ISGEC JOHN THOMPSON

WELCOME
TO THE STAFF OF

BHUSHAN ENERGY

FOR THE TECHNICAL TRAINING OF BOILER

ELECTRICALS

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 ISGEC JOHN THOMPSON

OPERATION & MAINTENANCE

OF THE ELECTRICALS

1. Explanation on type of Motors used in different sites and their

features

2. Discussion on construction features of Motor Control Centres

3. Configuration details of Variable Frequency Drives

4. Discussion on Electrical equipment locations and cable routing

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Explanation

on type of Motors

used

and their features

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MOTORS
INDEX
• Salient Features of Induction Motors

• 3 Phase Squirrel Cage Induction Motors of

TEFC Construction

• Exploded view of Motor

• Temp details of class of insulation

• IP Codes (Degree of protection)

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• Testing of Induction Motors .

• Pre – Commissioning checks of Motors.

• Trouble shooting of Motors

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SALIENT FEATURES OF INDUCTION MOTORS

• Motors are suitable for 3 Phase, 6.6 KV / 400 V ± 10% voltage

& 50 Hz. ± 5% frequency
• Motors are squirrel cage Induction type motors
• 400V Motor are Totally Enclosed Fan Cooled (TEFC) Motors &
6.6 KV Motors are Closed Air Circuit Air Cooled (CACA
• Motors are of Foot mounted type
• Motors are of continuous duty
• Motors are having class “F” insulation & temperature rise limited
to class “B”
• Motors are having Enclosure of IP55 degree of protection

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3 PHASE SQUIRREL CAGE INDUCTION MOTOR OF

TEFC CONSTRUCTION

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EXPLODED VIEW OF SQ. CAGE
MOTOR Terminal box

Lifting
lugs
Cooling
Fan
Bearings

Sealing
Cage Rotor

Frame
Corrosion protection
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EXPLODED VIEW OF SQ. CAGEISGEC
MOTORJOHN THOMPSON

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TEMP. DETAIL OF CLASS OF INSULATION

1. CLASS-Y - 9O°C 2.CLASS-A - 105°C

3. CLASS-E - 120°C 4. CLASS-B -130°C

5. CLASS-F - 155°C 6.CLASS-H - 180°C

7. CLASS-C - ABOVE 180°C

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IP CODES (DEGREE OF PROTECTION)

FIRST NUMERCAL INDICATES:-

PROTECTION AGAINST CONTACT & INGRESS OF
FOREIGN BODIES I.e. SOLIDS
SECOND NUMERCAL INDICATES:-
PROTECTION AGAINST INGRESS OF LIQUIDS I.e. WATER
FIRST NUMERIC SECOND NUMERIC
0 No Protection No Protection
1 Protection against solid Water falling vertically
objects greater than 50 shall not harm
mm dia. (eg. Hands)
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IP CODES (DEGREE OF PROTECTION)

FIRST NUMERIC SECOND NUMERIC

2 Protection against solid Water falling up to 15°

objects greater than 12 from vertical shall not
mm dia. (eg. Fingers) harm
3 Protection against solid Water falling up to 60°
objects greater than 2.5 from vertical shall not
mm dia. (eg. Tools, wires) harm

4 Protection against solid Water splashes shall not

objects greater than 1.0 harm
mm dia. (eg. Wires or
Strips)
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IP CODES (DEGREE OF PROTECTION)

FIRST NUMERIC SECOND NUMERIC

5 Protection against ingress of Water hosed shall not harm

dust is not totally protected, (water jets)
but does not enter in
sufficient quantities to harm
equipment
6 Protection against ingress of Water from powerful jets
dust (Dust Tight) comparable to heavy seas
shall not harm
7 Protection against effects of
immersion to depths of
between 0.15 & 1 m
8 Protection against effects of
prolonged immersion at depth

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TESTING OF INDUCTION MOTORS

A. ROUTINE TEST

B. TYPE TEST

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ROUTINE TESTS
1 INSULATION RESISTANCE TEST NOT LESS THEN 10MEGA OHM
500V INSULATION TESTOR
2 HIGH VOLTAGE TEST:- IT SHOULD STAND FOR ONE
E=1K+2E,WHERE E= APPLIED MINUTE
VOLTAGE
3 NO LOAD TEST IN DE COUPLED THE INPUT POWER,CURRENT &
CONDITION SPEED SHALL BE MEASURED
&USED IN THE DETERMINATION
OF NO LOAD LOSSES.
4 LOCKED ROTOR TEST TO DETERMINE THE COPPER
LOSSES

