ WARNINGS SYMBOL

All personnel working with this device must be familiar with the safety
and warning instructions in this manual and observe the instructions
instru given
Safety warning signs and instructions on the device must be observed and
followed to avoid personal injury or property damage.
For your own safety and the safety of others, and to prevent damage to
the equipment and components upon which it is used, it is important that this
manual be read and understood by all persons operating or coming into
contact with the equipment.
WARNING Risk of electric shock.
• Disconnect all test leads and turn diagnostic tools off before removing end
grips.
• Do
o not operate diagnostic tools without properly installed end grips.
• Do not attempt to disassemble any battery or remove any component
projecting from or protecting the battery terminals.
Developed by Focaal Autom

mation (P) Ltd age 5 of 197
Pag
• Do not remove covers or attempt to disassemble. No user serviceable

parts inside. Refer to qualified service personal. Electric shock can cause
injury. Surface Rubber mat to avoid Electric shock.
• Measurement Category I is for measurements performed on circuits
notdirectly connected to MAINS or MAINS circuits (an example of MAINS
circuit is 120VAC or 240VAC and 440VAC household or industrial-
electricity).
• Do not connect this product to MAINSor MAINS circuits.
• Do not exceed voltage limits between inputs as indicated on the rating

label.
• Use extreme caution when working with circuits that have greater than 40
volts AC or 24 volts DC.
• Do not apply more than 75 volts DC or 50 volts AC between inputs as
indicated on the rating label on the diagnostic tool unit.
• The serial port is electrically isolated from other inputs however; do not
allow a voltage differential greater than 75 volts DC or 50 volts AC to
develop between the serial port and any other input.
• Do not attempt to connect your scopes and/or meters to a PC USB port
while measuring signals with the test leads.

• Do not connect Inductive RPM Pickup, Secondary Ignition Clip-on Wire

Adapter, or any other probe to damaged or un-insulated conductors.
• Do not use scope or Multimeter on Hybrid electric vehicle high-voltage
systems, batteries, or circuits. Electric shock can cause injury.
Caution!
Before opening the control cabinet, the main switch must be
switched to position OFF. When the control cabinet is opened, live parts
may be exposed. Before performing a repair or exchanging parts, the
unit must be separated from the circuit
Do’s
1. Always, install safety Equipments like Earth leakage / overload & short
circuit protection (circuit breakers / switches) near point of supply.
2. Ensure healthy earthing is installed at your premises.
3. Ensure only ISI marked cables of proper capacity are used for your
installation and get the wiring done through only licensed Electrical
Contractors.
4. Pay the energy bills regularly at E&PD's authorized cash collection centers
and within due date to avoid inconvenience due to disconnection.
5. Use electricity only when needed; switch off the supply when not required.
6. Always use proper capacity fuse wire in main switches.

7. Use only ISI marked electrical Equipments.
8. Ensure safety of energy meter and metering Equipments in your premises.

Provide weather Proof enclosures to meters and metering Equipments.
9. For rectification of faults in your installations, call licensed electrical

contractors only.
10. For any difficulty related to electricity supply, always contact E&PD
authorities at their offices.
11. If energy meter provided is found stopped / faulty, please bring the facts
to the notice of E&PD authorities immediately.
12. Apply for your service connection for Electricity in the prescribed form
obtainable free of cost from the Section Office.
13. Enter all the particulars required in the application form.
14. Produce proper documents/records to prove the legal ownership of the

premises for which electricity supply is required. In case you are a tenant,
produce evidence for lawful occupation of the premises.
15. Either deliver the application to the Section Office in person and obtain
proper acknowledgement or send it to the section officer by registered post
acknowledgement due Either deliver the application to the Section Office in
person and obtain proper acknowledgement or send it to the section officer
by registered post acknowledgement due.
16. Pay security deposit and service connection charges before the specified
date to avoid cancellation of the application.
17. Provide space for fixing the meter at a convenient place in the ground
floor for easy accessibility to the Assessor for taking meter reading.

18. In all storied buildings, irrespective of the number of floors, provide space
for fixing meter, cut -out etc., in the ground floor only.
19. Use electricity only for purpose for which the service connection has been
given (i.e. domestic).
20. Safeguard the meter and other Equipments of the E & PD Dept. in your
premises.
21. Construct your building with proper clearance from the existing High
Tension/Low Tension lines as per the Indian Electricity Rules 1956. (Vide rule
79 & 80).
22. Get your supply converted from single-phase to three–phase if the total
connected load exceeds 4000 watts.
23. Observe safety precautions to avoid electrical accidents.
24. Replace promptly defective electrical fittings and appliances.
25. Pay electricity consumption bills and additional security deposit promptly
at authorized cash counters only.
26. Pay the electricity consumption charges at the beginning of the month to
avoid rush on the last date. 27. If your service connection has been
disconnected for non-payment, you may pay the amount due and the
reconnection charges and intimate the Revenue Section, E &PD and avail
reconnection.
28. If the meter is found to be defective and not running, bring the matter to
the notice of the Section Officer in writing for replacement by a healthy meter.
29. Get the internal wiring checked up periodically not only to avoid leakage
of electricity but also to safeguard the lives of the inmates in the premises.

Don’ts
1. Do not connect multiple Equipments to a single point outlet to avoid excess

loading.
2. Do not use bare wires for extending supply from one point to other or from
one premise to other premises. It is hazardous and causes accidents.
3. Avoid loose connections and joints.
4. Avoid theft of electrical energy, It is cognizable offence and attracts penal

charges and / or imprisonment.
5. Do not tamper with energy meters, meter seals or metering Equipments, it

is an offence.
6. Do not pay your bill amounts to unauthorized persons. Pay only at E&PD /
Authorized cash collections centre and obtain receipts.
7. Do not plant trees below the overhead power lines.
8. Do not meddle with live wires/points. It may cost your life.
9. Don't get the wiring works done by unauthorized persons, which is an

offence under the Indian Electricity Rules 1956.
10. Don't use substandard wires and wiring accessories. Don't install fittings
and appliances of poor quality.
11. Don't construct your building underneath a High Tension or LowTension

line without proper clearance.

4.SYSTEM CONFIGURATION

5.General Description For Reclaimer
• Full Portal Reclaimer machine is used to reclaim the material from the
stockpile. This machine will travel over the rail and it is situated on top of
yard conveyor.
• Land mounted buffers provided at both the rail ends help to stop the
machine travel beyond the rail. The machine is operated by electrical
drives, limit switches and sensors for which the electrical power supply to
be given through composite Cable reeling drum (Power+ control) (CCRD).
• The cables are routed from a land mounted central anchorage and land
mounted junction box. The Central control room (CCR) control signals and
feedbacks are transferred to machine PLC through CCRD and RTU and
wireless radio modem communication.
Basically, the portal scraper reclaimer consists of the following
components:
1. Scraper Chain drive ( hydraulic drive)

2. Hoist drive
3. Travel drive 1,2,3,4,5,6 Fixed side
4. Travel drive 7,8,9 Pendulum side
5. Power and control Cable Reeling Drum
6. Hydraulic Rail clamp
7. Plain water dust suppression system

a) MODES OF CONTROL
A. Local mode (Maintenance / commissioning purpose)

B. Type of material selection from HMI
C. Remote – Manual
D. Remote – Auto
a. Auto Desk
b. Auto CCR.
Refer below configuration for detailed modes of operation.
LOCAL SELECTED
MODE SELECTION
REMOTE SELECTED
MANUAL MODE SELECTED

AUTO MODE
SELECTED 1. Sequence Start command
2. All selected equipment shall start in
sequence manually by initiating respective
start pushbuttons in HMI.
AUTO DESK SELECTED AUTO CCR SELECTED
1. Sequence Start command from HMI 1. Sequence Start command from CCR
2. All selected equipment shall start in 2. All selected equipment shall start in
sequence automatically. sequence automatically.
MAINTENANCE / LOCAL MODE
Individual operation shall be through

dedicated LCS provided near the equipment.
Sequence interlock shall not be possible.

AUTOMATIC MODE
• The co-ordination of scraper chain conveyor, Scraper chain hoist up/down

and travel during operation is achieved automatically in this mode.
However, all drives in the machine should be healthy and ready before
auto start i.e., individual starting of drives and positioning of machine and
scraper boom (in- slow speed) should be done in Manual mode only. Once
the machine is ready, auto operation is initiated by auto start push button
on the control desk in E-house. It stops the entire operation in sequence
whenever a fault occurs or auto stop button is pressed.
MANUAL MODE
• The scraper hoist, scraper chain drive and Travel motion of machine are
controlled individually by the operator by touch screen (HMI) in control
desk. It stops the entire operation in sequence whenever a fault occurs or
stop button is pressed.
MAINTENANCE MODE
• This mode is generally used for maintenance purpose. No- load operations
are recommended in this mode of operation. This mode of operation is
used only for maintenance or Trail run of the respective drive. Scraper
Hoist, scraper chain drive and Travel drive are controlled individually from
the respective local control stations without sequential and minimum safety
interlocks. The Local Control Stations are located close to the respective
Motors in the field.

6.) OPERATION OF MACHINE - RECLAIMING OPERATION
a) RECLAIMING IN AUTO MODE
Once the machine is ready and checks are satisfied, auto reclaiming can
be initiated by pressing auto start push button on the control desk.
• Type of material selection from HMI

• Put the selector switch in Remote in Control desk
• Select Auto in the “Auto / manual selector” switch provided in Control desk
• Select Auto Desk in “Auto Desk / Auto CCR” selector switch in Control
desk.
• After selecting Auto Desk mode & Reclaiming yard conveyor healthy
feedback received from CCR and same will display in the machine HMI.
After receipt of yard conveyor healthy feedback Siren ON command to be
given.
• Siren will be ON for predetermined time and once the siren is OFF,
Scraper chain drive will start & feedback will be transferred to CCR to
initiate reclaiming yard conveyor starting.
• Once the scraper chain drive started, after few seconds the Travel drive
will be started with predefined speed. Operating End proximity and Travel
Absolute encoder will decide direction of travel.
• Based on the depth of cut programmed, the scraper boom will be lowered
at every end point of the layer. This will continue till the particular total pile
is reclaimed.
• Once the pile is fully reclaimed, the scraper hoist will be raised at full
speed manually and travel drive will also be run at full speed manually to
ensure efficient and quick transfer of machine from one pile to another.
• The auto reclaiming operation will stop in anyone of the following
conditions:
• Auto stop push button on CD is pressed.
• Any fault occurs.
• Yard conveyor is stopped.

b)CHECKS TO START AUTO RECLAIMING SEQUENCE

a) Incomer Healthy
1. Emergency stop circuit healthy
a) Emergency Stop PB Station-1 healthy
b) Emergency Stop PB Station-2 healthy
c) Emergency Stop PB Station-3 healthy
2. Hoist Up/Down Emergency L/S FB
3. Hoist Rope slack FB
4. Travel Fwd/Rev Emergency L/S FB
5. Skew Left/Right Emergency L/S FB
6. Anti-collision Trip FB
7. Wind speed very high FB
b) Scraper chain drive healthy
c) Hoist drive healthy
d) Travel drive 1,2,3,4,5,6,7,8,9 healthy
9. Travel Brakes 1,2,3,4,5,6,7,8,9 L/S FB
10. Rail clamps A&B are opened
e) Composite CRD healthy
f) Common Checks
11. Reclaimer yard conveyor run FB
12. Long travel not over travelled
13. Depth of cut programmed
14. Travel set point programmed

A fault will occur when any one of the above condition fails.
DEPTH OF CUT DETAILS FOR IRON ORE FINES 40 d
DEPTH OF CUT DETAILS FOR COAL 38 deg
DEPTH OF CUT DETAILS FOR FLUX 38 deg

c)MANUAL RECLAIMING
• Positioning of machine for reclaiming the pile manually
• Put the selector switch in Remote in Control desk.
• Select Manual in the Auto / manual selector switch provided in Control

desk
• Reclaimer yard conveyor running feedback to be ensured in HMI
• Now the Full Portal Reclaimer is ready for manual Reclaiming.
• Warning siren to be pressed from HMI.
• The siren will be switched on for a pre-determined time.
• Press Start PB of Scraper chain drive in HMI after the siren gets OFF
• Start travel drive from HMI (forward/Reverse-depends on the machine

position in pile)
• Change the direction of travel drive based on the operating end LS,
meanwhile scraper boom will be lowered to the next layer
• Last two operations will be repeated upto the end of the layer
• Once the pile is fully reclaimed, the scraper hoist will be raised at full
speed manually and travel drive will also be run at full speed manually
to ensure efficient and quick transfer of machine from one pile to
another.
CHECKS FOR MANUAL RECLAIMING
Same as auto reclaiming.

7. HMI SCREENS
i)HOME SCREEN
• The Home Screen display is having Pushbuttons for all the screens .By
pressing the button corresponding screen is displayed.

ii)POWER STATUS
• In Power Status screen, The Power status of HT Panel, LT Panel

Travel, Scrapper, Hoist, MFM And UPS is displayed.
• If Home button is pressed the Home screen will display similarly for
PREV and NEXT buttons are pressed previous and next screens will be
displayed.

iii.a)HT BOARD 1
• In this screen, The Current and Voltage status of the HT Board is

displayed. The temperature of the transformer winding degree is also
displayed.

iii.b)HT BOARD 2
• In this screen, The VCB, TRIP, Spring Charged, Emergency,

Local/remote, Lockout Relay status, VCB mode.
• The VCB status is ON when VCB is on and displays OFF when VCB is off.
The Trip status is HEALTHY when the HT board is healthy and displays
TRIPPED when HT Board trips. The VCB is on when the mode is in
SERVICE and off when the mode is in TEST condition.
• The UNCHARGED state of Spring Charged Status indicates the charging
and CHARGED state indicates the charged condition. Emergency status is
UNHEALTHY when the emergency button is pressed, HEALTHY when not
pressed. LOCAL/REMOTE status displays the Mode of operation (Local or

Remote).The Lockout relay status is HEALTHY when the signal is Healthy,

becomes UNHEALTHY.
• when signal is unhealthy. If the Power Status navigation button is pressed
the Power Status screen is displayed.
iii.c)HT MFM
• This screen displays the values of the Multifunction Meter in HT panel.

iv.a)LT INCOMER
• In this screen the ACB status of Open, Close, Trip is displayed when the
corresponding condition occurs. The Vaccum Contactor status also
displayed as OPEN and CLOSE displaying the current status of the
Vaccum Contactor.
• The Trip status is HEALTHY when the LT Incomer is healthy and displays
TRIPPED when LT Incomer trips. The ACB is on when the mode is in
SERVICE and off when the mode is in TEST Condition.
• Emergency status is UNHEALTHY when the emergency button is
pressed, HEALTHY when not pressed. If Trip occurs in Anti-Collision the
TRIPPED condition displays, else HEALTHY condition displays.

iv.b)LT MFM
• This screen displays the values of the Multifunction Meter in LT panel.

v)UPS
• This screen displays the UPS status. If the battery is low then it is
displayed as BATTERY LOW else displayed as HEALTHY.
• The battery discharge is displayed as DISCHAGE if it is using the UPS
supply and when charged it is displayed as CHARGED. If the rectifier is
failed it is displayed as FAULTED and when the rectifier is not faulted it
is displayed as HEALTHY.
• The Alarm for the panel is displayed as HEALTHY when the system is
using the UPS supply during drain condition and displays UNHEALTHY
when it is not used in drain condition.

vi)TRAFO STATUS
• This screen displays the Power Status of Hoist, Travel Drives and
Scrapper Chain.

vii)SYSTEM CONFIGURATION
• This screen displays the Overall System Configuration by mentioning all

the possible major components.
• Orange color cable is Modbus communication
• Red color cable is Ethernet communication

viii)EMERGENCY
• This screen displays the safety feedback for the system operation. The
Skew right & left safety feedback are HEALTHY when it is within limits
and displays UNHEALTHY when it is beyond the limits.
• The Hoist and travel safety feedback is HEALTHY when it is within limits
and displays UNHEALTHY when it is beyond the limits.
• The value of Wind speed feedback is displayed in this screen. The
Travel EMG/SKEW bypass feedback is UNHEALTHY when emergency
is pressed or Skew Bypass is pressed, becomes HEALTHY when
released.

ix)MANUAL SCREEN
• The Manual operation screen is displayed here. The Mode selection

has MANUAL, REMOTE and DESK indications on which the operation
is performed. The BYPASS Pushbutton is used to skip the Safety
Feedback and start the system. The General safety interlock is used to
indicate the Feedback status HEALTHY or UNHEALTHY.
• The Permissive-1 and Permissive-2 pushbuttons are used to select the
Scrapper chain feeder by pressing it and then press the START or
STOP button which performs the on and off operation.
• The Permissive pushbutton is used to select the Scrapper chain feeder
by pressing it and then press the START or STOP button which

performs the on and off operation. The RAIL CLAMP, DSS, AIR
COOLER will be started by pushing the START PB and stopped by
STOP PB.
• The Permissive-1 and Permissive-2 pushbuttons are used to select the
Travel Drive by pressing it and then press the START or STOP button
which performs the on and off operation.
• The Multistate indication displays the HEALTHY/ UNHEALTHY
condition and also ON/ OFF state. The GOTO Display button is used to
navigate to the corresponding screen on which it is pressed.
• The AUTO GOTO Display button is used for switching to AUTO screen
and the ALARM GOTO Display button navigates to Alarm screen.

x)AUTO SCREEN
• The Auto operation screen is displayed here. The Mode selection has
MANUAL, REMOTE and DESK indications on which the operation is
performed. The General Interlocks, Scrapper chain, Travel drive, Hoist
drive has HEALTHY/UNHEALTHY and ON/OFF indications.
• If the system is healthy the Corresponding HEALTHY and ON status
indication is displayed, if unhealthy the UNHEALTHY/OFF indication is
displayed. The AUTO START Push Button is to start the Auto
Sequence. The AUTO STOP Push Button is to stop the Auto
Sequence. The BYPASS Push Button is used to start the sequence by
skipping the safety feedback. T

• he MANUAL GOTO Display button is used for switching to MANUAL

screen and the ALARM GOTO Display button navigates to Alarm
screen.
xi.a)TREND
• This screen displays the Values of Transformer winding temperature,

Chain Drive-1 Current Transducer feedback, Chain Drive-2 Current
Transducer feedback, Chain Drive Air Cooler Current Transducer
Feedback.

xi.b)TREND 1
• This screen displays the values of DSS water tank level transmitter,
Travel speed (increment &decrement), BSWR machine speed position
and Travel speed reference from CCR.

xi.c)TREND 2
• This screen displays the value of Wind speed signal feedback, Chain
tank temperature feedback, Chain working pressure feedback , Chain
charge pressure, Chain drive speed feedback.

xii.a)ANALOG SETPOINT 1
• The Analog Reference & Feedback are displayed in this screen. The
Speed reference of the Travel drive -1, Travel drive-2 and Hoist drive
are displayed here.
• Current transducer feedback of Chain drive-1, Chain drive-2, Chain
drive Air Cooler Current Transducer are displayed. Travel position
feedback from CCR, Wind signal, Scrapper travel temperature,
Scrapper working pressure feedbacks are displayed in this screen.

xii.b)ANALOG SETPOINT 2
• The Analog Feedback & Outputs are displayed in this screen. The
feedbacks of Scrapper Chain Hydraulic charge Pressure, Tank
Temperature, Drive Speed, Working Pressure are displayed in this
screen. The Scrapper Chain Hydraulic Speed Command and Scrapper
Drive Speed Feedback Outputs are also displayed.

xiii)ANTI COLLISION
• This screen displays the BSWR Position, Anti-collision, Scrapper chain

reclaimer position and Difference between the machines values.

xiv)SKEW CONTROL
• This screen displays the Encoder values of Travel drive on Fixed and
Pendulam side. The Correction value of these two values is also
displayed in this screen.

xv)ALARM SCREEN
• The alarm screen displays information if there is any fault or trip

condition occurs. The most recent information is displayed in top.

xvi)RTU
• The RTU screen displays the Digital input to Machine PLU from RTU
and Digital output from Machine PLC to RTU. If the Auto feedback is
starts it displays started else stopped displays. The EMG push button is
pressed it displays PRESSED else HEALTHY displayed.
• The ANTI-COLLISION Zone Alarm is displayed ALARMED when then it
is triggered else displayed NORMAL. The Anti-collision zone trip
displayed as TRIPPED when system is tripped else displayed
NORMAL.
• The Auto CCR Mode selected command displays the mode which is
selected CCR/DESK. The Reclaimer healthy, Scrapper chain running,

Travel end operator, Radio Modem Healthy commands are displayed

as HEALTHY when the signals are healthy else displayed as
UNHEALTHY.
xvii)SCRAPPER CHAIN
• The Ready to Start & Motor ON feedback are displayed as HEALTHY in

chain drive 1&2 if the Ready interlock conditions are healthy else
displayed as UNHEALTHY.
• Motor Trip feedback displayed as TRIPPED if the motor is tripped else
displayed as HEALTHY.LOCAL/REMOTE mode is displayed when
either of the modes are selected.

