Electrical Panel Boards - Engineering Training Report

HIGHER NATIONAL DIPLOMA IN
ENGINEERING
ADVANCED TECHNOLOGICAL INSTITUTE

COLOMBO 15
NAME
: G.K.T.PREMARATHNA
FIELD
: ELECTRICAL ENGINEERING (POWER)
PREFACE
Industrial training is an important experience in the learning procedure of an Engineering student

which provides an opportunity to utilize the knowledge in a real working environment under the
guidance of competent engineers.
Higher National Diploma in Engineering six months Industrial Training is coordinated by

National Apprentice and Industrial Training Authority (NAITA) in association with Industrial
training division of the Higher National Diploma in Engineering in Advanced Technological
Institute. I tried my best to keep to the guidelines stipulated by NAITA. This is succeeded by my
own training experience, which is detailed to the most possible extent.
This report presents the experiences and knowledge I have gathered during the first 3 months
training period starting from 10th February 2014 to 09th May 2014 at Orange Electric of OREL
Corporation (Pvt) Limited.
Chapter one reviews information about the training organization, its main functions,
organizational structure, business products, welfare and safety practices. The experience and
knowledge gained within the period of industrial training are presented in the second chapter.
Information about the work shop I visited, duties and functions performed during the training
period is included. Problems encountered during training and solutions found are also discussed
in the second chapter. In the third chapter, gives a conclusion of training and of this report.
Kasun Premarathna
Higher National Diploma in Engineering [HNDE]- Electrical 23-batch
ACKNOWLEDGEMENT
I would like to offer my sincere gratitude to the Advanced Technological Institute (ATI)
Colombo 15, National Apprentice and Industrial Training Authority (NAITA) and OREL
Corporation (Pvt) Limited for offering this training opportunity.
Further I must extend my deepest gratitude to Mrs. Anodya Ariyarathna, Director of ATI
Mattakkuliya. In addition, Mr. Yogaganeshan, Head of Department Electrical Engineering and
all academic staff of my Institute who guides me at all the times.
I am grateful to Factory Manager of OREL Corporation (Pvt) Limited. for giving us this
opportunity. I also appreciate the cooperation from Mr. Ekanayaka the training coordinator of
Orange Electric. I would be grateful to thanks Production Manager Mr. Gervin Sugath, who gave
me the guidance for a better training. My special gratitudes also offered to all the Engineers and
other officers. My sincere thanks also belong to Head of Department and supervisor in the
Electrical department. Also I would like to thank all the other Electricians and Operators who
helped me in many ways during this training period.
Above all the things, it is the efforts of my parents and the family members gave me strength and
support. Finally I wish to convey my gratitude to everyone that I may have forgotten to mention
above, who supported me to complete my In-plant Training successfully.
G.K.T.Premarathna,
Student of HNDE,
Department of Electrical Engineering,
Advanced Technological Institute,
Colombo 15.
Kasun Premarathna
CONTENTS
Title
Page
1.0. CHAPTER 01- INTRODUCTION
1.1. Introduction of OREL Corporation Private Limited ..................................... 10

1.1.2. Vision ..... 11
1.1.3. Mission ... 11
1.1.4. Businesses together with OREL Corporation ... .11
1.1.5. Products Range of Orange Electric Factory ....12
1.1.6. Quality Assurance ...... 13
1.1.7. Organization ... 13
1.1.8. Employee Facilities & welfare ... 14
1.2. Safety Practices ...... 15

2.0. CHAPTER 02 TRAINING EXPERIENCE
2.1. Orange Industrial Electrical workshop 17

2.1.1. Panel assembling procedure ... 18
2.1.2. Power circuit wiring procedure .. 19
2.1.3. Control circuit wiring procedure .... 19
2.2. Tools & Machines used in workshop ..... 20

2.2.1. Basic tools .. 20
2.2.2. Machineries 21
2.2.3. Nuts and bolts .... 22
2.2.4. Panel accessories used in workshop .. 22
2.3. Electrical Protective Devises Used in the Panels ......... 24

2.3.1. Fuses .. 24
2.3.2. Miniature Circuit Breakers (MCB) .... 25
2.3.2.1. Standard dimensions of MCBs ... 25
Kasun Premarathna
2.3.2.2. MCB Distribution Box designing ... 26

2.3.3. Residual Current Circuit Breaker (RCCB) .... 26
2.3.4. Moulded case circuit breakers (MCCB) .... 27
2.3.4.1. The Shunt trip coil and Under Voltage Tripping Coil .... 29
2.3.4.2. Auxiliary contacts ... 29
2.3.4.3. Installation process of MCCB internal accessories 30
2.3.5. The Surge Protection Device . 31
2.3.6. Phase Failure Relay (PFR) . 31
2.3.7. Overload Relay .. 32
2.3.8. Earth Leakage Relay (ELR) ... 32
2.3.9. Earth Fault Relay (EFR) 33
2.3.9.1. Characteristic settings procedure of Earth Leakage Relay ..... 33
2.4. Measuring Devises Used in the Panels... 34

