CONTENTS

1. Introduction 03

1.1About SAPTARSHI PROCESS P.LTD. 03

2. Electrical basics 05

2.1 Basic electrical theory 05

2.2Hazards 05

2.3 Electrical appliances to prevention 12

3. Circuit breakers 14

3.1 Operation 14

3.2 types 16

4. MCB 18

4.1 Introduction 18

4.2 Working 21

4.3Features 22

4.4Types 0f Characteristics 26

5. ELCB 28

1
 5.1 introduction 28

5.2 Features 28

5.3 Purpose 28

5.4 operation 30

5.5 Advantages and Disadvantages 30

6. ELR 33

6.1 General 34

6.2 Operation 34

6.3 Features 35

6.4 Applications 35

7. ELCB+MCB 36

7.1 Introduction 36

7.2 Features 36

8. ELR+MCB 38

8.1 Usage 38

8.2 Characteristic graph 38

8.3 The function and features 39

9. ROBOT 40

9.1 Introduction 40

9.2 Product catalogue 40

9.3 technical details 43

10. Enclosures 45

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 CHAPTER- 1

Introduction

1.1 About SAPTARSHI PROCESS P.LTD.

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This company is a 1st company to introduce various Branded ELR+MCB (electrical shock
guard) with various facilities, simultaneously giving live demonstration of 5mA leakage
current and has achieved a leading position by launching such a revolutionary
instrument in the field of electrical in India by the consulting Mr.Jayantilal D. ghonia .
Introduce ROBOT is designed with high technology keeping in view welfare of the users
for safety.

Ch1,fig 1.1 company picture

SAPTARSHI PROCESS P.LTD., Rajkot is the first company to introduce ROBOT brand
ELCB + MCB in market with various unique facilities. Being a pioneer in the field of
switch gear manufacturer, we have been accredited with ISO 9001: 2000 for the quality
also. We are giving the challengeable live demonstration for electric shock on single

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phase and three phase open wire since last 16 years. Our revolutionary product is a
hallmark in the field of electrical in India.

ROBOT is designed with incorporation of high technology for ensuring the safety,
protection and satisfaction to its customers. The company's own R& D department is keen
to give a sophistication touch to ROBOT to keep pace with changing technology and
ever expanding necessity of electric power. Our product is being used by thousands of
homes, factories, semi-government and government institutes since many years. ROBOT
is Government approved and CPRI tested and which assures the technology, quality,
service and seniority in the market

Since the launching of the product in the field in 1985, SHOCKGUARD has always
proved its worth by ensuring welfare and safety of the users. Today, our well developed
and managed R & D department allow us to come up with a reliable product range that
helps in preventing fatal accidents as well as injuries that occur from electric shocks.
Giving sophisticated touch to product so as to keep pace with changing technology &
ever expanding necessity of electric power, we also ensure that each of the equipment
being offered is tested in our own well equipment Laboratory. This assures us of its
delivering consistent performance for years in thousands of homes, Factories and
government and semi-government institutes.

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 CHAPTER-2

ELECTRICAL BASICS

2.1 Basic Electrical Theory

 Voltage [driving force] causes current [e - ] to flow
 AC / DC - from safety perspective - negligible difference
 Single Phase / Three Phase. 3φ get a professional
 Circuit / loop is necessary for current to flow
 a start point - a route - an end point

Voltage, Current and Resistance

 Voltage increases => Current increases
 Resistance decreases => Current increases

Voltage = Current / Resistance - Ohms Law

2.2 Electric hazard

Agenda
 Electrical Injuries
 Classification of Exposure
 Electrical Hazards
 Electrical Hazard Control

Electrical Injuries

Electrocutions:
 1970s: 600-700 per year
 1990s: 300-400 per year (NIOSH, 1998)

5th leading cause of occupational fatalities.

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 7% of total deaths, ranked after motor vehicle crashes, homicide, falls, and
mechanical trauma.
 Each year, electrical accidents cause as many as 165,380 electrical fires and 7,000
injuries.

Classification of Exposure

High Voltage
 >600 volts: typically associated with “outdoor”

electrical transmission.

Accounts for 60% of electrocutions .

Note: some people classify >480 volts as high voltage.

Low Voltage:
 <600 volts: typically associated with “indoor”

electrical service.

Accounts for 32% of electrocutions

Low voltage does not imply safe voltage.

Electrical Hazards
• Shock

: Conductors vs. Resistors

: Grounding

: The Ground Fault Accident

: GFCIs

• Burns

• Falls

• Fire
Overhead Power line Hazards
• Most people don’t realize that overhead power lines are usually not
insulated

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 • Power line workers need special training and personal protective
equipment (PPE) to work safely
• Do not use metal ladders – instead, use fiberglass ladders Beware of power
lines when you work with ladders and scaffolding
Electrical Shock

• Shock occurs when current passes through the body.

• Severity of the shock depends on:

– Path of current

– Amount and type of current

– Duration of exposure

• Electrocution is a fatal electrical injury.

Conductors vs. Resistors

• All materials exhibit some resistance to electrical current.

• Materials with low resistance are called conductors (ex. copper, aluminum,
gold, water).

