MCB Work Instruction

MCB WORK INSTRUCTION
Work: Magnetic Tripping of MCBs

1. Clean the table & remove unwanted material.
2. First tightened the terminal screws of all the MCBs with Pneumatic screw
driver.
3. Set the current according to specifications.
PI. Verify with dommy also & the data could be variable as per materials.
Should be verified with in three month.
4. Check instantaneous tripping of MCBs according to chart
i.e. 5 times of rated current for B Curve
10 times of rated current for C curve.
5. After tripping, Check ON/OFF operation, it should not be delatch & had no
hard operation.
6. Mark the non confirming/rejected MCBs & keep it aside on a fixed place for
rework.
7. After performing a the magnetic tripping test, forward the MCBs for
calibration test at 2.55 in as per STI.
8. The rejected MCBs will be set for rework.
Approve By:
M.R.
Work: Calibration of MCBs

2. First tightened the terminal screw of all the MCBs with Pnematic Scerw
driver.
3. Check ON/OFF operation, it should not be loose contact.
4. Set the Calibration test at 2.55 In according to ration wise.
5. Mark the non confirming I rejected MCBs & keep it aside on a Fixed place
for rework.
6. Testing after all MCBs, Forward the MCBs for paint filling in Calibration
Screw.
7. The Rejected MCBs will be set for rework.
dk;Z %
,lSEcyh M.S Pin, lkbZM iRrh] ySp] LykbMj]
ckbeSVy] ,eSLfiu@,l,lfiu] es DySEi vkSj
ckbesVy ,lsEcyh] LybMj] vVjjsVhax] YkSp
,slkehd IysV] Dokby ,lsEcyh] ukSc ,lsEcyh]
vkWd pSEcj] ,sjkfed IysV] ekmUVhax [kyai]
dk;j vkSj fjeksVA
funsZ'k%
1-pSfll esa yS'k ugha gksuh pkfg,A
2-dEiksuSVL; gkFk ls iQhfVax djus pkfg,]
gFkkSM+k ugha ekjuk pkfg,A
3-LykbMj ewoeSaV iQzh gksuk pkfg, vkSj LykbMj ij
dfVax cj ugha gksuk pkfg,A
4-vkWijsfVax ySp vkmVj vkSj buj ySp VkbV ugha
gksuh pkfg,A
5-J-Clamp ,lsEcyh dks fiQV djs vkSj ckbeSVy pSfll ls
touch ugha gksuk pkfg,A
6dksby ,lsEcyh ds nkSjku ,udj fLizax vkSj
dksby 'khV MS01 ds vuqlkj gksuh pkfg,A
7blds ckn uksc vkSj nwljs ikVZ fiQV djs]

uksc dh ewoesaV lgh gksuh pkfg,A
8iQkbuy bULiSD'ku ds nkSjku] xSi
(ckbeSVy vkSj LykbMj) esa 'khV Standard ds
vuqlkj gksuk pkfg,A
9blds ckn fjfofVax djds MCBs dks VSfLVax
ds fy, HkstsA
Approved By:
M.R
Pnuematic Work Instruction

Work: Chord Crimping with Moving Contact.
1. Check the machine, the fixture & all the nut/bolt should be
tightened properly.
2. Place the Moving Contact in right position in the fixture.
3. Place the cord in the Moving contact in right position in
bending ends.
4. After crimping, check the Crimping by pulling the chord
from, it should not be pulled off.
5. Ensure the chord should not be cutted threads after
crimping.
Approved by:
M.R.

Work : Punching on J-Clamp
Instruction to be followed
1. Check the machine, the fixture & all the nut/bolt shold be
tightened properly.
2. Place the J-Clamp straight/Properly in the fixture.
3. Rationg will be punched according to bimetal
specifications MS02.
4. The punching should be illegible.
5. Ensure the chord should not be cutted thereds after
crimping.
Approved By:
M.R.

