My experience in drafting the layout of an LV switchgear

(equipment, inside installations)

electrical-engineering-portal.com/experience-drafting-layout-lv-switchgear

By Bishal Lamichhane March 22, 2021

LV switchgear layout: Design & Size

Low voltage (LV) switchgear is a broad terminology that includes a wide range of equipment
like circuit breakers, switches, offload isolators, MCCBs, etc. within the 1 kV rating required
to protect the LV system. The most common use of LV switchgear is in the LV distribution
board which further comprises multiple segments like the main incomer, sub-incomers,
feeders, etc. the size, configuration, and physical layout for switchgear vary as per specific
requirements and standards.

My experience in drafting the layout of an LV switchgear (equipment, inside installations)

In this article, we will discuss multiple factors to consider for sizing and designing the layout
of LV switchgear for real-world application. The design engineer must go through various
phases and iteration before finalizing the layout, which later is realized physically.

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Original Equipment Manufacturers (OEMs) and independent manufactures produce
thousands of LV switchgear assemblies each year, and properly designed layouts are
mandatory to ensure that it meets the requirements.

Table of Contents:

1. Classification and critical features

The switchgear is of different type based on the voltage level at which it operates. HV
switchgear operates at a voltage level of above 33 kV. MV switchgear operates at the
voltage level of 33 kV and below. Likewise, LV switchgear operates at the voltage level of 1.1
kV maximum.

Irrespective of particular voltage levels, switchgear are known for their complete reliability,
quick operation, and absolute isolation compared to other similar devices.

Figure 2 – MV switchgear cubicle (Left) and LV switchgear cubicle (right) inspection

Figure 1 – MV switchgear cubicle (Left) and LV switchgear cubicle (right) inspection

Figure 1 displays the internals of cubicles of typical MV and LV switchgear. Physically, higher
voltage creates extra complexity because of the higher risk of arc flashes and insulation
failures. Apart from that, MV and LV switchgear shares a lot of similarities in terms of design
and construction.

There has been substantial advancement in technology which started from the simplest form
of switchgear, like a tumbler switch used widely for controlling small lights and household
circuitry.

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Switchgear protection plays a vital role in the modern power system- generation,
transmission, and distribution. The modern advancement in technology has allowed multiple
switchgear applications in the end-use level as well, which includes various industrial,
commercial, and domestic purposes.

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2. LV switchgear introduction and functionality

LV switchgear is one of the most integral parts of low voltage power distribution and
protection. They primarily comprise high-energy components capable of isolating or
containing the downstream faults to secure the rest of the upstream network. Switchgear
acts as a logical combination of electrical switching devices like circuit breakers, contactors,
isolators, switches, etc working collectively to switch, control, measure, and protect the
associated electrical circuits.

Some of these components operate under abnormal while others for serving normal
operations like switching and power distribution. The two most important and frequently used
elements in LV switchgear are Molded Case Circuit Breakers (MCCBs) and Air-Circuit
Breakers (ACBs). MCCBs are usually preferred for relatively low current usage between 20-
3200A while ACBs are preferred for considerable power applications with high current usage
between 800-6400A.
ACB is far more advanced than its counterparts and also equipped with additional features
like Under Voltage Trip (UVT), automatic turn on with closing coils, etc.

Figure 2 – An example of low voltage switchgear layout

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 Figure 2 – An example of low voltage switchgear layout

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2.1 What differentiates switchgear from switchboards, MCCs, and PBDs?

Switchgear, Switchboards, Motor Control Centers (MCCs), and Panelboard all are essential
parts of LV power distribution, control, and protection. They primarily function to receive
primary power and distribute it to downstream equipment as per requirements.

However, since we are focusing on the functionality of the latest form of LV switchgear in this
article, it is important to point out what distinguishes it from the rest of its family members.

Switchgear belongs to the most upstream portion among all other mentioned LV members
like switchboards and MCCs. Primarily, switchgear comprises equipment that contains very
high-energy compartments capable of isolating the downstream faulty portion completely,
keeping the rest of the distribution system intact and running. Switchgear act as the last
line of defense and hence are more robust to withhold fault for a relatively long period.
In most cases, incomers and main outgoing feeders in LV switchgear are equipped with
ACBs while the downstream switchboards have MCCBs and MCBs for protection.