• Materials with high resistance are called Resistors (ex. rubber, glass, air,
most plastics)
• Electricity wants to find the path of least resistance to the ground.
• Human tissues and body fluids are relatively good conductors because of
high water content.
So if a person touches an energized bare wire or faulty equipment while
grounded, electricity will instantly pass through the body to the ground,
causing a harmful, potentially fatal, shock.
Grounding
• Grounding is a method of protecting employees from electric shock.
• By grounding an electrical system, a low-resistance path to earth through a ground
connection is intentionally created.
• This path offers low resistance and has sufficient current-carrying capacity to
prevent the build-up of hazardous voltages.
• A three pronged cord offers a grounding connection.
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• White wire (neutral or common wire), returns the power.

Ch2, f ig. 2.1 Grounding

• Black wire (hot wire), is connected to the switch and fuse and carries the power.
• Green (or ground wire).
• Three wires for each cord and terminal.
• A two prong plug has a hot prong and a return prong, no ground prong.
• In any case, never remove the third (grounding) prong from any three-prong piece
of equipment.

9
 Ch2,fig 2.2 prong plug

The “Ground Fault” Accident

• A ground fault accident occurs when a person touches or grasps an electrically

energized object while the feet or other bod

y parts are in contact with the ground or a grounded surface.

• In some cases a ground fault accident occurs when the opposite hand touches the ground
or a grounded object.
Ground Fault Accident Example

A woman was putting up her Christmas tree. When she went to plug in the strands
of lights, her finger was touching the metal prong on the plug. Her other hand was
touching a metal coffee table leg for support. The current went through her body as a
result, causing cardiac arrest and death.

Electrical Shock Example

A worker came out of the bathroom with her hands dripping wet, and reached
down to plug in a lamp. She got a shock but survived. The same worker was cleaning
walls with a sponge and a bucket of soapy water. Not paying attention she washed over
an outlet, which also gave her a shock. The shock was intensive enough to stop her
breathing. She survived this time as well.
Effects of Electric Current on the Human Body

Current Reaction

1,000 – 4,300 Ventricular fibrillation (heart pumping action not rhythmic)

milliamps (1 -4.3 amps)
10,000 milliamps (10
amps)
15,000 milliamps (15
amps)
occurs. Muscles contract; nerve damage occurs. Death is
likely.
Cardiac arrest and severe burns occur. Death is probable.
Lowest overcurrent at which a typical fuse or circuit breaker opens
a circuit! Effects are for voltages less than about 600 volts.Higher
voltages also cause burns. Differences in muscle and fat content
affect the severity of shock.

Information in this table and the pictures on the following two slides was taken from the NIOSH
Publication: “Electrical Safety and Health for the Electrical Trades, Student Manual, January
2002, Publication No. 2002 -123, which is in the public domain.

10
Effects of Electric Current on the Human Body

Current Reaction

1 milliamp Just a faint tingle

5 milliamps Slight shock felt. Disturbing, but not painful. Most people
can “let go.” However, strong involuntary movements can
cause injuries.

6-25 milliamps (women) Painful shock. Muscular control is lost. This is the range where
9-30 milliamps (men) “freezing currents” start. It may not be possible to “let go.”

50-150 milliamps Extremely painful shock, respiratory arrest (breathing stops),

severe muscle contractions. Flexor muscles may cause holding on;
extensor muscles may cause intense pushing away. Death is
possible.

Electrical Burns

• Most common nonfatal electrical injury.

• Types:

– Internal: “deep tissue”.

– Skin: “entry” and “exit” points.

– Arc: “flash” burns from heat and radiant energy.

• Common sites of visible skin burns are the hands and feet.
• Most common shock-related, nonfatal injury
• Occurs when you touch electrical wiring or equipment that is improperly used or
maintained
• Typically occurs on the hands
• Very serious injury that needs immediate attention

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 Ch2, fig 2.3 Electrical Burns human hand

Circuits may produce electrical burns with relatively massive amounts of tissue
destruction by heating the tissues.

Electrical Burns Example

A worker was mounting a large mirror onto the wall of an office. He was using a
metal power tool which accidentally severed a wire causing a shock and massive burns.
The victim exhibited deep tissue destruction along the entire current path, along with
surface tissue damage at the point of entry and exit.

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2.3 Electrical Appliances to prevention

Ch2,fig, 2.4 Electrical Appliances

Fuses

Ch2, fig 2.5 Fuses

A fuse is a very basic protection device which is destroyed (i.e. it 'blows') and breaks the
circuit should the current exceed the rating of the fuse. Once the fuse has blown, it needs
to be replaced.

In older equipment, the fuse may just be a length of appropriate fuse wire fixed between
two terminals (normally screw terminals). These are becoming rarer as electrical

13
installations are updated - the presence of such fuses usually indicates that it is about time
that the installation is updated.

Modern fuses are generally incorporated within sealed ceramic cylindrical body (or
cartridge) and the whole cartridge needs to be replaced.

Ch2,fig 2.6 types of Fuses

Ch2,fig 2.7 Fuses notification

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 CHAPTER-3

Circuit breakers

A circuit breaker is an automatically-operated electrical switch designed to protect an

electrical circuit from damage caused by overload or short circuit. Its basic function is to
detect a fault condition and, by interrupting continuity, to immediately discontinue
electrical flow. Unlike a fuse, which operates once and then has to be replaced, a circuit
breaker can be reset (either manually or automatically) to resume normal operation.
Circuit breakers are made in varying sizes, from small devices that protect an individual
household appliance up to large switchgear designed to protect high voltage circuits
feeding an entire city.