Work : Rivetting of MCBs
1. Check the machine, the fixture & all the nut/bolt should be
tightened properly.
2. Fix the riveting tool according to chassis Design (Brass
Gutka/Cu. Strip design)
3. Place the MCBs properly in the riveting fixture.
4. After riveting, ensure the rivets should be properly flared &
should not cut off.
5. The punch of the riveting tool should be proper shape and
should be replaced with in 1 mont ( 1.5 Lac Stocks)
Approved By:
M.R.
ELLEYS INDUSTIRIES (I) PVT. LTD.

Manufacture of Electrical Accessories & Switch Gear Product
CORPORATE OFFICE : Unit No. 9, Sati Ind. Estate, I.B. Patel Rd, Goregaon (E) Mumbai- 400 063. INDIA
Tel : (022) 2685 8145, 2365 7789, Telefax : (022) 2686 8146 E-mail:elleys_ho@yahoo.com
Q. A Plan MCB
Sr.
No
.
1
Stage
Observations
Extent of
Check
Equipment
Frequency
Acceptance Norms
Resp.
MT
MT
100%
M.T. Bench
Every Lot
Should trip at specified (IS 88 28)
QA Incharge
Knob Tight (KT)

NC
Delatch (DL)
Knob Free (KF)
Body Broken
Early Trip
No Trip
Grub Screw
NC
Delatch (DL)
Knob Tight (KT)
Knob Free (KF)
Knob Tight (KT)
NC
Delatch (DL)
Knob Free (KF)
Body Broken
Printing
Paint Sealing
Batch No.
Hologram
Colour
Rivet
Packing
Visual
M.T.
Calibration
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
10 Pcs / Lot
10 Pcs / Lot
10 Pcs / Lot
10 Pcs / Lot
Operational
M.T. Bench
Operational
Operational
Visual
Calibrating Bench
Calibration Bench
Mannual
Calibration Bench
Operational
Operational
Operational
Operational
Continuity Testing Bench
Operational
Operational
Operational
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
M.T. Bench
Calibration Bench
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Every Lot
Operational
Operational
Operational
Operational
Visual
According to time Band
According to time Band
Operational
Operational
Operational
Operational
Operational
Operational
Operational
Operational
Operational
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Operational
According to time Band (IS 8828)
--- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do----- do---
Calibration
Final Inspection
Final Audit
Authorized Signatory:
Please
Visit
Next page

MCB ASSEMBLY & TESTING PROCESS FLOW CHART
Start Assembly
First fit the M.S. Pin, Side strip,

Slider, Latch Assy & J
Clamp/Bimetal Assy
Fit Cermic Plate , Coli, Archute &
Knob
Final Inspection
Reworking
Cover Assy
Rivetting
100% Magnetic Tripping Test
100% Calibration Test at 2.55 in
Paint Sealing
Printing
100 % Final Inspection
Not O.K.
Packing
Sampling Inspection
Ware House
Dispatch to Customer
End
Approved By:
M.R.

Magnetic Tripping ( Coil & Anchor spring Data)
Sr. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Note:
B Curve
C Cruve
Rating
0.5
1
1.5
2
3
4
5
6
8
10
16
20
25
32B
32 C
25
25
21
21
19
19
19
19
17
17
17
15
14
14
13
40 13
50 13
63 13
Coil SWZ
No of Turns
95.5
47.5
35.5
23.5
14.5
14.5
14.5
14.5
9.5
9.5
9.5
7.5
5.5
5.5
4.5
4.5
4.5
4.5
Anchor Spring
A
B
--0.22
--0.22
--0.22
--0.22
--0.22
--0.22
--0.22
0.18
0.25
0.22
0.28
.25
0.27
.27
0.30
.27
0.30
.27
0.35
.30
---0.35
.30
0.4
.35
4.50
.35
0.45
Holding at 3 in i.e. No Trip > 1 Sec

Tripping at 5 In i.e. Trip <. 1 Sec
Holding at 5 In i.e. No Trip > 1 Sec.
Tripping at 10 In i.e. Trip <. Secs.
Approved By:
Note: Data change implemented with modified Anchor Depth : 2.1 + 0.5 instead of 2.5 + 0.5
To be Verified
To be Verified
To be Verified
To be Verified
To be Verified
To be Verified
To be Verified

Spot Welding Work Instruction ( Biemetal Assy.)