• The ready to start and motor on feedbacks are displayed as HEALTHY

when the ready signal and motor on condition occurs else displayed as
UNHEALTHY. The motor trip feedback is displayed as TRIPPED when
motor is in trip condition else displayed as HEALTHY
xviii)SCRAPPER HYD

xix.a)SCRAPPER 8F MPR
• This screen displays the trip status of MPR in Scrapper Chain 1. It has
trip signals of Overload, Phase loss, Ground fault current, Stall, Jam,
Under load, Current imbalance, and Under Current (L1, L2, and L3)
trips. If a trip signal is received the corresponding trip status is
displayed as TRIPPED else displays HEALTHY.

xix.b)SCRAPPER 8F MPR1
trip signals of Over Current (L1, L2, and L3) and Line loss (L1, L2, and
L3) trips. If a trip signal is received the corresponding trip status is

xx.a)SCRAPPER MPR 9F
trip signals of Overload, Phase loss, Ground fault current, Stall, Jam,
Under load, Current imbalance, and Under Current (L1, L2, and L3)
trips. If a trip signal is received the corresponding trip status is

xx.b)SCRAPPER MPR1 9F
trip signals of Over Current (L1, L2, and L3) and Line loss (L1, L2, and
L3) trips. If a trip signal is received the corresponding trip status is

xxi)TRAVEL DRIVE 1
• This screen displays the indications of Travel drive 1 Feedback Signals.

The Feedback signals are VFD ON, VFD healthy, Brake (1-6) Trip,
Ideal, Fixed side selection, Ready to start, Forward selected, Reverse
selected of the Travel drive 1. If the Feedbacks are received then
HEALTHY is displayed else UNHEALTHY is displayed.
• The LOCAL/REMOTE selected feedback displays the LOCAL or
REMOTE mode which is selected. The Fast selected and Slow selected
feedbacks of Travel drive 1 displayed as FAST SELECTED and SLOW
SELECTED in Green when it is selected and displayed in Red when not
selected.

xxii.a)TRAVEL DRIVEL 2
• This screen displays the indications of Travel drive 2 Feedback Signals.

The Feedback signals are ON, VFD Healthy, Brake (7-9) Trip,
Pendulam side selection, Ready to start, Forward selected, Reverse
selected of the Travel drive 2. If the Feedbacks are received then
HEALTHY is displayed else UNHEALTHY is displayed.
• The LOCAL/REMOTE selected feedback displays the LOCAL or
REMOTE mode which is selected. The Fast selected and Slow selected
feedbacks of Travel drive 2 displayed as FAST SELECTED and SLOW
SELECTED in Green when it is selected and displayed in Red when not
selected.

xxii.b)TRAVEL DRIVE TRIP
• This screen displays the Travel Drive Trip Feedback status (Travel
Drive Motor (1-9) & Travel Drive (1&2) Brake (1-6 & 7-9). If the motor
trip signal is received the TRIPPED indication is displayed else
HEALTHY is displayed.

xxiii)PCRD
• This screen displays the feedback status of the Power Cable Reeling
Drum. If the PCRD Ready to start and Motor ON feedback is displayed
as HEALTHY when healthy signal is received else UNHEALTHY is
displayed. The PCRD motor trip feedback displays TRIPPED when the
motor trips else HEALTHY is displayed. The PCRD cable over tension
and slackness feedback displays UNHEALTHY when Over tension or
slackness signal is received else displays HEALTHY.
• The PCRD chain snap operated Feedback displays UNHEALTHY when
the snap operated signal is not received else displays HEALTHY. The

PCRD Forward Run feedback is displayed as HEALTHY when the

Forward run feedback is received else UNHEALTHY displays.
• Similarly the PCRD Reverse Run feedback is displayed as HEALTHY
when the Forward run feedback is received else UNHEALTHY displays.
xxvi)RAIL CLAMP
• This screen displays the Rail Clamp Feedback Status. The Rail clamp
Ready to Start feedback is displayed as HEALTHY when the rail clamp
ready feedback signal is received else displays UNHEALTHY. The Rail
Clamp Motor 1&2 ON feedback displays HEALTHY when the Motor is
ON else it displays UNHEALTHY.

• The Rail Clamp Motor 1&2 Trip feedback displays HEALTHY when the
Motor is tripped else it displays UNHEALTHY.
• The Rail-A side Clamp oil Level Low & Rail-B side Clamp oil Level Low
feedback displays HEALTHY when the oil level is not low and displays
UNHEALTHY when oil level is low.
• The Rail-A side Hydraulic Pressure Switch and Rail-B side Hydraulic
Pressure Switch feedback displays HEALTHY when the pressure
switch is not actuated and displays UNHEALTHY when pressure switch
is actuated. The Rail-A side Hydraulic Released Limit switch & Rail-B
side Hydraulic Released Limit switch is displayed as HEALTHY when
the limit switch is not actuated and displayed as UNHEALTHY when the
limit switch is actuated.
xxv)DSS

• This screen displays the DSS Pump Feedbacks. The DSS Pump On
feedback is HEALTHY when the pump is ON and displays
UNHEALTHY when pump is OFF.
• The DSS trip feedback is UNHEALTHY when the pump motor is tripped
else displays HEALTHY. The DSS water tank Differential Pressure
feedback displays HEALTHY when the differential pressure is within
limits else displays UNHEALTHY.
• The DSS water tank Pressure switch feedback displays HEALTHY
when the pressure switch is not actuated and displays UNHEALTHY
when the switch is actuated.
• The DSS LOCAL/REMOTE Mode selection feedback indication
displays LOCAL when local mode is selected and displays REMOTE
when remote mode is selected. The DSS Water Tank Level Transmitter
displays the level of water available in the Tank.

xxvi)HOIST DRIVE
• This screen displays the Hoist Drive feedbacks and indications. The
Hoist drive ON feedback displays HEALTHY when the hoist drive is
ON, displays UNHEALTHY when the drive is OFF.
• The Hoist drive Motor Trip feedback displays TRIPPED when the motor
trips and displays HEALTHY when the motor runs.
• Hoist LOCAL/REMOTE mode selected feedback displays LOCAL when
local mode is selected and displays REMOTE when remote mode is
selected. The Hoist ready to start feedback is HEALTHY when the hoist
drive ready feedback signal is healthy else displays UNHEALTHY. The

Hoist UP selected feedback displays HEALTHY when the hoist up

command is enabled else displays UNHEALTHY.
• The Hoist DOWN selected feedback displays HEALTHY when the hoist
down command is enabled else displays UNHEALTHY. The Hoist down
operating end proximity is HEALTHY when the hoist drive is not
reached the Bottom End of the Line, if reaches the Bottom End it
displays UNHEALTHY. The Hoist up operating end proximity is
HEALTHY when the hoist drive is not reached the Top End of the Line,
if reaches the Top End it displays UNHEALTHY. The Hoist Brake 1&2
Released Limit Switch displays HEALTHY when the Limit switches are
not actuated and displays UNHEALTHY when the Limit Switches are
actuated.
xxvii)CONTROL DESK

• This screen displays the Control Desk features. The CD Material

displays the Material which is selected (COAL, IRON ORE, and FLUX).
• The CD LOCAL/REMOTE selection displays LOCAL when local mode
is selected and displays REMOTE when remote mode is selected. The
CD AUTO/MANUAL selection displays AUTO when auto mode is
selected and displays MANUAL when manual mode is selected.
• The AUTO DESK/AUTO CCR selection displays DESK when AUTO
DESK is selected and displays CCR when AUTO CCR is selected. The
LDB indoor lighting stats displays ON when the indoor lighting is ON
and displays OFF when the indoor lighting is OFF.
• The LDB outdoor lighting stats displays ON when the outdoor lighting is
ON and displays OFF when the outdoor lighting is OFF.

xxviii)CCR
• This screen displays the hardware communication of the system. The

Yard conveyor feedback displays HEALTHY when the Yard conveyor is
running, if not running it displays UNHEALTHY.
• If Emergency stop is pressed from CCR UNHEALTHY is displayed if
not pressed it displays HEALTHY. The AUTO START/AUTO STOP
from CCR displays START when AUTO START is pressed and
displays STOP when AUTO STOP is pressed.
• The full portal reclaimer healthy feedback is HEALTHY when the portal
is not full, if the portal is full it displays UNHEALTHY. If the Scrapper
chain is running HEALTHY is displayed and if not running UNHEALTHY
is displayed. The FPR AUTO CCR mode selected displays AUTO

DESK when DESK is selected and displays AUTO CCR when CCR is
selected.
• The Travel Speed Reference from CCR is displayed as Analog value.
The Machine Position Feedback is displayed as Analog output.
xxix)MIMIC
SCRAPPER CHAIN
This all the Inputs are comes From Field For Scraper Chain Motor.

This all the Inputs are comes From Field For Scraper Chain Motor.

TRAVEL DRIVE
This all the Inputs are comes From Field For Travel Drive -2.

This all the Inputs are comes From Field For Travel Drive -1.

FAPJ 310-PHASE-II-10MTPA
10MTPA EXPANSION PROJECT
HOIST
This all the Field Inputs from Hoist Drive.
Developed by Focaal Autom

mation (P) Ltd age 63 of 197
Pag
OVERALL SCREEN
This screen displays over all view of portal scrapper reclaimer. Anemometer
and warning siren is field inputs.

8. BILL-OF-MATERIAL FOR PLC PANEL

QT
S.N DESCRIPTION RATING MODEL NO MAKE
Y
Cisco SG350-
1 MANAGED SWITCH 110VAC CISCO 1
28P
SINGLE CHANGE OVER
2 24VDC P2RF-05-PU OMRON 6
RELAY
8CHANNELS 1C/O
3 24VDC G2R-1SN(S) OMRON 12
RELAYBOARD
4 1769-L33ER- Processor 24VDC 1769-L33ER AB 1
85-
5 Rack power supply 1769-PA4 AB 3
265VAC
6 1769-SM2-modbus Module - 1769-SM2 AB 1
1769-AENTR -Ethernet
7 - 1769-AENTR AB 1
Comm.Module
1769-IA16 Digital INPUT
8 110VAC 1769-IA16 AB 13
Module
1769-OB16 Digital OUTPUT
9 24VDC 1769-OB16 AB 6
Module
10 1769-IF8 Analog Input module 24VDC 1769-IF8 AB 3
1769-OF8 Analog OUTPUT
11 24VDC 1769-OF8 AB 1
module
12 MCB(110V AC UPS SUPPLY) 6A,DP 5SL42067RC SIEMENS 1
13 MCB(24VDC SUPPLY) 10A,DP 5SL42107RC SIEMENS 1
16 MCB(230V AC LDB SUPPLY) 6A,DP 5SL42067RC SIEMENS 1
17 MCB(110V AC UPS SUPPLY) 2A,SP 5SL41027RC SIEMENS 21
18 MCB(24VDC SUPPLY) 6A,SP 5SL41067RC SIEMENS 16
19 MCB(230V AC LDB SUPPLY) 6A,SP 5SL41067RC SIEMENS 2
21 POWER SUPPLY 230/24VDC 10A 1606-XLE240E AB 1
22 DOOR LIMIT SWITCH 1C/O 600NOLP KAYCEE 2

QT
Y
GIRISHEG
23 SPACE HEATER 240VAC 80W 1
O
GIRISHEG
24 THERMOSTATS(205C) 20930285 1
O
25 POWER SOCKET 3PIN 6A 38841 ANCHOR 1
26 PANEL LAMP 230VAC 11W PHILIPS 2
COOLING FAN WITH
27 230VAC 6INCH REXNORD 2
LOUVER
28 LOUVER WITH FLITER ----- 6INCH ELETTRO 2
AS
INTERNAL CONTROL
29 ----- ------ POLYCAB RE
CABLE
Q

9.TECHNICAL DATA OF COMPONENTS

(a) 1769-L33ER
Product Description
• Controller, 2MB Memory, No Embedded I/O, 1769 Power Supply
Controller, CompactLogix L3, 2 MB User Memory, 1 GB Secure
Digital Memory Card, No Embedded I/O, 1769 Power Supply.
Expanding on the scalability of the Logix family of controllers, the

CompactLogix 5370 L3 programmable automation controllers (PAC) are
designed to meet the growing need for a higher performance controller in a
compact and affordable package.

As part of the Integrated Architecture system, the CompactLogix 5370 L3

controllers use the same programming software, network protocol, and
information capabilities as all Logix controllers, providing a common
development environment for all control disciplines.
Integrated Motion on EtherNet/IP

The CompactLogix 5370 L3 controller provides a strong motion solution for
customers looking for performance and cost competitiveness.
• Supports up to 16 axes of integrated motion
• Together with the Kinetix 350, offers cost-effective, scalable motion
solution
Network Capabilities
With dual Ethernet ports and an integrated Ethernet switch, these controllers
now support Device Level Ring (DLR) network topologies, simplifying
integration of components in your control system and reducing system cost:
• Provides resiliency from loss of one network connection.
• Allows replacement of devices one at a time without stopping production
• Reduces the number of Ethernet switches in the control system
Features
• Includes a built-in RS-232 serial port on every 1769-L3x controller
• Offers built-in communication ports for EtherNet/IP or ControlNet networks
• Includes a 1769-SDN communication interface module for I/O control and
remote device configuration over DeviceNet
• Lets you control distributed I/O via EtherNet/IP, ControlNet, or DeviceNet
(select models only)
• Provides seamless bridging with data control and collection over the same
network
• Integrates with 1769 Compact I/O™ modules

Step by step procedure for Processor startup
Step1:
To Disable MAC Address should be connect with PC through

Ethernet/IP
communication cable and disable the MAC Address by toolkit
BOOTP/DHCP
of Allen Bradley software.
Step2:
Open BOOTP/DHCP tool of Allen Bradley software for disable MAC
address and then create IP address for the processor. For more Details
to click here bootp_guide.pdf
Step3:
Done flashing a 1769-L33ER Allen Bradley processor through Control
flash 15.03V. For more Details to click here Firmware_guide.pdf
Step4:
Build ladder logic throughRS logix 5000 V20.03 Programming. For

more Details to click here RS5000_Guide.pdf

(b) 1769-PA4
Power Supply Units
• Used to power CompactLogix controller and I/O modules

May also power additional I/O banks in MicroLogix 1500 (series A, revision
C and FRN 3 or higher) systems.
• Each CompactLogix I/O bank requires a power supply
Up to 8 modules may be fitted each side of PSU depending on loading &
individual module restrictions
Allen Bradley Power Supply
• The Allen Bradley power supply is designed to be used with the compact
I/O module. It has an input supply voltage rating of 120VAC/240VAC and
output voltage rating of 5VDC and 24VDC. It has an output current rating
of 5A. It can fit up to 8 modules from each side of the PSU, depending on
loading and individual module restrictions

Features and Benefits
• Used to power CompactLogix controller and I/O modules

May also power additional I/O banks in MicroLogix 1500 (series A,
revision C and FRN 3 or higher) systems.
• Each CompactLogix I/O bank requires a power supply
specifications
Attribute Value
Manufacturer Series 1769 Series
For Use With Compact I/O Module
Line Voltage 85 → 265 V ac
User Power Output Voltage 5 V dc, 24 V dc
Output Current 4A
Length 70mm
Width 118mm
Depth 87mm
Minimum Operating Temperature 0°C
Maximum Operating Temperature +60°C
Dimensions 70 x 118 x 87 mm

(c) 1769-SM2
FEATURE
The 1769-SM2 Compact I/O to DSI module features include:
• Three Compact I/O connection channels for PowerFlex 4-Class drives. Up
to 3 drives can be connected in Single mode (1 per channel) and up to 15
drives can be connected in Multi-Drive mode (5 per channel).
• Any channel in Multi-Drive mode can also be configured to operate as a
Modbus RTU Master, allowing connectivity to a maximum of 31 other
Modbus RTU Slave devices, such as PowerFlex 7-Class drives with 20-
COMM-H RS485 HVAC adapters.
• Use as expansion I/O on MicroLogix 1500 and CompactLogix controllers
or with a remote 1769-based adapter. It receives the required power from
the Compact I/O backplane.
• Parameter-configurable I/O, including Logic Command/Reference and
Logic Status/Feedback for each connected drive.
• Explicit messaging (parameter read/write, etc.) support for: – MicroLogix
1500 LRP Series C systems when used with RSLogix 500 v6.30 (or
higher) – Enhanced CompactLogix processors, such as the -L31, -L32E,

and -L35E Explicit messaging is NOT available for CompactLogix -L20

and -L30 processors, or 1769-ADN DeviceNet adapters.
• User-defined fault actions to determine how the module and connected
drives respond to controllers in idle mode (Idle Action)
• Bi-color (red/green) status indicators to report the status of the module and
channel communications.
• Compatibility with various configuration tools to configure the module and
connected drive(s). The tools include an optional, external PowerFlex 4-
Class HIM (22-HIM-A3 or 22-HIM-C2S), and drive-configuration software
such as DriveExplorer v3.01 (or higher) or DriveExecutive v4.01 (or
higher).
SPECIFICATIONS
Attribute Value
Use with PowerFlex Drive. 4M, 4, 40, 40P,

Application
400
Brand Name Allen-Bradley
Class Programmable Logic Controller Module
Compatibility Connects to MicroLogix 1500
Depth 87mm, 3.43"
Height 118mm, 4.65"
Configurable for single-drive or multi-drive
Interface/Ports
mode Modbus RTU master
Mounting DIN Rail / Panel Mount
Number Of Nodes 3
Operating Temperature 0...60 °C (32...140 °F)
Remote 1769 nodes,I/O messaging
Special Features includes logic comm,status,supports
parameter read/write object
Sub Brand CompactLogix
Type Communication
communications kits Compact I/O to DSI Module
module type remote terminal unit

d)1769-AENTR
Rockwell Automation 1769-AENTR 1769 Network Adaptor, Ethernet,69-
I/O,24.0V DC, Dual Port
SPECIFICATIONS
Attribute Value

Communication Ethernet/IP
Depth 87mm
Display Status LEDs
Enclosure None (open-style)
Height 4.65 in
Interface 2 Ethernet RJ45 Category 5
Isolation 50V (continuous), basic insulation type
Mounting DIN Rail, Panel Mount
Type Ethernet/IP Adapter
Width 50mm

(e)1769-IA16
Product Description
I/O Module, 16-Point, Solid State, Source, Input, 100/240VAC
I/O Module, CompactLogix, 16 Point, Solid State, AC Source, Input, 100/240
Volt AC

Specifications
Attribute Value
Manufacturer Series 1769 Series
Number of Inputs 16
Input Type Analogue
Power supply 1769-PA2, 1769-PB2, 1769-PA4, 1769-PB4
Voltage Category 100 → 240 V ac
Module Type Input Module
(f)1769-OB16

Attribute Value

Class Programmable Logic Controller Module
Depth 87mm, 3.43"
Display Status LEDs
Height 118mm, 4.65"
Isolation 1200V AC for 1 s or 1697V DC for 1 s, output
Number Of Channels 16
Output 16 current sourcing point at 0 .5 A
Type digital output
g)1769-IF8
Product Description
I/O Module, CompactLogix, 8 Point Analog, Voltage/Current Input, 24 Volt DC
Rockwell Automation ALLEN-BRADLEY 1769-IF8 COMPACTLOGIX 8 PT
ANALOG INPUT MODULE

