I have the following questions, please advise.
1. Why you state
a) ...315 kw delta star motors. It should be 315kW star delta?
b) ... star vacuum contactor closes... Check whether the three contactors are vacuum contactors on 525V system?.
2. ... line voltage drops from 525v to 420v. ...trips on over-current. Do you mean the Breaker (not the thermal overload relay) tripped after a short duration while it is on Star running up stage i.e. before the Delta stage? What is the motor rated current and the breaker Ir current setting?
3. Attention: for SD starting, there are 6 wires from the starter to the motor. Check carefully for correct connection.
4. This is not applicable to your case.
Info: If the Breaker trips on Instantaneous (Imag) [during the instant of transfer from S to D], revisit the "revised" SD circuitry. The old circuitry which had been in used for the past 70+ years had been proven with flaw.
Che Kuan Yau (Singapore)