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Figure 3 – LV distribution principle

Figure 3 – LV distribution principle

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3. Layout design and construction details

Electrical switchgear often comes as an assembly or combination of multiple switching
devices grouped in adjacent cubicles to facilitate power distribution and protection. Each
component in the assembly has its function, starting from the enclosing body to the circuit

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breaker itself. Many additional components are added in between as per incoming and
outgoing feeders in that case.

While doing so, the switchgear must meet the prevalent standards and must address
many factors related to practical usages. First, let’s discuss those factors in a
brief. Meanwhile, the figure below is the LV switchgear assembly installed in the power
distribution room of an under-construction airport facility.

Figure 4 – LV Switchgear assembly for radial distribution in an under-construction distribution

substation

Figure 4 – LV Switchgear assembly for radial distribution in an under-construction distribution substation

(Image Credit- Er. Rajan Bhattarai)

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3.1 Factors to consider while designing the switchgear layout

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3.1.1 Prevalent standards

While designing the layout of LV switchgear, the engineer must make sure they meet
respective IEC standards. IEC 61439 applies to all the LV switchgear assemblies that do not
exceed the voltage level of 1000V AC or 1500V DC. Apart from that, the electrical safety
standards, standards for GI sheets of exoskeleton used in cubicles, standard cubicles size
for easy ingress and egress, etc. are critical as well.

The latest revision and packaging of IEC 61439 include six different specific standards (IEC
61439-1 to IEC 61439-6). IEC 61439-1 is the most important in terms of LV switchgear,
which lays the general rules for LV switchgear assemblies while other specific packages
cover the rest of the portion.

Recommended Reading – An overview of standards IEC 61439-1 & 2 (PDF document)

IEC 61439-1-2 Overview

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3.1.2 Component selection and clearance

The switchgear assemblies come with multiple components connected in logical order to
allow the desired power distribution and protection. Circuit-breakers, conductors, and
busbars are the major live components that require specific clearance requirements. Apart
from that, earth busbar, metal frame-works, insulators, bushing, etc. are some non-live
components inside the switchgear assemblies which require proper attention too. There
should be a separate cable trunk for control cables separating them from power lines.

Likewise, placing indicators and HMI should be in height and place, which is easy to operate.

Figure 5 – Air-circuit breaker (ACB) with busbar coupling in LV switchgear assembly

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 Figure 5 – Air-circuit breaker (ACB) with busbar coupling in LV switchgear assembly

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3.1.3 Temperature control and ingress protection

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While designing the LV switchgear layout, the provision of ingress protection can easily
slip out of consideration. This is one important factor to consider. The type of door or hinge
module, provision of ventilations, all affect the type of ingress protection adopted by the
switchgear. In case of a dusty environment or during the time of the explosion in the vicinity,
these are useful to keep the inner functionality of switchgear intact and unaffected.

However, protection has a direct effect on heat dissipation. The higher the degree of
protection, the more likely the switchgear is to face the problem of temperature rise.

Most of the switchgear used in industrial uses like beverage manufacturing, glues, bottles,
laundries, soaps, etc. do fine with the protection level of IP 31-41 and IP43. Likewise, a more
intense and critical environment like chemical fabrication, explosive factories, butchers,
diaries, etc. is better served by the switchgear rated with IP-65.
The temperature dissipation is also greatly affected by the orientation of switchgear
assembly. For example, separately enclosed switchgear exposed on all sides is more
comfortable in terms of permissible temperature rise when compared to the orientation
where the enclosures are wall-mounted or group with no or minimum spacing.

IEC 61439-1 prescribes the temperature rise limits for circuit breakers inside switchgear
assemblies, which allow a maximum of 70K for PVC insulated cable connection.

Recommended Reading – What affects the operating temperature within the LV switchgear?

What affects the operating temperature within LV switchgear

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3.1.4 Safety factors

While designing the layout of the switchgear or assembling them, all essential safety
factors must comply. The layout must ensure that it well covers live parts with durable and
firm insulations. There should be enough stability and durability to resist the stresses of
normal operation while also maintaining the minimum required clearances. With open type
assembly, the layout must include a proper obstacle or barricade.