3.1 Operation

All circuit breakers have common features in their operation, although details vary
substantially depending on the voltage class, current rating and type of the circuit breaker.

The circuit breaker must detect a fault condition; in low-voltage circuit breakers this is
usually done within the breaker enclosure. Circuit breakers for large currents or high
voltages are usually arranged with pilot devices to sense a fault current and to operate the
trip opening mechanism. The trip solenoid that releases the latch is usually energized by a
separate battery, although some high-voltage circuit breakers are self-contained with
current transformers, protection relays, and an internal control power source.

Once a fault is detected, contacts within the circuit breaker must open to interrupt the
circuit; some mechanically-stored energy (using something such as springs or compressed
air) contained within the breaker is used to separate the contacts, although some of the
energy required may be obtained from the fault current itself. Small circuit breakers may
be manually operated; larger units have solenoids to trip the mechanism, and electric
motors to restore energy to the springs.

The circuit breaker contacts must carry the load current without excessive heating, and
must also withstand the heat of the arc produced when interrupting the circuit. Contacts
are made of copper or copper alloys, silver alloys, and other materials. Service life of the

15
contacts is limited by the erosion due to interrupting the arc. Miniature and molded case
circuit breakers are usually discarded when the contacts are worn, but power circuit
breakers and high-voltage circuit breakers have replaceable contacts.

When a current is interrupted, an arc is generated. This arc must be contained, cooled, and
extinguished in a controlled way, so that the gap between the contacts can again
withstand the voltage in the circuit. Different circuit breakers use vacuum, air, insulating
gas, or oil as the medium in which the arc forms. Different techniques are used to
extinguish the arc including:

• Lengthening of the arc

• Intensive cooling (in jet chambers)
• Division into partial arcs
• Zero point quenching (Contacts open at the zero current time crossing of the AC
waveform, effectively breaking no load current at the time of opening. The zero
crossing occures at twice the line frequency i.e. 100 times per second for 50Hz ac
and 120 times per second for 60Hz ac )
• Connecting capacitors in parallel with contacts in DC circuits

Finally, once the fault condition has been cleared, the contacts must again be closed to
restore power to the interrupted circuit.

3.1.1 Standard current ratings

International Standard IEC 60898-1 and European Standard EN 60898-1 define the rated
current In of a circuit breaker for low voltage distribution applications as the current that
the breaker is designed to carry continuously (at an ambient air temperature of 30 °C).
The commonly-available preferred values for the rated current are 6 A, 10 A, 13 A, 16 A,
20 A, 25 A, 32 A, 40 A, 50 A, 63 A, 80 A and 100 A[3] (Renard series, slightly modified
to include current limit of British BS 1363 sockets). The circuit breaker is labeled with
the rated current in amperes, but without the unit symbol "A". Instead, the ampere figure
is preceded by a letter "B", "C" or "D" that indicates the instantaneous tripping current,
that is the minimum value of current that causes the circuit-breaker to trip without
intentional time delay (i.e., in less than 100 ms), expressed in terms of In:

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3.2 Types of circuit breaker

1. Low voltage circuit breakers

• MCB (Miniature Circuit Breaker)

• MCCB (Molded Case Circuit Breaker)—rated current up to 2500 A

• Low voltage power circuit breakers can be mounted in multi-tiers in LV

switchboards

2. Medium-voltage circuit breakers:

• Vacuum circuit breaker—With rated current up to 3000 A, these breakers

interrupt the current by creating and extinguishing the arc in a vacuum container

• Air circuit breaker—Rated current up to 10,000 A. Trip characteristics are often

fully adjustable including configurable trip thresholds and delays.

• SF6 circuit breakers extinguish the arc in a chamber filled with sulfur hexafluoride
gas.

Ch3, Fig 3.1 - High-voltage circuit breaker

3. High-voltage circuit breakers:

• Bulk oil
• Minimum oil

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• Air blast
• Vacuum
• SF6

4. Other breakers:

o Residual-current device (RCD, formerly known as a residual current circuit

breaker) — detects current imbalance, but does not provide over-current protection.
o Residual current breaker with over-current protection (RCBO) —
combines the functions of an RCD and an MCB in one package. In the
United States and Canada, panel-mounted devices that combine ground
(earth) fault detection and over-current protection are called Ground Fault
Circuit Interrupter (GFCI) breakers; a wall mounted outlet device
providing ground fault detection only is called a GFI.
o Earth leakage circuit breaker (ELCB) — This detects earth current directly
rather than detecting imbalance. They are longer seen in new installations
for various reasons.

18
 Ch3, Fig3.2 -115kV Oil Circuit Breaker

• Autorecloser — A type of circuit breaker which closes again after a delay. These
are used on overhead power distribution systems, to prevent short duration faults
from causing sustained outages.
• Polyswitch (polyfuse) — A small device commonly described as an automatically
resetting fuse rather than a circuit breaker.

CHAPTER-4

Miniature Circuit Breaker (MCB)

The Miniature Circuit Breaker (MCB)/ Manual Motor Controller is a circuit protection
device, which is able to protect the wiring and the loads of electrical circuits. These
MCB’s are a Thermal-Magnetic type circuit breaker.

The wiring/cabling will be protected from overloads by the MCB’s Thermal part and the
loads (motors, heaters, power supplies, etc.) will be protected from short circuits by its
magnetic parts.