2.4.1. Current transformer .... 34
2.4.2. Core Balance Current Transformer 35
2.4.3. Indicator ..36
2.4.4. Ammeter .... 36
2.4.4.1. Connecting process an Ammeter 36
2.4.5. Voltmeter ... 37
2.4.6. KWh Meter (Energy meter) ... 37
2.4.7. Digital Power Analyzer .. 37
2.5. Switching Devises Used in the Panels 38

2.5.1. Relay .. 38
2.5.2. Contactor 38
2.5.3. Timer Relay .... 39
2.5.4. Push Buttons .. 40
2.5.5. Selector Switches ... 40
2.6. Cables .. 41
2.6.1. Cable Insulation Materials . 41
2.6.2. Cable Lug ... 41
2.6.3. Cable Numbering Tube .. 42
Kasun Premarathna
2.6.4. Current ratings of single core PVC insulated cable ... 42
2.7. Bus bars ... 43

2.7.1. Bus bar sizes and current capacity . 43
2.8. Distribution Panels .... 44

2.8.1. Main Distribution Panel ..... 44
2.8.2. Sub Distribution Panel ... 44
2.8.3. The pump house distribution panel wiring procedure ... 45
2.9. Changeover Panels .... 47

2.9.1. Manual Changeover Panel ..... 47
2.9.2. Automatic Changeover Panel (ATS panel) 47
2.9.3. Automatic Changeover Panel wiring ..... 48
2.10. Motor Control panels . 50

2.10.1. Direct Online Starter (DOL) panel .. 50
2.10.2 Cooling tower panel wiring .. 51
2.10.3. Star-Delta Starter panel 53
2.10.4. Fire pump panel wiring .... 54
2.11. Power Factor Correction Capacitor Bank 57

2.11.1. Components Used in Capacitor Bank .. 58
2.11.2. 6 steps Capacitor Bank Panel wiring .. 59
2.12. Electrical Panel testing ..... 62

2.12.1. Testing equipment .... 62
2.12.2. Panel tests . 64
2.12.2.1. Visual inspection procedure... 64
2.12.2.2. Insulation resistance testing procedure ... 65
2.12.2.3. Functional test ... 66
3.0. CHAPTER 03 - CONCLUSION
3.1. Conclusion .. 67
3.2. Abbreviations . 68
3.3. References ...... 69