SPECIFICATIONS
Attribute Value
Inputs 8 differential or single-ended
Power supply 1769-PA2, 1769-PB2, 1769-PA4, 1769-PB4
Power supply distance rating 8 modules
Module location DIN rail or panel mount
Dimensions (HxWxD), 118 x 52.5 x 87 mm (4.65 x 2.07 x 3.43 in.)
500V AC or 710V DC for 1 minute (qualification

Isolation voltage test), group to bus 30V AC/30V DC working
voltage (IEC Class 2 reinforced insulation)

h)1769-OF8
Product Description
I/O Module, CompactLogix, 8 Point Analog, Current Output, 24 Volt DC
Rockwell Automation 1769-OF8C Output Module,CompactLogix,Analog,8
Point, Current Only
SPECIFICATIONS
Attribute Value
8 Channel Analog Current Output
Analog Output Modules Module
Programmable Logic Controller
Class Module
Depth 87mm, 3.43"
Display Status LEDs
Enclosure None (open-style)
Height 4.65 in
500VAC,710VDC 1 min(qual
test),output group to bus,
30VAC/30VDC working volt
Isolation (IEC Class 2 reinforced insulation)


Number Of Channels 8
PRODUCT_STATUS 1
Product File Manager GMAYO
Resolution 16 b
Special Features Current Only, 16 bits resolution
Standard C-TICK,CUL,GOST,KC,MARINE,UL
Type analog output
WES_CIMM_BRAND ROCKWELL AUTOMATION
i)Power Supply Unit 1606-XLE240E
Product Description
Power Supply, 240W, 24 - 28VDC, Output, 120/240V AC Input
Power Supply, Essential, 240 Watt, 24 - 28 Volt DC Output, 120/240 Volt AC
Input

SPECIFICATIONS
Attribute Value
Product Series Bul. 1606-XLE
Input Type AC: 1-Phase
Input Voltage, AC, Min 100 V AC min
Input Voltage, AC, Max 240 V AC max
In, Nominal Current 5A
Inrush Current, Max 3A
Indicator Type LED
Output Voltage, DC, Nom 24 V DC min
Output Voltage, DC, Max 28 V DC max
Electrical, Min Mounting DIN-35 Rail Mount
IP Rating IP20

j)Managed Ethernet Switches

• Easy-to-Use Managed Switches That Provide the Ideal Combination
of Features and Affordability
• To stay ahead in a competitive marketplace, businesses need to make
every dollar count. That means getting the most value from your
technology investments, but it also means making sure that employees
have fast, reliable access to the business tools and information they need.
• Every minute an employee waits for an unresponsive application and
every minute your network is down has an effect on your profits.
• The importance of maintaining a strong and dependable business network
only grows as your business adds more employees, applications, and
network complexity.
• Cisco 350 Series Switches
• The Cisco 350 Series, part of the Cisco Small Business line of network
solutions, is a portfolio of affordable managed switches that provides a
reliable foundation for your business network.
• These switches deliver the features you need to improve the availability of
your critical business applications, protect your sensitive information, and
optimize your network bandwidth to deliver information and applications
more effectively. Easy to set up and use, the Cisco 350 Series provides
the ideal combination of affordability and capabilities for small businesses
and helps you create a more efficient, better-connected workforce.

Business applications
Whether you need a basic high-performance network to connect employee
computers or a solution to deliver data, voice, and video services, the Cisco
350 Series offers a solution to meet your needs. Possible deployment
scenarios include
• Secure desktop connectivity: Cisco 350 Series Switches can simply and
securely connect employees working in small offices with each other and
with all of the servers, printers, and other devices they use. High
performance and reliable connectivity help speed file transfers and data
processing, improve network uptime, and keep your employees connected
and productive.
• Secure wireless connectivity: With its advanced security features, Power
over Ethernet, Auto Smart ports, QoS, VLAN, and access control features,
the Cisco 350 Series Switches are the perfect foundation to add business-
grade wireless to a business network.
• Unified communications: As a managed network solution, the Cisco 350
Series provides the performance and advanced traffic-handling
intelligence you need to deliver all communications and data over a single
network. Cisco offers a complete portfolio of IP telephony and other unified
communications products designed for businesses. Cisco 350 Series
Switches have been rigorously tested to help ensure easy integration and
full compatibility with these and other products, providing a complete
business solution.
• Highly secure guest connectivity: Cisco 350 Series Switches let you
extend highly secure network connectivity to guests in a variety of settings,
such as a hotel, an office waiting room, or any other area open to
nonemployee users. Using powerful but easy-to-configure security and
traffic segmentation capabilities, you can isolate your vital business traffic
from guest services and keep guests’ network sessions private from each
other.
Features and benefits
Cisco 350 Series switches provide the advanced feature set that growing
businesses require and that highbandwidth applications and technologies
demand. These switches can improve the availability of your critical
applications, protect your business information, and optimize your network
bandwidth to more effectively deliver information and support applications.
The switches provide the following benefits.

The USB port on the front panel of the switch enables easy image and
configuration transfer for faster deployment or upgrade.
• Simple-to-use graphical interfaces reduce the time required to deploy,
troubleshoot, and manage the network and allow you to support
sophisticated capabilities without increasing IT head count.
• The switches also support Text view, a full Command-Line Interface (CLI)
option for partners that prefer it.
• Using Auto Smart ports intelligence, the switch can detect a network
device connected to any port and automatically configure the optimal
security, Quality of Service (QoS), and availability on that port.
• Cisco Discovery Protocol discovers Cisco devices and allows devices to
share critical configuration information, simplifying network setup and
integration.
• Support for Simple Network Management Protocol (SNMP) allows you to
set up and manage your switches and other Cisco devices remotely from a
network management station, improving IT workflow and mass
configurations.
High reliability and resiliency
In a growing business where availability 24 hours a day, 7 days a week is
critical, you need to assure that employees can always access the data and
resources they need. The Cisco 350 Series supports dual images, allowing
you to perform software upgrades without having to take the network offline
or worry about the network going down during the upgrade
Strong security
Cisco 350 Series switches provide the advanced security features you need
to protect your business data and keep unauthorized users off the network:
• Embedded Secure Sockets Layer (SSL) encryption protects management
data traveling to and from the switch.
• Extensive Access Control Lists (ACLs) restrict sensitive portions of the
network to keep out unauthorized users and guard against network
attacks.
• Guest VLANs let you provide Internet connectivity to nonemployee users
while isolating critical business services from guest traffic.
• Support for advanced network security applications such as IEEE 802.1X
port security tightly limits access to specific segments of your network.
Web-based authentication provides a consistent interface to authenticate

all types of host devices and operating systems, without the complexity of
deploying IEEE 802.1X clients on each endpoint.
• Advanced defense mechanisms, including dynamic Address Resolution
Protocol (ARP) inspection, IP Source Guard, and Dynamic Host
Configuration Protocol (DHCP) snooping, detect and block deliberate
network attacks. Combinations of these protocols are also referred to as
IP-MAC port binding (IPMB). © 2020 Cisco and/or its affiliates. All rights
reserved. Page 6 of 32
• IPv6 First Hop Security extends the advanced threat protection to IPv6.
This comprehensive security suite includes ND inspection, RA guard,
DHCPv6 guard, and neighbor binding integrity check, providing
unparalleled protection against a vast range of address spoofing and man-
in-the-middle attacks on IPv6 networks.
• Time-based ACLs and port operation restrict access to the network
during predesignated times such as business hours.
• Uniform MAC address-based security can be applied automatically to
mobile users as they roam between wireless access points.
• Secure Core Technology (SCT) helps ensure that the switch is able to
process management traffic in the face of a Denial-of-Service (DoS)
attack.
• Private VLAN Edge (PVE) provides Layer 2 isolation between devices on
the same VLAN.
• Storm control can be applied to broadcast, multicast, and unknown uni
cast traffic.
• Protection of management sessions occurs using RADIUS, TACACS+,
and local database authentication as well as secure management
sessions over SSL, SSH, and SNMPv3.
• DoS attack prevention maximizes network uptime in the presence of an
attack.
Power efficiency
The Cisco 350 Series integrates a variety of power-saving features across all
models, providing the industry’s most extensive energy-efficient switching
portfolio. These switches are designed to conserve energy by optimizing
power use, which helps protects the environment and reduce your energy
costs. They provide an eco-friendly network solution without compromising
performance. Cisco 350 Series switches feature:

• Support for the Energy Efficient Ethernet (IEEE 802.3az) standard, which
reduces energy consumption by monitoring the amount of traffic on an
active link and putting the link into a sleep state during quiet periods
• The latest Application-Specific Integrated Circuits (ASICs)
• Automatic power shutoff on ports when a link is down
• LEDs that can be turned off to save power
• Embedded intelligence to adjust signal strength based on the length of the
connecting cable.
K)THERMOSTATS
GIRISHEGO thermostats are ideal for temperature control of space heaters

used
In LT & HT switchgear & panel boards etc.
Principle of operation
With temp rise, the principle of differential expansion of brass tube and a
Nickel/Iron (inver) Rod is used to actuate a highly accurate snap action micro
gap switch located in the head which makes it keep the temperature constant
within the differential i.e. A single pole, single throw, normally closed circuit
breaks (opens) on rise of temperature.

Construction
The micro gap switch assembly is mounted on a heat resistant base, with
rigid brass pillar terminals. Heavy duty Ag cdo contacts are provided for long
trouble free life. A thermosetting cover with clear and precise graduations is
provided along with a setting knob. Thermostat can be fixed in any
position.Two fixing holes of Dia. 5mm are provided at a center distance of
58mm in Thermostat with fixing Bracket model.
These are available in standard stem lengths of 7"(175mm), 11" (275mm).
Also Available in 110 V & 415 V.
l)SPACE HEATER
Box type Space Heaters are ideal for prevention of condensation, corrosion.
Leakage currents in L.T. & H.T. Switchgear panel boards , electronic
nstruments & panels etc. The specially developed design incorporates a Hiqh
Quality mica insulated Kanthal heating element in Aluminum enclosure.
A 2 x 2.5 mm² terminal block is provided for electrical connection. Installation
can be done in vertical or horizontal position, although horizontal mounting is
preferred. Distance from surface of panel should be at least 10 mm. and
distance from plastic parts should be at least 50 mm.
Each heater is tested for following specific tests.
1) High Voltage Test At 2Kv for 1min.

2) Insulation Resistance > 10 Mega Ohms.
3) Power rating within ± 5%.

10.BILL OF MATERIAL FOR MCC PANEL

Incomer (1F1 &
QT
S.N METERING FEEDER 1250A POWER MAKE
Y
1F2)
ACB with Motorized 1250A,ED
1 Operating Mechanism O,LSIG,1 3WT8121 Siemens 1
110VAC 10AC
Shunt Release or Closing
2 Coil 110VAC 3WT9851-1JH00 Siemens 1
3 Under Voltage Release 110VAC 3WT9853-1JH00 Siemens 1
Amber,11
4 Potential transformer 0V AC Pragathi 1
1250/5A,
CL-
5 Current transformer 1,15VA Pragathi 3
6 DIGITAL Ammeter 110VAC SMP9635SAS MECO 1
3PH,3WI
7 DIGITAL Voltmeter RE SMP9635SVS33 MECO 1
6A-S6-61038-
8 Selector Switch 2 WAY D13-TDRY Salzer 1
11KW,12. 25A-S25-72009-
9 TNC SWITCH 8A B03-PGGB Salzer 1
CL:1,Aux
Sup:110V
AC with
10 MFM Meter RS485 EM6400NG Conzerv 1
11 Indication lamp-RED 110V AC 3SB5285-6HC03 Siemens 1
12 Indication lamp-YELLOW 110V AC 3SB5285-6HD02 Siemens 1
13 Indication lamp-BLUE 110V AC 3SB5285-6HF02 Siemens 1
14 Indication lamp(RED) 110V AC 3SB5285-6HC02 Siemens 2
220V-
15 Indication lamp(GREEN) 240VAC 3SB5285-6HD03 Siemens 1
16 Indication lamp(AMBER) 110V AC 3SB5285-6HL02 Siemens 1
17 Indication lamp(WHITE) 110V AC 3SB5285-6HG02 Siemens 1
18 Indication lamp(YELLOW) 110V AC 3SB5285-6HD02 Siemens 1

QT
Y
19 MPCB 0.28-0.4A 3RV2011-0EA10 Siemens 1
20 Vacuum Contactor 820A 3TF6944-0CF7 Siemens 1
21 ON PUSHBUTTON Red 3SB5400-0E Siemens 1
22 OFF PUSH BUTTON GREEN 3SB5400-0F Siemens 1
Emergency Stop Push Red with
23 button 2NC 3SB5400-0F Siemens 1
24 Control MCB 6A,DP 5SL42067RC Siemens 1
25 Control MCB 2A,TP 5SL43027RC Siemens 1
26 Auxillary Contactor 110VAC 3RH2140-1AF00 Siemens 18
1 No
Alarm &
1NO Trip CDG11AF004SA ALSTO
27 Earth Fault Relay Contact CH M 1
0.05Sec-
28 Timer 100hrs Siemens 1
terminal blocks Connect
29 well 2
terminal blocks Connect
30 well 3
Connect
31 Control terminal blocks 4Sq.mm CX4 well 84
Panel Lamp With Door Philips/K
32 limit Switch 230V AC aycee 1
Auxiliary Incomer(2F1) 160A Power 1
TP,160A,
MCCB with MP Based 55KA,LSI 3VA1116-5ED32-
1 O/L,S/C &E/F G 0AA0 Siemens 1
2 Extended handle Siemens 1
3 MCCB Aux Switch 1NO+1NC Siemens 1
4 MCCB Alarm Switch 1NO+1NC Siemens 1
Control
transformer(2F2) 1
1 MPCB 7-10A 3RV2411-1JA10 Siemens 2

QT
Y
415/110V
2 Control transformer AC, Pragathi 2
3RP1513-
3 Timer 110VAC 1AQ308K Siemens 1
4 MCB DP,25A, 5SL42257RC Siemens 2
5 Power Contactor 32A, 3RT2027-1AG20 Siemens 2
7 Indication lamp Red,110V 3SB5285-6HC02 Siemens 1
Connect
8 Terminal Blocks 6sqmm CX6 well 22
Lighting Trasformer
feeder(2F3) 63A Power 1
MCCB with Thermal TP,63A,5 3VA1163-5ED32-
1 Magnetic Release 0KA 0AA0 Siemens 1
2 Extended handle 3UA9175-0GK00 Siemens 1
3 Spreader Links Siemens 1
6 MPCB 0.28-0.4A 3RV2011-0EA10 Siemens 1
7 Control MCB 2A,TP 5SL43027RC Siemens 1
415V/220
8 Lighting Transformer V Pragathi 1
415/√311
9 Potential transformer 0V/√3 Pragathi 1
10 Indication lamp-RED 110V AC 3SB5285-6HC03 Siemens 1
11 Indication lamp-YELLOW 110V AC 3SB5285-6HD02 Siemens 1
12 Indication lamp-BLUE 110V AC 3SB5285-6HC02 Siemens 1
13 MCB 32A,DP 5SL42327RC Siemens 1
Air Oil Cooler for Chain
Drive Hydraulic-1(3F1) 11KW DOL 1
3VA1125-5ED32-
1 MCCB 25A 0AA0 Siemens 1

QT
Y
3 MCCB Auxiliary Switch 1NO+1NC Siemens 1
30/5A,CL:
Disconnecting terminal Connect
5 blocks well 3
6 DIGITAL Ammeter SMP9635SAS MECO 1
I/P:4-
7 Current transducer 20mA 53135 MECO 1
10 Auxiliary Contactor 110VAC 3RH2140-1AF00 Siemens 2
11 Power contactor 32A, 3RT2027-1AG20 Siemens 1
12 OLR 20-25A 3RU2126-4DB0 Siemens 1
13 Indication lamp Red 3SB5285-6HC03 Siemens 1
14 Indication lamp Green 3SB5285-6HE02 Siemens 1
15 Indication lamp Amber 3SB5285-6HL02 Siemens 1
Connect
16 Power terminal blocks 10sqmm CX10 well 5
Connect
17 ControlTBs 4Sq.mm CX4 well 16
SPARE (3F2) 25A Power 1
7 Indication lamp Red 3SB5285-6HC03 Siemens 1
8 Indication lamp Green 3SB5285-6HE02 Siemens 1

QT
Y
9 Indication lamp Ambe 3SB5285-6HL02 Siemens 1
Connect
Connect
11 Power terminal blocks 10sq.mm CX10 well 3
Rail Clamp Fixed
Side(3F3) 2*3.7KW 1
3 MCCB Auxiliary Switch 1NO+1NC Siemens 1
DP,6A,10
5 MCB KA 5SL42067RC Siemens 1
DP,6A,10
8 Power contactor 16A, 3RT2025-1AG20 Siemens 2
9 OLR 6-25A 3RB3026-1QB0 Siemens 2
10 Indication lamp Red, 3SB5285-6HC03 Siemens 1
11 Indication lamp Green, 3SB5285-6HL02 Siemens 1
12 Indication lamp Amber, 3SB5285-6HE02 Siemens 1
Connect
Connect
Plan Water Dust
Suppression
System(3F4) 1.1KW Power 1

QT
Y
DP,6A,10
Red,110V
7 Indication lamp AC 3SB5285-6HC03 Siemens 1
Green,11
8 Indication lamp 0V AC 3SB5285-6HE02 Siemens 1
Amber,11
9 Indication lamp 0V AC 3SB5285-6HL02 Siemens 1
Connect
Connect
11 Power terminal blocks 10Sq.mm CX10 well 3
PCRD(3F5) 5.16KW DOL 1
1 MPCB 10-16A 3RV2021-4AA10 Siemens 1
2 MPCB Auxiliary Switch 1NO+1NC 3RV2901-1E Siemens 1
5 MPCB Alarm Switch 1NO+1NC 3RV2921-1M Siemens 1
DP,6A,10
6 AUX MCB KA 5SL42067RC Siemens 1
DP,6A,10
17A,110V
9 Power contactor AC 3RT2025-1AG20 Siemens 1
12A,110V
10 Power contactor with 1NC AC 3RT2017-1AF00 Siemens 2
11 OLR 6-25A 3RB3026-1QB0 Siemens 1
Red,110V
13 Indication lamp Siemens 1

QT
Y
Amber,11
15 Off Delay Timer (5-100S) 3RP1533-1AQ30 Siemens 1
Connect
Connect
AC at E-HOUSE
1&SPARE(4F1-4F2) 63A Power 2
3VA1163-5ED32-
MCCB with Thermal TP,63A,5 0AA0/3VA1063-
1 Magnetic Release 0KA 4ED32 Siemens 1
3 Spreader Links Siemens
DP,6A,10
Red,110V
Green,11
Amber,11
Connect
Connect
11 Power terminal blocks 50sq.mm CX50 well 3
UPS INCOMING
SUPPLY 1&2(4F3-4F4) 100A Power 2
MCCB with Thermal TP,100A, 3VA1110-5ED32-

QT
Y
DP,6A,10
Red,110V
Green,11
Amber,11
Connect
Connect
11 Power terminal blocks 50sq.mm CBB50 well 3
WELDING SOCKET
(4F5) 100A Power 1
DP,6A,10
Red,110V
Green,11
Amber,11
Connect
Connect

QT
Y
WARNING SIREN (4F6) 0.9-1.25A Power 1
1 MPCB 0.9-1.25A 3RV20110KA10 Siemens 1
9A,110V
2 Power contactor AC 3RT2023-1AF01 Siemens 1
DP,6A,10
Red,110V
Green,11
Amber,11
Connect
Connect
5.5KW*3
Travel Drive7-9(5F) NOS VFD 1
104
Amps,
55kW ND,
PowerFlex 753 AC Drive, 45kW HD,
with Embedded 400 VAC, 20F11NC104JA0
1 Ethernet/IP 3 PH, NNNNN AB 1
PF750-24V I/O 20-750-2262C-
2 Module 2R AB 1
PF750 Incremental
3 Encoder Module 20-750-ENC-1 AB 1
PF750 Dual-port
4 EtherNet/IP Module 20-750-ENETR AB 1
PowerFlex Architecture
Class Remote Enhanced
5 HIM 20-HIM-C6S AB 1
28 OHM
6 DBR 6.6 KW GR 1