NOTE: The Altech MCB can only be used as a “supplementary Protector”. It CANNOT
be used as a branch circuit protector (Molded Case Circuit Breaker (MCCB) or UL listed
RK5 fuse).

19
 Ch4,Fig4.1- Miniature Circuit Breakers( MCBs)

4.1 INTRODUCTION

The circuit breaker plays an important role in providing over-current protection and a
disconnect means in electrical networks. Recent advancements in circuit breaker
technology has increased breaker performance and protection.

OVERLOAD

A slow and small over current situation that causes the ampacity and temperature of the
circuit to gradually increase over time. This type of event is characterized by a slight
increase in the load (ampacity) on the circuit and is interrupted by the thermal trip unit
of the breaker

Short circuit

A rapid and intense over current situation that causes the ampacity of the circuit to
increase. This type of event is characterized by a dramatic increase in the load (ampacity)
on the circuit and is interrupted by the magnetic trip unit of the breaker.

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MCB (BD-63T Series)

Ch4, fig 4.2 1p, 2p, 3p MCB

MCB (BD-63 Series)

21
 Ch4,fig 4.3 1p,2p,3p,4p MCB

4.2 Working:

Thermal Principle
(Overload Protection)

22
 Ch4, Fig4.4 - Thermal Principle of MCB

The thermal part of the circuit breaker utilizes a bimetallic strip electrically in series with
the circuit. The heat generated by the current during an overload deforms the bimetallic
strip and trips the circuit breaker.

Example:

Overload occurs when the vacuum is obstructed and the power cord gets overheated.

NOTE: The thermal part of the circuit breaker is temperature sensitive and can be
adversely affected by changes in ambient temperature (MCB calibrated at 40° C (104° F)

Magnetic Principle

23
 Ch4,Fig4.5- current limiting path of MCB

• The magnetic part of the circuit breaker consists of an electromagnetic coil and an
armature device that opens the movable contact quickly to protect the circuit whenever
the current (short circuit current) exceeds a predetermined value. This happens because
the current in the coil generates sufficient magnetic flux to attract the armature. Reset is
manual and rapid.
– Example:
• Short circuit occurs when the hot wire and neutral/ground
accidentally come together.
• SALIENT FEATURES

• MCBs having breaking capacity of 10kA, 2 positions and 20kA, 3 positions.

• Current limiting design – low ‘let-through’ energy.

• Silver graphite contacts for weld-free operation.

24
• Trip-free mechanism ensures tripping even if operating knob is held forcibly in
‘ON’ position.

• Terminals on both sides, with pressure plates suitable for 25 sq.mm cables.

• Shrouded terminal on both sides make MCBs finger - touch proof.

• Neutral advance mechanism, i.e. neutral contact opens last and closes before
phase contact, which always ensures zero potential before phase potential.

• Padlocking facility in ON/OFF position.

TECHNICAL SPECIFICATIONS

10 kA, 2 Position MCBs

• Specifications conforming: IEC 898-1995.

• No. of poles : 1,2,3 and 4 pole (SP, SPN, DP, TP, TPN and FP).

• Tripping characteristics : B, C and D.

• Current ratings: 6, 10, 16, 20,25, 32, 40 and 63A. On request,1A to 5A.

• Rated voltage : Upto 415V, AC.

• Frequency : 50/60Hz Fixing : On 35 mm DIN rail.

• Breaking capacity : 10 kA.

• Mechanical Life : 100,000 operations.

• Electrical life : 20,000 operations.

• Temperature : -5°C to 55°C, Terminals : On both sides, with pressure plates for
25 sq.mm cable.

Trip-Characteristics & Applications

25
Type Instantaneous tripping current

B above 3 In up to and including 5 In

C above 5 In up to and including 10 In

D above 10 In up to and including 20 In

THE B-TRIP CHARACTERISTIC

Thermal operations are as per IEC898-1995. Magnetic operating limit is3 to 5 times rated
current. MCBs withB characteristics are used primarilyFor wiring protection in lighting,
socketOutlet and control circuit.

26
 Ch4,Fig 4.6- THE B-TRIP CHARACTERISTIC of MCB

THE C-TRIP CHARACTERISTIC

Thermal operations are as per IEC 898-1995. Magnetic operating limit is 5 to 10 times
rated current. MCBs with C characteristics are used for overload and short circuit
protection primarily to protect equipment with high making current (e.g. motors and
transformers)

27
 Ch4,Fig4.7- THE C-TRIP CHARACTERISTIC of MCB

THE D-TRIP CHARACTERISTIC

Thermal operations are as per IEC 898-1995. Magnetic operating limit is 10 to 20 times
rated current. Miniature Circuit Breakers with D characteristics ensure that even electrical

28
equipment with very high making current as starting of heavy motors, transformers,
capacitor switching, group of lights etc. do not lead to undesired early tripping.

Ch4, Fig4.8-
THE D-TRIP

CHARACTERISTIC of MCB

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30
 CHAPTER-5

Earth leakage circuit breaker (ELCB)

An Earth Leakage Circuit Breaker (ELCB) is a safety device used in electrical

installations with high earth impedance to prevent shock

INTRODUCTION

The technology for ELCBs is imparted by F&G (Germany), leading manufacturers of

ELCBs and further developed inhouse for 10 kA. Residual Current Operated Earth
Leakage Circuit Breakers are internationally accepted means of providing protection from
electric shocks and fires caused due to earth leakage currents

FEATURES

1.Conforms to IEC 1008.