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LIST OF FIGURES
Figure 1.1
Orange Electric factory
10
Figure 1.1.4
OREL Corporation businesses
11
Figure 1.1.5
Orange Electric Logo
12
Figure 1.2.1
Electrical Safety Signs
15
Figure 2.1
Standard Panel Design
18
Figure 2.2.1
Tool box
20
Figure 2.2.1.1
Cable Cutter
20
Figure 2.2.1.2
Crimping Tool
20
Figure 2.2.2.1
Jig Saw
21
Figure 2.2.2.2
Electric Drill
21
Figure 2.2.2.3
Pneumatic Pop-Rivet Gun
21
Figure 2.2.2.4
Industrial Heater
21
Figure 2.2.3
Nuts and bolts
22
Figure 2.2.4.1
Din rails
23
Figure 2.2.4.2
Insulator mounts
23
Figure 2.2.4.3
Cable ducts
23
Figure 2.2.4.4
Wire End Caps
23
Figure 2.3.1
Cartridge Fuse
24
Figure 2.3.2
HRC Fuse with holder
24
Figure 2.3.2
MCBs
25
Figure 2.3.2.1
Standard dimensions of MCBs
25
Figure 2.3.2.2
MCB Distribution Box wiring diagram
26
Figure 2.3.3.1
Internal connection of RCCB
26
Figure 2.3.3.2
2 poles and 4 poles RCCB
27
Figure 2.3.4
MCCB and its auxiliary components
28
Figure 2.3.4
I - Thermal adjustment
28
Figure 2.3.4
II - Magnetic adjustment
28
Figure 2.3.4.2
Auxiliary contacts and Tripping Coil arrangement
29
Figure 2.3.4.3
Installation of MCCB internal accessories
30
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Figure 2.3.5.1
SPD device
31
Figure 2.3.5.2
wiring diagram of OBO SPD device
31
Figure 2.3.6
ANLY PFR and its connection diagram
31
Figure 2.3.7
LS Overload relay and symbol
32
Figure 2.3.8.2
DELAB ELR
32
Figure 2.3.8.2
connection of ELR
32
Figure 2.3.9
DELAB EFR and its connection
33
Figure 2.4.1.1
Types of CTs
34
Figure 2.4.1.2
Working principle of CT
34
Figure 2.4.1.3
CT connection
35
Figure 2.4.2
Core Balance Current Transformer
35
Figure 2.4.3
Connecting diagram of an Ammeter
36
Figure 2.4.4
Voltmeter and selector
37
Figure 2.5.1
Relay and relay base
38
Figure 2.5.2.1
ABB contactor
39
Figure 2.5.2.2
Auxiliary components
39
Figure 2.5.3.1
Timers
39
Figure 2.5.3.2
Analog timer internal connection
39
Figure 2.5.4
Push button and emergency button
40
Figure 2.6
PVC insulated cable
41
Figure 2.6.2
Cable Lugs
41
Figure 2.6.3
Cable Numbering Tube
42
Figure 2.7
Bus bars
43
Figure 2.8.1
Main Distribution panel
44
Figure 2.8.2
Sub Distribution panel
45
Figure 2.8.3
The pump house distribution panel wiring diagram
45
Figure 2.9.2
Automatic Changeover Panel
47
Figure 2.9.3
Automatic Changeover Panel control wiring diagram
48
Figure 2.10.1
Power circuit and control circuit of DOL panel
50
Figure 2.10.2.1
Power circuit of cooling tower panel
51
Figure 2.10.2.2
Control circuit of cooling tower panel
51
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Figure 2.10.3
Power circuit and Control circuit of star delta panel
53
Figure 2.10.4
Control circuit of Fire pump panel
55
Figure 2.10.4.1
Timer connection of fire pump panel
56
Figure 2.11
Power factor triangle
57
Figure 2.11.1
Capacitor Bank
57
Figure 2.11.1.1
Power capacitor
58
Figure 2.11.1.2
Capacitor switching contactors
58
Figure 2.11.1.2
Automatic power factor controller
58
Figure 2.11.2
Capacitor Bank power circuit drawing
60
Figure 2.11.3
Capacitor Bank control circuit drawing
61
Figure 2.12.1.1
Test Lamps
62
Figure 2.12.1.2
Clamp meter
62
Figure 2.12.1.3
Continuity tester
63
Figure 2.12.1.4
Megger tester
63
Figure 2.12.2.1
Visual inspection test report
64
Figure 2.12.2.2
Insulation Resistance test report
65
Figure 2.12.2.3
Functional tests reports
66
LIST OF TABLES
Table 2.4.1
Metering Accuracy Classes of CTs
34
Table 2.6.4
Current ratings of single core PVC insulated cable
42
Table 2.7.1
Bus bar current capacity
43
Kasun Premarathna
1.0. CHAPTER 01- INTRODUCTION

1.1. Introduction of OREL Corporation Private Limited
Figure 1.1- Orange Electric factory

OREL Corporation Private Limited (Orange Electric Corporation) is the biggest electric
company, which is manufacturing, exporting and importing world class Electrical Products based
in Sri Lanka.
With their customer oriented approach, all the business policies are based on high ethical values.
They endeavor to maintain complete transparency in all the business procedures. All the 1000
employees of the company stand by the companys vision of attaining complete client
satisfaction. They have earned the confidence of many eminent clients from countries like India,
England, Australia, Austria, Maldives, Bangladesh, Pakistan, Singapore, Korea, Japan, Taiwan,
Cypress, Nepal, Dubai, and Uganda.
The Orange Electric was started in 1978. It started as an Australian Sri Lankan joint venture with
Clipsal, with a simple assembly line producing a limited range of switches and sockets. From
then on, the company experienced phenomenal growth and market leadership, manufacturing a
complete range of electrical products. The sale of Clipsal Australia to the French multinational
company Schneider Electric was a turning point in the history of the company, as this twist of
fortune led to the foundation of Orange Electric. At this critical juncture it was decided to resist
against the sale of the company to a multinational.
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Kasun Premarathna
Orange Electric was launched as the companys main brand in 2004. With the increase of their
product portfolio the company has five major factories in Maharagama, Boralesgamuwa,
Ratmalana, Meegoda and Ranala. In these five factories they manufacture more than one million
items for a month. Under the proficient headship of Mr. Kushan Kodituwakku, our respected
MD, the Orange brand became an overnight success, securing market leadership within a short
period in the field of manufacturing, exporting and importing of Electrical Products.
1.1.2. Vision
"To create a billion dollar global electrical brand"
1.1.3. Mission
"To add more to life with electricity"
1.1.4. Businesses together with OREL Corporation

OREL Corporation is converged 16 businesses
Figure 1.1.4 - OREL Corporation businesses

