CHAPTER- 1

Introduction

1.1 About SAPTARSHI PROCESS P.LTD.

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

1
 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 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.

2
 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:

3
 • 1970s: 600-700 per year
• 1990s: 300-400 per year (NIOSH, 1998) 5th leading cause of occupational
fatalities.
• 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

4
Overhead Power line Hazards

• Most people don’t realize that overhead power lines are usually not
insulated
• 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.

5
 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.
• White wire (neutral or common wire), returns the power.

Ch2, fig. 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.

6
• A ground fault accident occurs when a person touches or grasps an electrically
energized object while the feet or other body 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.

Ch2,fig 2.2 prong plug The “Ground Fault” Accident

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

7
 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.

Ch2, Table 2.1 Effects of Electric Current on the Human Body

Effects of Electric Current on the Human Body

Current Reaction

1 milliamp Just a faint tingle

5 milliamps
6-25 milliamps (women)
9-30 milliamps (men)
Slight shock felt. Disturbing, but not painful. Most people
can “let go.” However, strong involuntary movements can
cause injuries.
Painful shock. Muscular control is lost. This is the range where
“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.
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 Ch2, Table 2.2 Effects of Electric Current on the Human Body

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

9
 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.

2.3 Electrical Appliances to prevention

10
 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
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.

11
 Ch2,fig 2.6 types of Fuses

Ch2, fig 2.7 Fuses notification

12
 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.

13
 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 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 )

14
 • 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:

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.

15
• 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
• 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.

16
 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.

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)

17
 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).

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

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 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.

MCB (BD-63T Series)

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

MCB (BD-63 Series)

19
20
 Ch4,fig 4.3 1p,2p,3p,4p MCB

4.2 Working:

Thermal Principle
(Overload Protection)

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.

21
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

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

22
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.

4.3 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.

• 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).

23
• 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

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

Ch4,table 4.1 Instantaneous tripping current

THE B-TRIP CHARACTERISTIC

24
 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.

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

THE C-TRIP CHARACTERISTIC

25
 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)

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

26
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 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

27
Ch4,table 4.2 current required for instaneous tripping

28
 Ch4,table 4.3 maximum fault loop inpedance in ohms for CB

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

5.1 INTRODUCTION

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

manufacturers of ELCBs and further developed inhouse for 10 kA. Residual Current

29
Operated Earth Leakage Circuit Breakers are internationally accepted means of providing
protection from electric shocks and fires caused due to earth leakage currents

5.2 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.

5.3 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:

30
 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)

31
 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.

5.4 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

32
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.

5.5 Advantages and Disadvantages

• Advantages

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.

33
 * 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.

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.

34
 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
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.

35
 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

37
 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 (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.

6.1 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
unauthorized persons. It may also be coupled to any of our CT-1 Toroidal Transformers.

6.2 Operation

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 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.

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.

6.3 Features

• Precision digital settings

• LED bargraph display

• 10 selectable trip levels – 30mA to 10A

• 16 selectable time delay – 0ms to 10 seconds

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• 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

6.4Applications

• Switchgear

• Distribution systems

• Generator sets

• Control panels

• Building management

• Utility power monitoring

• Process control

• Motor protection

• Transformer protection

CHAPTER 7

ELCB + MCB Combinations

7.1 INTRODUCTION

40
 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 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 .

7.2 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

41
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.

• 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

8.1 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.

8.2 Characteristic graph of ELR+MCB:

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

8.3 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

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• Phase interchange prevention

• Variable I ⧍n setting with color bar code

• 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
45
 ROBOT

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.

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

46
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

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

48
 Ch9,fig 9.3ROBOT , 3Ø, 4-Pole, 415V, 50Hz

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.

9.3 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
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

49
7 Over Volt Cut – Off 290V, 50Hz., + 5% respect to neutral
8 Over Volt Cut - Off Time Less than 0.1 Second
9 Rated Frequency 50Hz. to 60 Hz.
10 Breaking Capacity 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
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 deliver include:

51
 • 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

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

52
 • 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

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