Low Volt Switchgear

Low Voltage Switchgear
© ABB Automation Technologies
Prepared by :
Eng.Elmamoun Ibrahim Mustafa
1- Introduction to the switchgear
LV Switchgear Functions
LV-Switchgear protection
Switchgear control
2-Switchgear Main components

LV Switchgear Product Features & Ranges
LV Switchgear Product S/C Breaking Capacity
3-Low Voltage Switchgear Terminology

4-Switchgear Assembly
Contactors
Relays
Circuit Breakers.
Fuses
Switches isolators,disconnectors.
5- protection SWGR common main parts

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Incomers.
Feeders
6-Motor Overloads relays
7- Circuit Breaker
Air circuit breaker(ACB).
Utilization categories.
ACB features .
ACB components.
8-MCCB
Accessories of MCCB
Types of MCCB
Selection of MCCB
9-Fuses
Fuse type (rewirable,t otally eclosed)
Let through energy
Selection parameter
Coordination type1&2
10- Switches ,Dis-connecter ,Isolator

Isolation
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Capability
Utilization category
11- SWGR Main common part
Incomers
Feeders
Bus-section
Standard color code and numbers of Control wires
Enclosure degree of protection (Ingress protection)
12-SWGR Types
Main Distribution Boards(MDB)
Sub distribution Board (SDB)
Motor control Center(MCC)
Automatic Transfer switch (ATS)
13-fault level calculation

14- SWGR construction
15- factory and site Tests
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Introduction to the switchgear
Definitions Switchgear
A general Term covering Switching devices &
their combination with associated control
,measuring ,protective and regulating
equipment ,also assemblies of such devices and
equipment with associated interconnects
,accessories, enclosures and supporting
structure, intended in principle for use in
connection with generation , transmission ,
distribution& conversion of electric energy.
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 The term switchgear, used in association with the
electric power system, or grid, refers to the
combination of electrical disconnects, fuses and/or
circuit breakers used to isolate electrical
equipment.
 Switchgear is used both to de-energize equipment
to allow work to be done and to clear faults
downstream.
 This type of equipment is important because it is
directly linked to the reliability of the electricity
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supply.
Applications
 Low voltage switchgear exist in
 Upstream of components Critical power
 Downstream of transformers
Industrial facilities
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Utilities
Oil and gas
By voltage class there are three types

of switchgears:-
Low voltage switchgear (less than 1,000
volts AC / 3200 volts DC)
Medium voltage switchgear (1,000–35,000
volts AC)
High voltage switchgear (more than 35,000
volts AC)
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As per IEC 60038 Table I-IV
Voltage System Nominal voltage (Vr) Kv
LV Vr < 1
MV 1 < Vr < 35
HV 35 < Vr < 230
EHV(Extra high voltage) 230 < Vr < 800
UHV(Ultra High Voltage ) 800 < Vr

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Switchgear is Generic name to cover

 Air Circuit-breakers (ACBs).
 Moulded –Case Circuit –breakers (MCCBs).
 Switches.
 Fuse.
 Switch-Disconnect-Fuses(SDFs).
 Contactors.
 Relays.
 Motor-starters.
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 Control Device.
 Switchboards
 Electrical protection
 Protection of circuit elements against the thermal and
mechanical stresses of short-circuit currents
 Protection of persons in the event of insulation failure
 Protection of appliances and apparatus being supplied
(e.g. motors, etc.)
 Electrical isolation of sections of an installation
 Local or remote switching
 Over-voltage protection
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 Under-voltage protection
Switchgear Functions
Switchgear
Switching Protection
On/Off Close/Open Abnormal Condition
Connect / Dis-connect Over current E/F
Start / Stop O/L S/C
Make /Carry/ Break
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Normal & Abnormal Condition

Switchgear Functional
Switchgear Switching Protection

Contactor Y N
Relay N Y
starter Y N
Switch/SD Y N
HRC FUSE N Y
ACB Y Y
MCCB Y Y
MPCB Y Y
RCCB Y Y
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LV-Switchgear protection
 The protection of circuit-Against overload;

a condition of excessive current being drawn from a
healthy (un-faulted) installation-Against short-circuit
currents due to complete failure of insulation between
conductors of different phases.
 The protection of persons
Against insulation failures. According to the system of
earthing for the installation the protection will be
provided by fuses or circuit-breakers, residual current
devices, and/or permanent monitoring of the
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insulation resistance of the installation to earth.

The protection of electric motors
Against overheating, due, for example,
to long term overloading, stalled rotor,
single-phasing, etc. Thermal relays,
specially designed to match the
particular characteristics of motors are
used.
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Switchgear control
Switchgear control
Switchgear-control functions allow system operating
personnel to modify a loaded system at any moment,
according to requirements ,and include:
 Functional control (routine switching, etc.)
 At the origin of any installation
 At the final load circuit or circuits (one switch may
control several loads)
 Emergency switching
 Maintenance operations on the power system
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Switchgear Main components
1. Contactor.
2. Relay.
3. Fuse.
4. ACB (Air Circuit Breaker).
5. MCCB(Molded Case Circuit Breaker).
6. MPCB(Motor protection Circuit Breaker).
7. MCB (Miniature Circuit Breaker).
8. RCCB/ELCB (Residual current/Earth leakage circuit Breaker ).
9. RCBO.
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10. EL+MCB.
LV Switchgear Product Features & Ranges
 Contactor 9 to 550 A (ON/OFF)
 Relay 0.6 to 450 A (O/L +Single Phasing )
 Fuse 2 to 800 A (S/C)
 ACB 400 to 6300 A (ON/OFF+ O/L+ S/C)
 MCCB 16 to 1600 A (ON/OFF+ O/L+ S/C)
 MPCB 0.16 to 63 A (ON/OFF+O/L+ S/C+ Single Phasing)
 MCB 0.5 to100 A (ON/OFF+ O/L+ S/C)

 RCCB/ELCB 25 to100 A (Earth leackage or I∆n)
 RCBO 6 to 32 A
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(ON/OFF+ O/L+ S/C+ I∆n)

 EL+MCB 6 to 63 A (ON/OFF+ O/L+ S/C+ I∆n)
LV Switchgear Product S/C Breaking Capacity
 Contactor 9 to 550 A (ON/OFF)

 Relay 0.6 to 450 A (O/L +Single Phasing )
 Fuse 2 to 800 A S/C [100KA]
 ACB 400 to 6300 A (ON/OFF+ O/L+ S/C )100KA
 MCCB 16 to 1600 A( ON/OFF+ O/L+ S/C ) 50/65KA
 MPCB 0.16 to 63 A( ON/OFF+O/L+ S/C+ Single Phasing ) 50KA
 MCB 0.5 to100 A( ON/OFF+ O/L+ S/C )10KA

 RCCB/ELCB 25 to100 A (Earth leackage or I∆n)
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 RCBO 6 to 32 A( ON/OFF+ O/L+ S/C+ I∆n )6KA

 EL+MCB 6 to 63 A ( ON/OFF+ O/L+ S/C+ I∆n) 6KA
Low Voltage Switchgear Terminology
Low Voltage Switchgear Terminology are generally with

respect to the following parameters:-
 Voltage
 Currents
 Behavior under normal & overload conditions.
 Behavior under short circuit conditions
 Utilization categories
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Low Voltage Switchgear Terminology
VOLTAGES
Rated Operational Voltage (Ue).
Rated Insulation Voltage (Ui).
Rated Impulse Voltage(Uimp)

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Low Voltage Switchgear Terminology-voltage
RATED OPERATIONAL VOLTAGE (Ue).

This is the voltage that would normally be
available continuously across the terminals of
the different phases of switchgear .Unless
otherwise specified. this rating will be 415 V for
LV switchgear. This implies that even while
415V @50Hz is present between the terminal
there will not be any flash-over.
That means the insulation between phases is
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sufficient to tolerate a potential difference of

415 V continuously.
RATED INSULATION VOLTAGE (Ui).

One might ask, at what Voltage the inter-phase
insulation would fail if it would not fail for 415V?
What is the be the probability of such a
happening that the system voltage can go
beyond 415 V?
There are two possibilities
1- tap changer of transformer .
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2- system flctuation on the upper side.

RATED INSULATION VOLTAGE (Ui).
Considering that the worst condition of transformer tap
changer in the maximum position (12.5%) and at the
same time the system voltage fluctuation at the
maximum(10%),so the net system voltage could be
varying of up to +25% on the Switchgear.
if the Switchgear is exactly rated for 415 V. then nder the
above conditions it would fail. so for this propose
another rating called (Ui) is specified and normally this
would be 690 V for low voltage Switchgear.
Even under the worst condition as described above ,the
415 V system voltage would not go beyond 690 V,so a
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Switchgear rated for Ui of 690 V would very well

withstand the above condition.
Rated Impulse Voltage(Uimp)

The impulse voltages are very high in magnitude ,with
very short duration of voltage waves, typically have very
high frequency.
The impulse voltage either lightening Impulse(LI) or
switching Impulse (SI).
they can strike our system and our Switchgear might
fail. so also this rating given for switchgear
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Low Voltage Switchgear Terminology-Currents
Currents
 Conventional Free Air Thermal Current (Ith).
 Conventional enclosed Thermal Current (Ithe).
 Rated operational Current(Ie).
 Rated uninterrupted Current(Iu).
 Rated Current(In).
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Rated Free Air Thermal Current (Ith).

This specification implies the maximum current that the
switchgear can carry continuously for period of 8 hours,
without the temperature rise of any part reaching beyond
permissible limits. This test is conducting in open –air
conditions.
Rated enclosed Thermal Current (Ithe).
This specification implies the maximum current that the
switchgear can carry continuously for period of 8 hours,
without the temperature rise of any part reaching beyond
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permissible limits. This test is conducted in enclosed

conditions.
 Rated operational Current(Ie).
The making and breaking capacities would vary
depending upon the application of the switchgear and are
normally specified as multiple of the rated continuous
current. So the continuous current of a switchgear would
also vary depended upon the application and the making
& breaking capacities expected in that application.
 Rated uninterrupted Current(Iu).
This rating obviously implies the maximum current that
the switchgear can carry continuously for periods
extending even hours ,weeks& months without the
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temperature rise of any part reaching beyond permissible

limits. Un less otherwise specified.
 Rated Current(In).
The rating is similar to the rated operational current

rating ,but is applied to fuses & circuit breakers.
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Low Voltage Switchgear Terminology-
Normal condition behavior
 Rated making capacity.
 Rated breaking Capacity.
Rated making capacity:-
This specification implies the maximum current - multiple
of (Ie) – that the Switchgear can safely make ,without fail
or causing any damage to itself or to the installation or to
the operator.
Rated breaking Capacity:-
This specification implies the maximum current - multiple
of (Ie) – that the Switchgear can safely Break, without fail
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or causing any damage to itself or to the installation or to

the operator.
Short circuit condition behavior
 Rated short circuit making current (Icm).
 Rated short time withstand current (Icw).
 Rated short circuit breaking current (Icn).
Rated short circuit making current (Icm):-