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I was mainly involved with the Orange Electric of OREL Corporation during the period of
industrial training, which is situated at Megoda, Padukka. This factory manufactures electrical
components to the highest quality and most stringent international standards.
1.1.5. Products Range of Orange Electric Factory
Figure 1.1.5 - Orange Electric Logo
Low Voltage Switchgear
Low Voltage Switchgear which Designed for a flawless performance, the Low Voltage
Switchgear available with us is largely used in varied industrial applications for providing
isolation switching and earth leakage protection of electrical circuits.
.
Electrical Accessories
Electrical Accessories is assorted variety of Electrical Accessories includes Electrical Mounting

Boxes, Electrical Plug Top, Electric Lamp Holder, and Electrical Ceiling Rose.. Designed to
perfection, the Electrical Accessories provided by them comply with the set industrial standards.
Bulbs
CFL Lamps are created a strong foothold in the business of manufacturing and exporting world
class CFL Lamps. Tube lights and LEDs also produced in orange
Cables
The Electrical Cables are specially manufactured using the best grade raw materials. Thus, these
Electrical Cables are the best choice that is available in the markets all across the world.
Moreover, the clients can access this enviable range of Electrical Cables in varied specifications
that too at very reasonable rates.
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Industrial Electrical Application

They have made a mark in the field of manufacturing and exporting products for Industrial
Application. These products are specially manufactured using premium grade raw materials and
electronic components.
o
Power Distribution Panel
One of the major Manufacturers and Exporters is Power Distribution Panel. These Power
Distribution Panels are trusted for Safety Reliability and Quality in LV Power
Distribution.
o
Steel Enclosure
The Steel Enclosures for Power Distribution Panels is fabricated using the finest grade raw
materials.
1.1.6. Quality Assurance

We are a quality oriented organization and so we make regular up gradations of the Electrical
Products that are also inspected on varied parameters in compliance to our policies. Further, to
add credibility to our name, we have been Awarded ISO-9002 in 1994 and ISO-9001 in 2000 for
quality management system in the manufacture of electrical accessories. Also super brand status
for the superior quality Electrical Products offered by us.
1.1.7. Organization
Orange electrical is very highly organized company and It has very complicate organization
system. The total number of employees at Orange electric is about 1000. This is main
organization structure of orange electric.
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Board of Directors
Chairmen
Managing Director
Other Director
Factory Production Manager
1.1.8. Employee Facilities & welfare

Employees Trust Fund (ETF) and Employees Provided Fund (EPF)
EPF is required Employees contribution is 8% of the total monthly earnings (To be deducted
from the Employees Salary) and Employers contribution is minimum of 12% of the total salary
of the employee monthly.
ETF is required Employees contribution of 3% percentage of the earning of an employee.
Working hours and Leaves

The normal working hours of the Orange Electric Factory are 7.30 am to 5.00 pm. Excess of
normal working hours to be treated as overtime. The transport service is gone on according to the
working times.
An office employee shall be granted 14 days annual leave with pay in respect of the second and
any subsequent year if he has been continuously in employment during the year.
Welfare
Orange Electric, a company who places great emphasis on the welfare of its employees has
recently implemented several distinctive programs, giving new meaning to work life balance
whilst taking their Healthy Employee concept to an altogether higher plain. The Company has
devised some interesting and special programs that greatly contribute.
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Kasun Premarathna
Yoga and Karate sessions.
Meditation programs and First Aid facility.
Changing Room and Lockers.
Meals, Tea & Washing facilities.
Annual cricket match, New Year festival and annual trip.
Bonus and Loans.
Transport service.
Welfare shop.
1.2. Safety Practices

In the Orange Electric workshop, we used safety methods, because of electrocution is mainly due
to serious injury. The operation of tools and machineries also cause to hazards. We considered
about personal safety, human health and equipment safety.
Below safety instructions were followed in workshop for the prevent from electrical hazards,
Before installation, wiring, operation, maintenance and inspection of the panel,

instructions or the catalogue were studied carefully to ensure proper operations.
We got the assistance from supervisor, before testing the experiment with electrical
supply.
Proper testing and checking instruments were used to find the live parts.
We used only tools and equipment with non-conducting handles when working on
electrical devices.
We kept in mind to never handled electrical equipment when hands, feet, or when
standing on a wet floor.
We kept the workplace dry and free from oil, water and grease.
The power source was disconnected before servicing or repairing electrical equipment.
We kept in mind to use the equipment in a range of the rated voltage and current shown
on the name plate.
Figure 1.2.1 - Electrical Safety Signs

