Karnataka (Govt.

) Evening Polytechnic,
Kadri Hills, Mangaluru

Protective relays and servicing lab Manual

2019-20
2
SLNo. 09 Hours
STUDY EXPERIMENTS

01 SI symbols for most commonly used Electrical protective devices and their
ANSI Codes. Identify different types of LV Fuses- Rewireable, Cartridge,
HRC fuse, Switch Fuse Unit (SFU) and their applications. Note down the
specifications. Identify different types of LV circuit breakers and their 03
applications- MCB, MCCB, ELCB, RCCB and MPCB. Note down the
specifications. Identify the class of MCB - B, C, D and Z classes and their
applications.
02 Identify and study power contactors and auxiliary contactors. Note down the 03
specifications. Identify and Study- Spike busters and Domestic range
Electronic Voltage Stabilizer. Note down the specifications.

03 Identify Time Multiplier Setting (TMS) and Plug Multiplier Setting (PMS) 03
devices in Electro-mechanical relays. Note down the specifications of the
Electro-mechanical Relay. Identify DIP switch settings and jumper settings in
static relays (Microprocessor/microcontroller based relays) for setting Fault
Voltage Level / Fault Current Level and Time Multiplier Settings as per
supplier’s user manual. Note down the specifications of the Static Relay.
Understand time setting and current setting procedure in Numerical relays /
Digital relays. Note down the specifications of the Relay. Identify CBCT and
its applications. Identify lockout relay. Understand the meaning of 1.3 Sec and
3 Sec relays.

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 PART A
PROTECTIVE DEVICES AND RELAYS

CONDUCTING EXPERIMENTS 30 Hours

1. Plot the operating characteristics of Fuse. 03

2. Plot the operating characteristics of MCB. 03

3. Test the operation of an Earth leakage Circuit Breaker. 03

4. Test the operation of a static type Earth leakage relay with CBCT 03
(Adjust mA sensitivity and trip time using DIP switches).
5. Test the operation of a relay type domestic stabiliser for voltage stabilisation 03
and under voltage- over voltage tripping.
6. Test the operation of thermal overload relay and plot the time - current 03
characteristics.
7. Plot the operating characteristics of electromechanical Over current IDMT 03
relays.
8. Program, Test and Plot the operating characteristics of Over Voltage Relay. 06

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 PART B
TROUBLE SHOOTING AND SERVICING

SLNo. 39 Hours
LIST OF GRADED EXERCISES

9. Trouble shoot and suggest suitable remedies for Fluorescent lamp fitting. 3

10. Trouble shoot and suggest suitable remedies for High pressure sodium vapour 3
lamp sets.
11. Dismantle, Identify the parts and assemble:- Electric iron box (automatic) .Trouble 3
shoot and suggest suitable remedies for the above. Note down name plate details.
12. Dismantle, Identify the parts and assemble:- Table fan. Trouble shoot and suggest 3
suitable remedies for the above. Note down name plate details.
13. Dismantle, Identify the parts and assemble:- Ceiling fan. Trouble shoot and 3
suggest suitable remedies for the above. Note down name plate details.
14. Dismantle, Identify the parts and assemble :- food mixer. Trouble shoot and 3
suggest suitable remedies for the above. Note down name plate details.
15. Dismantle, Identify the parts and assemble :- Electric Geyser. Trouble shoot and 3
suggest suitable remedies for the above. Note down name plate details.
16. Dismantle, Identify the parts and assemble:- Induction heater. Note down name 3
plate details.

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NOTE:

1. Relay based experiments may be done using trainer kits and other
experiments may be done using discrete components.

2. Proper protections like fuse and MCB should be used for all circuits as a
safety precaution.

3. All the experiments shall be done for low current and voltage ranges.

4. The circuit diagrams given are for reference only. Alternate safe methods
may be adopted.

PART A
PROTECTIVE DEVICES AND RELAYS
CONDUCTING EXPERIMENTS

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CIRCUIT DIAGRAM

TABULAR COLUMN

Sl no Current I amps Time in seconds

SAMPLE GRAPH

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Ex No 1 FUSE

AIM:
To study the operation of a fuse and plot the time-current characteristics.

APPARATUS REQUIRED:
1. Fuse wire (preferably lower rating like 1A, 2A, 2.5A and 5A).
2. AC Ammeter 0-5/10A MI
3. SPST Knife switch
4. 5A,230V single phase variable lamp/resistive load.
5. Stop clock / digital watch.