2. Truly Current Operated i.e. operation even at nominal one volt.

3. Repeat accuracy ±5%

4. Neutral Advance Mechanism.

5. Operation even in case of neutral failure i.e. it operates even if leakage occurs when
incoming /

6. Outgoing neutral is snapped.

7. Tripping time within 30m.sec.* Trip free mechanism - i.e. during fault, resetting is
impossible and it trips internally, even if

8. held in ‘ON’ position forcibly. Held in ‘ON’ position forcibly. Operates on Core
Balance

9. Current Transformer principle.

10. Provides optimum protection.

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Purpose

Many electrical installations have a relatively high earth impedance. This may be due to
the use of a local earth rod (TT systems), or to dry local ground conditions.

These installations are dangerous and a safety risk if a live to earth fault current flows.
Because earth impedance is high:

1. not enough current exists to trip a fuse or circuit breaker, so the condition persists
uncleared indefinitely

2. the high impedance earth cannot keep the voltage of all exposed metal to a safe
voltage, all such metalwork may rise to close to live conductor voltage.

These dangers can be drastically reduced by the use of an ELCB or residual-current

device (RCD).

The ELCB makes such installations much safer by cutting the power if these dangerous
conditions occur. This approach to electrical safety is called EEBAD. In Britain EEBAD
domestic installations became standard in the 1950s.

In non-technical terms if a person touches something, typically a metal part on faulty

electrical equipment, which is at a significant voltage relative to the earth, electrical
current will flow through him/her to the earth. The current that flows is too small to trip
an electrical fuse which could disconnect the electricity supply, but can be enough to kill.
An ELCB detects even a small current to earth (earth leakage) and disconnects the
equipment (circuit breaker)

32
 Ch5, Fig5.1- ELCB circuit

Connection

The earth circuit is modified when an ELCB is used; the connection to the earth rod is
passed through the ELCB by connecting to its two earth terminals. One terminal goes to
the installation earth CPC (circuit protective conductor, aka earth wire), and the other to
the earth rod (or sometimes other type of earth connection). Thus the earth circuit passes
through the ELCB's sense coil.

Operation

An ELCB is a specialised type of latching relay that has a building's incoming mains
power connected through its switching contacts so that the ELCB disconnects the power
in an earth leakage (unsafe) condition.

The ELCB detects fault currents from live (hot) to the earth (ground) wire within the
installation it protects. If sufficient voltage appears across the ELCB's sense coil, it will
switch off the power, and remain off until manually reset. An ELCB however, does not
sense fault currents from live to any other earthed body.

Advantages

33
ELCBs have one advantage over RCDs: they are less sensitive to fault conditions, and
therefore have fewer nuisance trips. (This does not mean they always do, as practical
performance depends on installation details and the discrimination enhancing filtering in
the ELCB.) Therefore by electrically separating cable armour from cable CPC, an ELCB
can be arranged to protect against cable damage only, and not trip on faults in downline
installations.

Disadvantages

ELCBs have some disadvantages:

* They do not detect faults that don't pass current through the CPC to the earth rod.

* They do not allow a single building system to be easily split into multiple sections
with independent fault protection, because earthing systems are usually bonded to
pipework.

* They may be tripped by external voltages from something connected to the earthing
system such as metal pipes, a TN-S earth or a TN-C-S combined neutral and earth.

* As with RCDs, electrically leaky appliances such as some water heaters, washing
machines and cookers may cause the ELCB to trip.

* ELCBs introduce additional resistance and an additional point of failure into the
earthing system.

Earth bypassing

It is not unusual for ELCB protected installation to have a second unintentional

connection to earth somewhere, one that does not pass through the ELCB sense coil. This
can occur via metal pipework in contact with the ground, metal structural framework,
outdoor home appliances in contact with soil, and so on.

34
When this occurs, fault current may pass to earth without being sensed by the ELCB.
Despite this, perhaps counterintuitively, the operation of the ELCB is not compromised.
The purpose of the ELCB is to prevent earthed metalwork rising to a dangerous voltage
during fault conditions, and the ELCB continues to do this just the same, the ELCB will
still cut the power at the same CPC voltage level. (The difference is that higher fault
current is then needed to reach this voltage.)

Nuisance trips

While voltage and current on the earth line is usually fault current from a live wire, this is
not always the case, thus there are situations in which an ELCB can nuisance trip.

When an installation has two connections to earth, a nearby high current lightning strike
will cause a voltage gradient in the soil, presenting the ELCB sense coil with enough
voltage to cause it to trip.

If the installation's earth rod is placed close to the earth rod of a neighbouring building, a
high earth leakage current in the other building can raise the local ground potential and
cause a voltage difference across the two earths, again tripping the ELCB. Close earth
rods are unsuitable for ELCB use for this reason, but in real life such installations are
sometimes encountered.

Both RCDs and ELCBs are prone to nuisance trips from normal harmless earth leakage to
some degree. On one hand ELCBs are on average older, and hence tend to have less well
developed filtering against nuisance trips, and on the other hand ELCBs are inherently
immune to some of the causes of false trips RCDs suffer, and are generally less sensitive
than RCDs. In practice RCD nuisance trips are much more common.