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Fallowing safety methods were used to prevent from hazards while machinery works in
workshop.
We used personal protective equipment such as Safety shoes, Gloves, Ear Plugs,
Mufflers, Safety Goggles and etc.
Used appropriate tools and equipment for work.
Before done the work, instruction was read properly.
We followed out to wear suitable cloth, not too tight and not too loose.
After the work was finished, cleaned the surface and electrical switch off the machineries
power supply.
We kept the floor of workplace free from oil, water and grease.
Used cleaners for the clean the body.
The company has a response for all electrical work, systems and equipment under their control.
They must ensure that and are given sufficient information of any known hazards or risks to
health and safety to enable them to work safely;
Suitable control measures are in place and followed.
Installed suitable equipment for perform and the environment within which it will be
expected to work.
Equipments were calibrated correctly.
Danger signs, Warning information and other safety procedures were presented in
working place.
16
First aid facilities and sick room was arranged in the company.
Safety equipment and cleaners were provided in the workshop.
Working areas were marked according to the proper standard.
Kasun Premarathna
2.0. CHAPTER 02 TRAINING EXPERIENCE

2.1. Orange Industrial Electrical workshop
In Orange Industrial Electrical workshop, Power Electrical Panels were designed as per the IEC
standards. These power electrical panels were trusted for Safety Reliability and Quality in Low
Voltage Power Distribution. Power Electrical Panels made available in various specifications in
Industrial Electrical workshop,
Distribution panels
o Main distribution panels
o Sub distribution panels
Changeover panels
o Manual Changeover Panels
o Automatic Changeover Panels (ATS panel)
Motor control panels
Capacitor Bank panels
Steel enclosures
The Power Electrical Panels consist of metering devices, protective devices, switching devices,
conductors, bus bar chambers, indicators, circuit breakers, capacitors and many other types of
equipment.
Before designing electric panel the following details should be incorporated into it.
17
Location and dimension of the panel
Load description, Amperage, Voltage required
Cable size and conduit size
Type of insulation.
Ventilation, temperature and space arrangement in the panel
IEC regulation
Kasun Premarathna
Figure 2.1 Standard Panel Design

I was able to practice the process of panel assembling and panel wiring in Orange Electric
workshop.
2.1.1. Panel assembling procedure
First of all, the panel box, cover plates, panel door, mounting plate and benches were
selected according to the given drawing.
Door arrangement was fixed by using Panel hinge according to general arrangement.
The door Beading and panel key mount was attached to the door.
The cover plate bracket was prepared by using drill machine, tap cutting tool, flat screw
driver.
Switch gear benches and din rails were arranged on the mounting plate according to
drawing.
Mark holes position to fix the benches, din rail bracket, profile using pencil and drilled all
holes using drilling machine.
Taped all holes using tap cutting tool.
Din rails and benches were fixed by using flat screw.
Arrange bus bars, bus bar insulators, neutral link, neutral bar, earth bar, earth link as
general arrangement using bus bar bend machine.
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Made the holes to fix bus bar insulators, earth link, and neutral link etc. on mounting
plate and all holes were taped.
All items were fixed according to general arrangement using proper tools.
The door arrangement of indicators and other equipments was prepared according to
drawing by using drill machine and Jig saw.
All electrical equipments were fixed in to the proper place and mounting plate was fixed
in to the panel box.
2.1.2. Power circuit wiring procedure
The cable ducts was cut in to suitable size and fixed in to the panel box.
The relevant wire size was selected according to current rating chart.
The cable length was defined and cut the wires using wire cutter.
The Lug was fixed to the wires using lug cramping tool and End cap was fixed in to the
cable according to phase colour.
Wiring was done according to the wiring diagram, Allen key, Phillips and flat screw
drive.
Marked the tighten nut using permanent maker pen.
Checked the wire connection, cable size and connection.
2.1.3. Control circuit wiring procedure
Auto cable was used to wire the control circuit.
The cable length was defined and cut the wire using side cutter, wire striper.
Print the tube number using ferrule print machine.
Lugs were fixed to cable using cramping tool.
The control side was wired by including numbers, Phillips and flat screw drive were
used.
19
Wire combines between control side and power side.
The control line was neatly arranged by using spirals and cable ties.
Checked the wires connection.
Kasun Premarathna
2.2. Tools & Machines used in workshop

When I was assembling the panels in the workshop, Fallowing tools and machineries were used.
Before I used these tools and machineries safety rules and operating instruction were fallowed
correctly.
2.2.1. Basic tools
Hammer
Screwdriver (Slot-head)
Phillips Screwdriver
Pliers
Hacksaw
Allen Keys
Side Cutter
Wrench (Box-End Wrench, Socket Wrench, Pneumatic Wrench, Open-end Wrench)
Measuring Tape
Cable Cutters
Figure 2.2.1 - Tool box
Cable cutters are useful to cut cables. Gilbow cutter (heavy-duty cable cutters) cuts the large
size cables & common bas bar.
Figure 2.2.1.1- Cable Cutter
Crimping Tool
A crimping tool is a tool designed to crimp or connect a connector or lug to the end of a
cable. To use this crimping tool, each wire is first placed into the correct position. The
hydraulic crimping tool crimps high gauge wire easily with steady hydraulic power.
Figure 2.2.1.2- Crimping Tool
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2.2.2. Machineries
Jig Saw
A Jig Saw is a useful in cutting shapes, curves and removing parts from the panels.
Figure 2.2.2.1 - Jig Saw
Electric Drill
A Drill is a driving tool attachment, usually a drill bit. It is used for drilling, tapping and
boring holes in various materials. Some electric drills drown with rechargeable batteries.
Figure 2.2.2.2 - Electric Drill
Pneumatic Pop-Rivet Gun
A pneumatic pop rivet gun is designed to fix the rivet nuts together without too much effort
from the person handling the gun. The pneumatic pop rivet gun used compressed air hoses.
Figure 2.2.2.3 - Pneumatic Pop-Rivet Gun
Industrial Heater
Industrial Heater is used to plastic welding, bending, bus bar insulation and many other
purposes.
Figure 2.2.2.4 - Industrial Heater