MCCB with Thermal TP,63A,5 3VA1163-5EE32-

63/5A,CL:
11 blocks well 3
12 Semiconductor Fuse 125A 3NE4122 Siemens 3
14 MPCB 9-12.5A 3RV2011-1KA10 Siemens 3
15 MPCB 0.22-0.32 3RV2011-0DA10 Siemens 3
16 MPCB 1.8-2.5A 3RV2011-0CA10 Siemens 3
MPCB Alarm Switch-
18 MPCB 1NO+1NC 3RV2921-1M Siemens 9
21 Control MCB 110VAC 6A,DP 5SL42067RC Siemens 2
DP,6A,10
22 MCB 230VAC KA 5SL42067RC Siemens 5
Red,110V
23 Indication lamp-On AC 3SB5285-6HC02 Siemens 1
Green,11
24 Indication lamp-Off 0V AC 3SB5285-6HE02 Siemens 1
Amber,11
25 Indication lamp-Trip 0V AC 3SB5285-6HL02 Siemens 10
Red with
26 Emergency Stop PB 1NC 3SB5400-0C Siemens 1
6inch,230
27 Cooling CF V AC Rexnord 1
Tube Light with door limit Philips/K
28 switch 230V AC aycee 1
Space heater with
29 thermostat 230V AC Girishco 1

QT
Y
Connect
30 power TBs 6Sq.mm CX6 well 33
Connect
31 Control TBs 4Sq.mm CX4 well 76
Connect
31 Control TBs 50sq.mm CBB50 well 2
Travel Drive Air Cooler
Motor(7-9) VFD 1
20A,110V
32 Power Contactor AC 3RT2018-1AF01 Siemens 2
5.5KW*6
Travel Drive1-6(6F) NOS VFD 1
104
Amps,
55kW ND,
with Embedded 400 VAC, 20F11NC104JA0
PF750-24V I/O Module- 20-750-2262C-
2 2AI,2AO,6DI,2RO 2R AB 1
PF750 Incremental
PF750 Dual-port
4 EtherNet/IP Module 20-750-ENETR AB 1
10.9 OHM
6 DBR 16.5 KW GR 1
Extended handle &
100/5A,C
10 Current transformer L:1,15VA Pragathi 3

QT
Y
Connect
11 Disconnecting TBs well 3
13 MPCB 9-12.5A 3RV2011-1KA10 Siemens 6
14 MPCB 0.22-0.32 3RV2011-0DA10 Siemens 6
15 MPCB 1.8-2.5A 3RV2011-1CA10 Siemens 6
20 AUX MCB 110VAC 6A,DP 5SL42067RC Siemens 2
6A-56-61100-
22 Selector Switch 4P-4W B13PDRY Sazer 1
Red,110V
Green,11
Amber,11
26 button 1NC 3SB5203-0UC01 Siemens 1
27 Cooling CF 6inch Rexnord 1
28 Tube Light with DLS 230V AC Philips 1
Space heater with ENCOR
29 thermostat 230V AC E 1
Connect
30 Power terminal blocks 6Sqmm CX6 well 66
Connect
31 Control TBs 4Sq.mm CX4 well 127
Travel Drive Air Cooler
32 Motor(1-6) VFD 1

QT
Y
Power Contactor with 16A,110V
33 2NO+2NC AC 3RT2018-1AF01 Siemens 2
Hoist Drive(7F) 55KW VFD 1
104
Amps,
55kW ND,
with Embedded 400 VAC, 20G11NC104JA0
PF750-24V I/O Module- 20-750-2262C-
2 2AI,2AO,6DI,2RO 2R AB 1
PF750 Incremental
13OHM GR/Rep
5 DBR 55 KW uted 1
100/5A,C
10 Current transformer L:1,15VA Pragathi 3
11 blocks well 3
0.45-
13 MPCB 0.63A 3RV2011-1GA10 Siemens 2
16A,110V
16 Power Contactor AC 3RT2018-1AF01 Siemens 2

QT
Y
DP,6A,10
19 MCB 230V AC KA 5SL42067RC Siemens 3
20 Isolator Swiitch 415VAC 3KA8111-3TE00 Siemens 1
Red,110V
Green,11
Amber,11
24 button 1NC 3SB5203-0UC01 Siemens 1
6inch,230
Tube Light with door limit Philips/K
26 switch 230V AC aycee 1
Space heater with
27 thermostat 230V AC Girishco 1
Connect
28 Power terminal blocks 6Sq.mm CX6 well 11
Connect
Scrapper Chain Drive-
1(8F) 160KW SD 1
MCCB with Thermal TP,400A, 3VA2340-5HL32-
350/5A,C
4 Current transformer L:1,15VA T15852-5 Pragathi 3
350/5A,C
5 Protection CT L:1,15VA T15852-5 Pragathi 3
Disconnecting Terminal Connect
6 blocks well 3

QT
Y
Power Contactor with 330A,110 3RT1066-
8 2NO+2NC V AC 6LA068K Siemens 2
330A,110 3RT1066-
9 Power Contactor V AC 6LA068K Siemens 1
140A,110
10 Auxiliary Contactor VAC 3RH1054-6 Siemens 3
11 Relay 2C/O 24VDC MY2N-GS Omran 1
14 Motor Protection Relay 110VAC E300 AB 1
30mA-
15 CBCT 30A 17H7NNKN3 Pragathi 1
I/P:4-
16 Current transducer 20mA PD1-53135 AE 1
Red,110V
Green,11
Amber,11
6inch,230
21 Tube Light 230V AC Philips 1
1Sec-
22 Timer 100hrs 3RP15251BW30 Siemens 1
23 Door limit switch 230V AC Kaycee 1
Space heater with
24 thermostat 230V AC Encore 1
Connect
25 Power terminal blocks 95Sq.mm CBB95 well 6
Connect
Scrapper Chain Drive-
2(9F) 160KW S/D 1

QT
Y
350/5A,C
350/5A,C
6 blocks well 3
140A,110
10 Auxiliary Contactor VAC 3RH2140-1AF00 Siemens 3
14 Motor Protection Relay 110VAC AB 1
30mA-
I/P:4-
20mA,110
16 Current transducer VAC PD1-53135 AE 1
Red,110V
Green,11
Amber,11
6inch,230

QT
Y
1Sec-
Space heater with
24 thermostat 230V AC Encore 1
Connect
Connect
SPARE(10F) 160KW SD 1
350/5A,C
350/5A,C
6 blocks well 3
7 DIGITAL Ammeter 110VAC SMP9635SAS MECO 1
14 Motor Protection Relay 110VAC E300 AB 1
30mA-
I/P:4-
16 Current transducer 20mA PD1-53135 AE 1

QT
Y
Red,110V
Green,11
Amber,11
6inch,230
1Sec-
Space heater with
24 thermostat 230V AC ESH-02 SC Encore 1
Connect
Connect
CABLE CHAMBER
2 Tubelight 230V AC Philips 2
3 Space heater 230V AC ESH-02 SC Encore 2
4 Thermostat 230V AC 205C Girishco 2
DP,6A,10
5A,230V
6 Power Socket AC Anchor 2
Connect
7 Terminal Blocks 4sqmm CX4 well 2

a) Air Circuit Breakers
OVER VIEW
1.Withdrawable circuit breaker

2.Indication and reset button after tripping for tripped signaling switch and
mechanical closing lockout
3.Spring charge indicator
4.Contact position indicator
5.Ready-to-close indicator
6.ON button, mechanical
7.OFF button, mechanical
8.Indication of circuit breaker position
9.Guide frame
10.Guide rails
11.Auxiliary circuit plug-in system
12.Crank hole
13.Hand lever

Benefits
Safety and reliability
•High degree of protection with door sealing frame in the case
of exclusively local operation of the circuit breaker
• Infeed supply from above or below, as required
• Locking of the withdrawable circuit breaker against moving, as
standard
• Locking of the guide frame with the circuit breaker removed, as
standard
• Signaling switch for overload and short-circuit tripping with
mechanical closing lockout
•High degree of protection with cover IP55
• Mechanical closing lockout after overload or short-circuit tripping
as standard
• The circuit breaker is always equipped with the required number
of auxiliary supply connectors
Easy to operate
•Unambiguous ON-OFF indicator with auxiliary switch for signal
• Ready-to-close indicator with signaling switch as safety
standard.
Modular
Many components, such as auxiliary releases, motorized operating
mechanisms, electronic trip units and current transformers
can be replaced or retrofitted to adapt the circuit breaker to
changing requirements.
Minimal power loss and therefore low energy consumption

The low power consumption of the electrical components also
saves money when it comes to purchasing the control-power
transformers. Where space is at a premium or ventilation is limited.

Design
Versions
Breaking capacity: 55/66 kA at 500 V
Rated current: from 400 A to 4000 A
Rated operating voltage: AC 500 V
The 3WT circuit breakers are supplied complete with an operating
mechanism, electronic trip unit and auxiliary switches and
are fitted with auxiliary releases.
The non-automatic circuit breakers are supplied without electronic
trip unit
Standard version
• Electronic trip unit with LSI protection, LCD display with backlight,
• LEDs for the cause of tripping, LED status indicator, query and test
button
• Auxiliary supply connector: The circuit breaker is equippedwith the
required number of connectors
• Mechanical ON and OFF pushbutton
• Door sealing frame IP40
• Tripped signaling switch (1 NO)
• Ready-to-close indicator with signaling switch
• Spring charge indicator
• Auxiliary switches (2 NO + 2 NC)
• Rear horizontal main circuit connections for fixed mounted and
withdraw able versions
• For 4-pole circuit breakers, the fourth pole (N) is installed onthe left
and is 100 % loadable
Indication and reset button after tripping for
- tripped signaling switch and

- mechanical closing lockout
•User manual in English/Chinese/Spanish/Russian/Portuguese/
German/Turkish
Additional features of the with draw able version:

• Main contacts:
Laminated receptacles in the guide frame, penetration blades
on the withdraw able circuit breaker
• Position indicator in the control panel of the withdraw able circuit
breaker
•Guide frame with guide rails for easy moving of the withdraw able
circuit breaker
• The with draw able circuit breaker can be locked to prevent it
being pushed out of position
Standard version for non-automatic circuit breaker

• Same features as the circuit breaker, see "Standard version" but
•No electronic trip unit
Function
Operating mechanisms
(see illustration "Motorized operating mechanism")
The circuit breakers are available with various optional operating
mechanisms:
• Manual operating mechanism with memory, with mechanical
closing
•Manual operating mechanism with mechanical and electrical
closing
• Motorized operating mechanism that can also be operated
manually, with mechanical and electrical closing.
The operating mechanisms with electrical closing can be used
for synchronization tasks.
EMERGENCY-STOP facility
The 3WT circuit breakers can be used as an EMERGENCY-STOP
facility to DIN VDE 0113 if the circuit breaker is equipped with an
under voltage release and is used in conjunction with an EMERGENCY-
STOP control device.

Auxiliary and signaling switches

• Ready-to-close
If all the conditions are fulfilled, so that the circuit breaker is ready to close, this
is indicated visually on the operator panel as well as by means of an indicator
switch (S7).
• Contact position-independent auxiliary switches
The circuit breakers are supplied with 2 NO and 2 NC contacts or with 2 NO
and 2 NC and 2 CO contacts according to order.
• "Tripped" signaling switch and mechanical closing lockout
As standard, the circuit breaker is equipped with an S11 signaling switch and
a mechanical closing lockout for the common overload and short-circuit signal
and, depending on the setting and version of the electronic trip unit, the
ground-fault signal.
The tripped signal and the standard mechanical mechanism to prevent
closing remain active until the reset button is operated on the circuit breaker.
When the circuit breaker has tripped, this is indicated by the protruding reset
button.
If the circuit breaker has to be ready to close immediately after tripping, an
automatic mechanical reset mechanism is available, but this does not reset
the electrical signal from the "tripped" switch S11. The "tripped" signal then
has to be reset by operating the Reset button.
Auxiliary supply connections

The type of connection for the auxiliary switches depends on the
type of installation:
• Withdrawable version:
The internal auxiliary switches are connected to the male connector
on the circuit breaker side. When fully inserted, the connector makes a
connection with the sliding module in the guide frame.
• Fixed mounting:
In this case the auxiliary supply connectors are engaged directly onto the
circuit breaker.

Fixed-mounted and with drawable version

Fixed-mounted and with drawable circuit breakers
• Protective measures against arcing gases
For 3WT circuit breakers with voltages up to AC 500 V, screening from
vertical busbars is not necessary. Electrical add-on devices on the side of the
circuit breaker must be separately covered. Also see notes under "Project
planning aids", "Dimensional drawings".
•Operator panel
The operator panel is designed to protrude from a cutout in the door providing
access to all operator controls and displays with the door closed.
The operator panels for all circuit breakers (fixed mounted/ withdraw able
versions, 3-pole, 4-pole) are identical.
The operator panel ensures degree of protection IP41.
•Door sealing frame
The door sealing frame seals the cabinet door with the operator panel. With
the cabinet door closed, the IP degree of protection is achieved for the circuit
breaker.
Withdraw able circuit breaker
The withdraw able version comprises a withdraw able circuit
breaker, a guide frame and a hand crank for moving the withdraw able
circuit breaker. The guide frames are fitted with guide rails as standard for
easy handling of the withdraw able circuit breaker.
• Auxiliary supply connections
The auxiliary supply connections make contact automatically
when the circuit breaker slides into the guide frame (test position,
connected position).
• Switch positions in the guide frame
The withdraw able version has three switch positions in the
switchgear cabinet behind the cabinet door:
- Connected position
(main circuit and auxiliary circuit ready)
- Test position
(main circuit disconnected, auxiliary circuit ready)
- Disconnected position

(main circuit and auxiliary circuit disconnected) In the disconnected position,

the withdraw able circuit breaker complies with the "isolation condition" with a
visible isolating distance in the main circuit and auxiliary circuit.
The circuit breaker must always be switched off before it is moved. The
"OFF" button must be held down when the slide in the crank hole is opened.
Ground-fault protection
Description
Ground-fault releases "G" sense fault currents that flow to ground and that
can cause fire in the plant. Multiple circuit breakers connected in series can
have their delay times adjusted so as to provide time-graded discrimination.
The reason for tripping is indicated by means of an LED when the query
button is activated.
Measurement method
• Vectorial summation current formation (measurement method 1)
The three phase currents and the N-conductor current are measured
directly.
• The electronic trip unit determines the ground-fault current by means of
vectorial summation current formation for the three phase currents and
the N-conductor current.
• Direct measurement of the ground-fault current (measurement method
2)
• A standard transformer with the following data is used for measurement
of the ground-fault current:
• 1200 A/1 A, Class 1 (the internal load of 3WT is 0.11 Ω). The
transformer can be installed directly in the grounded neutral point of a
transformer.
3-pole circuit breakers, current transformers in the neutral conductor

3-pole circuit breakers, current transformers in the grounded neutral point of

the transformer
4-pole circuit breakers, current transformers in the grounded neutral point of

the transformer
Module for mutual mechanical interlocking

• The module for mutual mechanical interlocking can be used for one or
two 3WT circuit breakers and can be adapted easily to the
corresponding versions.
• The fixed-mounted and with drawable circuit breaker versions are fully
compatible and can therefore be used in a mixed configuration in an
installation.
• The circuit breakers can be mounted alongside each other or one
above the other, whereby the spacing of the circuit breakers is
determined solely by the length of the Bowden cable.
• TheBowden cables are supplied in standard lengths of 2 m (length:
• 2 m/3 m/4.5 m). Interlock signals are looped through via the Bowden
cables. Interlocking is only effective in the connected position in the
case of withdrawable circuit breakers.
• The mechanical endurance of the Bowden cables is 10000 operating
cycles.
• The interlocking module is mounted on the right-hand side of the

• fixed-mounted circuit breaker (see illustration) or the guide frame.

Minimum requirements must be fulfilled in the switchgear for the
interlocking to function:
• Bowden cables must be installed as far as possible in a straight line
with minimum bending.
• The bending radii of the Bowden wire must be greater than 500 mm.
• The sum of all bending angles along the Bowden cable must not
exceed 640°.
• In a vertical arrangement of circuit breakers to be interlocked,
the interlocking mechanisms must be in line.
• Circuit breakers to be interlocked must be arranged so that
Bowden cables can be optimally installed in compliance with
the conditions mentioned in the above points.
• The installed Bowden cable must be fixed (with cable ties or
the like) before the interlock is adjusted.

b)MCCB
MCCB is Moulded Case Circuit Breaker. An MCCB provides protection by
combining a temperature sensitive device with a current sensitive
electromagnetic device.The molded-case circuit breaker uses
electromechanical (thermal magnetic) trip units that may be fixed or
interchangeable. An MCCB provides protection by combining a temperature
sensitive device with a current sensitive electromagnetic device. Both these
devices act mechanically on the trip mechanism. Depending upon the
application and required protection, an MCCB will use one or a combination
of different trip elements that protect against the following conditions:
• Thermal overloads
• Short circuits
• Ground faults
Thermal Overload
In an overload condition, there's a temperature build-up between the

insulation and conductor. If left unchecked, the insulation's life will drastically
reduce, ultimately resulting in a short circuit. This heat is a function of the
square of the rms current (I squared), the resistance in the conductor (R), and
the amount of time the current flows (t).If you monitor current flow and time,
you can somewhat predict and detect overload conditions.
Short-Circuit Condition
Usually, a short circuit occurs when abnormally high currents flow as a result
of the failure of an insulation system. This high current flow, termed short-
circuit current, is limited only by the capabilities of the distribution system. To
stop this current flow quickly so that major damage can be prevented, the
short circuit or instantaneous element of an MCCB is used.

Ground Fault Condition
A ground fault actually is a type of short circuit, only it's phase-to-ground,

which probably is the most common type of fault on low-voltage systems
(600V or less). Usually, arcing ground-fault currents are not large enough to
be detected by the standard MCCB protective device. But, if left undetected,
they can increase sufficiently to trip the standard protective device. When this
happens, it usually is too late, and the damage is already done.
An example of this is a motor having an internal insulation failure. While the

current flow may be small, it must be detected and eliminated before major
motor damage takes place.

Benefits of MCCB:
• MCCB has a prevent the electrical device from faulty situation.
• The maintenance cost fee is free and recurring costs are less.
• This device is compact in the measure. hence saves wide space in the
panel design.
• MCCB can clear several faults before it is due for replacement.
• In this circuit breaker, some multi-purpose accessories can be fitted
with the MCCB.
• When we have to use MCCBs, there is no possibility of single phasing
due to fault in only one phase.
• MCCB takes less time to reset and to switch on while it trips down
during the faults.
• Along with MCCBs, there are certain accessories that can be fitted and
few also act as multi-purpose usage.
• Some multi-reason adornments can be fitted with the MCCB.
• MCCBs have to limit downtime. Unlike in a fuse based system, there is
no searching for a replacement fuse. It is very well may be reset and
switched on again instantly in the wake of finding the blame that caused the
stumbling amid activity.
• MCCBs can clear a few blame previously it is expected for substitution.
• MCCBs are used for electrical feeder protection against overcurrent,
earth fault and under voltage.

c)MCB
• A miniature circuit breaker (MCB) automatically switches off electrical

circuit during an abnormal condition of the network means in overload
condition as well as faulty condition. Nowadays we use an MCB in low
voltage electrical network instead of a fuse. The fuse may not sense it
but the miniature circuit breaker does it in a more reliable way. MCB is

much more sensitive to over current than fuse=Handling an MCB is

electrically safer than a fuse. Quick restoration of supply is possible in
case of a fuse as because fuses must be re-wirable or replaced for
restoring the supply. Restoration is easily possible by just switching it
ON. Let’s look at the working of the miniature circuit breake
The working principle of MCB
• Whenever continuous over current flows through MCB, the bimetallic
strip is heated and deflects by bending. This deflection of bimetallic strip
releases a mechanical latch. As this mechanical latch is attached with
the operating mechanism, it causes to open the miniature circuit
breaker contacts, and the MCB turns off thereby stopping the current to
flow in the circuit. To restart the flow of current the MCB must be
manually turned ON. This mechanism protects from the faults arising
due to over current or overload.
• But during short circuit condition, the current rises suddenly, causing
electromechanical displacement of plunger associated with a tripping
coil or solenoid. The plunger strikes the trip lever causing immediate
release of latch mechanism consequently open the circuit
breaker contacts. This was a simple explanation of a miniature circuit
breaker working principle.
• An MCB is very simple, easy to use and is not generally repaired. It is
just easier to replace. The trip unit is the main part, responsible for its
proper working. There are two main types of trip mechanism. A bi-
metal provides protection against overload current and an
electromagnet provides protection against short-circuit current.