Work : Flexible Cord Spotting / Forming
Instruction to be Followed
1. Tungstun Electrodes should be used of upper Dia. 6 MM & downward side of
specific dia. Of 8 mm.
2. Set the data according to specifiecied limit in Machine.
3. Spotting area should be strengthened.
4. Length should be specified as per requirement 40 MM ( + 2 mm)
5. The electrodes should be grinned in proper shap weekly and replace the
electrodes after 1 month app 1.5 lacs spots.
6. Ensure there should be no cracks on the spotted chord.
Approved by:
\
M.R.

MCB Work Instruction

Work : Rework of MCBs
Instruction to be followed:
1.
2.
3.
4.
Clean the table & removed unwanted material.

Derivet / Open the Defective MCBs.
First Check the continuity of the MCBs with the help of Continuity tester.
After opeining check all the fitment, assembly of the MCBs according to defect
mentioned chord setting, Knob movement, Fix & Moving Contact, Grubscrew,
Anchor spring, Plunger Length etc.

5. Change the defective component & Keep it in separate bin.
6. Now rejected components will be scrapped or sent back to the supplier.
Approved by:
M.R.


Work : Printing & Packaging
1.
2.
3.
4.
Clean the table & remove unwanted material.

The printing should be legible according to requirements.
The printing should not be smerged & rubbed.
After final Inspection and putting O.K. Tested sticker, Pack the MCB in
individual packing and mark the lable according to rating.
5. After individual packing, Pack the MCBs in secondary packing & also mark the
label according to rating.
6. After Secondary packing, pack the MCB in master packing.
7. The Master carton height should not be placed more than 10 cartons in a column.
8. Finally dispatch the material to warehouse after final Audit.
9. During final Audit the rejected material will be again retested & repacked
accordingly.
10.
Finally dispatch the material according to customer requirement.
Approved by:
M.R.


Work : Final Inspection of MCBS
2. Check 100% the pointing of the MCBs, there should not be any hard or soft
operation.
3. Continuity of MCBs should be 100% checked with help of continuity tester at
terminals the continuity testor should glow.
4. MCBs should be 100% checked for other aesthetics such as snap Pusher, Seled
grup screw, Chassis crack etc.
5. Mark the non confirming / rejected MCBs and keep it aside on a fixed place for
rework.
6. After final testing, Past the O.K. Sticker on Grub Screw are of MCB.
7. After performing all the MCBs inspection, the MCBs should be packed.
8. The Rejected MCBs will be sent for rework.
Approved by
M.R.
\

Work: Assembly of M.S. Pin, Side Strip, Operation Latch Slder, JCALMP & Bimetal
Assy, M.S/s pin, MS Rail, J-Clamp & bimetal assembly, Shider, Operating, Latch,
Caramic plate, Coil assembly, Knob assembly, Arc chambe, Caramicplate, Mounling,
Clip/Spring, Covers & ririt.
1. The Chassis should be flash and ribs free.
2. All the components should be easily fit/thumb fit ie do not use hammering.
3. The slider movement should be free, There should not be cutting burr on the
slider.
4. There should not be flashes on the operating latch and the inner latch movement
should be free.
5. Fit the J-Clam Assy, the bimetal should not touch the chassis.
6. During Coil assembly, Assembly the anchor spring & coil according to
specification as per standard.
7. After this fit the knob & Other parts, There should not be fashes on the knob &
knob movement should be free.
8. During final Inspection set the gat between slider & Bimetal &Slider according to
Standard.
9. Finally fit the cover & rivet the MCB.
10.
The riveted will be sent for further testing M.T. Calibration etc.
Approved By;
M.R.

MCB Work Instruction

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MCB Work Instruction

Uploaded by

Copyright:

Available Formats

MCB WORK INSTRUCTION

Work: Magnetic Tripping of MCBs

Work: Calibration of MCBs