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Kasun Premarathna
2.2.3. Nuts and bolts

The fallowing nuts and bolts were used for the panel assembling and connecting devices in to the
panel box by me.
Nail
Screw
Flat washer
Spring washer
Bolt
(CSK Bolt - 4x10mm, 4x12mm, 5x10mm, 5x12mm, 5x16mm, 5x20mm)

(PH Bolt - 5x35mm, 5x20mm, 4x10mm, 4x12mm)
(Hex Bolt - 8x30mm, 8x15mm, 6x8mm, 612mm, 615mm, 620mm)
Allen Bolt
Self tapping bolt
Nuts
Stud nuts
Figure 2.2.3 - Nuts and bolts
2.2.4. Panel accessories used in workshop
22
Panel plate
Beading
Panel hook
Cables ties
Panel holder
Name plates & danger stickers
Panel hinge / Chrome hinge
Earth bar
Panel key
Kasun Premarathna
Din rail
Din rail is a metal rail of a standard type widely used for mounting circuit breakers and
industrial control equipment inside panel.
Figure 2.2.4.1 - Din rails
Insulator Mounts
Bus Bar Insulator mounts are used for connecting line and neutral bar with panel mounting
board and connecting bus bar with panel board.
Figure 2.2.4.2 - Insulator mounts
Cable Duct
Cable duct is wire and cable management product for routing and concealing electrical
wiring in control panels. Available in many sizes
Figure 2.2.4.3 - Cable ducts
Wire End Caps
The wire end caps are used for easily identified wire. These end caps can be obtained various
colour according to electrical colour code.
Figure 2.2.4.4 - Wire End Caps

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2.3. Electrical Protective Devises Used in the Panels

The electrical panel was designed with protective devices. Protective devises were used for
human protection, system protection and equipment protection. In Orange Electrical panels were
consisted with various types of protective devises. I was able to get knowledge about using
purpose, working principle, connection and testing of these protective devices.
2.3.1. Fuses
A fuse is a type of protection device in electrical applications. Fuses are designed to open circuits
the filament when excessive currents are present due to overloads or faults and to prevent further
damage to the system. Short circuit, system overload, other device failures, lightning, static
electricity or system overload are some common results in blown fuses.
Cartridge Fuse
In cartridge fuse the fuse wire is enclosed in a transparent glass tube or bulb, the whole unit is
sealed off. In case the fuse blows, it is to be replaced by new one as the cartridge fuse can not be
rewired due to its sealing. In cartridge type fuses have many other sub types as MCB type, screw
type, etc.
HRC Fuse (High Rupturing Capacity Fuse)

HRC Fuse consists of highly heat resistant material (such as ceramic) body having metal-end
caps, which is welded by silver current carrying element. HRC Fuse has high rupturing capacity.
It has constant fusing characteristics and operates fast.
Figure 2.3.1 - Cartridge Fuse
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Kasun Premarathna
Figure 2.3.2 - HRC Fuse with holder
2.3.2. Miniature Circuit Breakers (MCB)

In electrical panels, MCB was used as the basic protective device.
MCBs are designed to automatically protect against
overloads and short circuits, preventing damage to cables
and equipment. Trip characteristics normally can not
adjustable. MCB has thermal-magnetic operation. Over
current protection is got the system by the thermal trip unit
of the breaker. Short circuit protection is got to system by
Figure 2.3.2 - MCBs
the magnetic trip unit of the breaker. The MCBs are in

single pole, double pole, try pole and four pole types.
Every circuit breaker has a voltage rating that designates the maximum voltage it can handle and
a continuous current rating, which is the maximum continuous current carry without tripping.
The value of the kA rating, determines how much current the circuit breaker can withstand under
fault conditions. When we consider MCBs we can see various MCBs with different ampere
ranges and internal situations (Tripping). MCBs are classified according to the ampere.
Type B - operate 3-5 times rated current and suitable for lighting loads
Type C - operate 5-10 times rated current and suitable for lighting and motor loads.
Type D - operate 10-20 times rated current and suitable for heavy units, welding plants
My experience
2.3.2.1. Standard dimensions of MCBs
I was able to measure the standard size (in mm) of the MCB and RCCB. It was very
important for the panel designing and arranging the panel box.
Figure 2.3.2.1- Standard dimensions of MCBs