PROCEDURE:
1. Connections are made as per the circuit diagram.
2. Close the SPST switch.
3. Switch ON the main supply and adjust the load current at 1.25 times the rated current of
fuse.
4. Now open the SPST switch and note the time taken by fuse to melt. (from the instant the
SPST switch is opened till the fuse melts and ammeter reads zero).
5. Replace the fuse wire and repeat the procedure for 2, 3, 4 times the rated current of the
fuses.
6. Tabulate the readings.
7. Plot the time- current characteristics.

RESULT:

It is observed that the fusing time decreases with increase in overload current.

Viva Questions
1 Characteristics of fuse wire.
2 Comparisons of fuse and circuit breaker
3 Types of fuses and their applications
4 Type of fuse required for protection of transformer, generator and induction motor

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CIRCUIT DIAGRAM:

TABULAR COLUMN

Sl no Current I amps Time in seconds

SAMPLE GRAPH

9
Ex No 2 MCB

AIM:
Study the operation of MCB and plot the operating characteristics.

APPARATUS REQUIRED:
1. Single Pole MCB 3A
2. AC Ammeter 0-10A MI
3. 15 A SPST switch.
4. 5A,230V single phase variable lamp/resistive load.
5. Stop clock / digital watch.

PROCEDURE:
1. Connections are made as per the circuit diagram.
2. Close the SPST switch.
3. Switch ON the main supply and adjust the load current at 1.25 times the rated current of
MCB.
4. Now open the SPST switch and note the time taken by MCB to trip. (from the instant the
SPST switch is opened till the MCB trips and ammeter reads zero).
5. Repeat the procedure for 2, 3, 4 times the rated current of the MCB.
6. Tabulate the readings.
7. Plot the time- current characteristics.

RESULT:
It is observed that the tripping time of the MCB in inversely proportional to the load current.

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CIRCUIT DIAGRAM:

11
Ex No 3 ELCB

AIM:
To test the operation of single phase ELCB / RCCB

APPARATUS REQUIRED:
1. 10A /16 A, 30 mA / 60mA sensitivity single phase ELCB.
2. 5A socket with Earth pin connected to the earthing.
3. 0-100 mA Ammeter.
4. 1A, 250 V ,4k POT.
5. 100 W incandescent bulb.

PROCEDURE:
1. Connections are made as per the circuit diagram.
2. Switch ON the main supply and ELCB.
3. Switch ON SPST.
4. Vary the POT and note down the current at which the ELCB trips.
5. Verify the whether the ELCB tripped as per current sensitivity specification.

RESULT:
The ELCB trips at _______mA.

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CIRCUIT DIAGRAM:

TABULAR COLUMN

Sl no ELR Trip current ELR Secondary CB Trip Time

setting (amps) current (amps) (seconds)
1

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Ex No 4 ELR

AIM:
To test the operation of an earth fault/ earth leakage relay.

APPARATUS REQUIRED:
1.Power contactor with 230 V coil voltage.
2.Earth Leakage Relay with suitable CBCT set.
3.Push button switches
4.SPST
5.Lamps

PROCEDURE:
1. Connections are made as per the circuit diagram.
2. Connect a clamp-on-meter in the secondary circuit of CBCT to measure the current.
3. Switch ON the main supply with SPST switch in open condition.
4. Turn ON lamp.
5. Now close SPST switch and observe the Earth Leakage Relay trip the Circuit Breaker.
6. Verify and note down the tripping time and current as per DIP settings.
7. Draw Trip current vs Trip time curve.

RESULT:
It is observed that the tripping time is inversely proportional to the earth fault current.

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CIRCUIT DIAGRAM

TABULAR COLUMN

Under voltage and over voltage tripping test

Low voltage trip in volts High voltage trip in volts

Voltage stabilisation test

Input voltage Output Voltage

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Ex No 5 VOLTAGE STABILISER

AIM:
To study the operation of domestic voltage stabiliser and test it.

APPARATUS REQUIRED:
1. Single phase Voltage stabilizer 500 VA.
2. Voltmeter 0-300V MI
3. 10A 0-300 V Single phase Autotransformer (dimmerstat)

PROCEDURE:
1. Connections are made as shown in the circuit diagram.
2. Keep the power ON switch of the stabilizer in OFF condition.
3. Switch On the main supply and set the voltmeter Vin to normal operating voltage (220V).
4. Switch on the stabilizer and note the output voltage Vout.
5. Now slowly increase the voltage by varying the autotransformer and observe both Vin
and Vout until the stabilizer trips. Note down the over voltage Vin at trip.
6. Repeat the above procedure for under voltage trip by decreasing the input voltage.