This specification implies the maximum current that
switchgear can safely make under the short circuit
conditions without fail or causing any damage to itself or to
the installation or to the operator.
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Short circuit condition behavior
Rated short circuit breaking current (Icn).
This is the maximum current that the switchgear can
safely break under short circuit conditions, without fail or
causing any damage to itself or to the installation or to
the operator.
Rated short time withstand current (Icw).(Picture)
This is the ability of the switchgear to carry the short
circuit for the coordinated short circuit time ,it is called
(Icw). This normally specified as 50KA for 1 sec.
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Switchgear Assembly
Various components such as
 contactors, relays, Circuit Breakers
(MCB,MCCB,MPCB,ACB) (Air Circuit Breaker).
 Fuses
 Switches ,Dis-connecter ,Isolator.
 Transformers.
 instrumentation and control equipment,
 three-phase bus work.
 all internal wiring,
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and other supporting equipment are included in each

switchgear assembly. These units can be direct coupled to
motor control center if desired.
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Contactors
Switchgear Products & components
Contactors
A mechanical Switching Device having only one position
of rest operated otherwise than hand, capable of making
,carrying and breaking currents under normal circuit
condition including overload condition.
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Contactors
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Left – Vacuum Contactor 6kV 400A; Right – 12 kV, 40 kA Indoor Vacuum Circuit Breaker
Contactors
Working principle
When power is supplied to the coil from the control
circuit, a magnetic field is produced, magnetizing the
electromagnet. The magnetic field attracts the armature
to the magnet, which in turn closes the contacts. With
the contacts closed, current flows through the power
circuit from the line to the load. When current no longer
flows through the control circuit, the electromagnet’s coil
is de-energized, the magnetic field collapses and the
movable contacts open under spring pressure.
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Contactors
Contactors circuits
 Power circuit
 Control circuit
 Auxiliary Circuit
Notice:
No electrical connection between them, and all can have
different supply.
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Contactors
 Power circuit
 Consists of main contacts.
 Make, carry & break load Current.
 Control circuit
 Consists of coil of contactor.
 For operating the contactor.
 Pick up: at 85% & withstand up to 110% of Uc.
Definition ( the Min voltage at which the contactor picks up satisfactorily)
 Drop off :75 to 20% of Uc.
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Definition:(the Max voltage at which the contactor will droop off completely)
Contactors
 Auxiliary Circuit
 Accessory part.
 Consist of NO or NC contacts.
 Does not affect the contactor operation.
 Gets affected by contactor operation.
 Used for indication, interlocking ..ect.
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Contactors
Limits of operation :
Pick Up – 85% to 110% of Uc.
Drop Off - 75% to 20% Of Uc(For A.C)
75% to 10% Of Uc(For D.C)
Terms:
 Power contactor.
 Control contactor.
 Capacitor Duty contactor.
 AC contactor.
 DC Contactor.
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 Vacuum Contactor
Contactors
Application Area:
 Switching Of Motors.
 Switching Of Lighting Loads.
 Switching Of Heating loads.
 Switching Of Capacitor.
Features :
 Long operational Life.
 High frequency of Operation.
 Can operated from remote.
 Can be used for Automatic switching operation.
 Can offer no volt protection
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Contactors
Utilization Categories
 What is the meaning of the utilization categories for
the contactors?
The standard utilization categories defines the current
making and breaking values for contactors. They depend
on the following:
1. The type of load to be controlled (squirrel cage or slip
ring motor, resistors)
2. The operating cycle conditions (motor running, stalled
or starting, reverse operation, …ect)
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Contactors
Utilization Categories
 AC1:Non –Inductive/ Slightly Inductive Loads &
Resistance Furnaces.
 AC2: Slip ring motors : Starting/ Switching off.
 AC3:Squirrel Cage Motors : Starting /Switching Off
during Running.
 AC4:Squirrel Cage Motors : Starting Plugging &Inching.
 DC1:Non-Inductive or Slightly Inductive loads,
Resistance Furnaces.
 DC3:Shunt Motors: Starting Plugging and Inching.
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 DC5:Series Motors: Starting Plugging and Inching.

Contactors
Selection of Contactors
Parameters :
 Rated Operational Voltage Ue .
 Rated Operational Current Ie.
 Free Air or Enclosed thermal current Uth I th.
 Utilization Category.
 Electrical & Mechanical Life.
 Rated conditional s/c current.
 Frequency of operation.
 coil voltage.
 Number of Auxiliary contacts.
 Dimensions.
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 Terminal Size.
 Easy of maintenance.
 Availability of Spares.
Contactors
 Selection of Guidelines:
 Study the Application & find out Utilization Category.
 Select a contactor with current rating for that particular
Utilization Category equal or more than full load current.
 Contactor should have Sufficient making capacity to
close on in rush currents.
 No of operations required should be fulfilled by contactor
for that Utilization Category.
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RELAY
Protective relaying is
the Science or Art of
detecting faults on
power systems and
clearing those faults
from the power
system as quickly as
possible.
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Protection relays
Protective relays are designed to be installed

within switchgear panels and they provide
electrical protection by measuring electrical
quantities such as ( current, voltage,
frequency ,temp…ect) use this values to initiate
opening or tripping signal to the circuit breaker
or contactor which feeds the electrical load in a
fault condition.
This prevents the fault from cascading further
into the electrical infrastructure which will cause
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equipment damage and power outages.

Relays
Classification of Relays:
Classification can be done by different ways, such as by
function, input and performance characteristics …etc. so
it can be divided into following types:
(i) Protective Relays:
Protective relays and fuses operate on the intolerable
power system conditions. They are applied to all parts of
the power system; generators, busbars, transformers ,
transmission lines , distribution lines , feeders, motors
loads, capacitors banks and reactors.
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(ii) Regulating Relays:
Regulating relays are associated with tap changer of
transformers , on governor of generating equipment to
control the voltages level with varying load (used during
normal conditions).
(iii) Monitoring Relays:
This type of relays are used in energizing or restoring lines
to service after an outage and in interconnecting pre-
energizing parts of the systems.
(iv) Auxiliary Relay:
There are two categories:
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1- contact multiplication (repeat contactors) .

2- circuit isolation.
Relays categorization
 Types according to construction

 Electromechanical Relays.
 Static Relays.
 Digital Relays.
 Numerical Relays.
 Types according to functions

 Over current relay.
 Over, under voltage relay.
 Differential relay.
 Impedance relay
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Relays categorization
 Based on actuating parameter the protection relay can

be categorized as
1. Current Relays
2. Voltage Relays
3. Frequency Relays
4. Power Relays.
5. Pressure relays.
6. Temperature relays.
7. Velocity relays.
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8. Others.
SWGR panel Sections Protection
Protection applied for different sections of the SWGR:-
1- Incomer section which could be:-
a- Transformer.
b – Public utility supply.
c – Generator (emergency Gen Set).
2-outgoing feeders
Loads (Motor feeder) , sub distribution boards
A - Motors
B - Lighting
C- Heating loads
D-Air conditioning.
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E- Other sub distribution

1- Incomers
A- Transformer protection:-
The different protection schemes to protect the incomer is
mainly the standard transformer protection:-
A- Main Electrical protection
1- Overcorrect/Earth fault(50/51= 50N/51N).
2-Under/Over voltage(27).
3- Restricted Earth Fault(87N).
4- Differential protection relay(87)
B- Mechanical protection
1- Oil & winding Temperature relay.
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2-Sudden pressure relay.

3-Buchlouze relay.
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Incomers
B – Public utility supply.

the protection schemes to protect the incomer is mainly
typical to the standard protection used at the electrical
Authority substation otherwise it may contains fuses or
over load protection only and it mainly governed by the
owner criteria and his own protection philosophy to
protect his facility.
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Incomers
C – Generator (emergency Gen Set)
LV Generator Sets are mainly used:
 to supply safety equipment
 to replace the Main source
 to supply temporary installations
The sectors of activity where it is necessary to have a
replacement and/or Safety source, are very vast ranging
from residential to Industry.
Residential sector industrial

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Hospitals Process
Public building(bank, etc.) cement works (furnace,
Computer Centre motor….etc)
Incomers
Generator protection
Electrical protections
1- Over current & earth fault.
2-Over /under voltage.
3-Over/Under Frequency.
4- Reverse active power.
Mechanical protections
1-Over /under speed.
2-Lub oil Temp
3-Oil pressure.
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4-Water coolant temp.

Feeders
a) Motor feeder
Motor feeder should be protected against over load,
short circuit, over current up to locked rotor condition
and single phasing.
b) Industrial Machinery load feeder
Feeder connected industrial machinery load like oven,
electroplating bath etc are commonly protected by
MCCBs and switch fuse units
c) Lighting load feeder:-
This is protected similar to industrial machinery load but
additional earth leakage current protection is provided
in this case to reduce any damage to life and property
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that could be caused by harmful leakages of electric

current and fire.
Motor Overloads relays
Motor Overloads relays

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Overloads:
 There are basically three types of overloads:

Traditional thermal overloads
Traditional thermal overloads are either bimetallic or
melting alloy. These traditional overloads were originally
built using bimetallic strips that actually warped when
heated to break contact and trip the devices. This
created problems when ambient temperatures fluctuated
greatly. Melting alloy overloads were added to overcome
this temperature problem until ambient compensated
bimetallic overloads were introduced. These overload
devices are still slow and inaccurate and don’t protect
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the motor against single phase or unbalance conditions.

Overloads:
Solid state overloads
combined electronic component to measure temperature
rise in a conductor, thereby adding reliability to the
equation.
The dimension of adjustability was added so that trip
points were pre-calculated and the user simply sets the
adjustment at the FLA level of the motor.
The limiting factor is that set points are still extreme.
Settings are pre-calculated at the manufacturing level
and attempts are made to generically protect yet still
avoid nuisance tripping. The device is still not designed
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to protect against single phase or unbalance conditions.

The question arises as to price vs. protection.

Overloads:
Electronic overloads:-
are the newest form of overloads. They replace thermal
based protection with electrical measurements.
Electronic overloads can be simple and inexpensive or
quite sophisticated, premium priced devices.
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Tripping class
Tripping classes of the thermal overload relays
Overload relays typically operate on an inverse time
curve where the tripping time becomes less as the
current increases. They are rated by trip class. Trip class
specifies the length of time it will take for the relay to
open in an overload condition.
Standard tripping classes are10, 20, 30. The tripping
class indicates according to IEC 60947-4-1 the
maximum tripping time in seconds under specified
conditions of test at 7.2 times the setting current and
specifics tripping and non tripping times for 1.5 and 7.2
times the setting current.
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Tripping classes
 Class 10 is commonly used to protect artificially cooled

motors such as submersible pump motors of low thermal
capacity.
 Class 20 is usually sufficient for general purpose
applications.
 Class 30 is usually required for high inertial loads to help
prevent nuisance tripping. Refer to the figure below for trip
curves.
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Tripping classes
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Circuit Breakers
Circuit Breaker
Circuit Breaker is :
 A switching Device.
 Capable Of making , Carrying & breaking normal or fault
currents.
 Must offer short circuit current.
Circuit Breaker Types:
 MCB(Miniature Circuit Breaker) UP to 125 A.
 MCCB (Molded Case Circuit Breaker) Up to 1600 A.
 MPCB (Motor protection Circuit Breaker) Up to 63 A.
 ACB (Air Circuit Breaker) Up to 6300 A.
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Air Circuit Breaker
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Air Circuit Breaker
 Methods
Method of operation
 Manual operated
 Electrically operated.
Method of Installation
 Fixed
 Draw out
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Air Circuit Breaker
Applications
 As a switching & protection Device for Power
Distribution ( As incomer, Bus-coupler & out going
feeder).
 For Transformer protection.
 For Bus bar / Cable protection.
 Switching protection of motors ,lighting loads, heating
loads, capacitor etc.
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Air Circuit Breaker
Specifications
 Rated operational Voltage Ue .
 Nominal Rated current In .
 Rated Ultimate S/C Breaking capacity Icu.
 Rated Service S/C Breaking capacity Ics.
 Rated S/C Making capacity Icm.
 Rated Short time withstand current Icw.
 Utilization category B.
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Air Circuit Breaker
 Rated Ultimate S/C Breaking capacity Icu.
Circuit Breaker can break two faults of claimed Value and
can make one fault of the claimed value .
in other words: the circuit breaker must be able to break this
current two times without causing damage, the breaker must
be replaced or tested sub-sequently after two short circuits
(Test sequence: Icu: O-t-CO)
The test is use to see the performance of the contacts (Fix &
Moving) of a circuit breaker (as per standard), earlier it was
called as P1 duty (O-CO)
O=open
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T=relaxation
C=close
Test of Performance of the contacts
 Rated Service S/C Breaking capacity Ics.
Circuit Breaker can break three faults of claimed Value and
can make two fault of the claimed value.
in other words: the circuit breaker must be able to break this
current three times without causing damage, the breaker
must sub-sequently be able to conduct its rated current
without prior maintenance (Test sequence: Ics: O-t-CO-t-CO)
Also earlier this test was called P2 duty (O-CO-CO).
O=open
T=relaxation
C=close
 Rated Shorted time Withstand Capacity Icw.
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is specified as the current value with a corresponding time

duration e.g.50KA for 1 sec or 50 KA for 0.5 Sec. that mean this
breaker can withstand 50KA for 1 or 0.5 sec without any damage.
Utilization categories
According to IEC 60947-2, Utilization category of a
circuit breaker shall be stated with reference to whether
or not it is specifically intended for selectivity by means
of an intentional time delay with respect to other circuit
breakers in series on the load side under short-circuits
conditions.
 Utilization category A
Circuit-breakers not specifically intended for selectivity
under short-circuit conditions without A short time
withstand current (MCCB)
 Utilization Category B
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Circuit-breakers specifically intended for selectivity

under short-circuit conditions without A short time
withstand current (ACB)
ACB Features
 Wide range 400 to 6300 A as following:

400,630,800,1000,1250,1600,2000,2500,3200,4000,5000
,6300.
 High making and breaking capacities.
 High short time withstand current rating.
 Discrimination between various levels.
 Various over current releases
 Various accessories
U/V,E/F release, locks& interlock,Elctrical Indication.
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 Designed for Accessible Maintenance & repair.