5 MEASUREMENT OF RESISTANCE OF THE STATOR AT AMBIENT

TEMPERATURE

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TYPE TESTS
1 FULL LOAD TEST TO DETERMINE FULL LOAD
CURRENT, POWER, P.F. &
EFFICIENCY
2 MOMENTARY OVER LOAD TEST 160% FOR 15 SECONDS

3 TEMPERATURE RISE TEST TEST CONDUCTED AT FULL

LOAD TILL TEMPERATURE
STABILISED
HIGH VOLTAGE ( HV ) &
INSULATION RESISTANCE ( IR )
TEST SHALL AGAIN BE
CONDUCTED IN HOT CONDITION
AFTER COMPLETION OF TEMP.
RISE TEST

4 OVER SPEED TEST 120% FOR 2 MINUTES

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5 TEST FOR NOISE LEVEL OF SHALL BE AS PER THE MUTUAL

MOTOR AGREED NOISE LEVELS
6 TEST FOR VIBRATION SEVERITY SHALL BE AS PER THE MUTUAL
OF MOTOR AGREED VIBRATION LEVELS

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PRE-COMMISSIONING CHECKS OF LOW -

VOLTAGE INDUCTION MOTORS

Pre-commissioning checks

1.1 Connections & their tightness :

1.2 Earthing of Motor :
1.3 Check Freeness of Motor Shaft :
1.4 IR values of stator/rotor winding with 500 V insulator tester.
Stator
R-ph & E : UI & VI :
Y-ph & E : UI & WI :
B-ph & E : WI & V1 :

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1.5 IR valves of cable with 500 V /1000 V insulation tester

R-ph & E : R-ph & V-ph :

Y-ph & E : R-ph & B-ph :

B-ph & E : B-ph & Y-ph :

1.6 Healthiness of Space Heater Circuit including cable :

1.7 Healthiness of thermistors / RTDs circuit including cable :

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 ISGEC JOHN THOMPSON

TROUBLE SHOOTING CHART OF MOTORS

TROUBLE CAUSE WHAT TO DO
Motor fails to Blown fuses Replace fuses with proper type and
start ratings
Overload trip Check and reset overload in starter 

Improper line Check connections with diagram

connection supplied with motor
Mechanical Check motor and driven equipment
failure rotates freely. Check bearing and
lubrication
Open circuit in Indicating by humming sound when
winding motor is switched ON. Check for loose
wiring connections. Also ensure that all
control contacts are closing
Short circuited Indicated by blown fuses. Motor must be
stator rewound 20
 ISGEC JOHN THOMPSON

TROUBLE CAUSE WHAT TO DO

Motor stalls One phase may Check Lines for open phase
be open
Over load Reduce load

Open circuit Fuses blown, check over load relay,

Stator and push buttons
Wrong wrong Reverse connections at motor or at
rotation sequences of switchboard
phases
Motor vibrates motor Re-align
misaligned
Weak Support Strengthen base
Coupling out of Balance coupling
balance

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TROUBLE CAUSE WHAT TO DO

Motor Over load Reduce load
overheats
Motor may have Check to make sure that all leads are
one phase open well connected

Improper Open vent holes and check for

ventilation continuous stream of air from the motor

 Unbalanced Check the voltage across the terminal of

terminal voltage the motor

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Discussion

on

Construction features

of

Motor Control Centres

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MOTOR CONTROL CENTRE ( MCC )

INDEX
• Salient Feature of Motor Control Centre

• Detail of Outgoing Feeders

• Pre - Commissioning Checks of MCC

• Trouble shooting of MCC

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SALIENT FEATURES OF MCC

• 3 Phase, 4 Wire, 400 V ± 10% voltage & 50 Hz. ± 5%

frequency
• MCC design to with stand Fault level of 50 KA for 1 second
• Control supply of MCC is 220V through control Transformer ,
however standby Transformer also been provided with Auto
change over
• All Motor feeders are Direct on line operated ( DOL)
• All Motorised valves are Reversible direct on line operated
( RDOL) – if applicable
• All Motors driven by VFDs are having Switch Fuse Feeders
(SFU)

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• Each Motor can be switched ON & OFF from Push Button

Station installed near the individual Motor and also from
PLC.Selection is done through an selector switch mounted on
the MCC
• Dust, Damp & Vermin proof Construction
• Totally Enclosed, Fully Compartmentalized
• Floor Mounting, Self Standing & Fully Draw Out Type or Fixed
Type.
• Single or Double Front Operated
• Aluminum or Copper Bus Bars with heat shrinkable PVC
sleeves
• All identical feeders and corresponding parts are
Interchangeable with each other in case of Draw-out MCC.
• All hardware is corrosion resistant
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Detail
of
Outgoing Feeders