RESULT:
The domestic stabiliser trip at _____V for under voltage and ______V for over voltage
protection.

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CIRCUIT DIAGRAM

A

AC 5/10 A
Ammeter

P 15A
230 V SPST 230 V, 40 W
AC Switch Bulb
N

Lamp
Load

TABULAR COLUMN

Sl. Current setting on Tripping current Tripping Time in

No. OLR in Amps Amps secs.

EXAMPLE GRAPH

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Ex No 6 OLR

AIM:
To test the operation of thermal overload relay and plot the time - current characteristics.

APPARATUS REQUIRED:
1. Thermal overload relay 2.5-4.5 A ,415 V
2. Ammeter 0-10A MI
3. 15A SP switch
4. Lamp Load
5. Stop clock / digital watch.

PROCEDURE:
1. Connections are made as per the circuit diagram.
2. Adjust the current rating on OLR (using pointer or knob in the frontside).
3. Switch ON the main supply by keeping SPST in closed position.
4. Switch ON the lamp load and set the ammeter current to the desired test current (say 1.5
times the rated current of the OLR)
5. Now open the SPST and observe the OLR to trip.
6. Note down the time for tripping.
7. Reset the OLR and wait for 10 minutes for the OLR to cool down.
8. Repeat the above experiment for 2, 2.5, 3, 4 times the rated current of OLR.
9. The operation of NO and NC contacts of OLR, while tripping, may be checked with the
help of series test lamp as shown in the circuit diagram.
10. Plot the time-current characteristics.

RESULT:
It is observed that the tripping time is inversely proportional to the overload current.

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CIRCUIT DIAGRAM

230 V, AC
P N 230 V, 40 W
Bulb
MCB Over Current Relay P

0 – 10 A
10/5 CT Ammeter
A N
Sensing
circuit

Single Phase
Lamp Load

TABULAR COLUMN

Sl. PSM CT Secondary Tripping Time in

No. current in secs.
Amps
1

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Ex No 7 ELECTROMECHANICAL OVER CURRENT RELAY TESTING

AIM:
Plot the operating characteristics of electromechanical Over current IDMT relays.

APPARATUS REQUIRED:
1. Electromechanical Over current Relay
2. Ammeter 0-10A MI
3. Lamp Load
4. Current Transformer 10/5 A

PROCEDURE:
1. Connections are made as per the diagram.
2. Set the PSM and TSM of the electromechanical over current relay.
3. Switch ON the main supply and apply load slightly more than the full load current rating
of the CT.
4. Note down the time taken by the relay to trip the circuit breaker.
5. Repeat the experiment for different overload currents.
6. Tabulate the readings.
7. Plot the time-current characteristics.

RESULT:
It is observed that the tripping time is inversely proportional to the overload current.

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CIRCUIT DIAGRAM

230 V, AC
N P 230 V, 40 W
Bulb

MCB Over Voltage Relay P

0 – 300 V 230 V, AC
Voltmeter
N
Sensing
V circuit

Autotransformer 0 – 300V,
10A

TABULAR COLUMN

Sl. PSM Autotransformer Tripping Time in

No. output voltage in secs.
volts
1

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Ex No 8 ELECTROMECHANICAL OVER VOLTAGE RELAY TESTING

AIM:
Plot the operating characteristics of electromechanical Over Voltage IDMT relays.

APPARATUS REQUIRED:
1. Electromechanical Over voltage Relay
2. Voltmeter 0-300V MI
3. Lamp Load
4. Dimmerstat 0-300 V, 10 A

PROCEDURE:
1. Connections are made as per the diagram.
2. Set the PSM and TSM of the electromechanical over voltage relay.
3. Switch ON the main supply and apply a voltage slightly more than 110V (this voltage is
secondary voltage rating of a Potential Transformer).
4. Note down the time taken by the relay to trip the circuit breaker.
5. Repeat the experiment for different voltage outputs of autotransformer.
6. Tabulate the readings.
7. Plot the time-voltage characteristics.

RESULT:
It is observed that the tripping time is inversely proportional to the overvoltage.

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