ACB component
1. Releases.
2. CTs
3. Micro-switches.
4. Lock & Interlocks.
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ACB component
1-Releases
 Fault diagnostics Units(O/L,S/C,U/V,E/F).
 Generate mechanical tripping command.
 Magnetic ,thermal, semiconductor ,Microprocessor
principles.
Releases
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Over load & Earth fault

Short circuit Under voltage Remote trip
component
Over current Release (O/L+S/C)
 Thermo Magnetic.
 Solid state.
 Microprocessor(SR18,SR21,SR61C,SR71).
Magneto Thermal Release(O/L)
Over load
Bimetal
Time Delayed operation (IT Characteristics)
Settings
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1.0=100% 0.9=90% 0.75=75%

ACB component
Magneto thermal releases(S/C)
Short Circuit
Coil +Plunger
Instantaneous operated
Setting
M1 M2
500% 700%
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Exemplar LV -SWGR
ACB component
ACB component
Under Voltage Release

 Versions : Instantaneous operated ,time delay.
 240 VAC 415 VAC Operating voltages.
 Pick Up Voltage 80% Ue.
 Operating 70% to 35 % Of Ue.
 Trip under extreme under volt or no voltage.
 Used for electrical interlocking.
 offer no voltage protection.
Exemplar LV -SWGR
ACB component
Shunt Release
 Versions : AC coil,DC coil
 240 VAC 415 VAC Operating voltages.
 24VDC,48VDC,110VDC,220VDC.
 Operating 70% to 110% Of Vn of AC coil.
 Used for remote tripping.
 Electrical Interlocking.
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ACB component
Earth fault Release

Versions
(1) Fixed Setting of 10%,20% Of In.
(2) Fixed Setting of 30%,40%,50% Of In.
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ACB component
Solid State/Microprocessor Release:

Over load protection Long time zone (L)
Short circuit protection Short time zone (s)

Instantaneous Zone(I)
Earth fault protection Ground fault zone (G)
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Exemplar LV -SWGR
ACB component
Exemplar LV -SWGR
ACB component
ACB component
Sold state/Microprocessor Release

 Current setting BCD Switches.
 Power on led
 On/Off switch for thermal memory.
 Button to test the SR21 release.
 Time delay setting BCD Switches.
 Button to clear previous fault indication.
 Connector for external testing through SRT-2 Kit.
 Query button for indicating the last fault.
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 Leds for fault communication

ACB component
Sold state/Microprocessor Release

Zone (Current ) I (Time) T
Long time 0.4 to 1 2 to 35 Sec
Short Time 2 to 10 20 ms to 600 ms
Instantaneous 2 to 16 -
Ground Fault 0.1 to 0.6 100 ms to 400 ms

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ACB component –SR 21
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CTs & PTs(VTs)
Current transformers
 Current transformers shall comply with IEC 185 and
BS 3938 as necessary.
 The conditional ratings of current transformers shall
correspond with the SWGR rating, and shall be such as to
maintain the overall metering accuracy as is necessary to
operate relays within the tolerances specified by the
manufacturer.
 Current transformer terminal marking shall comply with
IEC standards and shall indicate polarity.
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CTs & PTs
 Current transformer secondary ratings shall be:-
for protection (1or 5) A
for metering(1or 5) A
 Current transformers shall have the following accuracies
as a minimum:
Differential and REF protection Class X
Other protection applications Class 5P
Indication Class 3
Metering Class 0.5
 Current transformer secondary wiring shall be earthed on
one side through a removable link. Where current
transformers are connected in star, the star point shall be
earthed through a removable link.
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 Shorting links shall be provided for each current

transformer.
 Current transformers shall be cast resin insulated.
2-CTs & PTs
Voltage transformers
 Voltage transformers shall comply with IEC 186,and it
shall be suitable in rating and accuracy for their functions,
loads and duties. As a minimum they shall have the
following accuracy :-
 Protection applications Class 5P
 Indication and metering Class 0.5
The primary and secondary circuits of the voltage
transformers shall be protected by fuses and the secondary
winding shall be earthed at one point through a removable
link. Voltage transformers shall be cast resin insulated.
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MCBs with auxiliary contacts or alternatively 4 poles. MCBs

on the secondary side of the voltage transformers should be
provided.
3-Microswitches
Microswitches Applications:
 Are Nothing but limited switch
 They are auxiliary switches for position sensing.
 Used of various indication :-
i) Service position.
ii) Test or lsolated position.
Exemplar LV -SWGR
Exemplar LV -SWGR
Micro switches
4-Lock & Interlocks
 Mechanical and electrical interlocks are included on

mechanisms and in the control circuits of apparatus
installed in SWGRs.
 Interlock are used as a measure of protection against an
incorrect sequence of maneuvers by operating personnel.
 Basic interlocking functions can be introduced in one
given functional unit.
 It is important to provide for a scheme of interlocking in
the basic design stage of planning a MV/LV substation. In
this way, the apparatuses concerned will be equipped
during manufacture in a coherent manner, with assured
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compatibility of keys and locking devices.

ACB component –ACB maintenance
When ACB maintenance?
 If the ACB completed 500 operations on normal load.
 If the ACB has cleared 10 faults of the order of 10 times its rated
capacity.
 it has cleared 1 fault of the order of its rated breaking capacity.
 If the ACB has been operating for more than 6 months in dusty
atmosphere.
 If the ACB Was out of service for more than 6 months.
 The activities to be done are:-
 Clean
 Inspect
 Lubricate
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 Tighten
 Test
Molded Case Circuit Breaker
MCCB
(Molded Case Circuit Breaker)
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Exemplar LV -SWGR
Why using MCCBs.
 Lower Downtime.
 Reduced Running cost.
 Low inventory.
 Accessories e.g
 Trip indiction.
 Remote Tripping.
 UV Protection.
 Auxiliary contact.
 In built O/L + S/C Protection.
 Occupies less space.
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 Clear trip indication.

 Can interrupt within 10 msec
Accessories For MCCBs

Under voltage Release
 Protection Against Dip in system.
 Prevention of “Switching on” on supply restoration.
Shunt Release
 Remote tripping
Aux contact Block
 For indication & control circuit use
Trip Alarm contact
 Trip indication
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Types
Conventional type
Operating time :15 to 20 msec.
Higher let though Energy.
Current Let though energy.
Current limiting MCCB
Lower Let through energy
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By fault limiting
Limiting the fault current
Low let through energy
Using Repulsion Principle
Operating time : Within 10 msec
Low let through energy
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The current limiting MCCB must respond quickly in case
of a fault. To achieve high speed contact separation,
closely spaced contact fingers carrying current in
opposite directions create a strong magnetic repulsion
between the conductors (see Figure below). High speed
contact separation is actually produced by
electromagnetic repulsion forces generated by the fault
current itself. The higher the current, the greater is the
force pushing the contacts apart.
Exemplar LV -SWGR
Selection of MCCBs
Current rating.
Overload & short circuit release settings.
Breaking Capacity.
Fault level at the point of the installation.
Mechanical & electrical life.
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Exemplar LV -SWGR
GUIDELINES FOR SELECTION FOR MOTOR

STARTER FEEDERS
 Rating of MCCB should Be higher than the motor FLC
 Magnetic threshold be selected to avoid nuisance
tripping during starting of load.
 Crossover current should be less than the breaking
capacity of the contactor.
 Breaking Capacity should be> or = to the fault level the
point of the installation.
 Contactor should be able to break any current up to
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magnetic threshold of the MCCB

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Exemplar LV -SWGR
Fuses
Fuses
A fuse is a type of over-current protective device that is

designed to be a sacrificial element in an electrical
power system.
Fuses are designed to open circuits when excessive
over-currents are present and are designed to prevent
further damage to the system that might result if the fuse
were not present.
The use of fuses in a circuit provides cheap insurance of
protection, in case of an accidental or unintentional fault
in the system wiring or components.
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Fuses
Fuse Type
In general, there are two categories of fuses
 Low voltage fuses.
 High voltage fuses.
LOW VOLTAGE FUSES

Low voltage fuses can be further divided into
two classes namely:-
Semi-enclosed or Rewireable
Totally enclosed or Cartridge type.
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Fuses
1. REWIREABLE FUSES
The most commonly used fuse in 'house wiring' and
small current circuit is the semi-enclosed or rewireable
fuse.(also sometime known as KIT-KAT type fuse).
fuse wire may be of lead, tinned copper, aluminum or an
alloy of tin-lead. The actual fusing current will be about
twice the rated current.
such fuses have the advantage of easy removal or
replacement without any danger of coming into the
contact with a lie part and negligible replacement cost
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Fuses
but suffers from following disadvantages:

1. Unreliable Operation.
2. Lack of Discrimination.
3. Small time lag.
4. Low rupturing capacity.
5. No current limiting feature.
6. Slow speed of operations
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Fuses
2.TOTALLY ENCLOSED OR CARTIDGES TYPE FUSE.
The fuse element is enclosed in a totally enclosed container
and is provided with metal contacts on both sides. These
fuses are further classified as
I) D-type.
II) Link type.
 I) D-Type Cartridges Fuses
. The standard ratings are 6, 16, 32, and 63 amperes. The
breaking or rupturing capacity is of the order of 4kA for 2
and 4 ampere fuses the 16k A for 63 A fuses.
D-type cartridge fuse have non of the drawbacks of the re-
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wireable fuses and their operation is reliable.

Fuses
II) Link type Cartridge or High Rupturing Capacity(HRC)

Link type cartridges are again of two types viz. Knife
blade or bolted type.
High rupturing capacity cartridge fuse, commonly called
HRC cartridge fuses , usual fusing factor for the link fuses
is 1.45 the fuses for special applications may have as low
as a fusing factor as 1.2.
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Fuses
High Rupturing Capacity(HRC) Fuse Application Area:
As S.C.P.D (short circuit protective device ) In
motor Starter Feeders,
Protection of lighting & heating circuits.
Protection of transformer.
Protection of cable.
Back up of CBs where Fault level Exceeds
Breaking capacity Of the CB.
Protection of small loads on circuit having high
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fault levels.
Fuses
 HCR Fuse Construction

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Fuses
HRC Fuse Type and size
HRC Fuse
Contacts for
Cylindrical Contact Blade Contacts bolted
Cap
connection
Size 0 A1,A2,A3,A4
Size 10X38
Size 1 B1,B2,B3,B4
Size 14X51
Size 2 C1,C2,C3
Size 22X58
Size Diameter X D1
Size 3
length
Size
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4
Fuses
Using HRC Fuse

Extremely High breaking capacity of up to 100 KA.
Very Fast Operation in the event of Heavy S/C (can
interrupt Even In less than 5 msec).
Current limiting Device
Limiting S/C Current to Amp value.
Less than prospective peak.
Very low Let through energy.
No maintenance Required.
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Very small /compact size.