Lids and doors of critical sections must have proper locks to avoid any false intervention. The
layout should include provision for body earthing to avoid electric shocks.

Figure 6 – The safety of LV switchgear operator – Racking in and out of Masterpact MTZ
circuit breaker

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 Figure 6 – The safety of LV switchgear operator – Racking in and out of Masterpact MTZ circuit breaker

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3.2 Power flow, interlink, and placement of components

Placement and number of components in a switchgear assembly vary as per the requirement
and the original manufacturer’s catalog, all guided by respective IEC standards. Irrespective
of the number of components, there are some general design techniques that the engineer
must consider while drafting the internal layout for the switchgear assembly.

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3.2.1 Placement of circuit breakers:

Assuming that the designer has already defined the outer dimension of the assembly based
on the space availability and actual usage, it is wise to place the circuit breakers in a way
that reduces the path of higher current inside the assembly.

This is very important in terms of temperature control and economic perspective too.

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For a radial electrical system with multiple switchgear columns, it is better to place the
incomer circuit breaker in the center with other outgoing circuit breakers on either
side. This divides the total current in the busbar. Likewise, to allow easy ingress and egress
of cables, the large apparatus are better placed at the lower part of the switchgear layout
with enough spacing of 0.8-1.2m from the bottom. This is important for mechanical stability
and installation flexibility as well.
Figure 7 illustrates an example of a switchgear assembly 3D layout with the main incomer
ACB placed in the center and other components arranged in optimized orientation.

Figure 7 – Physical 3D layout of LV Switchgear assembly

Figure 7 – Physical 3D layout of LV Switchgear assembly

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3.2.2 Provision for terminations, anchoring, and bends:

The layout shall consider the requirement of switchgear to allow required clearance for large
busbar and cable termination in ACBs, MCCBs, and other apparatus as required. The length
of anchor plates and couplings varies as per the circuit breaker types, which is best stated in
their catalog.

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Major horizontal and vertical terminations usually require clearance of 150-250mm.

The cross-section of the coupling and busbar also varies according to the current rating and
heat exchange requirements. For instance, for the current rating of 1600A, a busbar with a
cross-section of at least 2mm x 120mm x 5mm is considered appropriate. Vertical
terminations are appropriate for the apparatus with a higher current rating to allow easy heat
dissipation because of natural air circulation underneath.

Figure 8 – Low voltage switchgear: Horizontal & vertical busbars, cable terminations and
busbar connections

Figure 8 – Low voltage switchgear: Horizontal & vertical busbars, cable terminations and busbar
connections

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3.3 Housing, frameworks and dimensions

The housing and framing layout decision relies on gravity, stability, and other ergonomic
factors apart from the adequacy of electrical compliance. The designer must make sure that
the layout allows the final product to be mechanically stable, respect the ergonomics and

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homogenous weight distribution.

The layout of the switchgear assembly must be modular to allow easy transportation and
positioning. There should be a clear indication of separation and coupling between the
individual cubicles. The layout must comply with the specific test for a lifting capacity of
individual cubicles as defined by IEC 61439-1.

Sometimes, the switchgear assembly needs to be designed based on the specific

requirements of clients, like space constraints, weight constraints, dimensions to fit the
existing trenches and foundation, etc.
The designer must make sure that the requirements are best met while also making sure all
standards comply.

Figure 9 – Assembling low voltage switchgear at the workshop

Figure 9 – Assembling low voltage switchgear at the workshop

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3.4 Single-line diagram to switchgear assembly, the final layout

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3.4.1 Taking a base of the single line diagram

The most important and initial reference for any switchgear assembly is the single-line
diagram of the power distribution system. The single-line diagram helps to determine the
tentative component requirement to meet the desired level of distribution and protection. The
total number of incoming feeders, outgoing feeders, busbars, power factor compensators,
interlocking, etc. are all stated in the single line diagram.

Initial space allocation and layout of switchgear assembly are prepared based on this
information.

Figure 10 – Single line diagram (SLD) of primary LV distribution assembly

Figure 10 – Single line diagram (SLD) of primary LV distribution assembly

Let’s assume a real-world scenario of LV radial distribution with one main primary LV incomer
and three outgoing feeders as illustrated by above Figure 10. In this case, the air circuit
breaker is chosen as the primary protection device for the main incomer while one ACB and
two MCCBs protect three respective outgoing feeders.