Another cause of nuisance tripping is due to accumulated or burden currents caused by

items with lowered insulation resistance. This may occur due to older equipment, or
equipment with heating elements, or even wiring in buildings in the tropics where
prolonged damp and rain conditions can cause the insulation resistance to lower due to
moisture tracking. If there is a 30 mA protective device in use and there is a 10mA burden
from various sources then the unit will trip at 20 mA. The individual items may each be
electrically safe but a large number of small burden currents accumulates and reduces the

35
tripping level. This was more a problem in past installations where multiple circuits were
protected by a single ELCB.

Heating elements of the tubular form are filled with a very fine powder that can absorb
moisture if the element has not be used for some time. In the tropics, this may occur, for
example if a clothes drier has not been used for a year or a large water boiler used for
coffee etc has been in storage. In such cases, if the unit is allowed to power up without
RCD protection then it will normally dry out and successfully pass inspection. This type
of problem can be seen even with brand new equipment.

Failure to respond

Some ELCBs do not respond to rectified fault current. This issue is the same in principle
with ELCBs and RCDs, but ELCBs are on average much older and specs have improved
considerably over the years, so an old ELCB is more likely to have some uncommon fault
current waveform that it will not respond to.

With any mechanical device, failures occur, and ELCBs should ideally be tested
periodically to ensure they still work.

If either of the earth wires become disconnected from the ELCB, it will no longer trip and
the installation will often no longer be properly earthed.

36
 CHAPTER-6

Earth leakages relay (ELR)

Ch-6, Fig 6.1- earth leakage relay

The ELR-3E, maintain all the basic characteristics of ELR-3C type, with

reduced dimensions. It comes to complete the range of relays, built in a

modular enclosure, according with DIN 43880 Standard, with a three

modules width (module base 17.5 mm).

It has a wide setting ranges and the accurate tripping current selection

37
(by means of dip switches), in order that the contact voltage values are

maintained below 50V as required by the CEI 64-8Standard

This is also the suitable answer for a proper selectivity, whenever there

are other ELR’s or/and RCD’s downstream or upstream in the line to be

protected.

General

An outstanding characteristic of the present relays, is the permanent Control of the

Toroidal - ELR circuit. Its interruption brings along the immediate trip of the protection.
This allows to identify the anomaly, without waiting to the periodical control, made with
the Test push button. The instrument, fitted with filters at the input circuits, is practically
immune to external disturbances, so as the pulse currents with dc components,
complying with the requirements of VDE 0664 and project IEC 23 Standards.The ELR-
3E has a manual reset option only, in order to avoid unexpected reset, whilst undergoing
repairs and maintenance works.

Its sealable front transparent cover may be used to avoid access to the settings to
unauthorised persons.It may also be coupled to any of our CT-1 Toroidal Transformers.

Operation

ELR features two incremental rotary selector switches on the front panel and a series of
LED annunciators. The 10 position trip current switch offers selectable earth leakage
current settings from 30mA to 10 Amps, and the 16 position time delay setpoint switch
offers additional delay for fault discrimination, selectable from 0 to 10 seconds. When the
30mA trip current leakage is selected, the time delay is disabled.

38
Once the trip current and time delay selections have been made, a green LED provides
indication of mains healthy supply. The red LED will automatically illuminate if the pre-
set leakage level has been exceeded, after any selected time delay.

The unit also incorporates a bargraph of 5 yellow LEDs providing indication of the level
of leakage in 20% increments. When all 5 LEDs are illuminated the leakage level has
reached 100% of the setpoint setting. The enhanced pre-alarm single pole change over
relay contact version also incorporates a red LED providing indication that the level of
leakage has reached 60% of the selected range, and that the pre-alarm relay has operated.

The unit features a combined reset and test button. A short press of the button will reset
the unit after a trip, and one long press initiates an electronic confidence check.

The relay latches on to a fault until the test/rest button is pressed or the auxiliary power is
removed. The relay will de-energize on trip (fail safe) as standard. Fitting a link between
two terminals will select energize on trip.

Features

• Precision digital settings

• LED bargraph display

• 10 selectable trip levels – 30mA to 10A

• 16 selectable time delay – 0ms to 10 seconds

• Less than 40ms response time 0-1mA analog output 8 Amp 250V rated relay
contac

• User selectable energize or de-energize link

• Double pole change over relay

• Single pole pre-alarm option

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Applications

• Switchgear

• Distribution systems

• Generator sets

• Control panels

• Building management

• Utility power monitoring

• Process control

• Motor protection

• Transformer protection

CHAPTER 7

ELCB + MCB Combinations

INTRODUCTION

ELCB+MCB combination offers comprehensive protection against overcurrent, short

circuit, earth leakage and earth fault. ELCB+MCB is recommended to be used as the
main incoming circuit breaker instead of conventional iron clad main switches. Further,
downstream distribution with this combination will also replace DP/TPN interruption and

40
switching devices. The high breaking capacity of 9kA at 440 V allows safe, fuseless
distribution. Typical short circuit faults in real life situation do not exceed 3000A .

FEATURES

• All protections truly current operated

• No nuisance tripping

• Current limiting design

• High breaking capacity

• Maintenance-free

• Neutral advance mechanism

• Operation even in case of

• neutral failure i.e. it operates if leakage occurs even when incoming neutral is
snapped Time / Current tripping

• characteristics of B and C types are available.