Relatively low cost.
Fuses
Current limiting feature
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Fuses
Current limiting feature
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Fuses
Let through Energy
Energy (I2 t) passed on to the downstream by the
S.C.P.D while clearing A short Circuit fault. And it:-
 Reflect the quality of the short S/C protection
 Reflect the current limiting capability of S.C.P.C.
 Indicates the limits of electro- Dynamic stress that the
down stream Device have to withstand.
Let through Energy =

= I2 t
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Fuses
 Example: Using the 30 ampere
fuse curve, what is the fuse
opening time in seconds at a
current of 160 amperes? At the
bottom of the sheet (Current in
Amperes) find 160 amperes (Pt.
A) and follow that line straight
up to the point where it
intersects the 30A curve (Pt. B).
Then follow that line to the left
edge (Time in Seconds) and
read 10 seconds. (Pt. C). This
tells us that the AJT30 will open
in 10 seconds on a current of
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160 amperes.
Fuses
Selection Guideline for motor Application

Check
1st fuse should not blow during running.
2ed fuse should not blow during starting
 12 Ie for 10 mSec
6 Ie for motor starting time
3rd Co-ordination with starter
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Exemplar LV -SWGR
Fuses
Fuses
 Type 1 coordination:
type 1 coordination requires that, under short circuit
conditions, the contactor or starter shall cause no danger
to persons or installations and may not be suitable for
further service without repair and replacement of parts.
 Type 2 coordination:
type 2 coordination requires that, under short circuit
conditions, the contactor or starter shall cause no danger
to persons or installations and shall be suitable for further
use. The risk of contact welding is recognized, in which
case the manufacturer shall indicate the measures to be
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taken as regards the maintenance of the equipment.

Fuses
Fuse selection Parameters

 Rated Voltage.
 Rated current.
 Rated breaking capacity.
 Type.
 Size.
 Time current characteristics.
 Coordination with starter.
 Rated power dissipation
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RCCB( Residual Current Circuit Breaker)
RCD (Residual Current Device)

RCCB( Residual Current Circuit
Breaker)
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RCCBs
Residual-current Circuit Breaker :
Earth Leakage Circuit Breaker-ELCB (old name)or
Residual-current Circuit Breaker-RCCB- an electrical
wiring device that disconnects a circuit whenever it detects
that the electrical current is not balanced between the
energized conductor and the return neutral conductor.
Such an imbalance is sometimes caused by current
leakage through the body of a person who is grounded
and accidentally touching the energized part of the circuit,
A lethal(‫اتل‬YY‫ )ق‬shock can result from these conditions.
Exemplar LV -SWGR
3phase RCCB schematic
RCCB designed to
disconnect quickly enough
to mitigate the harm caused
by such shocks although
they are not intended to
provide protection against
overload or short-circuit
conditions.
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A two-pole residual current device wiring
1. Electromagnet with help electronics

2. Current transformer secondary winding
3. Transformer core
4. Test switch
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L =live conductor
N =neutral
A two-pole residual current device wiring
 The most widely used are 30 mA (milliamp) and 100 mA
devices. A current flow of 30 mA (or 0.03 amps) is
sufficiently small that it makes it very difficult to receive a
dangerous shock. Even 100 mA is a relatively small figure
when compared to the current that may flow in an earth
fault without such protection (hundred of amps)
 A 300/500 mA RCCB may be used where only fire
protection is required. eg., on lighting circuits, where the
risk of electric shock is small
 RCDs are an extremely effective form of shock protection
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RCCB - sensitivity ∆In
 10mA (wet area)

 30mA ( socket outlets)
 100mA ( 1- installation )
 300mA ( 3- installation )
Sensitivity I∆n = 100mA

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Sensitivity I∆n =30mA

RCCB 4POLES 2POLES
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Operation of Single Phase RCCB
 Ip = In : and < ∆ In, not TRIP

 Ip ≠ In : and > ∆ In , TRIP
 ∆ In = sensitivity
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Operation of Single Phase RCCB
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Limitation of RCCB:
 RCDs don’t offer protection against current

overloads.
 Nuisance tripping of RCCB:
Sudden changes in electrical load can cause a small, brief
current flow to earth, especially in old appliances. RCDs
are very sensitive and operate very quickly; they may well
trip when the motor of an old freezer switches off. Some
types of computer equipment, and large television sets, are
widely reported to cause problems.
 RCD will not protect against the overheating
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Switches ,Dis-connecter ,Isolator
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Isolation
 The function intended to cut off the supply
from all or discrete section of installation
by separating installation or section from
every source of electrical energy for
reasons of safety.
 Isolation Distance between contacts.
 Clearance And Creepage.
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Switch
 A manual Switching device.
 Shall make, break and carry current under normal
&Specified overload condition.
 Shall be capable of carrying for A specified time, short
circuit currents.
 Shall withstand short circuit till S.C.P.D clear the fault
( With A minimum of 12 Ie for 1 sec)
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Switch-Switching capability
Function Make carry Break

/operation
Normal Yes Yes Yes
Overload Yes Limited Yes
Short circuit Yes Limited No

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Dis-connecter
 A mechanical Switching Device.
 In open position complies with requirements specified for isolating.
 Carry normal and over load.
 Carry short circuit currents for specified time.
 Switching on and off in no load.
Exemplar LV -SWGR
Switch- Dis-connecter
 For Isolating the motor feeder for any maintenance
work.
 Can be used as back-up switching device in case of
emergencies (like contactor welding).
 Positive opening of main contacts.
 Additional facilities like door interlock and padlocking.
 A switch which in opening condition satisfies the
isolating requirements specified for disconnector.
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Positive Opening Mechanism

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Utilization categories of LV AC switches
according to IEC 60947-3
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Utilization categories of LV AC switches
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Fuse combination units
Make –Carry – Break Isolation & carry Make –Carry Break

& Isolation
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Design Example
Switchgear common main parts
Exemplar LV -SWGR
Low voltage switchgear common main parts
The most common use of LV switchgear is in LV Distribution
Board so This systems has the following parts
(1) Incomer
The incomer feeds incoming electrical power to the
incomer bus. The switchgear used in the incomer
section should have a main switching device.
The switchgear devices attached with incomer
should be capable of withstanding abnormal current
for a short specific duration in order to allow
downstream devices to operate. But it also be
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capable of interrupting maximum value of the fault

current generated in the system.
It must have interlocking arrangement with downstream

devices. Generally Air Circuit Breakers are preferably used
as interrupting device. Low voltage air circuit breaker is
preferable for this purpose .because of the following
features
A. Simplicity
B. Efficient performance
C. High normal current rating .
D. High fault withstanding capacity up to 63 kA
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Low voltage switchgear common main part
(2)Feeders
Different feeders are connected to the bus to feeds
different loads like, motor loads, lighting loads, industrial
machinery loads, air conditioner loads, transformer
cooling system loads etc.
All feeders are primarily protected by switch fuse unit & in
addition to that, depending upon the types of load
connected to the feeders, the different switchgear devices
are chosen for different feeders. Let’s discuss in details
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(3)Bus-bar and bus section

 A bus Section is generally a circuit breaker which helps
in connecting one bus to another thereby enabling
uninterrupted supply in the event of fault in one bus.
Switch over from one bus to another can be done either
in auto or manual mode.
 Bus Coupler Panels are used in Double Busbar
Switchboards to link the two sets of three-phase busbars
using a Circuit Breaker. This enhances the operational
flexibility of the switchboard.
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 In this panel, Current and Voltage Transformers are

fitted as required for the protection scheme.
Low voltage switchgear common main part
 In LV switchgear system, electrical appliances are

protected against short circuit and over load conditions
by electrical fuses or electrical circuit breaker. However,
the human operator is not adequately protected against
the faults occurs inside the appliances. The problem can
be overcome by using earth leakage circuit breaker. This
operates on low leakage current. The earth
leakage circuit breaker can detect leakage current as
low as 100 mA and is capable of disconnecting the
appliance in less than 100 msec.
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Busbar and bus section
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Control wires
Standard
color codes &numbers
for control wires
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Control wires
1. The entire wiring of circuitry for indications, alarms,

metering and protection should be permanent wiring.
2. The leads should be marked and identified by ferrules
near terminals.
3. Every lead should end at a terminal point and no junction
by twisting is allowed.
4. The wiring should be by copper leads for C.T secondary
for all cores i.e. metering cores as well as protection
cores and for PT secondary for protection core.
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Control wires
5. Aluminum leads can be used for indication, alarms and
PT secondary for metering but (stranded wires) only are
used. copper leads are always preferable for these said
purposes.
6. The terminations should be lugged by ring shape ‘O’ lugs.
‘U’ shape lugs should be avoided since ‘U’ shape lugs
may slip if terminal is loosen.
7. For CT Secondary terminations, two nuts with one spring
washer and two flat washers to be compulsorily used.
8. The CT terminal strips should be stud type with nuts and
not screw-in-type.
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Control wires
Standard color codes for wires in control circuit of different

sizes should be as follows,
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Control wires
The lead numbers are also standardized as follows so that

anyone can easily identify the purpose for which the lead
is connected
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lead numbers
Certain lead numbers are standardized as follows and
should be compulsorily adopted with ferrules at
terminations of leads.
Item Purpose Alphabetical
Main DC Positive supply – J1
Main DC Negative supply – J2
DC Positive bus inside panel – K1
DC Negative bus inside panel – K2
Remote Close - K15R
Remote Trip - K5R
Local Close -K15L
Local Trip - K5L
Metering CT secondaries – D11, D31, D51, D71 etc.
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Protection CT secondaries – C11, C31, C51, C71 etc.
Special Protection CT secondaries – A11, A31, A51, A71 etc.

PT scondaries –E11, E31,E51, E71 etc.