MCB operation
• If the circuit is overloaded for a long time, the bi-metallic strip becomes
overheated and deformed. This deformation of Bi-metallic strip causes,
displacement of latch point. The moving contact of the MCB is arranged by
means of spring pressure, with this latch point, that a little displacement of
latch causes, release of spring and makes the moving contact to move for
opening the MCB.
• The current coil or trip coil is placed so that during short circuit fault the
magneto-motive force (mmf) of the coil causes its plunger to hit the same
latch point and make the latch to be displaced. Again, when operating
lever of the miniature circuit breaker is operated by hand, that means
when MCB goes off position manually, the same latch point is displaced as
a result moving contact separated from fixed contact in the same manner.
• It may be due to deformation of a bi-metallic strip, or increased mmf of a
trip coil or maybe a manual operation, the same latch point is displaced
and same deformed spring is released, which ultimately responsible for
movement of the moving contact. When the moving contact separated

from fixed contact, there may be a high chance of arc. This arc then goes
up through the arc runner and enters arc splitters and is finally quenched.
• When we switch it on, we reset the displaced operating latch to its
previous on position and the MCB is ready for another switch off or trip
operation.
Benefits of MCB
• Easily identify the faulty zone of an electrical circuit.
• Simple to resume supply.
• Better interface: Knob.
• Electrically safer.
• More sensitive to current than the fuse.
• Less maintenance and replacement cost.

d) DIGITAL Ammeter
Specifications
Measuring Method
Dual Slope A/D Conversion
Sampling Rate
2.5 Samples per Second
Display Type
Maximum Display 1999 Counts
Resolution 0.001 to 1 Count depending on range
Decimal Selection Field Selectable
Maximum Overload Voltage : 1.2 times continuous, Current : 2 times
continuous
Frequency Response 40 - 400Hz
Faceplate / Lens Red Antiglare Faceplate with Annunciations
VA Burden (Typical) Auxiliary :<2.5VA
Voltage :<0.1VA
Current :<0.5VA,<0.2VA in 20A
Dielectric Strength 2.5 kV at 50Hz for 1 min. between Input - Auxiliary - Case
- Terminals
Case / Housing DIN Black ABS, Dimension as per DIN
Material 43700
Mounting Clamps Sturdy, Moulded ABS with suitable Hardware
Connectors Terminal Block : Thermoplastic (UL 94V-0) with Tin Plated Brass
Terminals,Display Stability Within±2 Digits

e)DIGITAL Voltmeter
Specifications
Measuring Method Dual Slope A/D Conversion
Sampling Rate 2.5 Samples per Second
Display Type Red LED Super Bright Display
Maximum Display 1999 Counts
Resolution 0.001 to 1 Count depending on range
Decimal Selection Field Selectable
Maximum Overload Voltage : 1.2 times continuous, Current : 2 times
continuous
Frequency Response 40 - 400Hz
Faceplate / Lens Red Antiglare Faceplate with Annunciations
VA Burden (Typical) Auxiliary :<2.5VA
Voltage :<0.1VA
Current :<0.5VA,<0.2VA in 20A
Dielectric Strength 2.5 kV at 50Hz for 1 min. between Input - Auxiliary -
Case - Terminals
Case / Housing DIN Black ABS, Dimension as per DIN
Material 43700
Mounting Clamps Sturdy, Moulded ABS with suitable Hardware
Connectors Terminal Block : Thermoplastic (UL 94V-0) with Tin Plated
Brass Terminals
Display Stability Within±2 Digits

f)MFM
Introduction
Meter overview
The EM6400NG series meters are digital meters that offer comprehensive 3-
phase electrical instrumentation and load management facilities in a compact
and rugged package.
The EM6400NG meters offer value for the demanding needs of your energy
monitoring and cost management applications. All meters in the
EM6400NGseries range comply with Class 1, Class 0.5S, or Class 0.2
accuracy standards and feature high quality, reliability and affordability in a
compact and easy to install format.
Meter features
The EM6400NG meter supports many features, a few of the features are
listed below:
• LED display screen: Intuitive self-guided navigation using three buttons LED
display, with three lines of concurrent values. Two columns of LEDs given on
the either side of the meter’s front panel indicate the parameter name being
displayed.
• Energy accounting and balancing.
• Measurement of both True PF and Displacement PF.
• EM6400NG POP (Class 1.0 and 0.5S) and RS-485
(Class 1.0, 0.5S, and 0.2)models.
• THD% and individual harmonics up to 15th order for voltage and current.
• Active, reactive, and apparent energy readings.
• Min/Max values of instantaneous parameters with timestamp.

• Cyber security: The meter enables disabling the RS-485 port through front
panel keys against unauthorized access. This feature can also be used for
toggling between the RTU devices in case of limited availability of nodes in
software system.
• Suppression current: The meter can be configured to disregard the
measurement of induced / auxiliary load current in the circuit (can be set
from5 to 99 mA).
You can use the meter as a stand-alone device, but its extensive capabilities
are fully realized when used as part of an energy management system.
Measured parameters Energy
The meter provides bi-directional, 4-quadrant, Class 1 / Class 0.5S / Class
0.2accurate energy metering.
The meter stores all accumulated active, reactive and apparent energy
parameters in non-volatile memory:
• kWh, kVARh, kVAh (delivered)
• kWh, kVARh, kVAh (received)
• kWh, kVARh, kVAh (delivered + received)
• kWh, kVARh, kVAh (delivered - received)
Demand
The meter provides last, present, predicted, and maximum (peak) demand
values,and a timestamp when the maximum (peak) demand occurred.
The meter supports standard demand calculation methods, including sliding
block, fixed block, rolling block, thermal and synchronized.
Peak demand registers can be reset manually (password protected).
Demand measurements include:
• W, VAR, VA demand total
• Amps demand average
Instantaneous
The meter provides highly accurate 1-second measurements, average
values,
including true RMS, per phase and total for:
• Per phase and average voltage (line-to-line, line-to-neutral)
• Per phase and average current, and neutral current

Power quality
The meter provides complete harmonic distortion metering, recording, and
real time reporting, up to the 15th harmonic for all voltage and current inputs.
The following power quality measurements are available:
• Individual odd harmonics up to 15th order (voltage and current, per phase)
• Total harmonic distortion (THD%) for current and voltage (displays line-to-
lineor line-to-neutral, based on selected system configuration)
Data display and analysis tools

Power Monitoring Expert
EcoStruxure™ Power Monitoring Expert is a complete supervisory software
package for power management applications.
The software collects and organizes data gathered from your facility’s
electrical network and presents it as meaningful, actionable information via an
intuitive reinter face.
Power Monitoring Expert communicates with devices on the network to
provide:
• Real-time monitoring through a multi-user web portal
• Trend graphing and aggregation
• Power quality analysis and compliance monitoring
• Preconfigured and custom reporting
See the EcoStruxure™ Power Monitoring Expert online help for instructions
on how to add your device into its system for data collection and analysis.
Power SCADA Operation
EcoStruxure™ Power SCADA Operation is a complete real-time monitoring
and control solution for large facility and critical infrastructure operations.
It communicates with your device for data acquisition and real-time control.
You can use Power SCADA Operation for:
• System supervision
• Real-time and historical trending, event logging
• PC-based custom alarms
See the EcoStruxure™ Power SCADA Operation online help for instructions
on how to add your device into its system for data collection and analysis.

Meter configuration
Meter configuration is performed through the display or through ION Setup.
ION Setup is a meter configuration tool that can be downloaded for free at
See the Conzerv EM6400NG Load Manager topic in the ION Setup online
help Orin the ION Setup device configuration guide.
Viewing meter data
Viewing meter data from the display
Voltage average, current average, and power factor average are displayed
the first time a meter is powered up, after which the last viewed screen or
locked(default) screen is displayed every time the meter is powered up.
Conzerv EM6400NG
Maintenance and upgrades

Maintenance overview
The meter does not contain any user-serviceable parts. If the meter requires
service, contact your local Schneider Electric Technical Support
representative.
NOTICE
METER DAMAGE
• Do not open the meter case.
• Do not attempt to repair any components of the meter.
Failure to follow these instructions can result in equipment damage.

Do not open the meter. Opening the meter voids the warranty.

Meter memory
The meter stores configuration and logging information in non-volatile
memory and a long-life memory chip.
The meter uses its non-volatile memory (NVRAM) to retain all data and
metering configuration values.
Meter battery
The internal battery in the meter keeps the meter’s clock running when it is
powered down to help maintain the meter time.
g)MPCB
Product description
3.1 Introduction
Applications
3RV motor starter protectors are compact current-limiting devices which have
been optimized for load feeders. They are used for protecting and switching
three-phase motors and other loads. The scalable setting ranges mean that a

suitable motor starter protector can provide protection for all standard motors
at ambient temperatures of ≤ 60 °C.
3RV1.11 motor starter protectors have a toggle switch. 3RV2 motor starter
protectors are uniformly fitted with rotary operating mechanisms.
Functions
The motor starter protectors protect loads against overloads and short
circuits. They also feature a lockable rotary operating mechanism / toggle
switch to facilitate manual switching on and off.
Motor starter protectors3RV2 motor starter protectors
Terminals:
• Up to two conductors with different cross-sections can be connected for
the main and auxiliary circuits.
• In the case of size S00 and S0 devices, the main circuit can be
connected by screw-type, spring-type and ring cable lug connection
terminals.
• In the case of size S00 and S0 devices,
• the auxiliary circuit can be connected using either screw terminals or
spring-loaded terminals.
• Some device versions are also available with ring cable lug connection.

Rotary operating mechanism :for switching on and off; display of a possible

trip; with integrated locking device. Switching on and off must be quick and
without interruption.
Label
Data Matrix code
Connection for mounting contactors, solid-state contactors, and soft starters
in various connection systems:
• Direct mounting using link modules
• Separately using connecting cables
TEST function:
• Enables testing of the release mechanism.
Motor current setting:

• The large rotary button provides an easy means of setting the device to
the rated motor
Functions
Motor and system protection is achieved using the following functions:
● Overload protection
● Short-circuit protection
● Phase loss sensitivity
Overload and short-circuit protection

Overload protection
● The rated current of the motor requiring protection (see rating plate) is set
on the setting scale. This sets the integrated overload protection to the motor
current.
Short-circuit protection
● The short-circuit release is factory-set to a multiple of the motor starter
protector's rated current (top value on the setting scale). The response value
of the short-circuit release (in A)is layered onto the front of the device. This
ensures problem-free ramping-up and safe protection for the motor.

Overload and short-circuit protectionRelease3RV motor starter protectors are

fitted with the following releases:
● Inverse-time delayed thermal overload release (exception: 3RV23)

The overload releases can be set on the load feeder (exception: 3RV16,
3RV27 and3RV28 circuit breakers).
● Instantaneous short-circuit release Tripping classes
3RV10 / 3RV20 / 3RV21 motor starter protectors conform to CLASS 10
according to IEC 60947-4-1. Some size S2 and S3 3RV20 motor starter
protector variants fulfill CLASS 20.
The tripping times according to IEC 60947-4-1 are as follows:
Table 5- 1 Tripping times dependent upon tripping classes according to
standard IEC 60947-4-1
Tripping class Tripping time tA in s at
7.2 x IA from cold
CLASS 10 A 2 < tA ≤ 10
CLASS 10 4 < tA ≤ 10
CLASS 20 6 < tA ≤ 20
CLASS 30 9 < tA ≤ 30
Short-circuit protection for starter combinations

• 3RV23 MSPs for starter combinations are motor starter protectors
without overload releases.
• They are always used in conjunction with a contactor and overload
relay, as the motor starter protector alone is not able to protect the
motor and itself against overloads.
• Function
• In the event of an overload, the overload relay opens the contactor. The
motor starter protector remains on. The motor starter protector will only
trip in the event of a short circuit in the feeder.
• The short-circuit release is factory-set to a multiple of the motor starter
protector's rated current (top setting scale). The response value of the
short-circuit release (in A) is layered onto the front of the device. This
ensures problem-free ramping-up and safe protection for the motor.

Advantage
• In the event of tripping due to overload, an automatic or manual reset

can be performed without having to open the control cabinet
• operation
• Setting the current
• Procedure Use a screwdriver to set the load's rated current (current
setting) on the scale on the motor starter protector.
In the context of this setting, a distinction is made between two fundamental

designs:
1. Stand-alone assembly: No directly mounted contactor and clearance of at
least 10 mm to left and right.
2. Side-by-side design: Directly mounted contactor or clearance to left and
right of less than10 mm (commonly used design).
Note the two possible setting marks on the adjusting knob:

● Dash marking: Setting mark for the motor starter protector in stand-alone
design.
● Triangular marking: Setting mark for the motor starter protector in side-by-
side design.
In both cases, you can use the full current range up to the scale mark at the
top forS00,S0, S2 and S3 motor starter protectors at ambient temperatures of
up to + 60 °C.
Testing the overload release The tables below show the procedures for
testing the motor starter protectors' over load release:
3RV2 motor starter protectors (size S00 and S0)

• Turn the rotary button from O to I.

• Insert a screwdriver into the test opening.
• Push the screwdriver to the left.
h)VACCUM CONTACTOR
Product designation Vacuum contactor

Product type designation 3TF6
General technical data
Size of contactor 14
Protection class IP
● on the front IP00
Reference code acc. to DIN EN 81346-2 Q
Ambient conditions
Ambient temperature
● during operation -25 ... +55 °C
Main circuit
Number of poles for main current circuit 3
Number of NO contacts for main contacts 3
Number of NC contacts for main contacts 0

Operating current
● at AC-3
— at 400 V rated value 820 A
● at AC-4 at 400 V rated value 360 A
3TF6944-0CF7 Subject to change without notice
● at AC-1
— at 400 V rated value 558 kW
● at AC-3
— at 400 V rated value 450 kW
● at AC-4 at 400 V rated value 191 000 W
Control circuit/ Control
Type of voltage of the control supply voltage AC
Control supply voltage at AC
● at 50 Hz rated value 110 ... 132 V
● at 60 Hz rated value 110 ... 132 V
Control version of the switch operating mechanism conventional
Auxiliary circuit
Number of NC contacts for auxiliary contacts
● instantaneous contact 4
Number of NO contacts for auxiliary contacts
● instantaneous contact 4
Installation/ mounting/ dimensions
Mounting type screw fixing
● Side-by-side mounting Yes
Height 295 mm
Width 230 mm
Depth 237 mm
Connections/Terminals
Type of electrical connection
● for main current circuit screw-type terminals
● for auxiliary and control current circuit screw-type terminals

i)Earth fault Relay
Features
• Identical time/ current characteristics on all taps.
• Self-powered, no necessity fo rseparate auxiliary supply.
• High torque, ensuring consistent timing even under adverse conditions.
• Very low overshoot.
• Simple construction, easily accessible.
Application
• Selective phase and earth fault protection, in time graded systems
for AC machines, transformers, feeders etc.

General description
• A non-directional heavily damped induction disc relay which has and
adjustable inverse time/current characteristic with a definite minimum
time. The relay has a high torque movement combined with low burden
and low overshoot.
• There lay disc is so shaped that as it rotates the driving torque
increases and offsets the changing restraining torque of the control
spring. This feature combined with the high torque of the relay ensures
good contact pressure even at currents near pick-up.
• Damping of the disc movement is by a removable high retentively
permanent magnet.
• The unique method of winding the operating coil ensures that the
time/current characteristics are identical on each of the seven current
taps. Selection of the required current setting is by means of a plug
setting bridge which has a single insulated plug.
• The maximum current tap is automatically connected when the plug is
withdrawn from the bridge, allowing the setting to be changed under
load without risk of open circuiting the current transformers.
• The IDMT relay has an auxiliary unit which is powered by a secondary
winding on the electromagnet through a rectifier and as such a separate
auxiliary supply is not required.
• The disc unit operates and closes its contacts, the auxiliary element
connected across the secondary winding on the electromagnet
operates, one normally open contact of the auxiliary element reinforces
the disc contact.
• Two other contacts of the auxiliary element are brought out to the
terminals of the relay The relay operating time can be adjusted by
movement of the disc backstop which is controlled by rotating a knurled
molded disc at the base of the graduated time multiplier scale.
• A high-set instantaneous over current/earth fault unit, typeCAG17 can
be fitted in the same case to provide instantaneous protection under
maximum short circuit conditions and to improved is crimination on time
graded protective systems.

• For full details of the high-set instantaneous units refer to relevant

publications.
• Type CDG 21 relay is a single pole type CDG 11 relay with a high-set
instantaneous unit. Type CDG 31 is a triple pole version of the type
CDG 11 with three over current units or two over current units and one
earth fault unit in the centre.
Type CDG 61 relay is a triple pole version of type CDG 21 relay.

ratings - 1A or 5A.
IDMT settings
• 50 - 200% in seven equal steps
of 25%.
of 10%.
of 5%.
• Other setting ranges available
on request.
Starting current
• 103 - 105% of current setting.
Closing current
• Not more than 130% of current
setting.
Instantaneous high set settings
• E/F 100 - 800%
• O/C 250 - 2000%
Time settings
Operating time
• 0 - 3 seconds or at 10 times
• 0 - 1.3 seconds current setting.
Resetting time
4 seconds for 1.3 with time seconds relay. multiplier9 seconds for 3 at 1.0.
seconds relay.

Overshoot
Overshoot time on removal of20 times setting current.
• Less than 0.065 second for 1.3seconds relay.
• Less than 0.04 second for 3seconds relay.
Thermal rating
• Maximum continuous current rating for 60ºC rise in coil
temperature.
• Withstand 20 times maximum setting current for 3 seconds.
Accuracy
Error class index
• E7.5 as per BS 142-19667.5 as per IS 3231-1965
Frequency error
• Timing error less than 8% for 2 Hz frequency variations. Time grading
unaffected by such small error, since all relays are similarly affected.
Temperature error
• For 10 times setting current, at ambient temperature between+45ºC
and .5ºC, percentage timing errors are as follows:
• 3 seconds relay: .3% and +4%
• 1.3 seconds relay: .4% and+4%.
Auxiliary units and operation indicators Self-powered auxiliary unit will have
following contact combinations:
1. S/R.2N/O
or
2.H/R.2N/O + 2 N/C.

j)TIMER
Introduction
Siemens offers 3RP15 electronic timers which meet the various control timing
requirements of industry. These timers comply with IEC 60 947-5-1IEC 61
000-6-2/EN 50 081-1 (EMC)Carry CE marking
Range
ON delay: Control supply voltage options -Discrete voltages Universal
voltage of 24 to 240V ac/dc
Time ranges - 0.5 -10 sec, 5 - 100 sec Universal time range of 0.05 sec to
100Hr
OFF delay: Control supply voltage options -Discrete voltages
Time ranges - 0.5 - 10 sec, 5 - 100 sec

Star Delta: Control supply voltage options -Discrete voltages Universal
voltages of 200 - 240V ac/dc, 380 - 440Vac/dc and 230 - 400V
ac/dc
Time ranges - 1- 20 Sec, 3 - 60 Sec with 50 msec changeover delay

Multifunction: 1 timer 8 functions (ON delay, OFF delay, ON+OFF delay,
Cyclic, Make Contact, Break contact, Pulse shaping, Additive ON
delay)

Control supply voltage options -Universal voltage of 24 - 240V ac/dc

Time ranges - Universal time range - 0.05 sec to 100Hrs
Application
• 3RP15 electronic timers can be used for all delayed switching applications
in control, starting and protection circuits. They are ideal for use in
application like machine tools, material handling, process control and
motor control.
• With multifunction timer, you can configure the same timer as per your
application need. Thus one timer is suited for many applications (refer
timing diagram)
Benefits
• Reduction in inventory cost (upto 80%) due to universal time and
universal voltage ON delay timers.
• High accuracy (<±1% repeat accuracy &<±5% setting accuracy) and
switching reliability.
6
• High mechanical endurance of 30x10 operations ensures trouble free
operation
• Integral surge suppression – No voltage surges during switching makes
them ideal for use with electronic circuits
• Clear visual status indication through 2 separate LEDs both for actuation
of control supply and the change over status.
• High level of Electromagnetic compatibility (EMC) i.e. maximum immunity to
interferences.
• No more failures of contactors in Star Delta starting during changeover
• Sleek 22.5mm wide housing and compact design saves panel space.
Thus 3RP timers ensure unmatched reliability and offer excellent ‘Value for
Money’

Note
• Changing the time setting ranges and the functions will only be effective
when carried out in de-energized (OFF) state.
• Start input B1 or B3 must only be triggered when the supply voltage is
applied.
• OFF delay timers are with aux. voltage (refer wiring diagram fig.1). Same
potential must be applied to A1 and B1, or A3 and B3.
• With the two-voltage version, only one voltage range must be connected.
• The activation of loads parallel to the start input is not permissible when
using AC control voltage (see diagram below).

k)Control Transformer
A control transformer is an isolation transformer designed to provide a high

degree of secondary voltage stability (regulation) during a short period
overload condition typically referred to as inrush to an inductive load.
Control transformers are also referred to as Industrial Control Transformers,

Machine Tool Transformers or Control Power Transformers.
Control Transformer Working Principle

Control transformer is a small dry-type transformer, which is mainly used to
change the voltage of AC power. It is wound by an iron core and a coil.
It can change not only the voltage of the alternating current, but also the
impedance. When the design power is not exceeded, the current can also be
changed. In different environments, the transformer also has different
applications.
Generally, it is used as a control lighting and indicator light source for

electrical appliances in machine tools and mechanical equipment.
The control transformer works according to the principle of electromagnetic

induction. A transformer has two sets of coils: A primary coil and a secondary
coil. The secondary coil is just outside the primary coil.
When alternating current is applied to the primary coil, the iron core of the
transformer generates an alternating magnetic field, and then the secondary
coil generates an induced electromotive force.
The primary winding and the secondary winding are commonly covered on
the iron core, so that they can be coupled with each other through magnetic
circuits and circuit coupling, so that energy is transmitted from the primary
winding to the secondary winding.
Relatively speaking, the main functions of more sophisticated equipment

include: Preventing electric shock to workers, preventing interference, and
obtaining appropriate voltage.

l)Variable Frequency Drives

How can they be operated properly and efficiently?