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DOL STARTER (POWER)
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DOL STARTER (CONTROL)
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STAR DELTA STARTER (POWER)
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STAR DELTA STARTER (CONTROL)
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LONG RETRACTABLE SOOT BLOWER (POWER)
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LONG RETRACTABLE SOOT BLOWER (CONTROL)
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ROTARY SOOT BLOWER (POWER)
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ROTARY SOOT BLOWER (CONTROL)
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MOTORISED CONTROL DAMPER (POWER)
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MOTORISED CONTROL DAMPER (CONTROL)
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MCCB FEEDER (POWER & CONTROL)
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PRE-COMMISSIONING & COMMISSIONING CHECKS

OF MCC
1 PRE-COMMISSIONING CHECKS

1.1 Visual Check

1.2 Tightness check of all the power & control terminals
1.3 Setting of overload relay / any other protection relay as per
motor Full load Current
1.4 Control wiring check as per control circuit.
1.5 Power wiring check
1.6 Overall cleaning of feeder
1.7 Earthing of Feeder Doors / Draw-out trolley

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- 2 FUNCTIONAL / COMMISSIONING CHECK

- 2.1 Control Circuit Check

- 2.1.1 Operation of contactors

- 2.1.2 Indication circuit
- 2.1.3 Inter-locking circuit (if any)
- 2.1.4 Protection Circuit

- 2.2 Power Circuit Check

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TROUBLE SHOOTING OF MCC

SL. FAULT CAUSE RECTIFICATION

NO.
1 INCOMING POWER NO INCOMING POWER CHECK INCOMING POWER
ON INDICATION SUPPLY FROM POWER SUPPLY IN THE POWER
LAMPS NOT HOUSE HOUSE AND SWITCH-ON
GLOWING

FUSE BLOWN OFF CHECK AND REPLACE

DEFECTIVE FUSES OF
INDICATION LAMPS

LAMPS DEFECTIVE CHECK AND REPLACE

DEFECTIVE LAMPS.
INDICATING LIGHT CHECK AND REPLACE
DEFECTIVE

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SL. FAULT CAUSE RECTIFICATION

NO.

2 INCOMING ACB OVER CURRENT CHECK OVERCURRENT

TRIPPED RELEASE OF ACB RELEASE SETTING OF ACB
ACTUATED AND ADJUST ACCORDING
TO LOAD

3 VOLT METER NOT VOLT METER FUSES CHECK AND REPLACE THE
WORKING BLOWN OFF. DEFECTIVE FUSES.
VSS DEFECTIVE CHECK AND REPLACE THE
DEFECTIVE SELECTOR
SWITCH.

LOOSE CONNECTION CHECK WIRING AND TIGHT

THE CONNECTIONS, IF
FOUND LOOSE.
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 ISGEC JOHN THOMPSON

SL. FAULT CAUSE RECTIFICATION

NO.
4 AMPERMETER SELECTOR SWITCH CHECK AND REPLACES
NOT WORKING DEFECTIVE THE SWITCH.

LOOSE CONNECTION CHECK WIRING AND TIGHT

THE CONNECTIONS, IF
FOUND LOOSE.

CT. DEFECTIVE CHECK AND REPLACE CT.

5 OUTGOING CONTROL FUSE BLOWN CHECK 220V CONTROL

FEEDERS OFF OR CONTROL SUPPLY
CONTACTOR NOT SUPPLY NOT AVAILABLE
CLOSING

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SL. FAULT CAUSE RECTIFICATION

NO.
LOCAL / PLC SELECTOR CHECK THE POSITION OF
SWITCH DEFECTIVE OR SWITCH IF IT IS ON PLC,
IN WRONG POSITION SIGNAL FOR ON & OFF
WILL BE AVAILABLE FROM
DCS OTHERWISE FROM
LOCAL PUSH BUTTONS.
INCASE SWITCH IS
DEFECTICE REPLACE IT.
OVER LOAD RELAY CHECK AND RESET THE
TRIPPED OVERLOAD RELAY AFTER
INVESTIGATING CAUSE OF
TRIPPING.

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SL. FAULT CAUSE RECTIFICATION

NO.
LOOSE CONNECTIONS CHECK WIRING AS PER
OR FAULT CONTROL CIRCUIT AND DO
CONNECTIONS THE NEW WIRING IF WIRES
ARE WRONGLY
CONNECTED OR TIGHTEN
THE WIRES IF THEY ARE
LOOSE.
COIL DEFECTIVE REPLACE COIL.