Enclosures and degrees of protection (IP)
 It is not sufficient that a piece of equipment fulfils the

functional requirements assigned to it. It also has to be
protected against possible adverse external influences,
and likewise to ensure that it is not harmful to the user or
to the environment.
 The extent of protection provided by an enclosure
against access to hazardous parts, against ingress of
foreign objects and/or against ingress of water and to
give additional information in connection with such
protection.
 This standardized code is intended to be used in product
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standards. It can also be used to describe an empty

enclosure.
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degrees of protection (IP)
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IP degree of protection
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IP degree of protection
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The minimum acceptable ingress protection for the LV
switchear shall be as mentioned below
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Low Voltage Switchgear -types
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Switchgear is switching device. As such it could be

employed for any kind of switching operation so it classify
as following:-
1) Main Distribution board (MDB) panel
2) Sub Distribution board (SDB)panel
3) ATS( Automatic transfer switch)
4) MCC (motor control center )(DOL, star delta Starter ,soft
starter)
Exemplar LV -SWGR
(1) Main Distribution board (MDB)

A main distribution board is the point at which an
incoming-power supply divides into separate circuits,
each of which is controlled and protected by the fuses or
switchgear of the board. A distribution board is divided
into a number of functional units, each comprising all the
electrical and mechanical elements that contribute to the
fulfillment of a given function.
An assembly containing switching or protecting devices
(e.g fuses, circuit breakers, residual current operated
devices) associated with one or more outgoing circuits
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fed from one or more incoming Circuits together with

terminals for the neutral and CPC.
Main Distribution board (MDB)
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Main Distribution board (MDB)
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(2)Sub- Distribution board (SDB)

A distribution board (or panel board) is a component of
an electricity supply system which divides an electrical
power feed into subsidiary circuits, while providing a
protective fuse or circuit breaker for each circuit, in a
common enclosure. Normally, a main switch, and in
recent boards, one or more Residual-current
devices (RCD) or Residual Current Breakers with
Overcorrect protection (RCBO), will also be
incorporated.
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Sub Distribution board (SDB)
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(3) Automatic Transfer Switch (ATS)
 A transfer switch is an electrical switch that
switches a load between two sources. Some
transfer switches are manual, in that an operator
effects the transfer by throwing a switch, while
others are automatic and switch when they
sense one of the sources has lost or gained
power.
 An Automatic Transfer Switch (ATS) is often
installed where a backup generator is located,
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so that the generator may provide temporary

electrical power if the utility source fails.
Automatic Transfer Switch (ATS) count ‘d
(1) Open transition (short-break changeover )
An open transition transfer switch is also called a break
before make transfer switch. A break before make
transfer switch breaks contact with one source of power
before it makes contact with another. It prevents back
feeding from an emergency generator back into the
utility line.
It is also called A short-break changeover it is carried
out if, during the changeover sequence, the
disconnected source and the replacement source do
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not feed the load in parallel. This means there is a brief

interruption of supply to the load.
Automatic Transfer Switch (ATS)
(2)Closed transition(no-break changeover )
A closed transition transfer switch is also called a make
before break transfer switch. A typical emergency system
uses open transition, so there is an inherent momentary
interruption of power to the load when it is transferred from
one available source to another (keeping in mind that the
transfer may be occurring for reasons other than a total loss
of power). In most cases this outage is inconsequential,
particularly if it is less than 1/6 of a second.
It is also called A no-break changeover it is carried out if,
during the changeover sequence, the two supplies feed the
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load in parallel, in which case they must be synchronous.

There is no interruption of supply to the load.
Low Voltage Switchgear –types
Automatic changeover
Distribution switchboards where loss of supply is critical are
generally fed from two or three sources, each capable of
acting as a back-up. Internal generator sets might
constitute one of these sources. Automatic changeover
controls the switchboard incoming switching devices. The
objective of automatic supply changeover is to:
1. improve supply availability. A supply with a fault on it is
replaced by a back-up.
2. make savings by feeding the switchboard from the
most economical source (where one of the sources is
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the internal generator sets).

3. provide the opportunity for maintenance of the normal
supply.
Control & Monitoring of system in changeover
management
Before a changeover can take place, the control and
monitoring system must first of all analyze the necessary
operating conditions:-
 the correct state of all isolating devices. For example, all
isolators are closed or all circuit breakers are plugged in.
 the voltage is correct, in the case of the replacement
supply coming from the same energy production source
 the voltage and frequency are correct, in the case of a
changeover without coupling to an internal generator set
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 the voltage, frequency and phase are correct, in the case
of changeover with coupling of two supplies coming from
different production sources
 the absence of voltage is not the result of a downstream
fault trip (otherwise the back-up supply would re-supply the
fault).
 the remanent voltage on bus-bars to which motors are
connected is below a given threshold. In fact, following a
supply disconnection, the motors maintain a remanent
voltage for the time it takes the flux to collapse (about a
second). Rapidly reconnecting the supply whose phase is
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in opposition to the remanent voltage could well provoke

transient electrical and mechanical phenomena likely to
damage the motor
In the case of a short-break changeover the

control and monitoring system will inhibit supply
reconnection until the remnant bus-bar voltage is
below a predefined threshold value (of the order
of 20 % of the nominal voltage).
Where a minimum remanent voltage protection
system (code ANSI 27R) is fitted to the bus bar,
reconnection is enabled directly through its
"digital" output signal.
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Changeovers in general involve load

disconnection (complete in the case of a short-
break changeover). The control and monitoring
system must manage automatic load
shedding/restoration and motor restarting in a
manner adapted to the type of changeover
being executed.
For a short-break changeover, control and
monitoring system performance is such that
there is loss of supply for a period of less than
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400 ms (where reconnection is not locked by the

remanent voltage monitoring).
The principle of the 1/2 changeover is shown in the

simplified diagram in figure below [figure (a)]
In normal operation only one source supplies the bus-bar.
[figure (a)]
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 1/2 changeover sequence
If one of the bus bar supplies is lost the power source

acting as back-up is connected
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description of a 2/3c changeover (with coupler circuit
breaker)
The principle of the 2/3c changeover is shown in the
simplified diagram in figure below [figure (b)]
[figure (b)]
Exemplar LV -SWGR
In normal operation the coupler circuit-breaker is open.

Each supply feeds one bus section.
2/3c changeover sequence
If one of the supplies is lost the coupler circuit-breaker is
closed, and the other supply feeds all the outgoing
feeders (see figure below).
Exemplar LV -SWGR
Control and monitoring of ATS
other automatic changeover systems
Other automatic changeover systems exist corresponding
to more complex electrical configurations, for example:
3 sources feeding a bus-bar with or without coupler (see
figure c)
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[figure (c)] triple fed LV switchboards with no coupler

 Switchboard S1 has a triple power supply with no

coupler via 2 MVILV transformers and an outgoing
feeder coming from another LV switchboard.
 During normal operation, the switchboard is fed by 2
transformers in parallel. If one or both of the
transformers fail, switchboard S1 is fed by the outgoing
feeder coming from another switchboard.
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triple fed LV switchboards with coupler

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[figure (d)]
automatic changeover modes
4 changeover modes are possible:

1- short-break changeover. The load is disconnected
before the internal generators come on line. The
generators then progressively restore the load
2- progressive no-break changeover. The utility and
internal generators are connected in parallel, generator
power being progressively increased until it reaches the
level required by the load. The utility supply is then
disconnected
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automatic changeover modes
3- instantaneous no-break changeover. As soon as the

generators are brought on line in parallel with the utility,
the latter is disconnected. The generator sets instantly
supply the load (inasmuch as they are able to)
4- changeover for a permanent operation of utility and
generators in parallel. The generators will then either
only supply a part of the energy required, or else deliver
power to utility network.
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automatic changeover systems
 Paralleling up the utility supply with the internal

generators requires the installation of a synchronizer, as
well as a fast-acting disconnection protection to enable
the industrial network to be isolated in the case of a short
circuit, a supply interruption or high levels of disturbance
on the utility distribution network.
 Synchronizing is an automatic function acting on the
frequency and voltage regulators. It allows sources of
supply to be coupled when the frequency, voltage and
phase of the internal generators are within their
predefined ranges.
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Motor control centers (MCC)
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A motor control center (MCC) is an assembly of one or
more enclosed sections having a common power bus and
principally containing motor control units.
Motor control centers are in modern practice a factory
assembly of several motor starters. MCC can include
variable frequency drives, programmable controllers, and
metering and may also be the electrical service entrance
for the building. MCCs are usually used for low
voltage three-phase alternating current motors from 208 V
to 600 V. Medium-voltage motor control centers are made
for large motors running at 2300 V to around 15000 V,
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using vacuum contactors for switching and with separate

compartments for power switching and control.
 A motor control center consists of one or more vertical
metal cabinet sections with power bus and provision for
plug-in mounting of individual motor controllers. Very
large controllers may be bolted in place but smaller
controllers can be unplugged from the cabinet for testing
or maintenance.
 Each motor controller contains a contactor or a solid-
state motor controller, overload relays to protect the
motor, fuses or a circuit breaker to provide short-circuit
protection, and a disconnecting switch to isolate the
motor circuit. Three-phase power enters each controller
through separable connectors. The motor is wired to
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terminals in the controller. Motor control centers provide

wire ways for field control and power cables.
 Each motor controller in an MCC can be specified with a
range of options such as separate control transformers,
pilot lamps, control switches, extra control terminal blocks,
various types of thermal or solid-state overload protection
relays, or various classes of power fuses or types of circuit
breakers. A motor control center can either be supplied
ready for the customer to connect all field wiring, or can be
an engineered assembly with internal control and
interlocking wiring to a central control terminal panel board
or programmable controller.
 MCCs usually sit on floors, which are often required to
have a fire-resistance rating. Firestops may be required for
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cables that penetrate fire-rated floors and walls.

Motor Control Centers are suitable for operation of
motors ranging from 0.5HP to 500 HP
capacity. It’s contains various types of starting viz Direct
on line (DOL), Star-Delta, autotransformer, Soft starter
etc. Local and remote operation facility, compatible to
PCC/DCS based operation. it is properly ventilated in
case of higher size of motor starter. Component layout is
made so as to facilitate ease of operation and
maintenance.
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Motor starting technique
the more commonly used methods of motor

starting, which are:
1. Direct On Line
2. Primary Resistance
3. Auto-Transformer
4. Star Delta
5. Electronic Soft Start
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Direct on line-DOL
Direct on line starter, often abbreviated DOL starter, is a

widely-used starting method of electric motors.
There are many types of motor starters, the simplest of
which is the DOL starter. A DOL starter connects the
motor terminals directly to the power supply Uses a main
contactor . Hence, the motor is subjected to the full
voltage of the power supply. Consequently, high starting
current flows through the motor.
Following Diagram showing :
 Power circuit
 Control circuit
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Direct on line-DOL starter
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Direct on line-DOL starter
This type of starting is suitable for small motors below 5
hp (3.75 kW). Reduced-voltage starters are employed
with motors above 5 hp. Although DOL motor starters are
available for motors less than 150 kW on 400 V and for
motors less than 1 MW on 6.6 kV.
Supply reliability and reserve power generation dictates
(Y‫مره‬Y‫ملىأوا‬Y‫ )أ‬the use of reduced voltage or not.
This starter is sometimes used to start water pumps,
compressors, fans and conveyor belts. With a 400V, 50
Hz, 3-phase supply, the power circuit connects the motor
to 400V. Consequently, the starting current may reach 3-8
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times the normal current.

Direct on line-DOL starting
Electrical impact of large starting current :

 Large voltage dip, operation of other equipment can
affect.
 Reduce life of switching device.
 Increase line losses.
Mechanical Impact of large starting current
Excessive Wear and tear on belts and pulleys, gear,
chains, coupling and bearings
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Unwanted Mechanical effects can result in:-

Unscheduled and more frequent maintenance with
further leads to productivity loss.
Oversize of mechanical & Electrical component.
Short life of components.
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Primary Resistance Starting method

 Resistor are connected in series with each
phase, between the isolation contactor and the
motor.
 The voltage drop across the resistors results in
reduced voltage applied to the motor thus
reducing starting current and torque.
 Generally starting current is limited 3.5 or 4 times
FLC.
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Exemplar LV -SWGR
Limitations:
 Difficult to change resistance.
 Dissipate a lot of heat.
 Limited number of starts per hours.
 Start characteristics change between starts if
the resistance have not totally cooled.
 Hard to start high inertia loads
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Auto transformer Starting method

An auto transformer is used to reduce the voltage during
starting.
The transformer has range of out voltage taps that can
be used to set the starter voltage.
The motor current is reduced by start voltage reduction
resulting in line current less than the actual motor
current.
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Draw Backs:-
 Requires frequent maintenance &
Inspection.
 Voltage applied to motor is in steps
& not continues, hence voltage
Flickers & mechanical jerks.
 Produces a very dangerous current
spikes.
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Star-Delta Starting Method
Star-Delta Starting
Method
The motor initial connected
in star configuration and
then ,after preset time, the
motor is disconnected for
the supply and
reconnected in delta
configuration
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Exemplar LV -SWGR
When compared to DOL starting current and toque
reduces by 1/3rd .
Open transition form star to delta cause high current &
torque transient.
Sequence
 Star-ON
 Main-ON
 Starting time (Seconds)
 Star-OFF
 Pause time (msec).
 Delta -ON
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Exemplar LV -SWGR
Electronic soft starter
Introduction
 Soft starters use a combination of power electronics and
electronic control circuitry to slow increase the voltage
on the motor during starting; ensuing a smooth
acceleration.
 Soft starters use thyristors-SCR- (Silicon Controlled
Rectifier) to control the energy delivered to the motor. A
thyristor is a device which turns on when a pulse is
applied to its gate and will continue to conduct until the
current drops to zero (at which time it turns off). In an
AC sine wave current goes to zero each half cycle,
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allowing the current to be turned off and making it

possible to use use thyristors to implement soft starting.
 Voltage applied the motor is gradually increased with
help of solid state AC Switches (SCR’s) in Series with the
supply to motor.
 By pulsing a thyristor it switches “OFF” to “ON” until the
current stops flowing through it which occurs every half
cycle in an AC supply.
 By controlling electronically the thyristor turn on point, it
is possible to regulate the energy passing through it.
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 By starting with a large delay angle and gradually

reducing it the motor terminal voltage is increased form
a low value to full load voltage giving a smooth step less
start.
 Soft starter controls the voltage ramp during 30%
(Adjustable) to 100% voltage of the rated voltage with on
site variety of time adjustments ranging for 0.5 to 120
Sec.