• The motor control world is very confusing, especially due to the use of
words interchangeably. A VFD (VARIABLE FREQUENCY DRIVE) IS
ALSO REFERRED TO AS A VARIABLE SPEED DRIVE, electronic motor
controller, adjustable speed drive, or an inverter.
• A VFD is an electric device that powers a motor by regulating the
frequency and voltage that is supplied to the electronic motor. Frequency
or hertz is closely related to the motor’s rotations per minute (RPMs)
which means that the faster the frequency, the faster the rotations per
minute.
• Therefore, in case an application doesn’t need the electric motor to run at
the maximum speed, the variable frequency device will be used to slow
down the frequency and voltage, and adjust to the electric motor’s load.
The VFD can turn the motor speed up or down depending on the
application’s motor speed requirements.
How to boost the efficiency of your VFD?
• Do your employees know how to maintain VFDs? To increase the

lifespan of your VFDs, ensure that your employees are well trained on
how to maintain and properly operate them. VFDs require similar safety
and equipment precautions applied to office equipment such as
computers and power supplies.
Keeping them clean:
• Variable frequency drives have side vents for cooling airflows that make
them susceptible to dust which can reduce their airflow and performance.
Dust on electronic devices causes malfunction and failure by absorbing
moisture.

Keeping them dry:

• VFDs rarely offer condensation protection. Therefore, if you operate your
VFD on a daily basis, the normal heat generated from the heat sink is
enough to protect it from condensation. However, if your unit is in
continuous operation, you should use a sealed and dust-tight enclosure
and a thermostatically controlled heater if the VFD is placed in a place
where condensation is likely to occur (like near a dehumidifier).
Keep all connections tight:
• While this is something obvious, checking connections is something most

people take for granted or do incorrectly. Mechanical vibrations, heat
cycles, and standard maintenance practices can all lead to substandard
connections. Excessive tightening or retorquing screws can ruin
connections. Poor connections lead to arcing of both input and output.
Arcing at the input can cause overvoltage faults and cause damage to
protective components. Arcing at the VFD output can cause overcurrent
faults and damage to power components. Additionally, loose wiring
connections also cause erratic operations, for instance, a loose speed
reference cable can eventually cause fluctuations in the drive speed,
which can result in machine damage, scrap, and injury.

i)POWER FLEX 755 AC DRIVE
Power Flex® 755 AC Drives are cost-effective and easy to use in

general purpose applications requiring safety features. They come standard
with built-in I/O, which is ideal for machine builders and system integrators
who want to reduce engineering costs, deliver machines to market faster, and
meet end user demand for more productive machines. Select size-optimized
drives for low-power applications where you have limited space available.
The Dual-port Ethernet/IP™ Option Module offers flexible, cost-effective
methods for leveraging Ethernet/IP networks.

Features
• Power ratings:
380…480V: 0.75…450 kW / 1…700 Hp / 2.1…832 A
• Frames 2 are IP20, NEMA/UL Type Open. Frames 1…7 can be
converted to IP20, NEMA/UL Type 1 with optional kit (20-750-NEMA1-
Fx), where x is the frame size of the drive.
• Light Duty rating only available on Frame 8…10 drives. Light Duty
allows 110% overload for 1 minute, and does not have a 3 second
overload rating.
• The 5th character determines Input Type; “1” = AC input with
precharge and DC terminals, and “A” = AC input with precharge and
no DC terminals. For DC input drives, see DRIVES-SG001, the Power
Flex Common Bus Configuration Selection Guide.
• The 11th character determines default Filtering and Common Mode
Cap jumper configuration; “J” = Installed, and “A” = Removed.
• The 12th character determines whether an internal dynamic braking
IGBT is included; “A” = Internal dynamic braking transistor installed,
and “N” = No internal dynamic braking transistor.
• The 6th character (designated by an * in this table) determines
Enclosure Type and Depth. “B” = IP20, NEMA/UL Type 1, MCC style
600 mm (23.6 in.) deep, and “L” = IP20, NEMA/UL Type 1, MCC style
800 mm (31.5 in.).
• Dual-port Ethernet/IP™ Option Module helps you leverage Ethernet/IP
networks, minimize the number of managed switches, and reduce
cabling needs when using Device Level Ring (DLR) networks.
• V/Hz control, vector control with FORCE™ technology and sensor
less vector control.
• Predictive diagnostics to extend the life of cooling fans and relay
outputs

• Slot-based architecture provides three option slots for feedback,

safety, communications, additional I/O or an auxiliary power supply.
• Configuration and programming via integral LCD Human Interface
Module (HIM), Drive Tools SP software, Connected Components
Workbench software or RS 5000 Logix Designer® software.
Available Embedded Safety Options

• Safe Torque-Off option is certified at PLe/SIL3 CAT 3,
• Safe Speed Monitor combines the Safe Torque-Off capability and an
embedded safety relay with the Rockwell Automation® Safe-Speed
Control core technology in one hardware option embedded in the
drive. Certified PLe/SIL3 CAT 4.
Device Logix
Control Technology Device Logix control technology provides you with

the flexibility to customize a drive to more closely match your application
needs. Device Logix controls outputs and manages status information locally
within the drive, allowing you to operate the drive independently or
complementary to supervisory control, helping to improve system
performance and productivity. You can use the Power Flex 750-Series.
• Speed reaction time by processing in the drive, which reduces

dependency on network throughput.
• Provide scaling, selector switches, or other data manipulations not already
built into the drive.
• Read inputs/write outputs and exclusively control the drive and Provide an
option for decision-making if communication is lost with main controller.
• Control other Power Flex drives via a Peer-to-Peer Ethernet/IP network
Device Logix is easily programmed via: RSLogix 5000 and Drive Tools SP
v 5.01.

Software
• Premier integration of RS 5000 Logix Designer and Power Flex® Drives
• Reduces drive system development time by as much as 70%
• Allows you to configure controller and drive network connections at the
same time
• Allows you to dynamically select drive parameters transmitted as network
I/O
• Offers continued use of Drive Tools™ SP software via import and export
functionality Includes built-in drive diagnostic, fault, alarm, and event
information
Drive Tools SP Software
• Family of software tools

• Easy online and offline programming
• RSLinx® connectivity
• Use Connected Components Workbench software with Microsoft
Visual Studio® technology to program your Power Flex® Drive

ii)PowerFlex 753 AC Drives

PowerFlex® 753 AC Drives are cost-effective and easy to use in general
purpose applications requiring safety features. They come standard with built-
in I/O, which is ideal for machine builders and system integrators who want to
reduce engineering costs, deliver machines to market faster, and meet end
user demand for more productive machines.
Select size-optimized drives for low-power applications where you have
limited space available. The Dual-port EtherNet/IP™ Option Module offers
flexible, cost-effective methods for leveraging EtherNet/IP networks.
Features
• Power ratings:
o 200...240V: 0.37…132 kW / 0.5…200 Hp / 2.2…477 A
o 380…480V: 0.75…250 kW / 1.0…350 Hp / 2.1…456 A
o 600V: 1.0…300 Hp / 1.7…289 A
o 690V: 7.5…250 kW / 12…263 A

• IP00/IP20 NEMA/UL Type Open, flange mount, IP54 NEMA/UL Type

12
• Dual-port EtherNet/IP™ Option Module helps you leverage EtherNet/IP
networks, minimize the number of managed switches, and reduce
cabling needs when using Device Level Ring (DLR) networks
• V/Hz control, vector control with FORCE™ technology and sensorless
vector control
• Predictive diagnostics to extend the life of cooling fans and relay
outputs
• Slot-based architecture provides three option slots for feedback, safety,
communications, additional I/O, or an auxiliary power supply
• Configuration and programming via integral LCD Human Interface
Module (HIM), DriveTools SP software, Connected Components
Workbench software, or Studio 5000 Logix Designer® software
Available Embedded Safety Options
• Safe Torque-Off option is certified at PLe/SIL3 CAT 3

• Safe Speed Monitor combines the Safe Torque-Off capability and an
embedded safety relay with the Rockwell Automation® Safe-Speed
Control core technology in one hardware option embedded in the drive.
Certified PLe/SIL3 CAT 4
Software
• Premier integration of Studio 5000 Logix Designer and PowerFlex®

Drives
o Reduces drive system development time by as much as 70%

o Allows you to configure controller and drive network connections
at the same time
o Allows you to dynamically select drive parameters transmitted as
network I/O
o Offers continued use of Drive Tools™ SP software via import and
export functionality

o Includes built-in drive diagnostic, fault, alarm, and event

information
o Provides one package to configure your entire Logix system
o Offers integrated drive profiles that reduce system development
time
• DriveTools SP Software
o Family of software tools
o Easy online and offline programming
o RSLinx® connectivity
o Includes DriveExecutive™ and DriveObserver™ software

m)OLR- Over Load Relay
SPECIFICATION
Product brand name - SIRIUS
Product designation solid-state overload relay
Product type designation - 3RB3
General technical data
Size of overload relay S0
Size of contactor can be combined company-specific S0
Power loss [W] for rated value of the current
● at AC in hot operating state 1.2 W
● at AC in hot operating state per pole 0.4 W
Insulation voltage with degree of pollution 3 at AC rated value 690 V
Surge voltage resistance rated value 6 kV maximum permissible voltage for
safe isolation
● in networks with grounded star point between auxiliary and auxiliary circuit
300 V
● in networks with grounded star point between auxiliary and auxiliary circuit
300 V
● in networks with grounded star point between main and auxiliary circuit
600 V

● in networks with grounded star point between main and auxiliary circuit
690 V
Protection class IP
● on the front IP20
● of the terminal IP20
Shock resistance 15g / 11 ms
● acc. to IEC 60068-2-27 15g / 11 ms; Signaling contact 97 / 98 in position
"Tripped": 9g / 11 ms Vibration resistance 1-6 Hz, 15 mm; 6-500 Hz, 20 m/s²;
10 cycles
Thermal current 25 A
Operating frequency rated value 50 ... 60 Hz Operating current rated value
25 A Operating power
● for three-phase motors at 400 V at 50 Hz 3 ... 11 kW
● for AC motors at 500 V at 50 Hz 4 ... 15 kW
● for AC motors at 690 V at 50 Hz 5.5 ... 22 kW
dimensions
• Mounting position any
• Mounting type Contactor
• mounting Height 87 mm
• mounting Width 45 mm
• mounting Depth 84 mm

n)SEMICONDUCTOR FUSE
• A fuse consists of a metal strip or wire fuse element, of small cross-
section compared to the circuit conductors, mounted between a pair of
electrical terminals, and (usually) enclosed by a non-combustible housing.
• The fuse is arranged in series to carry all the current passing through the
protected circuit. The resistance of the element generates heat due to the
current flow. The size and construction of the element is (empirically)
determined so that the heat produced for a normal current does not cause
the element to attain a high temperature.
• If too high a current flows, the element rises to a higher temperature and
either directly melts, or else melts a soldered joint within the fuse, opening
the circuit.
Breaking capacity
• The breaking capacity is the maximum current that can safely be
interrupted by the fuse. This should be higher than the prospective short-
circuit current. Miniature fuses may have an interrupting rating only 10
times their rated current. Fuses for small, low-voltage, usually residential,
wiring systems are commonly rated, in North American practice, to
interrupt 10,000 amperes.
• Fuses for commercial or industrial power systems must have higher
interrupting ratings, with some low-voltage current-limiting high
interrupting fuses rated for 300,000 amperes.
• Fuses for high-voltage equipment, up to 115,000 volts, are rated by the
total apparent power (megavolt-amperes, MVA) of the fault level on the
circuit.
• Some fuses are designated high rupture capacity (HRC) or high breaking
capacity (HBC) and are usually filled with sand or a similar material.

• Low-voltage high rupture capacity (HRC) fuses are used in the area of
main distribution boards in low-voltage networks where there is a high
prospective short circuit current.
• They are generally larger than screw-type fuses, and have ferrule cap or
blade contacts. High rupture capacity fuses may be rated to interrupt
current of 120 kA.
• HRC fuses are widely used in industrial installations and are also used in
the public power grid, e.g. in transformer stations, main distribution boards,
or in building junction boxes and as meter fuses.
• In some countries, because of the high fault current available where these
fuses are used, local regulations may permit only trained personnel to
change these fuses. Some varieties of HRC fuse include special handling
features.

o)current transformer
• A current transformer has a primary winding, a core and a secondary

winding, although some transformers, including current transformers,
use an air core. While the physical principles are the same, the details
of a "current" transformer compared with a "voltage" transformer will
differ owing to different requirements of the application.
• A current transformer is designed to maintain an accurate ratio between

the currents in its primary and secondary circuits over a defined range.
• The alternating current in the primary produces an alternating magnetic

field in the core, which then induces an alternating current in the
secondary. The primary circuit is largely unaffected by the insertion of
the CT.
• Accurate current transformers need close coupling between the primary

and secondary to ensure that the secondary current is proportional to
the primary current over a wide current range.
• The current in the secondary is the current in the primary (assuming a

single turn primary) divided by the number of turns of the secondary. In
the illustration on the right, 'I' is the current in the primary, 'B' is the
magnetic field, 'N' is the number of turns on the secondary, and 'A' is an
AC ammeter.
• Current transformers typically consist of a silicon steel ring core wound

with many turns of copper wire as shown in the illustration to the right.
• The conductor carrying the primary current is passed through the ring.
The CT's primary, therefore, consists of a single 'turn'.
• The primary 'winding' may be a permanent part of the current

transformer, i.e. a heavy copper bar to carry current through the core.
Window-type current transformers are also common, which can have
circuit cables run through the middle of an opening in the core to
provide a single-turn primary winding.

SPECIFICATION
range PowerLogic
product name CT
product or component type Current transformer
secondary current 5A
accuracy class Class 0.5 at 12 VA

Class 1 at 15 VA
p)Motor protection Relay
• Motor protection relay helps to prevent the motor burn when there is
any fault in motor that may cause more current than motor capacity is
flowing or for some reason more voltage is supplied than the prescribed
voltage.
• Motor Protection relay is used to provide various protections for
the motors.
E300/E200 Electronic Overload Relays
• Our Bulletin 193/592 E300™ (networked) and E200™ (non-networked)

Electronic Overload Relays are the newest technologies for overload
protection. The modular design, communication options, diagnostic
information, simplified wiring, and integration into Logix technology
make them the ideal overload for motor control applications in an
automation system.

Features
• Includes intelligent motor control (EtherNet/IP, DeviceNet, and non-

networked options available)
• Offers modular solution with wide current range & adjustable trip class
• Provides enhanced diagnostic information for single & three phase

applications
• Includes integrated I/O (additional expansion I/O available)
• Offers simplified wiring and easy integration into Logix

• Offers the ability to customize the E300 Overload Relay by selecting

one each of the following modules:
o 193-ECM E300/E200 Communication Module
o 193-EIO E300/E200 Control Module
o 193-ESM or 592-ESM E300/E200 Sensing Module
q)Core Balance Current Transformer-CBCT
• Core Balance Current Transformer or CBCT is a ring type current

transformer through center of which a three core cable or three single
core cables of three phase system passes.
• This type of current transformer is normally used for earth fault
protection for low and medium voltage system
• Secondary of CBCT is connected to Earth Fault Relay. During normal
operating condition as the vector sum of three phase current i.e.
(Īa + Īb + Īc =0) is zero therefore no residual current in the primary will
be present. Here residual current means zero sequence current.
Therefore there will not be any flux developed in the CBCT core and
hence no current in the secondary circuit of CBCT.

Advantage of Core Balance Current Transformer:
• The advantage of using CBCT for earth fault protectionis that only one
CT core is used instead of three core as in conventional system where
the secondary winding of three cores are connected residually.
• Thus the magnetizing current required for the production of a particular

secondary current is reduced by one third which is a great advantage
as the sensitivity of protection is increased.
• Also, the number of secondary turn does not need to be related to the
cable rated current because no secondary current flows under normal
operating condition as the currents are balanced.
• This allows the number of secondary turns to be chosen to optimize the

effective primary pick-up current.
• Core Balance Current Transformer is normally mounted over a cable at

a point close to the cable gland of the Switchgear. In case cables are
already laid in a Switchgear, physically split core, which is also known
as Slip-over type CT, are used.

r)Current Transducers
• Current Transducers convert various electrical power line parameters

viz. Voltage, Current, Frequency, Power Factor, Active power, Reactive
power, Apparent power into DC current or voltage output.
• The output of transducer is independent of load impedance.
• These are used in various electrical, thermal, chemical & other power
plants to monitor processed data either locally or from remote using
various devices such as indicating meters, data loggers, recorders,
SCADA systems.
• These transducers can also be used as external units in conjunction

with analog or digital indicators.
Features :
• TYPE:DC or AC : 1Ph / 3Ph -1 EL / 3Ph – 2EL 3W / 3Ph – 3EL – 4W

• Input Parameter: DC : Voltage, Current
• AC : Voltage, Current, Watt, Var, VA, Frequency, Power Factor
• VOLTAGE:DC : 500V, AC : 500V
• CURRENT:DC : 5A (for higher ranges: 50 — 300mV ext. Shunt) , AC :
1A / 5A.

• FREQUENCY: 50 / 60Hz ±5Hz., 400Hz ± 20Hz.(Any other Frequency

on request).
• POWER FACTOR:0.5 (Lag) — Unity — 0.5 (Lead)
• POWER: Please specify.
• OUTPUT RANGE: Single Output /Dual Output.
• Range :
• Current Max. Load :
• Voltage min. Load :
• Accuracy : ± 0.5% of full scale for Voltage, Current, Watt, Var, VA,
Power Factor
• Aux. Supply : 63.5V, 110V, 220V, 230V, 240V, 380V, 415V, 440V AC
(for ±10°/0V, 50 / 60Hz). 24V, 48V, 110V, 220V DC (for ± 10%V).
• VA Burden : For VOLTAGE ≤ 2, For CURRENT ≤ 0.5, For AUX.