• Trips at leakage current of 30mA within 30 ms

The use of ELCB+MCB will ensure total foolproof and reliable protection from all
hazards of low and medium voltage electricity. The operation of the device being
independent of extraneous parameters (like supply voltage, temperature, humidity etc.) it
provides dependable protection from all conceivable electrical faults which may cause
electrocution, fires and result in destruction of

life and property and excessive metering due to leakage. It is recommended to use,
ELCB+MCB combination for:

• Residential premises as main incoming protection after energy meter instead of

fuses and main switch

• Domestic equipment where there is proximity to moisture/ conductive liquids e.g.

water heaters, washing machines, electric irons, pump sets etc.

41
• Construction and outdoor electrical equipment such as lifts, hoists, vibrators,
polishing machines etc. as switchningand isolation device.

• Motors and Pumps.

• Operation theatres and electrically operated medical equipment such

as X-ray machines, saws etc.

• Neon sign installations. Low and medium voltage electrical distribution and
equipment

EFFECT OF TEMPERATURE

The calibration of the ELCB device being in conformity with BS 4293:1983, the
sensitivity of the device will be between 50% and 100% of the rated sensitivity. The
sensitivity of the ELCB+MCB combination will be within permissible limits when used
in the temperature range of -5° to 50° Centigrade.

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 CHAPTER 8

ELR+MCB

USAGE:

Our product ELR+MCB can be fitted at anywhere in single phase ,three phase +neutral to
get protection from electric shock, over load ,short circuit ,over voltage earth fault
,electric power wastage, neural return ,two phasing in single phase line, single phasing
in three phase line, phase interchanging in three phase line. after installing robot, the load
side electric power which flows out from robot is protected by the system .robot is
always fitted next to energy meter and main switch and before distribution board in good
ventilation. Robot can be installed in residential building banks
,hotels,hospitals,laboratories,offices,services station, factories where electric power is
used.robot can be installed in wiring made in different sections, or on special machine.
company advise to test the product frequently in schedule and to avoid bye pass mode
because of,in case of emergency mode ,robot will stop all protections except than mcb
functions only.

Characteristic graph of elr+mcb:

43
 Ch 8, Fir -8.1 Characteristic graph of ELR+MCB

THE FUNCTION &FEATURES OF ELR+MCB:

• Electric Shock

• Shoct circuit

• Over voltage respect to neutral

• Over voltage

• Power Wastage

• Neutral Return

• Two phasing

• Single phasing prevention

• Phase interchange prevention

• Variable I ⧍n setting with color bar code

44
• Multiple I⧍n setting with color code indicator

• Self testing

• On-OFF Knob guard

• Built in or external tripping lamp

• Without bye pass for better safety

• Bye pass for emergency

• Operates at least any two line wire

• Operates at any 1φ line wire repect to ground

• Tripping time interval siren

• Heavy duty design without competitor

• 100amps terminal connecter block

• Line &load interchange protection

• Bye pass audio/video indicator

• Degree of protection =IP20

• I2t=class 3

• Wide operating voltage

• Corrosion &shock proof cabinet

CHAPTER-9

ROBOT

45
9.1 INTRODUCTION

Company offer Robot brand Electric Shock Guards that are well recognized in the market
for their optimum performance in given conditions. Our expertise lies in offering these
with many features including Time Interval Siren, Working Bye Pass Audio & Video
Indicator, Tripping Lamp, Variable IDn Setting and Bye Pass options. The details
include:

9.2 Product catalogue

Saptarshi ,3Ø + Neutral Ground, 5-Pole, 415V, 50Hz

Ch 9,fig 9.1 Saptarshi ,3Ø + Neutral Ground, 5-Pole, 415V, 50Hz

Description/Specification:

3Ø + Neutral+Ground, 4-Pole, 415V, 50Hz

Protection: Electric Shock, Short Circuit, Over Load, Power Wastage, I 2 t =

Class-3, Degree of Protection=IP20.(Over Voltage REspect to Neutral,
Return/Two Phasing in Model-FV or Single Phasing, Phase Interchange in FS)
Feature: Heave Duty Design, Works At Least Any Two Line Wire or Any 1Ø
Line Wire Respect to Neutral of Ground, Multiple IDn Setting With Color Code
Indica

46
ROBOT , 1Ø, 2-Pole, 220V, 50Hz

Ch9 ,fig 9.2 ROBOT , 1Ø, 2-Pole, 220V, 50Hz

Description/Specification :

1Ø, 2-Pole, 220V, 50Hz

Protection: Electric Shock, Short Circuit Up to 10000A, Over Load, Power

Wastage, Over Voltage, Neutral Return, Two Phashing, Degree Of Protection
= IP 20. I 2 t = Class-3. Feature: Time Interval Siren, Working Bye Pass Audio
&amp; Video Indicator, Tripping Lamp, Variable IDn Setting, Bye Pass, Self
Testing, Built In 100A Terminal Connector Block, Corrosion &amp; Shock Proof
Molding Cabinet.