Exemplar LV -SWGR
 Features and Application
Soft starters have many features not found in traditional
starting methods and which can be of benefit in some
situations. These include:
 Adaptive Acceleration Control - soft starter learns
motor’s performance during start and stop, then adjusts
control to optimize performance
 Soft Stopping - slowly bring the motor to a stop
 DC Braking - injecting DC to reduce motor stopping time
 Soft Braking - changing contactors on starter input,
reversing motor direction and applying braking.
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 Current Limiting - limit starting current to a pre-defined
value (may lower torque to much and motor may not
accelerate)
 Current Ramping - increasing the current over a given
time to a specified limit
 Jog (‫)جُك‬- allows the motors to be run at reduced speed
for some time
 Kick Starting - using a brief high bust of current at the
motor start to get it going, then reducing the current
 Thermal Modeling - motors the motors thermal
characteristic, allow performance optimization,
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Communication - most industrial protocols will be

supported, enabling enhanced control/monitoring
 Line contactors can be used (but not strictly necessary) to isolate
the soft start when not in use (should be rated AC3). If required,
by-pass contactors can by used to minimize heat build up due the
to SCR's (can rated AC1 as they do not carry starting currents).
 Sequence starting - can be used to start several motors in
sequence (or parallel). Starters needs to be rated for full start
duty. Additional wiring, contactors and control relays may not
make this an economic option. Power factor correction if required
should only be installed on the line side and switched in when the
motor is at full speed (AC6 contactors). Capacitors installed on the
motor side can cause resonance, increased voltages and
equipment failure.
 Inside delta connection is a technique which can be used with six
winding motors. In this configuration, only have the delta is
Exemplar LV -SWGR
completed in that starter, thus reducing the current the starter is

required to carry. On some soft starters are able to be used in this
type of application.
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Exemplar LV -SWGR
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FAULT LEVEL CALCULATIONS
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WHAT IS FAULT LEVEL?
Fault Level At Any Given Point Of The Electric

Power Supply Network Is The Maximum Current
That Would Flow In Case Of A Short Circuit
Fault At That Point.
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PURPOSE OF FAULT LEVEL CALCULATIONS

 For Selecting Short Circuit Protective Devices Of
Adequate Short Circuit Breaking Capacity.
 For Selecting Circuit Breakers & Switches Of Adequate
Short Circuit Making Capacity.
 For Selecting Busbars, Busbar Supports, Cable &
Switchgear, Designed To Withstand Thermal &
Mechanical Stresses Because Of Short Circuit.
 To Do Current Based Discrimination Between Circuit
Breakers.
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TYPES OF SHORT CIRCUITS
Asymmetric Faults
 L – E (SINGLE LINE TO EARTH).
 L – L (LINE TO LINE).
 L – L – E (LINE TO LINE TO EARTH).
Symmetric Faults
 L – L – L (THREE PHASE).
SOURCES OF SHORT CIRCUIT CURRENTS
supply
 TRANSFORMER
 SYNCHRONOUS GENERATORS
Loads
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 Induction motors
 synchronous motors.
 Shunt capacitors
Nature Of Short Circuit Current The Short Circuit Current

Will Consist Of Following Components :
SOURCE : UTILITY SYSTEM
 The Ac Component With Constant Amplitude.
 The Decaying Dc Component.
SOURCE : SYNCHRONOUS GENERATORS &
MOTORS / INDUCTION MOTORS
The Short Circuit Current Will Consist Of Following
Components :
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 The Ac Component With Decaying Amplitude

 The Decaying Dc Component
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I”K = Initial Symmetrical Rms S/C Current

IK = Steady State Rms S/C Current
IP = Peak S/C Current
A = Initial Value Of Decaying Dc Component
Note: For s/c far from generator (e.g. L.V. System getting
power from utility through Transformers)
I” k = Ik Symbols used
Exemplar LV -SWGR
CALCULATION ASSUMPTIONS
WHY ?
 Simplifies calculation.
 Accuracy is not much affected.
 Calculated values will be higher than actual & hence
safe.
Exemplar LV -SWGR
CALCULATION ASSUMPTIONS
WHAT ?
Type of short circuit : three phase bolted short circuit
 Impedances of busbar /switchgear / c.T. /Joints are
neglected.
 Fault current from the transformer would be limited by the
source fault level
 Transformer tap is in the main position.
 Short circuit current waveform is a pure sine wave.
Exemplar LV -SWGR
 Discharge current of capacitors are neglected.

CALCULATION METHODS
DIRECT METHOD
PER UNIT METHOD
Advantages of direct method
 Uses system single line diagram directly.
 Uses system & equipment data directly.
 Uses basic electrical equations directly.
 Easier to comprehend
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FAULT LEVEL CALCULATIONS – DIRECT

METHOD – A STEP BY STEP APPROACH
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Step 1:
Prepare a single line diagram of the electrical power
supply and distribution network, clearly indicating all the
significant network elements, fault current contributors,
short circuit protective devices, etc.
Step 2: Get the following data:

(i) Transformer rated kVA, rated secondary voltage of the
transformer (UrT), %R & %X values.
(ii) Generator rated kVA, rated voltage (UrG),rated sub-
Exemplar LV -SWGR
transient reactance (%x”d) & rated Power factor

(Cos φrG).
(iii) Cable Resistance (RC) & Cable Reactance (XC) per unit
length and the actual length of the cable used.
(iv) Motors’ rated voltages (UrM), rated currents (IrM) and
locked rotor currents (ILR).
Step 3:
Convert %R into Ohmic values, to obtain RT.
10 x (%R) x (kV)2
RT (in Ω) = ------------------------ {multiple by10 to change from PU}
Exemplar LV -SWGR
kVA
Step 4:
Similarly, convert %X into Ohmic values, to obtain XT.
10 x (%X) x (kV)2
XT (in Ω) = ------------------------ {multiple by 10 to change from PU}
kVA
Step 5:
Similarly, convert %x”d of the generator into Ohmic
values, to obtain XG.
10 x (%x”d ) x (kV)2
Exemplar LV -SWGR
XG (in Ω) = ------------------------ {multiple by 10 to change from PU}

kVA
Step 6:
Now, the resistance of the generator, ‘RG’ is normally
given as a % of ‘XG’. For LV Generators, it is:
RG (in Ω) = 0.15 XG.
Step 7:
Calculate a correction factor ‘KG’.
Un c
KG = ------- -------------------------------
Exemplar LV -SWGR
UrG 1 + [(x”d ) (Sin φrG)]

where,
KG = Generator Correction Factor
Un = Nominal System Voltage, in Volts
URG = Generator Rated Voltage, in Volts
c = Voltage Correction Factor = 1.05
x”d = Sub-transient Reactance of the Generator, in p.u.
form Sin φrG = √(1 – Cos2φrG)
CosφrG = Rated Power Factor of the Generator
Exemplar LV -SWGR
Step 8:
Now find out the Corrected Generator Resistance (RGK)
& the Corrected Generator Reactance (XGK):
RGK = KG x RG
XGK = KG x XG
Step 9:
Now find out the cable resistance & reactance for the
actual length of cable used up to the point of fault:
Exemplar LV -SWGR
RL = RC x LC
XL = XC x LC
Where,
RL = Line or Lead Resistance, in Ω
XL = Line or Lead Reactance, in Ω/meter
RC = Cable Resistance per km, in Ω/meter
XC = Cable Reactance per km, in Ω
LC = Actual length of cable up to the point of fault, in m
Exemplar LV -SWGR
Step 10:
Now add all ‘R’ & all ‘X’ values; find out ‘Zk’.
Zk = √[(Re)2 + (Xe)2]
Re = RT or RGK + RL
Xe = XT or XGK + XL
Step 11:
Now find out the initial symmetrical short circuit current, I”k:
c Un
Exemplar LV -SWGR
I” k = -------
√3 Zk
where,
I”k = Initial Symmetrical short circuit current, in Amperes
Un = Nominal System Voltage, in volts
c = Voltage Correction factor = 1.05 for LV (for HV it is 1.10)
Zk = Equivalent Impedance up to the point of fault, in Ω
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Example of Fault level Calculation

Exemplar LV -SWGR
Fault level Calculation
Exemplar LV -SWGR
Step 2: System Data
Transformer 11/0.433 KV
1600 KVA
%R=0.94
%X=5.46
%Z=5.54
Standby Generator: Urg = 415 V
1250 KVA
%xd”=20
Exemplar LV -SWGR
Cosϕrg=0.8
Step 2: System Data
Cable : R= 0.062 Ώ/Km
X=0.079 Ώ/Km
Length of the cable 21 to 31 =100 M
Induction Motors : M1 Irt =70 A
M2 Irt =135 A
M3 Irt =40 A
M4 Irt =200 A
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Step 3: Calculation of Transformer Rt & XT

Exemplar LV -SWGR
Step 3: Calculation of Generator Rgk & Xgk
RG = 0.004134 Ohms
Exemplar LV -SWGR
 Step 3: Calculation of Generator Rgk & Xgk

Exemplar LV -SWGR
Step 4: Calculation of RL & XL
RL=0.062X0.1 =0.0062
XL =0.079 X0.1= 0.0079
Step 5: Calculation of Zk Up to the point of fault
Total Zk Up the point of fault location F1

Exemplar LV -SWGR
Step 6
Calculation of RMS Value at the point of the fault.
Ik “ At the fault location F1

Exemplar LV -SWGR
Step 7
Calculation of X/R up the point of the fault F1,F2,F3.
X/R up the point of the fault location F1

Exemplar LV -SWGR
Step 8:
Calculate the Asymmetry Factor (pronounced as ‘KI’).
Factor χ For fault location F1 from the Equation above

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Step 9: Calculate of Peak Value of S/C current at the

point of fault
Ip At fault location F1 =χ√2 IK” =1.6 √2 X 38.77=87.71 KA (Peak)
Exemplar LV -SWGR
Step 10:
Calculate the aggregate of the rated full load currents of
all the motors at a particular location (ΣIrM).
If (ΣIrM) at a particular location is less than 1% of the
short circuit current contributed by other sources for a
fault at that particular location, then contribution to the
short circuit, from the motors need not be considered.
Or else, the motors’ contribution to short circuit has to
be calculated. So for this case contribution by induction
motors to the RMS S/C current at the fault location
Exemplar LV -SWGR
F1,F2 &F3 as follows:-

ΣIrM =(70+135+40+200) = 445 A

Which is >(0.01 X 38765 = 387.65 A) for F1.
Which is >(0.01 X 9625 = 96.25 A) for F2.
Which is >(0.01 X 15665 = 156.65 A) for F3.
I”kM = c 6 ΣIrM, if the S/C is at the motor terminals
I”kM = c 5 ΣIrM, if the S/C is away from the motor terminals,
involving a cable
I”kM = c 5 ΣIrM =1.05 X 5 X 445 =2336 A
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Step 11:
contribution by induction motors to the Peak S/C
current at the fault location F1,F2 &F3
the peak current contribution from the motor group would
be:
IpM = χM √2 I”kM
Where:χM = 1.3 for an R/X ratio of 0.42 (Given as per IEC60909),
as in the case of LV Induction motors
{R/X of 0.2 in the case of LV asynchronous motors(Given as per IEC60909)}
Exemplar LV -SWGR
IpM = 1.3X√2 X2336 =4294 A(Peak)

Step 11:
Calculate the total fault level, both R.M.S. (I” KT ) and
the Peak (IpT) at the fault location:
I” KT = I”K + I” KM & IpT = Ip + IpM
Fault location F1
R.M.S Value (I” KT) =38.77 + 2.34=41.11 KA
Peak value (IpT )=87.71+4.3= 92.01 KA ( Peak)
Fault location F2
R.M.S Value (I” KT) =9.63 + 2.34=11.97 KA
Exemplar LV -SWGR
Peak value (IpT ) =21.79+4.3= 26.09 KA ( Peak)

Fault location F3
R.M.S Value (I” KT) =15.67 + 2.34=18.01 KA.
Peak value (IpT ) =27.70+4.3= 32 KA ( Peak).
Result of the fault level calculation
Fault location I” KT RMS IpT ( Peak).

