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Depending on the size of the building or factory site and whether the supply is high voltage
or low voltage, there may be requirements for both a main high voltage switchboard and
one or more low voltage switchboards or just a single low voltage switchboard. The
preferred name for the switchboard unit is a “Switchgear and Controlgear Assembly”
(SCA).
M
ajor components you can spot while looking at opened LV and MV switchboards (on photo:
Siemens gas insulated switchgear, 38KV, 1250 on left; LV switchboard and electrician
performing testing on right)
The basic aim of the switchboard is to take the electrical power from the main supply
source and then to feed or distribute power to the appropriate circuits within the building.
The switchboard has to perform this function in such a way that there is proper control of
power flow and proper electrical protection against the damaging effects of faults.
This protection is necessary to prevent personnel hazards and also equipment hazards
and possible fires. It should be able to operate to isolate a faulty section in the
minimum possible time consistent with the fault severity.
In many cases, work is performed on the switchboard components while they are still
live.
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The switchboard should also be designed to present no danger of electric shock or
injury to the operating personnel in the vicinity during normal or abnormal operation.
Explosions in switchboards are a not infrequent occurrence which can cause significant
injury to personnel.
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1.1 The Incoming Cables
These may be either high voltage (HV) or medium or low voltage (MV or LV). For high
voltage, they will normally be either impregnated paper insulation (unlikely these days),
cross linked polyethylene (XLPE) or ethylene propylene rubber (EPR) insulated cable.
The last two types are the preferred types for new installations, with XLPE being the most
common.
EPR cables are more flexible and are preferred for specialized applications such as trailing
leads in mines. For low voltages the cables may be XLPE or elastomer (EPR) type cable
In some cases busbars can be used instead of cables. This option is far more expensive
than cables, but it also offers better reliability. If you ask me, I prefer busbar systems,
where applicable of course.
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1.2 Outgoing circuit conductors
These may be any of the following types:
1.Insulated cables,
2.Insulated busbars,
3.Busbar trunking systems
4.Mineral insulated metal-sheathed (MIMS) cables
5.Fire-resistant cables
Figure 2 – Switchgear layout. (a) Switchboard with one incoming feeder. (b) Switchboard
with two incoming feeders.
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Figure 3 – MV Knife Switch
Mainly two types of load-break switches are used: knife-contact type with/without fuses
and slide-in type with/without fuses.
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Figure 4 – Load-break switch position in MV cubicle
Where:
1.Switchgear: Switch-disconnector and earthing switch in an enclosure filled with
SF6 and satisfying “sealed pressure system” requirements.
2.Busbars: All in the same horizontal plane, thus enabling later switchboard
extensions and connection to existing equipment.
3.Connection: Accessible through front, connection to the lower switch-
disconnector and earthing switch terminals or the lower fuse-holders. This
compartment is also equipped with an earthing switch downstream from the MV
fuses for the protection units.
4.Operating mechanism: Contains the elements used to operate the switch-
disconnector and earthing switch and actuate the corresponding indications
(positive break).
5.Low voltage: Installation of a terminal block (if motor option installed), LV fuses and
compact relay devices. If more space is required, an additional enclosure may be
added on top of the cubicle.
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1.5 Earthing Switch
Earthing switches are commonly used and installed in switchgear. When isolating any of
the feeders (incoming or outgoing) for maintenance, the feeder must be earthed by
closing the earthing switch to discharge any static charge carried by the feeder.
Earthing switches are mounted separately ahead of the switchgear, or in the base of load-
break switch or just underneath the circuit breaker.
Therefore, circuit breakers are mechanical switching devices able to make, continuously
carry and interrupt currents under normal circuit conditions and also within a limited time
under abnormal conditions, such as short circuits.
The basic elements of circuit breakers are operating mechanism, insulators, interrupting
chamber(s), capacitor and resistor.
The main types of circuit breakers include the following:
•Bulk oil
•Minimum oil
•Air
•Air blast
•Sulfur hexafluoride (SF6)
•Vacuum
•Explosive
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1.7 MV Fuses
They protect apparatus and equipment against the thermal and dynamic effects of short-
circuits. The outstanding features of MV fuse-links are:
It is important for MV fuse-links that they must be operated at the voltage for which
they have been rated. Accordingly, the operating voltage corresponds to the maximum
rated voltage of the fuse-link. Owing to the switching voltage occurring during arcing, the
fuse-link cannot be used at lower voltages without limitation
Medium voltage fuses generally fit into two categories: expulsion fuses and current
limiting fuses. The definitions per ANSI C37.40 are explained in the following technical
article:
Rating Definitions Applied to Medium Voltage Fuses
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1.8 Protection relay
Using simple words to describe: The ultimate goal of protective relay is to disconnect a
faulty system element as quickly as possible. Sensitivity and selectivity are essential to
assure that the proper circuit breakers will be tripped, but speed is the “pay-off.”