SUPPLY ≤ 4
• Voltage : 120% of nominal
• Short time : 150% of nominal
• Current : 120% of nominal
• short time : 10 times of nominal
• Response Time : 300 m. sec.

• Open Ckt. Voltage : 22V max.
• Impulse Voltage : 5kV, 1.2 / 50 psec. (0.5j)
• Dielectric Test : Greater than 20M ohms at 500V DC
• Operating temp : 2kV RMS for 1 minute. (4kV on request)
• Storage Temp : 0°C to 55°C.
• Humidity : Up to 95% RH
• Conforms To : I.S.12784 / I.E.C. 688.
Note:
1.TRUE RMS sensing Voltage & Current Transducers are available on

request – Crest Factor up to 3.
2.Transducers with specification other than mentioned above can be supplied

subject to technical feasibility.
3.In dual output Transducers, the output are available in two types-with &
without isolation between these outputs
4.Self-powered AC Voltage, Current, Frequency, PF & Power Transducers

are available on request.
Self – powered Voltage Transducer operates from 5% of input signal.
Self-powered Current Transducer operates from 2% of Input signal.
Self-powered Frequency, Power & Power Factor transducer operates on

±10% rated voltage.

s)Omron 2 C/O relay MY2N-GS AC220/240 with Base PYF08A-N, Coil

Supply 230VAC
• Electrical relays are one of the important electrical devices that are
used in many heavy-duty machines, such as air conditioners.
• These devices may be less known to common men, but any person
having some technical knowledge probably know about it.
• Let’s understand these devices and their usage in more details.
working
• A simple electromagnetic relay is made of an electromagnet, some

moving parts, and contacts. The electromagnet is used as a sensing
element which when receive electrical current, it closes or opens
contacts of the relay – depending on relay type – to turn ON or turn
OFF the load, e.g. compressor of an air conditioner and electricity
supply to the home.

• The load can be any electrical device which you want to switch with a
relay. The supply of electricity to the load goes from the contacts of
relays which are opened and closed by an electromagnet when they
receive electrical signal at their sensing element.
• Solid state relay works very differently than electromechanical relay;

they don’t have any moving parts.
• They rely on properties of the semiconductor for functioning. These

relays are very reliable, durable, and fast compared to
electromechanical relays, but they are very costly.
• we can switch a load with the help of a button on the electrical board,
then why there is a need of relays? As I mentioned before, relays have
the property that they can be switched electrical without the need of our
physical intervention.
• For example, If you want your water pump to be turned off automatically
when the water tank of your house fills completely.
• Then, you will use a relay and a kind of sensor for sending an electrical
signal to relay when the tank fills completely. After receiving the signal,
the relay opens its contacts to turn OFF the water pump.

12.BILL OF MATERIAL FOR LDB
S.NO DESCRIPTION RATING MODEL NO MAKE QTY

MCCB WITH
3VA1163-
1 THERMAL MAGNETIC TP,63A,50KA SIEMENS 1
5EE32-0AA0
RELEASE
3VA9157-
2 EXTENDED HANDLE --- 1
OFK51
3 RCCB DP,80A,30mA 5SV43170RC SIEMENS 1
2.5KVA,60MIN CRUZE+2.5KV LUMINOU
4 INVERTER 1
BACKUP A S
EXIDE SF
5 BATTERY 100AH,12V EP-100-12 3
Sonic
LOCAL& REMOTE 3SB5000-
6 230VAC SIEMENS 1
SELECTOR SWITCH 4AC01
3SB50 00-
7 PUSHBUTTON RED SIEMENS 1
0AC01
3SB50 00-
8 PUSHBUTTON GREEN SIEMENS 1
0AE01
3SB5000-
9 SELECTOR SWITCH 230VAC SIEMENS 1
2AB01
63A,1NO+1N 3RT2037-
10 POWER CONTACTOR SIEMENS 1
C 1AG20
16A,1NO+1N 3RT2018-
11 POWER CONTACTOR SIEMENS 1
C 1AF01
12 MCB 6A DP 10 KA 5SL42067RC SIEMENS 23
14 MCB 25A,DP,10 KA 5SL42257RC SIEMENS 2
17 RCCB DP,25A 5SV43120RC SIEMENS 11
18 RCCB DP,25A 5SV43120RC SIEMENS 3
230V/24V,2KV PRAGAT
19 TRANSFORMER 1
A HI

S.NO DESCRIPTION RATING MODEL NO MAKE QTY

CONTROL TB connectw
20 4Sq.mm CX4 110
SCREWLESS ell
POWER TB BUSBAR connectw
21 50SQ.mm CBB50 2
TYPE ell
PANEL ENCLOSURE
FABRICA
22 1000(H)*1200(W)*500( IP-54-RAL 7035 1
TED
D)
3RX25mmX6
COPPER BUSBAR
23 mm TINNED 1
(PH,N,E)
CU.
24 PANEL LAMP 230VAC,5W PHILIPS 1
25 DOOR LIMIT SWITCH 230VAC KAYCEE 1
26 SPACE HEATER 230VAC ESH-02SC ENCORE 1
GIRISEC
27 THERMOSTART 230VAC 205C 1
O


a) Contactor
A contactor is one of the main electrical circuit parts, which can stand on its
own power control device or a part of a starter. They are used to connect
and break power supply lines running through power lines or repeatedly
establish and interrupt electrical power circuits. These are used in light
loads, complex machine control. They are used with motors, transformers,
heaters. It can be considered as an intersection point between the control
circuit and power circuit because it is controlled by the control circuit, it also
controls the circuit between power and loads. This article focuses on the
importance of contactor in and electric field.
Definition: Contactors are electrically controlled switching devices which

are used for switching electrically. The basic operation of this is similar to a
relay, but the only difference is that contractors can carry large current
compared to relay up to 12500A. They cannot provide short circuit or
overload protection but can break the contact when coil excites.
Working
An electromagnetic field is generated whenever current flows where the
moving coils attract each other. A large amount of current is drawn initially
by an electromagnetic coil. The moving contact is pushed forward by
moving core, as a result, the force created by the electromagnet holds the
moving and fixed contacts together.
• On de-energizing, the contactor coil gravity or spring moves back the

electro-magnetic coil to its initial position and there is no flow of
current in the circuit.
• If contactors are energized with AC current, a small portion of the coil
is the shaded coil, where the magnetic flux in the core is slightly
delayed. This effect is too average as it prevents the core from
buzzing at twice line frequency. There are internal tipping point
processes to ensure rapid action so that contactors can open and
closed very rapidly.

• From the figure the supply is given using a switch that is when the
switch is closed current flows through the contactor coil and attaches
the moving core. The contactor attached to the moving core closes
and the motor starts running. When the switch is released the
electromagnetic energizes spring arrangement pause the moving coil
back to its initial position and power supply to the motor is cut off.
Features of Contactors
• A contactor is a relay that is used for switching power.
• They usually handle very heavy loads like an electric motor, lighting
and heating equipments and so on.
• Though their output is used for switching very high loads, they are
controlled by a circuit with very less power.
• According to the loads they handle, they vary in sizes from a small
device to as huge as a yard.

• Though they are used for switching purposes, they do not interrupt a
short-circuit current like a circuit breaker.
• They have ratings ranging from a breaking current of a few amperes
and 24 DC volts to thousands of amperes with many kilo volts.
Simple working
If the electromagnetic coil of the contactor is given an AC voltage source,

the switch on the contactor will be connected, or change its condition, the
original FF becomes ON and vice versa which initially ON becomes OFF.
To understand the working principle of a contactor can be seen from the

following contactor scheme image:
When the A1 and A2 terminals are given a voltage source, the coil will
dance the switch lever on the contactor, each switch with type NO (03 04,
13 14, 23 24) will turn ON and each switch type NC (31 32, 41 42) will be
changed to OFF.
NO type contactor switches generally have a capacity to flow larger than

the NC contactor type switch.

b)INVERTER
Homes and commercial establishments have higher power needs. Also,
frequent power cuts can hamper the overall
performance of the appliances. Luminous higher KVA offers high quality and
reliable power back-up solution for running officeBand sensitive equipments.
Key Features
• High over-load handling capacity
• Installation and maintenance friendly
• Advanced battery management which enhances battery life up to 70%
• Intelligent battery charging mechanism
TECHNICAL SPECIFICATIONS
Attribute Value
Model 2.5KVA
Input Voltage 100-285v
Output Max. Bulb Load 2KW
Battery Max. Charging Current 21A

Gross Weight in kg 23
Dimension LXWXH(cm) 28X30.5X28
Protection Overload, Short-circuit, Battery
Deep Discharge Protection &
Battery Reverse Polarity Protection
c)Residual Current Circuit Breaker (RCCB)
A Residual Current Circuit Breaker (RCCB) is an important safety measure

when it comes to protection of electrical circuits. It is a current sensing
device, which can automatically measure and disconnect the circuit whenever
a fault occurs in the connected circuit or the current exceeds the rated
sensitivity.
Purpose of RCCB
Residual Current Circuit Breakers are aimed at protecting an individual from
the risks of electrical shocks, electrocution and fires that are caused due to
faulty wiring or earth faults. RCCB is particularly useful in situations where
there is a sudden earth fault occurring in the circuit.

Principle of RCCB
RCCB works on the principle of Kirchhoff’s law, which states that the
incoming current must be equal to the outgoing current in a circuit. RCCB
thus compares the difference in current values between live and neutral
wires. Ideally, the current flowing to the circuit from the live wire should be the
same as that flowing through the neutral wire. In case of a fault, the current
from the neutral wire is reduced, the differential between the two known as
Residual Current. On spotting a Residual Current, the RCCB is triggered to
trip off the circuit.
A test circuit included with the Residual Current device ensures that the
reliability of RCCB is tested. When the test button is pushed, the current
starts to flow through the test circuit. As it creates an imbalance on the
neutral coil of the device, the RCCB trips and supply is disconnected thereby
checking RCCB’s reliability.
Benefits of RCCB
• Provides protection against earth fault as well as any leakage current
• Automatically disconnects the circuit when the rated sensitivity is

exceeded
• Offers possibility of dual termination both for cable and bus bar
connections
• Offers protection against voltage fluctuation as it includes a filtering
device that guards against transient voltage levels.
Sensitivity of RCCB
A human being is able to sustain an electric shock to the extent of 30 mA.
While upto 10 mA may just evoke a prickling sensation, 10 mA onwards may
lead to muscular contraction, further leading to a respiratory paralysis at
around 30mA. RCCBs are therefore designed to look for small changes in
residual current. In cases where protection from fire is sought, RCCBs are
also used to track higher changes in residual current of up to 300mA.

Limitations of RCCB
While RCCB has many advantages, it has some limitations as well:
• RCCB does not guarantee to operate if none standard waveforms are

generated by loads. It’s mainly because RCCB is designed to operate
on normal supply waveforms.
• There might be some unwanted tripping of RCCB. It’s mainly because
whenever there are sudden changes in electrical load, there can be
small current flow to earth especially in old appliance.
• RCCB does not protect from current overload. It has been designed to
protect only when the live current and neutral current are different.
However, a current overload cannot be detected.
• RCCB does not protect against line-neutral shocks. It’s mainly because
current in them is balanced. The current gets balanced as both
terminals are held together.
• RCCB does not protect from the overheating that strike if conductors
are not properly screwed into terminals.

14.BILL OF MATERIAL FOR CD
S.N ITEM DESCRIPTION

QTY SUPPLIER MODEL NUMBER
O DESCRIPTION DETAILS
PANEL
900HX1000WX6
FOCAAL -
00D WITH
1 CD PANEL 1 FABRICATE ____
100MM BASE
D
FRAME+15MM
AVP
2 MCB 6A,DP 1 SIEMENS 5SL42067RC
3SB5000-
LOCAL/REMOT 2WAY STAY PUT
9 1 SIEMENS 4AC01,3SB5400-
E SELECTOR SWITCH
0E,3SB5400-0F
3SB5000-
2WAY STAY PUT
10 1 SIEMENS 4AC01,3SB5400-
AUTO/MANUAL SELECTOR SWITCH
0E,3SB5400-0F
(AUTO 3SB5000-
2WAY STAY PUT
11 CCR/AUTO 1 SIEMENS 4AC01,3SB5400-
SELECTOR SWITCH
DESK) 0E,3SB5400-0F
EMERGENCY RED COLOR WITH 3SB52030UC01,3SB
12 1 SIEMENS
PUSH BUTTON 2NC 5400-0F
3SB5000-
0AC01,3SB5400-
RED& GREEN
SPARE PUSH 0E,3SB5400-
13 COLOR WITH 1 SIEMENS
BUTTON 0F,3SB5000-
2NO+2NC
0AE01,3SB5400-
0E,3SB5400-0F


3SB5000-0AC01,
BYPASS PUSH RED COLOR WITH
14 1 SIEMENS 3SB5400-0E,
BUTTON 2NO+2NC
3SB5400-0F
FAULT 3SB5000-0AG01,
WHITE COLOR
15 ACCEPT PUSH 1 SIEMENS 3SB5400-0E,
WITH 2NO+2NC
BUTTON 3SB5400-0F
3SB5000-0AB01,
FAULT RESET BLACK COLOR
PUSH BUTTON WITH 2NO+2NC
3SB5400-0F
SPEED INC.
YELLOW COLOR 3SB5000-0AD01,
17 PUSH BUTTON 1 SIEMENS
WITH 2NO 3SB5400-0E,
(HOIST)
SPEED DEC. 3SB5000-0AF01,
BLUE COLOR WITH
18 PUSH BUTTON 1 SIEMENS 3SB5400-0E,
2NO+2NC
(HOIST) 3SB5400-0F
3SB5000-0AE01,
SIREN ON GREEN COLOR
3SB5400-0F
AUTO START 3SB5400-7EC,
GREEN COLOR
20 IL PUSH 1 SIEMENS 3SB5400-0E,
WITH 2NO+2NC
BUTTON 3SB5400-0F
3SB5400-7EE,
AUTO STOP IL RED COLOR WITH
PUSH BUTTON 2NO+2NC
3SB5400-0F
CHAIN START 3SB5400-7EC,
GREEN COLOR
22 IL PUSH 1 SIEMENS 3SB5400-0E,
WITH 2NO+2NC
BUTTON 3SB5400-0F
3SB5400-7EE,
CHAIN STOP IL RED COLOR WITH 3SB5400-0E,
23 1 SIEMENS
PUSH BUTTON 2NO+2NC 3SB5400-0F


UP IL PUSH 3SB5400-
YELLOW COLOR
24 BUTTON 1 SIEMENS 7CD,3SB5400-0E
WITH 2NO+2NC
(HOIST) 3SB5400-0F
DOWN IL 3SB5400-7CF
BLUE COLOR WITH
25 PUSH BUTTON 1 SIEMENS ,3SB5400-
2NO+2NC
(HOIST) 0E,3SB5400-0F
HOIST STOP IL RED COLOR WITH 3SB5400-
26 1 SIEMENS
PUSH BUTTON 2NC 7EE,3SB5400-0F
INCOMER ON 3SB5400-7EC,
GREEN COLOR
27 IL PUSH 1 SIEMENS 3SB5400-
WITH 2NO+2NC
BUTTON 0E,3SB5400-0F
INCOMER OFF 3SB5400-
RED COLOR WITH
28 IL PUSH 1 SIEMENS 7EE,3SB5400-
2NO+2NC
BUTTON 0E,3SB5400-0F
INCOMER 3SB5400-
GREEN COLOR
29 VACCUM ON IL 1 SIEMENS 7EC,3SB5400-
WITH 2NO+2NC
PUSH BUTTON 0E,3SB5400-0F
INCOMER
3SB5400-
VACCUM OFF RED COLOR WITH
30 1 SIEMENS 7EE,3SB5400-
IL PUSH 2NO+2NC
0E,3SB5400-0F
BUTTON
WIND SPEED
31 HIGH & SPARE INDICATION LAMP 3 SIEMENS 3SB5285-6HC02
INDICATION
3SB5400-
DSS START IL GREEN COLOR
32 1 SIEMENS 7EC,3SB5400-
0E,3SB5400-0F
3SB5400-
DSS STOP &
RED COLOR WITH 7EE,3SB5400-
33 LDB OUTDOOR 2 SIEMENS
2NO+2NC 0E,3SB5400-0F
IL PB


3SB5400-7EC
GREEN & RED
SPARE IL &3SB5400-7EE,
34 COLOR WITH 1 SIEMENS
PUSH BUTTON 3SB5400-0E,
2NO+2NC
3SB5400-0F
INCOMER TRIP AMBER COLOR
35 1 SIEMENS 3SB5285-6HL02
LAMP INDICATION LAMP
3WAY 3SB5000-4HB01,
BLOCK COLOR
36 SELECTOR 1 SIEMENS 3SB5400-0E,
WITH 2NO+2NC
SWITCH 3SB5400-0F
37 HOOTER 230V AC HOOTER 1 SECO A102/AU-
230V AC GIRISH
38 THERMOSTAT 1 205-C
THERMOSTAT EGO
SPACE
39 80W SPACE HEATER 1 REPUTED ESH02SC
HEATER
ESSENTIAL-PS-
POWER
40 5A , 24V DC 1 PHOENIX 1AC/24VDC/120W/E
SUPPLY UNIT
E
41 HMI 19 inch 1 AB 2711P-T19C22D9P
POWER 230V AC
42 1 ROMA D-3 21372
SOCKET POWER SOCKET
230V AC , WL200W1XPL-
43 PANEL LAMP 1 PHILIPS
PANEL LAMP S/4P11WHFMACP
DOOR
DOOR LIMIT
44 OPERATED 1 KAYCEE KLS-001X-0A
SWITCH
SWITCH
45 FAN 4" 230V AC FAN 1 REXONARD REC=21725 A2
FILTER
WITH
FILTER WITH JS AV-03
46 LOUVERS 2 ELETTRO
LOUVERS
FINGER
GUARD


TERMINAL 6 SQ.MM SCREW CONNECTW
47 3 CX6
BLOCK LESS TYPE POWER ELL
TERMINAL 6 SQ.MM SCREW CONNECTW
48 3 CX6
BLOCK LESS TYPE EARTH ELL
AS
TERMINAL 4 SQ.MM SCREV PER CONNECTW
49 CX4
BLOCK LESS TYPE RE ELL
Q
4 SQ.MM SCREW AS
TERMINAL LESS TYPE FUSE PER CONNECTW
50 CXF4L110-240V
BLOCK WITH LED RE ELL
INDICATION Q
51 RELAY 2C/O,24VDC 2 OMRAN _
SINGE AXIS
52 JOY STICK JOYSTICK 1 GESSMANN CXF4L110-240V
CONTROLLER
AS
2.5SQ.MM CABLE
PER
53 FRLS CABLE (RD,BK,GN/YE,BU,W _ _
RE
H)
Q
AS
1.5SQ.MM CABLE
PER
54 FRLS CABLE (RD,BK,GN/YE,BU,W _ _
RE
H)
Q
AS
PANEL LIKE DUCT, DIN PER
55 _ _
ACCESSORIES RIAL,ETC RE
Q
CONTROL CHAIR WITH HEAD GREEN
56 1 _
DESK CHAIR REST SOUL

15.Technical data of components

a)Power supply unit
Primary-switched ESSENTIAL POWER supply for DIN rail mounting, input:
1-phase, output: 24 V DC /120 W
Technical data
1. Input data
• Nominal input voltage range 100 V AC ... 240 V AC
• Input voltage range 85 V AC ... 264 V AC (< 100 V AC derating 1%/V
AC)
• AC frequency range 47 Hz ... 63 Hz
• Discharge current to PE < 0.25 mA (264 V AC)
• Current consumption 2.2 A (115 V AC)
2. Output data
• Nominal output voltage 24 V DC ±2 %
• Setting range of the output voltage (USet) 22 V DC ... 28 V DC (max.
power ≤ 120 W)
• Nominal output current (IN) 5 A
3. General
• Net weight 0.54 kg
• Operating voltage display Green LED
• Efficiency 85 % (115 V AC)
• 88 % (230 V AC)
• Insulation voltage input/output 3 kV AC
• Insulation voltage input / PE 2 kV AC
• Insulation voltage output / PE 0.5 kV AC