F1 41.11 KA 92.01 KA
F2 11.97 KA 26.09 KA
F3 18.01 KA 32 KA
Exemplar LV -SWGR
Construction Specifications
Exemplar LV -SWGR
Panel Structure
Structure contains the following:-
1. Front doors.
2. rear doors.
3. left and right side panels.
4. rear panels.
5. Basic compartment.
6. rear extensions.
7. Internal Sheet Metal
8. Instrument compartment,
 breaker compartment.
 protection panel.
Exemplar LV -SWGR
 truck rail.
 riser support
9. Shipping Frame
Panel housing description
1.General
The switchboard shall be an indoor, air insulated
and metal enclosed in accordance IEC/AS 62271-
200 classification with single bus bar system. It
shall be suitable for local and remote control, and
may communicate to the control system by field
bus connection. Switchboard shall be designed in
order to:
1. ensure service continuity to IEC 60439/61439
Exemplar LV -SWGR

2. guarantee high degree of operator safety
ensure easy installation and reduced
construction costs be easily adaptable to future
arrangement and extensions on both sides of
the switchboard,
3. Power cable connection preferably will be done
by cable from bottom front.
4. Bus-bar shall be copper and insulated.
5. All operations shall be performed with arc fault
contained door closed for maximum operator
Exemplar LV -SWGR
safety. This safety regulation shall be observed

even during loss of control voltage.
2. Cubicle design and compartments
 Enclosure and internal partitioning of the cubicles are of
high quality aluminum-zinc coated steel sheets, 2 mm
thick.
 Every panel of the switchboard is divided in various
compartments both for power equipment (bus-bars,
circuit breaker, fused contactor, instrument transformers)
and for auxiliaries (instrument compartment, wiring ducts
for interconnections) which are segregated by metal
partitions.
 Correct operation performance is ensured by integrated
mechanical interlocks, mechanical position indicators
Exemplar LV -SWGR
and inspection windows to ensure utmost safety for

operators.
3.Main bus-bar compartment
This compartment located in panel upper back part
contains the main bus-bar system, which is
supported and connected to the circuit breaker and
fused contactor fixed insulating contacts by means of
branches.
Depending on rated current they have to carry the
main bus-bars are made of electrolytic copper flat
bars or D-shaped cross section tubes, suitable to
withstand thermal and electro dynamic stress of a
short circuit current.
Exemplar LV -SWGR
4 Feeder compartment
Feeder compartment should be accessible from panel front
by opening the door. This compartment should include:
1. branch system for connecting the power cables to the circuit
breaker or fused contactor fixed insulating contacts.
2. fault make earthing switch with operation from panel front(MV
SWGR)
3. mechanical interlock between circuit breaker or fused
contactor and earthing switch (MV SWGR).
4. current transformers.
5. voltage transformers, fixed or withdrawable.
4mm aluminum gland plate shall be provided for power
Exemplar LV -SWGR
cables entry. Cable sealing ends should be visible at any

time via viewing window on compartment door.
5 Circuit Breaker or Contactor compartment
This compartment is to accommodate withdrawable circuit
breaker or fused contactor, and for truck racking in and out
with door closed. The following components are mounted in
this compartment:
1. the primary disconnects, namely bushing insulators
containing power connections of the circuit breaker or fused
contactor, and bus-bar compartment.
2. metal shutters automatically operated by the movement of the
circuit breaker or fused contactor truck(MV SWGR).
3. shutters shall be independently operated and pad
lockable(MV SWGR).
4. the circuit breaker or fused contactor truck position switches.
Exemplar LV -SWGR
5. Position of the withdrawable truck can be observed at any

time via the viewing window on the door.
6. Low voltage compartment(For MV SWGR)
The low voltage compartment should be a separate
compartment from high voltage/Medium section and shall
be placed above the circuit breaker or fused contactor
compartment. The Low voltage compartment should house
the following equipment :-
 terminal links and wiring
 auxiliary equipment of circuit breaker or fused contactor,
and cubicle (fuses, low voltage MCBs, measuring
instruments, protection relays, control and signalling
devices, etc.).
Exemplar LV -SWGR
 truck operated auxiliary contacts signalling circuit

breaker or fused contactor service, test and isolated
7.Doors and external covers coating or painting on the
switchboard cubicles
The doors and cover plates shall be cleaned and treated
against corrosion before receiving a high quality powder
coating of paint. The finishing coat is standard colour Light
Grey
8.Degree of Protection
The protection degrees in compliance with IEC 60529 are
the following:
 IP4X on the external housing(Indoor and outdoor)
 IP2X inside the compartments
Exemplar LV -SWGR
Construction Specifications-Other main features
Other main features For MV SWGR
1. Earthing switches
 Each panel shall be equipped with a cable earthing switch to
earth power cables.
 Bus metering and bus section panel shall be equipped with a
bus-bar earthing switch to earth main bus.
 The earth switch shall have fault make capacity and can
withstand the short circuit current. Earthing switch shall be
interlocked and manually operated from the front of the
switchboard.
 It shall be possible to observe earth switch blade via viewing
window on panel front for operator safety.
Exemplar LV -SWGR
 Earth switch operations can be prevented by means of

padlocks.
2.Protection and control
The functions of protection, metering and control of the
switchboard should preferably be implemented by protection
relay. The hardware including wiring for detection of
measurements and switching conditions should facilitate
universal use of the switchgear panels.
 Setting of protection parameters must be possible both by
laptop/notebook and manually at the panel.
 The technology used must permit the connection to
control system by a bus system.
 In the case of interruption of the auxiliary power supply,
the entire software, all saved data and the counters must
Exemplar LV -SWGR
be preserved in a non-volatile manner without batteries.

 Technology used must be capable of monitoring both itself
and the release circuits.
3.Conventional instrument transformers
Conventional inductive resin insulated voltage and current
transformers according to IEC/AS 60044-2 and IEC/AS
60044-1 shall be applied and designed according to
metering and protection requirements. It is manufacturer’s
responsibility to match instrument transformer performance
to connected protection or metering devices.
Voltage transformers shall be either fixed installation or
mounted on withdrawable trucks as shown on single line
diagram.
4. Cable terminations
The cable compartment should be comfortably accessible
Exemplar LV -SWGR
from the front thus making switchboard a wall-standing

installation. Panels can be terminated with either single or
three core cables.
Interlocking features
Mechanical interlocks must be provided to ensure proper
operation, prevent dangerous situations and mal-operation
that might jeopardise operator. In particular the following
interlocks shall be provided:
 Circuit breaker or fused contactor truck can only be moved from
test/disconnected position (and back) when earthing switch are OFF.
 Circuit breaker or fused contactor truck is mechanically interlocked
OFF when racking.
 Circuit breaker or fused contactor truck can only be switched ON
when in the test or service position.
 in service or test positions, circuit breaker and fused contactor truck
Exemplar LV -SWGR
can only be switched OFF manually when no control voltage is applied

and cannot be closed ON.
 connecting and disconnecting of the control wiring is
only possible in the test/disconnected position of the
withdrawable part
 If the panel is equipped with an earthing switch, the
following mechanical interlocks shall be provided:
o earthing switch can only be switched ON if the
withdrawable part is in test/disconnected position or
outside of the cubicle
o if earthing switch is ON, the withdrawable part cannot
be moved from the test/ disconnected position
o switch disconnector and cable earthing switch shall
Exemplar LV -SWGR
be mechanically interlocked with each other

Interlocks between panels:
Bus-bar earthing switch can only be switched ON when all
withdrawable parts in the bus-bar section are earthed
Other interlocks:
the shutters can be independently padlocked
access to the earthing switch operating-shaft can be
padlocked
access to the low voltage compartment, circuit breaker or
fused contactor compartment, cable compartment and
withdrawable truck operating shaft can be padlocked
mechanical interlock to prevent racking in circuit breaker or
Exemplar LV -SWGR
fused contactor truck earth switch is in ON .

 Doors:
 Front doors - Semi-
concealed hinges
 Rear doors – Bolted,
optional hinge (with Pad-
locking & handles)
 Infrared Windows (Optional)
 Paint
 Electro static powder coat
(standard)
Exemplar LV -SWGR
 Other painting (Optional)

Construction
 Rear cable area

 Mechanical Lugs (standard)
 Compression Lugs (optional)
 Main Bus Barriers separating
bus compartment from cable
compartment (Standard)
 Vertical Steel Barriers between
sections in cable compartments
(Optional)
Exemplar LV -SWGR
Construction
Bus Design
Conductor material
A conductor material should therefore have the following
properties if it is to be produced efficiently and have low
running costs from the point of view of energy consumption
and maintenance:
1. Low electrical and thermal resistance.
2. High mechanical strength in tension.
3. High resistance to fatigue failure.
4. Ease of fabrication.
Exemplar LV -SWGR
5. High resistance to corrosion.