6 POWER FUSE WRONG SELECTION OF CHECK AND REPLACE THE

BLOWING FUSE FUSE AFTER REFERRING
THE SINGLE LINE
DIAGRAM.

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SL. FAULT CAUSE RECTIFICATION

NO.
POWER CIRCUIT FAULTY CHECK OUT GOING
POWER CABLE IF
DEFECTIVE THEN REPLACE
THE CABLE.
CHECK THE MOTOR
WINDING IF DEFECTIVE
THEN REPLACE MOTOR.

CHECK AND TIGHTEN THE

LOOSE CONNECTION IF
ANY

CHECK SUPPLY VOLTAGE

AND FREQUENCY IS IN THE
LIMITS.

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Configuration

details of

Variable Frequency Drives

( VFD )

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VARIABLE FREQUENCY DRIVE PANELS

INDEX
• Salient Feature of VFD Panels

• External view of VFD Panel

• SLD of VFD

• Pre – Commissioning checks of VFD Panels

• Trouble shooting of VFD Panels

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SALIENT FEATURES OF VFD PANELS

• Suitable for operation at 3 Phase, 415 V ± 10% voltage & 50 Hz.

± 5% frequency
• Following controls are available in the drive:-
# Continuous setting of speeds from lower to rated
speed
# Continuously adjustable acceleration and deceleration
timers
# Motor Voltage
# Torque boosting
# Flying start

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• Drives are having the following protections for the motor/drive :-

# Over Current
# Under and Over Voltage
# Earth Fault in Motor or cable
# Motor Stall
# Motor Over load
# Motor under load
# Drive Over temperature
# Short Circuit
# Single Phasing Prevention

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• Each VFD driven Motor can be switched ON & OFF from s Push
Button Station installed near the individual Motor and also from
PLC. Selection is done through an selector switch mounted on
the VFD Panel
• VFD Panel is Dust, Damp & Vermin proof Construction
• VFD Panel is Floor Mounting, Self Standing Type
• All hardware is corrosion resistant

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External View of VFD Panel

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SLD FOR VFD

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PRE-COMMISSIONING & COMMISSIONING CHECKS

OF VFD PANELS

1 PRE-COMMISSIONING CHECKS

1.1 Visual Check

1.2 Tightness check of all the power & control terminals
1.3 Setting of Programming as per the rating of motors
1.4 Control wiring check as per control circuit.
1.5 Power wiring check
1.6 Overall cleaning of Panel
1.7 Earthing of Feeder Doors / Draw-out trolley

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- 2 FUNCTIONAL / COMMISSIONING CHECK

- 2.1 Control Circuit Check

- 2.1.1 Operation of contactors & VFD

- 2.1.2 Indication circuit
- 2.1.3 Inter-locking circuit (if any)
- 2.1.4 Checking of Protection Circuit

- 2.2 Power Circuit Check

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TROUBLE SHOOTING OF VFD PANEL

WARNING / FAULT CAUSE WHAT TO DO
DISPLAY IN DRIVE
Drive temp high The drive Check ambient conditions
* (4210) temperature is Check air flow and fan
excessive operation
Check heat sink fins for dust
pick-up.
Check motor power against
unit power
Earth fault Drive has Check motor.
* (2330) detected load Check motor cable
unbalance Check there are no power
typically due to factor correction capacitors
earth fault in in the motor cable.
motor or motor
cable 56
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WARNING / FAULT CAUSE WHAT TO DO

DISPLAY IN DRIVE

Motor 1 temp Measured motor Check the value of the

*(4312) temperature has alarm limit.
exceeded the alarm Let the motor cool
limit set by parameter down Ensure proper
35.02. motor cooling, check
cooling fan, clean
cooling surfaces
Short circiut Short circuit in the Check motor and
*(2340) motor cable or motor motor cable
Check there are no
power factor
correction capacitors in
the motor cable.
Output bridge of
converter unit is faulty Consult ABB
representative
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WARNING / FAULT CAUSE WHAT TO DO

DISPLAY IN DRIVE

Motor stall the motor is operating in Check motor load

* (7121) the stall region. This can and the rating of the
be caused by excessive drive.
load or insufficient motor Check fault function
power. parameters.

Motor temp The motor temperature is Check motor

*(4310) excessive. This can be ratings, load and
caused by excessive cooling.
load, insuffient motor Check star-up data.
power, inadequate Check fault function
cooling or incorrect start-
parameters.
up data
* Please refer the complete manual of drives.

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THANKS

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