• Connection data, input

• Connection method Screw connection
• Conductor cross section AWG min. 18
• Conductor cross section AWG max. 8
• Stripping length 7 mm
• Connection data, output
• Connection method Screw connection
• Conductor cross section AWG min. 24
• Conductor cross section AWG max. 12
• Stripping length 7 mm
4. Dimensions
• Width 40 mm
• Height 123.6 mm
• Depth 117.6 mm
• Installation distances left/right 10 mm
• Installation distances top/bottom 50 mm
5. Ambient conditions
• Degree of protection IP20
• Ambient temperature (operation) -20 °C ... 70 °C
• Ambient temperature (storage/transport) -40 °C ... 85 °C
• Max. permissible relative humidity (operation) ≤ 95 % (at 25 °C, non-
condensing)
6. Standards and Regulations
• Electromagnetic compatibility Conformance with EMC Directive
2014/30/EU
• Noise immunity EN 61000-6-2 EN 61000-6-1
• Low Voltage Directive Conformance with Low Voltage Directive
2014/35/EC
• Standard - Electrical safety EN 60950-1
• Standard – Safety extra-low voltage EN 60950-1 (SELV)
• UL approvals UL/C-UL listed UL 508
• Shock IEC 60068-2-27, 27, half sinusoidal wave: 50g for 11 ms; 3x per
direction, 9x overall
• Vibration (operation) IEC 60068-2-6, sinusoidal waves: 10 Hz ... 500
Hz, 19,6 m/s² (2g peak),
• 10 min. per cycle, 60 min. in the X direction
• Approval - requirement of the semiconductor industry with regard to
mains voltage dips SEMI F47 - 0706 (200 V AC)

b)HMI
• Our Bulletin 2711P Panel View plus 7 Graphic Terminals are available in
standard and performance versions and offer display sizes from 4...19 in.
with widescreen options. You can use Factory Talk View Machine Edition
to build your application and help simplify configuration and strengthen
your Integrated Architecture solution. These terminals include Ethernet
connectivity and enable you to monitor applications from remote locations
with VNC connectivity
Product Specifications
Attribute 2711p-t19c22d9p
Display size 19 inch display (411 x 485 mm)
Display type Color TFT LCD, 18-Bit Color Graphics
Operating system Microsoft windows ce 6.0 r3
CPU X86 – 1.3 GHz
Ram 512 mb
Internal storage 512 mb storage, 80 mb nonvolatile
storage for applications
Real-time clock Yes, battery-backed time clock
timestamps critical data. Accuracy
+/-2 minutes per month

Input power Dc (18...30v dc) and ac (100...240v ac)

Standard software Factory talk machine edition 7.0 or later,
factory talk viewpoint, pdf viewer,
Activex controls, remote terminal control,
ftp server
Ports SD cord, USB, Ethernet.
Operator input Touch
Display size, diagonal 19-in.
Power consumption, DC 50 W max, 105VA
Performance Version: Offers display sizes from 7...19 in. with wide screen
and keypad options
• Includes video playback support which provides advanced user help
capabilities
• Includes RDP client feature to create thin client terminals
• Features Ethernet ports that support DLR, linear, or star network
topologies
• Includes option for hygienic stainless steel 304 bezel
• Includes option for conformal coating on 9 in. and 12 in. DC touch-only
displays
Features
• Uses Windows CE 6.0 standard features and color TFT LCD, 18-bit
color graphics
• Monitors applications from a remote location with VNC connectivity
• Uses an SD card to copy and restore the operator interface quickly
• Includes email and texting notification capabilities
• Includes 512 MB RAM and 512 MB nonvolatile memory
(approximately 80 MB free user memory)

c)HOOTER
1. Salient Features:
• Advanced fail proof piezo technology
• High Volume Audio output
• Multi tone selection
• Audio 'ON' LED indication
• Wide range of input supply
• Low power consumption.
• Reduced depth - 50mm
• Both Flush and panel mounting.
• Available in three color.
• Electronic Buzzer
2. Technical Specification
• Auxilary Supply:
− 75 to 275V AC / DC
− 20 to 60 Volt DC
− Output:
− 95 dB @ 1meter
• Burden:
− 1.5 Watt
− Tone:
− Site selectable 3 tones

3. Weight:
• 250 gms (Approx)
4. Panel Cutout:
• 91 X 91 mm (H X W) +/- 05mm

16. BILL OF MATERIAL FOR LCS
(PSR1
SL. MODEL
DESCRIPTION MAKE &PSR
NO NUMBER
2)
EMERGENCY STOP STATION 6
ENCLOSURE:
1 250(H)X170(W)X110(D), FOCAAL - 1
CANOPY
ILLUMINATION TYPE
EMERGENCY STOP PUSH
2 BUTTON(RED) MUSHROOM TEKNIC 2ALRMPP4L 1
HEAD WITH PADLOCKING
ARRANGEMENT
CONNECT
3 CX4 10
SCREWLESS TYPE TBS WELL
LCS TYPE -1 TRAVEL DRIVE
4
(FIXED&PENDULUM)
ENCLOSURE:
1 350(H)X300(W)X150(D), FOCAAL - 1
CANOPY
3SB5000-
TRAVEL FORWARD PUSH OAE01,3SB540
2 SIEMENS 1
BUTTON,GREEN COLOUR 0-OE,3SB5400-
WITH 2NO+2NC OF
3SB5000-
TRAVEL REVERSE PUSH OAC01,3SB540
3 SIEMENS 1
BUTTON ,RED COLOUR WITH 0-OE,3SB5400-
2NO+2NC OF
ILLUMINATION TYPE
EMERGENCY STOP PB 1
4 (RED) MUSHROOM HEAD TEKNIC 2ALRMPP4L
WITH PADLOCKING
ARRANGEMENT
3SB5000-
BY PASS PUSH BUTTON BULE OAF01,3SB5400 1
5 COLOUR SIEMENS -OE,3SB5400-
WITH 2NO+2NC OF

SL. MODEL
DESCRIPTION MAKE QTY
NO NUMBER
3SB5000-
4AC01,3SB5400
6 SIEMENS 1
TRAVEL LOCAL/REMOTE WITH -OE,3SB5400-
2NO+2NC OF
3SB5000-
TRAVEL SPEED INCREASE OAD01,3SB540
7 SIEMENS 1
PUSH BUTTON ,YELLOW WITH 0-OE,3SB5400-
2NO+2NC OF
3SB5000-
TRAVEL SPEED DECREASE OAF01,3SB5400
8 SIEMENS 1
PUSH BUTTON ,BULE COLOUR -OE,3SB5400-
WITH 2NO+2NC OF
9 SCREWLESS TYPE TBs C/W CX4 64
LCS TYPE-2(SCAPPER CHAIN
2
DRIVE-1&2)
ENCLOSURE:
1 350(H)X300(W)X150(D), FOCAAL - 1
CANOPY .
START PUSH BUTTON 3SB5000-
MOTOR-1, OAE01,
2 SIEMENS 1
GREEN COLOUR WITH 3SB5400-OE,
2NO+2NC 3SB5400-OF
ILLUMINATION TYPE
EMERGENCY STOP PUSH
ARRANGEMENT
3SB5000-
4AC01,3SB5400
4 SIEMENS 1
LOCAL/REMOTE WITH -OE,3SB5400-
2NO+2NC OF
3SB5000-
START PUSH BUTTON OAE01,
5 SIEMENS 1
MOTOR-2,GREEN COLOUR 3SB5400-OE,
WITH 2NO+2NC 3SB5400-OF
ILLUMINATION TYPE
6 TEKNIC 2ALRMPP4L 1
EMERGENCY STOP PB

SL. MODEL
NO NUMBER
SCREWLESS TYPE TERMINAL CONNECT
7 CX4 48
BLOCK, 4 Sq.mm WELL
LCS TYPE-3(HOIST DRIVE) 2
ENCLOSURE:
1 350(H)X300(W)X150(D), FOCAAL - 1
CANOPY.
ILLUMINATION TYPE
EMERGENCY STOP PUSH
ARRANGEMENT
3SB5000-
UP & SPEED INC PUSH OAD01,3SB540
3 SIEMENS 2
BUTTON,YELLOW COLOUR 0-OE,3SB5400-
WITH 2NO+2NC OF
DOWN & SPEED DEC PUSH 3SB5000-
BUTTON,BLUE COLOUR WITH OAF01,3SB5400
4 SIEMENS 2
2NO+2NC -OE,3SB5400-
OF
3SB5000-
4AC01,3SB5400
5 SIEMENS 1
LOCAL/REMOTE WITH -OE,3SB5400-
2NO+2NC OF
CONNECT
6 CX4 56
SCREWLESS TYPE TBs WELL
CJB-TRAVEL DRIVE -A&B SIDE 4
ENCLOSURE:
1 600(H)X500(W)X300(D), FOCAAL - 1
CANOPY.
CONNECT
2 CX4 152
SCREWLESS TYPE TBs WELL
CONTROL JUNCTION BOX(EHCJB-
2
01)
ENCLOSURE:
1 800(H)X700(W)X350(D), FOCAAL - 1
CANOPY.

SL MODEL
NO NUMBER
1
3 C/W CX10
SCREWLESS TYPE TBs
CONTROL JUNCTION BOX(EHCJB-
2
02)
ENCLOSURE:
1 600(H)X500(W)X300(D), FOCAAL - 1
CANOPY.
2 CX4 113
BLOCK, 4 Sq.mm WELL
3 CX10 1
BLOCK, 10Sq.mm WELL
POWER JUNCTION BOX-1(EHPJB-1) 2
ENCLOSURE:
1 1000(H)X1000(W)X350(D), FOCAAL - 1
CANOPY.
2 COPPER BUSBAR 40*10 mm 40*10 SQ MM 12
POWER JUNCTION BOX-2(EHPJB-
2
02)
ENCLOSURE:
1 600(H)X800(W)X350(D), FOCAAL - 1
CANOPY.
2 CX4 117
BLOCK, 4 Sq.mm WELL
3 CX6 6
BLOCK, 6 Sq.mm WELL
POWER JUNCTION BOX-3(EHPJB-03) 2
ENCLOSURE:1000(H)X850(W)X3
1 FOCAAL - 1
50(D), CANOPY.
2 COPPER BUSBAR 40*10 mm 40*10 SQ MM 6
SCREWLESS TYPE TERMINAL
CONNECT
3 BLOCK, CX4 (X1-X27) 81
WELL
4 Sq.mm
4 SCREWLESS TYPE TBs C/W CX6 (X28) 15
POWER JUNCTION BOX-
2
1(SCRAPER CHAIN DRIVE-1)
ENCLOSURE:700H)X400(W)X25
1 FOCAAL - 1
0(D), CANOPY.

SL. MODEL
NO NUMBER
2 COPPER BUSBAR 40*10 mm BUSBAR 6
POWER JUNCTION BOX-
2
2(SCRAPER CHAIN DRIVE-2)
1 FOCAAL - 1
0(D), CANOPY.
POWER JUNCTION BOX-3(HOIST
2
DRIVE)
1 FOCAAL - 1
0(D), CANOPY.
FIELD JUNCTION BOX 14
1 FOCAAL - 1
0(D), CANOPY.
WELDING SOCKET 1
1 FOCAAL - 1
0(D), CANOPY.
WALTHER
2 469 1
WELDING SOCKET -WERKE
WALTHER
3 269 1
WATERPROOF PLUG -WERKE
POWER SOCKET 1
ENCLOSURE:
1 150H)X200W)X110(D), FOCAAL - 1
CANOPY.
WALTHER
2 419306 1
POWER SOCKET -WERKE
WALTHER
3 219306 1
WATERPROOF PLUG -WERKE

17.Software
Studio 5000
The Studio 5000 environment combines elements of design into
one standard framework that optimizes productivity and reduces time
to commission. This intuitive integrated design environment focuses on
rapid design, re-use, collaboration and virtual design. The updated
user interface provides a common, modern user experience across all
Studio 5000 applications.
Features of (Version-32)
• Automation ML open data exchange allows the application to

exchange data with engineering tools.
• Simulation Interface tool uses the Functional Mock-Up Interface
(FMI) standard to allow data exchange with modeling software,
such as MATLAB and Simulink.

Support for 64-bit math in the Studio 5000 environment.
• Enhancements to Logix tag-based alarms including new

instructions and greater alarm visibility.
Library links in the Studio 5000 Application Code Manager tool
allow for the auto- creation of parent-and-child objects in design
projects
Benefits
• Single design environment

• Easy configuration
• Collaborative development
• Maintain uptime
• Reduce time to market
• Helps protect code
• Reduce programming
• Improved kinematics support
• Reduce overall machine costs

Factory tack view

Better than an extra set of eyes, the perfect machine-level human
machine interface provides realistic displays to aid in continual and fast
evaluation on performance. FactoryTalk View Machine Edition (ME)
software is a versatile HMI application that provides a dedicated and
powerful solution for machine-level operator interface devices. As an
integral element of the Rockwell Automation visualization solution,
FactoryTalk View Machine Edition provides superior graphics, runtime
user management, language switching and faster commissioning time
through a common development environment.
Factory Talk View Machine Edition (ME)

Factory Talk View Machine Edition (ME) software is a versatile HMI
application that provides a dedicated and powerful solution for
machine-level operator interface devices. As an integral element of the
Rockwell Automation visualization solution, Factory Talk View Machine
Edition provides superior graphics, runtime user management,
language switching and faster commissioning time through a common
development environment.
Factory Talk View Machine Edition allows for a consistent operator
interface across multiple platforms, including Panel View Plus and
Windows desktop solutions and consists of:
• Factory Talk View Studio: Configuration
software for developing and testing HMI
applications.
• Factory Talk View ME Station: A traditional "standalone" HMI
solution that provides an integrated operator interface that runs
the same HMI application on Panel View Plus 7, Panel View Plus
6, Mobile View terminal, Rockwell Automation Industrial
Computers, or other industrial personal computer.

Features of (Version-11)
• Better graphics: Graphic performance improvement for
PanelView Plus 7
• Time-saving audit trail: Optimization of the onboard audit trail
eliminates duplicate audit messages for operator actions,
reducing the frequency at which the onboard audit log needs to
be managed
• Simpler file management: Application Manager, File Transfer
Utility, and new version ID tool now display the version of the
.APA or .MER file, making management of runtime and archived
project files easier
Benefits
FactoryTalk View Machine Edition offers OEMs and end-
users features that reduce development and commissioning time,
while improving the operator‟s experience and retaining the plant-
wide scalability.
Reduce commissioning time

• A simplified installation process
• Reusable global objects
• Search and replace capability for tags and text
on multiple displays and global objects
• Hotlink to a specific tag location using the Cross
Reference capability
Design time effectiveness

• Define tags and graphic displays once and reference them
throughout the application
• Maximize productivity by directly accessing tag information in the
controller, eliminating need to create HMI tags
• Full featured graphics editor with powerful editing tools, drawing
objects, pre-configured operator devices, and animation
capabilities

• Graphics library with hundreds of graphic objects to drag-and-

drop into displays
• Reusable faceplates and global objects speed application
development
Expand machine flexibility and capability
• Data logging for trend analysis
• Recipe management
• Manage user and groups while application is running
• Access to run-time terminal information
• Access to documentation via the PDF Viewer
• ActiveX controls that simplify complex runtime tasks
.Supports regulated industry applications
• Onboard audit trail for applications requiring regulatory compliance
such as US 21CFR Part 11 or EU Annex 11

18. Annexure-I
a)compact logic power Supply User Manual 1769-PA4
b) compact logic L33ER User Manual 1769-l33ER
c) compact logic SM2 Module User Manual 1769-SM2
d) compact logic AENTR User Manual 1769-AENTR
e) compact logic Digital Input Module User Manual 1769-IA16
f) compact logic Digital Output Module User Manual 1769-OB16
g) compact logic Analog Input Module User Manual 1769-IF8
h) compact logic Analog Output Module User Manual 1769-OF8
Annexure-II
a)Air Circuit Breaker User Manual acb-Siemens
b) Ammeter & Voltmeter Data Sheet AM&VM-MECO
C) Motor Protection Circuit Breaker User Manual 3RV MPCB-Siemens
d)Earth Fault Relay User Manual EFR-CDF11
e) Vacuum contactor User Manual vc-siemens
f)molded case Circuit Breaker User Manual MCCB-Siemens
g) contactor User Manual 3RT contactor-Siemens
h)Timer User Manual 3RP Timer-Siemens
i)Semiconductor Fuse User Manual 3NE4122 SF-siemens
j) MFM Data Sheet MFM-Conserv
k)Power Flex 750 Serious User Manual Power Flex750-AB
l)Current Transducer User Manual Current Transducer-AE
m)TNC Switch Pdf file TNC Switch-Salzer
n)RCCB User Manual 5SV RCCB-Siemens
o)Inverter Pdf File Inverter-Luminous

p)power supply Data Sheet PSU- phoenix

q)HMI User Manual HMI-AB
s)Terminal Blocks Pdf File TBs-Connect well

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FAPJ 310-PHASE-II-10MTPA EXPANSION PROJECT

OPERATION & MAINTENANCE MANUAL

Project Name : - PHASE-II-10MTPA EXPANSION PROJECT

Developed by Focaal Automation (P) Ltd Page 1 of 197

Developed by Focaal Automation (P) Ltd Page 2 of 197

Sl. No Title Page No

Developed by Focaal Automation (P) Ltd Page 3 of 197

Sl. No Title Page No

Developed by Focaal Automation (P) Ltd Page 4 of 197

2. PURPOSE OF THIS DOCUMENTATION

3. SAFTY INSTRUCTIONS/ WARNINGS SYMBOL

WARNING Risk of electric shock.

Developed by Focaal Autom

• Do not remove covers or attempt to disassemble. No user serviceable

• Do not exceed voltage limits between inputs as indicated on the rating

Developed by Focaal Automation (P) Ltd Page 6 of 197

• Do not connect Inductive RPM Pickup, Secondary Ignition Clip-on Wire

2. Ensure healthy earthing is installed at your premises.

6. Always use proper capacity fuse wire in main switches.

Developed by Focaal Automation (P) Ltd Page 7 of 197

7. Use only ISI marked electrical Equipments.

8. Ensure safety of energy meter and metering Equipments in your premises.

9. For rectification of faults in your installations, call licensed electrical

13. Enter all the particulars required in the application form.

14. Produce proper documents/records to prove the legal ownership of the

Developed by Focaal Automation (P) Ltd Page 8 of 197

23. Observe safety precautions to avoid electrical accidents.

24. Replace promptly defective electrical fittings and appliances.

Developed by Focaal Automation (P) Ltd Page 9 of 197

1. Do not connect multiple Equipments to a single point outlet to avoid excess

3. Avoid loose connections and joints.

4. Avoid theft of electrical energy, It is cognizable offence and attracts penal

5. Do not tamper with energy meters, meter seals or metering Equipments, it

7. Do not plant trees below the overhead power lines.

8. Do not meddle with live wires/points. It may cost your life.

9. Don't get the wiring works done by unauthorized persons, which is an

11. Don't construct your building underneath a High Tension or LowTension

Developed by Focaal Automation (P) Ltd Page 10 of 197

Developed by Focaal Automation (P) Ltd Page 11 of 197

5.General Description For Reclaimer

1. Scraper Chain drive ( hydraulic drive)

Developed by Focaal Automation (P) Ltd Page 12 of 197

A. Local mode (Maintenance / commissioning purpose)

MANUAL MODE SELECTED

AUTO DESK SELECTED AUTO CCR SELECTED

MAINTENANCE / LOCAL MODE

Individual operation shall be through

Developed by Focaal Automation (P) Ltd Page 13 of 197

• The co-ordination of scraper chain conveyor, Scraper chain hoist up/down

Developed by Focaal Automation (P) Ltd Page 14 of 197

6.) OPERATION OF MACHINE - RECLAIMING OPERATION

a) RECLAIMING IN AUTO MODE

• Type of material selection from HMI

Developed by Focaal Automation (P) Ltd Page 15 of 197

b)CHECKS TO START AUTO RECLAIMING SEQUENCE

1. Emergency stop circuit healthy

a) Emergency Stop PB Station-1 healthy

b) Emergency Stop PB Station-2 healthy

c) Emergency Stop PB Station-3 healthy