6. Competitive first cost and high eventual recovery value.
Construction
Bus Design
Types of Busbar
Bus bars can be sub-divided into the following categories, with individual
bus bar systems in many cases being constructed from several different
types:
a. Air insulated with open phase conductors
b. Air insulated with segregating barriers between conductors of different
phases.
c. Totally enclosed but having the construction as those for (a) and (b)
d. Air insulated where each phase is fully isolated from its adjacent phase(s) by
an earthed enclosure. usually called 'Isolated Phase Bus bars'.
e. Force-cooled bus bar systems constructed as (a) to (d) but using air, water,
etc. as the cooling medium under forced conditions (fan, pump, etc.).
Exemplar LV -SWGR
f. Gas insulated bus bars. These are usually constructed as type (e) but use a
gas other than air such as SF6, (sulphur hexafluoride-SF6).
g. Totally enclosed bus bars using compound or oil as the insulation medium.
Exemplar LV -SWGR
(GIS) Gas Insulated Bus-bar
Exemplar LV -SWGR
Construction
 Bus Design
The type of bus bar system selected for a specific duty is determined
by requirements of voltage, current, frequency, electrical safety,
reliability, short-circuit currents and environmental considerations.
 Standard temperature rise Max 65ºC over 40ºC ambient
 Platting
 Silver platted (standard)

 Tin platted (optional)
 Insulation
 Bare (standard)
 Insulated bus (optional)
 Bus bracing using steel supported polyester type fingerplates
Exemplar LV -SWGR
Comparison of typical design requirements for power generation and
industrial process systems
Feature Generation Industrial Processes
1 Voltage drop Normally not important Important
2 Temperature rise Usually near to maximum In many cases low due

allowable. Capitalization becoming to optimization of first
important. cost and running costs.
3 Current range Zero to 40 k A a .c . with Zero to 200 kA a.c. and

frequencies of zero to 400 Hz. d.c.
4 Jointing and Usually bolted but high current Usually bolted. Joint
connections applications are often fully welded. preparation very
Joint preparation very important important.
5 Cross-sectional Usually minimum. Somewhat larger Usually larger than

Exemplar LV -SWGR
area if optimization is required. minimum required due to

optimization and voltage
drop considerations.
Comparison of typical design requirements
6 Construction Up to 36 k V. Individually Usually low voltage. Individually
engineered using basic engineered. Standard products
designs and concepts. for low current/voltage
applications.
7 Enclosures Totally enclosed with or Usually open. Enclosed or

without ventilation. protected by screens when using
standard products.
8 Fault capacity Usually large. Designed to Usually similar to running

meet system requirement. current. Standard products to
suit system short circuit.
9 Phase Normally 3 phase flat Normally flat but transposition

Exemplar LV -SWGR
arrangement used to improve current

distribution on large systems
Comparison of typical design requirements
10 Load Usually high. Usually high but many have
factor Normally 1.0. widely varying loads.
11 Cost Low when compared Major consideration in many

with associated plant. cases. Particularly when
optimisation/capitalisation is
used.
12 Effects of Very serious. High Limited by low voltage and bus

failure energies dissipated bar size.
into fault.
13 Copper High conductivity. High conductivity.

Exemplar LV -SWGR
type
Construction
Riser Bus
Main Bus
Runbacks
Exemplar LV -SWGR
Construction-Type of structure/installation
1- Wall-mounted structures
Exemplar LV -SWGR
Construction-Type of structure/installation
2- Floor-mounted structures
Exemplar LV -SWGR
Construction
 Control Wiring
 Inter-cubical wiring made easy
 Terminal strips
 Located in wire way on
top of enclosure
Exemplar LV -SWGR
Construction
Front door grounding
Inter-cubicle wiring made easy

Exemplar LV -SWGR
Construction
Instrumentation
Breaker door mounted lights, meters and control
 Indicating Lights
 Volt, amp, and watt meters
 control switch (Selector switchs)
 Multifunction Metering
 Relays
 Surge Protectors.
 LCD Display
Exemplar LV -SWGR
Key features and benefits
Section Widths samples
E4 3200 Amp E2/E3 800 – 1600 E2 800 - 1600A
E6 4000 Amp E3 2500 Amp (65 & 100 kA) (65 kA)
40” 32” 24” 20”

Exemplar LV -SWGR
Trip Units
 Protection Features
 LCD Display
 Current Measurement
 Contact Wear
 Communications option
 Harmonic Measurements
 Communications option
Exemplar LV -SWGR
Safety Features
Safety shutters (standard)
Exemplar LV -SWGR
Safety Features
Padlocking provisions
• Anti-insertion lock
• Disconnect.
• connect, and test position
Breaker compartment keyed

cells
Exemplar LV -SWGR
Form of internal separation
In accordance with IEC 60439-1,Depending on
requirements, the function compartments can be
subdivided as per the following table:
Exemplar LV -SWGR
Exemplar LV -SWGR
Exemplar LV -SWGR
Exemplar LV -SWGR
Exemplar LV -SWGR
Factory and site Tests
Exemplar LV -SWGR
Tests
1- Factory Test
(A)Electrical Tests
1. Megger test. Resistance between busbars and between
bus-bars and ground on each bus section.
2. High potential test 2500 VDC for 1 minute, unless
otherwise specified on each bus section.
3. Operating test of all protective relays.
4. Testing of thermal relays with time clock and current
injection set to check if relays stay within their curves.
5. Check correct bus phasing from each source and
Checking of all control wiring.
Exemplar LV -SWGR
6. All the auxiliary NO& NC points

Tests
(B) Mechanical Tests
1. Mechanical indicators(Postion indicators )
2. Mechanical tests (ACB open & close operation , Earth
Switch, door locks, etc. ).
3. Operating mechanism
4. Check accessibility of bus bar connection bolts and nuts
with normal tools.
5. proper mounting of components;
Exemplar LV -SWGR
Tests
(C) General inspections
1. Constructive aspect, Appearance test ( painting,,
nameplates,lables etc.).
i. Correct labeling of functional units.
ii. completeness of the data on the nameplate.
2. IP degree protection and the certificates.
3. Inspect indicating devices for correct operation.
4. Creepage distances and clearances.
5. interchangeability of electrically identical components.
6. non-interchangeability of mechanically identical but
Exemplar LV -SWGR
electrically different withdrawable unit.

Tests
2-Site Test
Test and Proof Operation to Be Carried Out at Site
1. Megger testing resistance between bus-bars and between
bus-bars and earth.
2. High potential test, 2000 V, 1 minute.
3. Check of all bolted bus, bus-duct and transformer
connections.
4. Check of all terminals.
5.Proof operation and test after announcement “power
available”.
Exemplar LV -SWGR
6.Visual inspection for freedom of dust and waste material.

Tests
General Test Procedure
1. All test equipment necessary for tests described shall
be furnished by vendor.
2. All tests shall be witnessed by a representative of
customer.
3. All test result should be recorded with the serial no of
the unit.
4. The mechanical and electrical operation of a number
of functional units, including their control and
protective devices, shall be tested on a random basis.
Unless otherwise specified in the requisition,
5. these tests shall be done on at least of 10% of the
Exemplar LV -SWGR
number of similar functional units with a minimum of

two units.
Factory Acceptance Test (Fat Procedure )
Technical Requirements Result
Structure (W) X (H) X (D)
 The Over all Dimensions and installation dimensions
should meet the requirements of the approved
drawings. Satisfied Y ,N
 When The doors is opened the Max Angle should
exeeds90.
Painting: Satisfied Y , N
The painting is homogenous and correct in color, is free
from light reflection, scratches, flowing path, flaws and
disposals, and it has good adhesive strength
Component Assembly Satisfied Y , N

All components and parts specifications are correct, the
name plate are correct, the component conform to the
requirements of the drawings, are assembled neatly(‫عناية‬YYY‫)ب‬,
Exemplar LV -SWGR
arranged safely and reliably, drevin flexibly, operated and

maintained conveniently
BusBar (W) X (H) X (D)
The bus-bars are overlapped smoothly and neatly, connected
well, and offered with measures to prevent electromechanical
erosion. There is no crack on the bent (‫نحناء‬Y‫ )ا‬bus-bars, phase Satisfied Y ,N
sequence and painting colors meet the regulations, cross
sections and connecting patterns of conductors conform to
approved drawings. All bus-bar are in heat shrinkable, and
spare wires end are in insulation lugs.
Wiring of Auxiliary Circuit: Satisfied Y , N
The wiring is neat and stable. The symbols are clear and
correct, the color ,cross section and arrangement of wires
conform to the approved drawings.
Elecrical clearance and creepage Distance of primary Satisfied Y , N
cuircuit :
In cabinets, between horizontal bus-bars, vertical bus-bars
Exemplar LV -SWGR
,branch bursars and primary patch plugs, and to earthing

metal parts, the electrical clearance and creepage Distance
should be>20 mm.
Elecrical clearance and creepage Distance of primary Satisfied Y , N
cuircuit :
In functional units the electrical clearance of live parts main
components subjected to the terminal distace of incoming and
out goining,or electrical parts adopted withcomposite
insulation should not be less then 10 mm and their creepage
distance should not be less than 12 mm.
Elecrical clearance and creepage Distance of Auxilary
cuircuit :
Electrical clearance >4 mm
creepage distance >6 mm
Interlock Devices:
Mechanical and electrical interlock devices in eachfunctional
unit are offered to ensure the correctness of procedure and
the safety of maintenance persons.
Exemplar LV -SWGR
Earthing device: Satisfied Y , N
Earthing patterns of the doors, cover plate and similar parts
meet the regulations.
Main earthing bus-bar provides earthing terminals.
Name plate ,Lable Satisfied Y , N
Name plate and Lables contents are correct, complete ,clear
and neat.
Mechanical Operation Test Satisfied Y , N
All manual operation parts for example, operating handles of
main switches should be operated 5 times and they function
properly.
Electrical operation test:
The simulated operation test should be performed according
to schematic diagram of auxiliary circuit,Each part functions
as per approved drawings.
Exemplar LV -SWGR
Insulation character test: 2000V for I1
1 second power frequency withstand voltage ,between phases minute test
and phase to earth for primary circuit,2000V.(incl.auxiliary withstand
circuit connected with primary circuit directly)
Protection Degree Internal
Enclosure IP42 at least (for indoor type). certificate
Enclosure IP55 at least (for the out door type) should be
provided
Exemplar LV -SWGR

Low Volt Switchgear

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Low Volt Switchgear

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Low Voltage Switchgear

© ABB Automation Technologies

2-Switchgear Main components

3-Low Voltage Switchgear Terminology

5- protection SWGR common main parts

10- Switches ,Dis-connecter ,Isolator

13-fault level calculation

By voltage class there are three types

HV 35 < Vr < 230

EHV(Extra high voltage) 230 < Vr < 800

UHV(Ultra High Voltage ) 800 < Vr

Switchgear is Generic name to cover

Normal & Abnormal Condition

Switchgear Switching Protection

 The protection of circuit-Against overload;

insulation resistance of the installation to earth.

 MCB 0.5 to100 A (ON/OFF+ O/L+ S/C)

(ON/OFF+ O/L+ S/C+ I∆n)

 Contactor 9 to 550 A (ON/OFF)

 MCB 0.5 to100 A( ON/OFF+ O/L+ S/C )10KA

 RCBO 6 to 32 A( ON/OFF+ O/L+ S/C+ I∆n )6KA

Low Voltage Switchgear Terminology are generally with

Rated Operational Voltage (Ue).

Rated Insulation Voltage (Ui).

Rated Impulse Voltage(Uimp)

RATED OPERATIONAL VOLTAGE (Ue).

sufficient to tolerate a potential difference of

RATED INSULATION VOLTAGE (Ui).

2- system flctuation on the upper side.

Switchgear rated for Ui of 690 V would very well

Rated Impulse Voltage(Uimp)

 Conventional enclosed Thermal Current (Ithe).

 Rated operational Current(Ie).

 Rated uninterrupted Current(Iu).

Rated Free Air Thermal Current (Ith).

permissible limits. This test is conducted in enclosed

temperature rise of any part reaching beyond permissible

The rating is similar to the rated operational current

or causing any damage to itself or to the installation or to

Rated short circuit making current (Icm):-

and other supporting equipment are included in each

 DC5:Series Motors: Starting Plugging and Inching.

Protective relays are designed to be installed

equipment damage and power outages.

1- contact multiplication (repeat contactors) .

 Types according to construction

 Types according to functions

 Based on actuating parameter the protection relay can

E- Other sub distribution

2-Sudden pressure relay.

B – Public utility supply.

Residential sector industrial

4-Water coolant temp.

that could be caused by harmful leakages of electric

Motor Overloads relays

 There are basically three types of overloads:

the motor against single phase or unbalance conditions.

to protect against single phase or unbalance conditions.

 Class 10 is commonly used to protect artificially cooled

is specified as the current value with a corresponding time

Circuit-breakers specifically intended for selectivity

 Wide range 400 to 6300 A as following:

 Designed for Accessible Maintenance & repair.

Over load & Earth fault