25
Kasun Premarathna
2.3.2.2. MCB Distribution Box designing
I designed fallowing Distribution Boxes for the 300 houses in the housing apartment. This
was designed for single phase 30A house.
I have been used 30A isolator switch, 30A RCCB, four MCBs of 10A and six MCBs of 6A
according to the requirement. All were Orange production.
4mm2 CU/PVC insulated wire was used for the wiring and single phase common bus bar was
used to connect the MCBs.
Figure 2.3.2.2 - MCB Distribution Box wiring diagram
2.3.3. Residual Current Circuit Breaker (RCCB)

The Residual Current Circuit breakers (RCCB or RCD) are the safest device to detect and trip
against earth leakage currents, thus ensuring protection against electric shock caused by indirect
contacts. These devices must be used in series with an MCB. RCCB Available in 2 Pole and 4
Pole for domestic and Industrial application
1. Electromagnet
2. Current transformer secondary winding
3. Transformer core
4. Test switch
L - Live conductor
N- Neutral conductor
26
Kasun Premarathna
Figure 2.3.3.1 - Internal connection of RCCB

RCCB works on the principle that in an electrical circuit the incoming current is the same as out
going current. RCCB incorporates a core balance. The primary winding lies in series with the
supply mains and load. Secondary winding is connected to a very sensitive relay. During flow of
leakage current in the circuit an imbalance is created in the circuit which gives rise to leakage
flux in the core. This leakage flux generates an electrical signal that is sensed by the relay and it
trips the Mechanism thereby disconnecting the supply. When pressing the TEST button 'T', a
fault is simulated via the Test resistance & RCCB trips.
Figure 2.3.3.2 2 poles and 4 poles RCCB

The RCCBs with a rated residual operating current (In) of 30mA or less are used in place of
more conventional RCCBs with higher residual operating current ratings. The Rated current
range varied 10mA to 1A.
2.3.4. Moulded Case Circuit Breakers (MCCB)

In every panel which I wired MCCB was used as the main breaker. I was able to connect trip
coils, auxiliary contacts, inter lock and panel holders with MCCB. In Orange Electric workshop
I had used ABB, Schneider, ATION, and Orange brands MCCBs.
The Moulded case circuit breakers have been developed for use in commercial and industrial
protection. MCCB has thermal-magnetic operation. Trip current may be adjustable in larger
ratings.
I was able to identify the main features of a MCCB more than MCB,
27
High short circuit current breaking capacity ( < 20kV).
Used for high current ratings ( < 10000A )
Adjustable current and tripping time rating.

Kasun Premarathna
Simultaneous opening and closing of all poles.
Test button which allows periodic testing of the mechanical trips
Accessories such as shunt trip, under-voltage trip, Rotary Operators, motorized kit units,
mechanical-electrical interlock, auxiliary contacts are available.
Figure 2.3.4 - MCCB and its auxiliary components
Thermal adjustment (overload)

MCCBs have a wide thermal adjustment range (long delay). The rated current current ( Ir ) it
continuously adjustable from 0.4 - 1 of its nominal current (In)
Magnetic Adjustment (short circuit)

Magnetic adjustment (short delay) is available on MCCBs. The magnetic setting (Im) is
continuously adjustable from 1 10 of its In.
Figure 2.3.4 - I - Thermal adjustment

28
Kasun Premarathna
Figure 2.3.4 - II - Magnetic adjustment
2.3.4.1. The Shunt trip coil and Under Voltage Tripping Coil (UVT)
Shunt and UVT coils are used for remote opening of circuit breaker. The Shunt trip coil consists
of an electro-magnetic trip coil that is connected in series with an external field wired switch.
When energized the shunt coil, causing the breakers mechanical latch to move to the open
position. Shunt coil supply is connected normally open (NO) contact point of the component.
Usually EFR, ELR are connected with the shunt coil
UVT coil is energized and activated to close the breaker when the coil supply voltage dips below
85% of the rated voltage. When we use the UVT coil with MCCBs we connect coil supply
through the normally close (NC) contact point of the component. At a fault condition, it stops the
supply flown through the UVT coil and then the UVT coil trips the breaker. So when a UVT coil
is used in a circuit, the MCCB cannot be switched on if there is no current supply.
2.3.4.2. Auxiliary contacts

Auxiliary contacts perform the function of electrically signaling the circuit breakers operating
status. The auxiliary contacts change state when the circuit breaker is opened, closed, or tripped.
Figure 2.3.4.2 - Auxiliary contacts and Tripping Coil arrangement