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The main busbar rated 3200A distributes the current from the main incomer to outgoing
feeders. The first step to designing the assembly layout would be the selection of the right
orientation of components.

Figure 11 displays an orientation of the switchgear assembly along with the busbar
placements. The exact size of the busbar depends upon the current rating of circuit breakers.
For this case of 3200 Amps of rated current, busbar compartment of width 450mm to
600mm shall suffice for four busbars – R-Y-B-N and PEN (Approximate cross-section area
for 3200A- 100x10mm each).

Busbar for branch currents are relatively small and require less space. There shall be
enough allowance for anchoring places coupling of switchgear.

Figure 11 – Switchgear Assembly layout design for single line diagram (SLD)

Figure 11 – Switchgear Assembly layout design for single line diagram (SLD)

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In Figure 8, the main incomer ACB remains at the bottom and separate compartment with
ample space to allow easy heat dissipation. Likewise, the spacing and mechanical coupling
must be as defined by IEC 61439-02 or other related standards.

NES 408.5 has mentioned the minimum clearance of 25.4 mm for the bare busbar of
opposite polarity inside a duct or panel.

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3.4.2 Determining the make and model of components

Usually, there are two different approaches to switchgear layout design. The first one is
adopted by the OEMs in which the original switchgear manufacturer has a dedicated group
of engineers for designing and optimizing the layout of the LV switchgear assembly based on
the client requirement. This makes the entire design process much easier for false proofing
and space optimization.

The second approach is adopted by the independent designer or third parties, which
involves receiving the order from the client and starting with the initial design layout. This
would be the more often case.
Later, after finalizing the make and model of components, space allocations and interlinks
are refined based on the exact dimensioning information available for each
component. Usually, the higher-rated LV circuit breakers require approximate space
allocation of 600mm width and 800-900mm depth in the switchgear assembly. This
allows ample spacing for busbar coupling and proper heat dissipation.

Figure 12 – LV switchgear layout drafted in software “Prisma Design” and exported in

AutoCAD for designing further details

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 Figure 12 – LV switchgear layout drafted in software “Prisma Design” and exported in AutoCAD for
designing further details (click to expand drawing)

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3.4.3 Additional ancillary components

Since the term LV assembly indicates a broad system with multiple LV switchgear and
apparatus combined to yield the desired result, the exact type and number of components
used is always influenced by the client’s requirement.

In most cases, the assembly requires multiple ancillary features which the design engineer
must include in the layout design.

Figure 13 – Power Factor compensator section in an LV switchgear assembly

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 Figure 13 – Power Factor compensator section in an LV switchgear assembly

Figure 13 illustrates a 450 kvar power factor compensation panel integrated with one of
the switchgear assemblies installed in an under-construction airport. The design engineer
must make sure that the integration decisions meet the space requirement, ventilation, and
connection facilitation. In this case, the compensator assembly comes with a ventilated
covering, short circuit protection for a rated current of 649Amps, and the modular
arrangement for each outgoing radial feeder.

It requires an approximate space of 600×600×2000 mm, which of course varies for each
assembly. Practically, it is better to place these compensators in the middle section of the
assembly layout as this allows easy connection to all outgoing feeders.

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Figure 14 – Automatic transfer switch section in an LV switchgear assembly

Figure 14 – Automatic transfer switch section in an LV switchgear assembly

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In radial feeder distribution of the critical load center, another important feature often
included in the single line diagram is the ATS feature. Figure 14 illustrates the placement of
two incomer circuit breakers along with the Automatic Transfer Switch interface in an LV
switchgear assembly. Likewise, many other features and components can be a part of an LV
switchgear assembly based on the requirements.

Overall, the principle of layout design remains the same, as discussed in this article.

Further reading – Single line diagrams of emergency and standby power systems with
automatic transfer switch (ATS)

Single line diagrams of emergency and standby power systems with automatic transfer
switch (ATS)

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4. Bonus – AutoCAD drawings and pictures

Download AutoCAD drawings and some pictures used in this article:
Download Drawings ❱❱

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