These are used for the higher voltages, together with their associated instrument
transformers (current transformers (CTs) and voltage transformers (VTs)).
Overcurrent protection units are used to activate timing relays so as to provide proper fault
protection operation
There are many different relays used to protect various substation equipment,
starting from transformers, incomers, feeders, capacitors, generators, motors, etc.
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2.1 The Incoming and Outgoing Cables/Busbars
Same as at MV switchboard, incoming cables can be cross linked polyethylene (XLPE) or
ethylene propylene rubber (EPR) insulated type.
Generally, busbars are more often used at low voltage level than at medium voltages.
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Figure 8 – Busbar Trunking Systems and Cables
It provides safe isolation of a circuit when locked in the open position. It is not
designed to make or to interrupt current, and no rated values for these functions are given
in the standards.
The isolator must be capable of withstanding the flow of short-circuit currents for a limited
time (short-time withstand capability), usually 1 second. For operational overcurrent, the
time is longer.
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Figure 9 – Isolating switch
In large capacity switchboards each phase may have a number of conductor sections.
Bare LV busbars are very close together and are thus subject to high electrodynamic
forces on short circuit and resonant force effects must be considered in determining
supports.
The resonant frequency must be calculated to ensure it is not close to 100 Hz.
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Figure 10 – Internal busbar system inside LV switchboard
Load break switch is used to close and open loaded circuits under normal conditions.
It does not provide any protection for the circuit it controls.
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Its characteristics are determined by the frequency of switch operation (600 close/open
cycles per hour maximum), mechanical and electrical endurance and current making and
breaking capacity for normal and infrequent situations.
Figure 12 – 4 pole load break switch with visible breaking and a remote tripping function
For low voltage (less than 1000 V) units, the circuit breakers are invariably of the air-break
type using the “de-ion” principle, with isolated metal splitter grids. Modern switchboards
have molded-case circuit breakers (MCCBs) for the higher current ratings (more than
about 100 Amps) and miniature circuit breakers (MCBs) for the lower rating levels (less than
100 Amps).
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Figure 13 – Compact NSXm range of molded-case circuit breakers
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MCBs would normally be used in the smaller sub-main and local switchboards in a
building.
Low voltage circuit breaker consists of the following principal parts to carry out four
essential functions:
•Circuit-breaking components, comprising the fixed and moving contacts and the
arc-dividing chamber.
•Latching mechanism that becomes unlatched by the tripping device on detection
of abnormal current conditions. This mechanism is also linked to the operation
handle of the breaker.
•Trip-mechanism actuating device (learn more here). It is either:
•Thermal-magnetic device in which a thermal-operated bimetal strip detects
overload conditions, while an electromagnetic striker pin operates at current
levels reached in short circuit conditions, or:
•Electronic relay operated from current transformers, one of which is installed
on each phase.
Additional modules can be added to the circuit breaker to be adapted to provide further
features such as sensitive detection (30 mA) of earth leakage current with CB tripping,
remote control and indication (on-off fault) and heavy-duty industrial circuit breakers of
large current ratings that have numerous built-in communication and electronic functions.
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2.6 Contactors
The contactor is very simple device. It is actually a solenoid-operated switching device
that is generally held closed by reduced current through the closing solenoid. Different
mechanically latched types can be used for specific applications (e.g., motor starting,
switching capacitors).
It consists of three-switch blades, each constituting a double break per phase. These
blades are not continuous throughout their length, but each has a gap in the center that is
bridged by the fuse cartridge. Figure 15 – Fuse switch
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2.8 Metering equipment
The metering of a switchboards usually include: line and phase voltage, line current in
each phase, total power, power factor metering.
The current is monitored by a current transformer (CT): in SWBs there may be two
CTs, one for protection and one for metering.
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Figure 17 – Auxiliary power supply metering
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Sources:
1.UNSW Sydney (the University of New South Wales)
2.Medium Voltage Technology Switchgear Application Guide by Siemens
3.The art and science of protective relaying by C. Rusell Mason
4.Electric distribution systems by Abdelhay A. Sallam and Om P. Malik
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