ROBOT, 3Ø, 4-Pole, 415V, 50Hz

47
 Ch9, fig 9.3 ROBOT, 3Ø, 4-Pole, 415V, 50Hz

Description/Specification :

3Ø, 4-Pole, 415V, 50Hz

Protection: Electric Shock, Short Circuit Up to 10000A, Over Load, Power

Wastage, over voltage respect to neutral, neutral return, two phasing respect
to neutral, Degree Of Protection = IP 20. I 2 t = Class-3. Feature: Time
Interval Siren, Working Bye Pass Audio &amp; Video Indicator, Tripping Lamp,
Variable IDn Setting, Bye Pass, Self Testing, Built In 100A Terminal Connector
Block, Corrosion &amp; Shock Proof Molding Cabinet, Line &amp; Load
Interchange

ROBOT , 3Ø, 4-Pole, 415V, 50Hz

Ch9,fig 9.3ROBOT , 3Ø, 4-Pole, 415V, 50Hz

48
Description/Specification

3Ø, 4-Pole, 415V, 50Hz

Protection: Electric Shock, Short Circuit Up to 10000A, Over Load, Power

Wastage, Degree Of Protection = IP 20. I 2 t = Class-3. Feature: Time Interval
Siren, Working Bye Pass Audio &amp; Video Indicator, Variable IDn Setting,
Bye Pass, Self Testing, Built In 100A Terminal Connector Block, Corrosion
&amp; Shock Proof Molding Cabinet, Line &amp; Load Interchange Protection,
ON-OFF Guard.

Shock Guards - Technical Details

The technical details of equipment offered by us include:

1 Number of Pole 2 Pole for 1 O and 4 Pole for 3 O

2 Rated Voltage
3 Permissible Ambient
Temperature
4 Permissible Ambient Voltage
5 Earth Leakage Sensitivity
6 Earth Leakage Tripping time
7 Over Volt Cut – Off
8 Over Volt Cut - Off Time
9 Rated Frequency
10 Breaking Capacity
240V. 50 Hz. for 1O & 440V, 50 hz. for 3O
-25 Degree C. to 55 Degree C
50V to 625V, 50 Hz. for 3O
3mA to 30mA in 1O & 5mA to 30mA in 3O
30 Milli Seconds to 70 Milli Seconds
290V, 50Hz., + 5% respect to neutral
Less than 0.1 Second
50Hz. to 60 Hz.
10KA

11 Operation Life Greater than 20,000 Operations

12 Product Life Greater than 10 years
13 Standard Govt. Approved CPRI Tested
14 Terminal 25 mm2
15 Mounting Screw mounting
16 Approx. Dimensions without 170 mm Length X 110 mm Width X 80 mm

49
Lamp Height for DP and DPSV 225mmlength X125mm
Width X 80mm Height for FP and FPSV

CHAPTER 10

Enclosures

50
Established at Rajkot, Gujarat, India, we “Saptarshi Process Pvt. Ltd.,” are one of the
leading manufacturers of Electric Shock guards. Available in different current ratings
and specifications, these are made available by us under different brand names
including Saptarishi, Robot and Vasundhara.

An ISO 9001:2000 Certified Company, our business operations are led by Mr. J D
Ghonia, ( B. Sc., B. E., D. B. M. & L. L. B ) who has with him rich experience in our
industry sector. His visionary guidance as well as strong service support provided by
experienced industry professionals assists us to successfully introduce in the markets
various Branded ELR + MCB (Electric Shockguard) for both single phase and three
phase operations. Our consistent performance has also helped us to achieve a leading
position by launching such a revolutionary instrument in the field of Power in India.

Company Offer

Backed by rich industry experience, well developed infrastructure facilities as well as

services of experienced industry professionals, we are successfully meeting the
demands of Shock guards that can be used with both single phase as well as three phase
connections. With extensive research going behind the manufacturing of the products,
these ensure complete safety to the varied electrical equipment and machinery from
overloads and short circuit conditions.

The brands under which we make the products available include:

• Saptarshi - Electric Shockguard

• Robot - Electric Shockguard

Functions

Very often, we come across news of lethal electric shocks that are suffered by human
beings and ensuing damages happening to human life & property while operating
electric appliances like immersion heater, electric heater, geyser, refrigerator, juicer,
grinder, washing machine and water pumps. Some of the functions these products

51
deliver include:

• Used in residences on single phase connection

• Used for machinery in industries on three phase power
• Safeguarding surroundings from short circuits and chances of
fire outbreak
• Safeguards damages to valuable instruments and wiring
• The ampere capacity is matched with the connection, thickness
of conductor and current flow of the circuit and overload so as
to achieve optimum performance
• Cuts main supply automatically in 30th fraction of a second,
when there is a nominal current with load side wiring
• Safeguards against drastic increase in voltage thus saving
electric bulbs, tube lights, computer, TV, VCR and others from
possible damages

• The equipment also covers faults of earth leakage including

slight currents felt in wall, doors and water taps where it helps
in detecting the leakage while switching 'ON' the equipment
and tripping the power supply

Usage, Benefits & Installation

some of the usage areas of the Electric Shock guards offered by us include:

• Schools & collages

• Hostel
• Hospitals
• Resident
• Office
• Industries

Benefits:

52
Our Product (ELR + MCB) can be fitted anywhere in single phase, three phase + neutral
(four wire) to ensure protection from:

• Electric Shocks
• Over Load
• Over Voltage
• Short Circuit
• Earth Fault
• Neutral Return
• Electric Power Wastage
• Two Phasing In Single Phase Line
• Single Phasing In Three Phase Line
• Phase Interchanging in Three Phase Line

Installation:

• After installing SHOCKGUARD, load side electric power which

flows out from SHOCKGUARD is protected by system
• It can be installed in residential buildings, hotels, banks,
hospitals, offices, laboratories, service stations, factories and
other areas where electric power is used

• SHOCKGUARD can be installed in wiring made in different

sections, or on special machines as well

53