29
Kasun Premarathna
My experience
2.3.4.3. Installation process of MCCB internal accessories
I was able to identify the procedure of installation
procedure of the Auxiliary contact, Alarm switch,
Shunt trip coil or Under voltage trip coil.
Before the installation process mechanical trip

button was pushed to trip the MCCB. MCCB must
on trip position.
Then bolt was unscrewed to open the front cover.
Outer cover was removed and identified the correct

installing position for auxiliary internal accessory.
The coil was inserted in to that position. Then the

terminal block was installed on the side of MCCB.
The front cover was closed and fixed it with 2

screws.
Then coil terminals were connected to the control

circuit.
Figure 2.3.4.3 - Installation of MCCB internal accessories
30
Kasun Premarathna
2.3.5. The Surge Protection Device

The Surge Protection Device (SPD) is a component of the electrical installation protection
system. This device is connected in parallel on the power supply circuit of the loads that it has to
protect. It can also be used at all levels of the power supply network. This is the most commonly
used and most efficient type of overvoltage protection. It is a device used on power systems
above 1000V to protect other Equipments from lightning switching & surges. It Does Clamp
(limit) the Voltage produced by the Lightning. It only protects equipment electrically in parallel
with it.
Figure 2.3.5.1 SPD device
Figure 2.3.5.2 wiring diagram of OBO SPD device
2.3.6. Phase Failure Relay (PFR)

Phase failure relay is adjustable under voltage over voltage control device with the option of
additional sequence control. If it detects any under voltage, over voltage and phase losses in
power system, the relay coils is energized and trip the MCCB using under-voltage(UVT)trip coil.
Figure 2.3.6 - ANLY PFR and its connection diagram

31 Kasun Premarathna
2.3.7. Overload Relay

In Orange workshop we used overload relays for the motor control panels as a motor protective
device. I observe that, overload relay was used only after the main contactor.
The overload is a heat operated relay where a coil heats a bimetallic strip and releasing a spring
to operate contacts. It has NO & NC auxiliary contact points for the controls. If the overload
senses excess current in the load, the coil is de-energized. Electric motors need over current
protection to prevent damage from over-loading the motor, or to protect against short circuits in
connecting cables or internal faults in the motor windings.
Figure 2.3.7 - LS Overload relay and symbol
2.3.8. Earth Leakage Relay (ELR)

Earth leakage relay monitor the leakage of current to earth on 3 phase electrical systems. The
earth leakage relay is used in conjunction with a core balance transformer (CBCT) which is
available in five different sizes to cover all sizes of three phase installations. If make a fault
condition, this core balance transformer send a signal to the ELR. The relays are available with
either a fixed 30mA or 300mA instantaneous trip point or with a user adjustable trip point and
time delay both adjustable.
Figure 2.3.8.2 DELAB ELR

Figure 2.3.8.2 connection of ELR
2.3.9. Earth Fault Relay (EFR)

Earth Fault Relay is used for the protection from earth faults. The function of EFR is as same as
ELR. Instead of a CBCT, four separate CTs are used to connect an EFR. It is an Electronic Trip
Unit, designed to protect the Electrical installation in case of faults or leakage currents beyond a
preset level. The tripping range for both fault current and delay time to be adjusted.
Figure 2.3.9 - DELAB EFR and its connection

It has four current transformers. If there is a fault condition, these CTs send a signal to the earth
fault relay. Then its electronic circuit sends a signal to the protection components normally open
contact. Then this normally open contact point gets closed. Now that signal is sent to the shunt
coil through the normally close contact point. Then the shunt coil is energized and trips the
breaker.
My experience
2.3.9.1. Characteristic settings procedure of Earth Fault Relay
I was able to perform the set fault current and trip time of DELAB Earth Fault Relay
Press [Select] once to enter mode (it will show the existing value Range 0.03 ~ 30 A)
Set the desired Fault current using the [Up / (+) or Down / (-)] button.
Press [ Select ] to store / confirm new value
Press [ Select ] until mode is displayed.(it will show the existing value Range 0.05 ~ 20s)
Set the desired trip time using the [Up / (+) or Down / (-)] button.
Press [ Select ] to store / confirm new value.
2.4. Measuring Devises Used in the Panels

2.4.1. Current Transformer
Current transformers can reduce or "step-down" current levels from thousands of amperes down
to a standard output of a known ratio to either 5 Amps or 1 Amp for normal operation. CTs are
used with watt meters, power factor meters, watt-hour meters, protective relays and metering
applications, because they are insulated away from any high-voltage power lines. Its primary
winding is just a conductor or bus bar placed through a central hole. The secondary winding may
have a large number of coil turns wound on a laminated core as shown below.
Figure 2.4.1.1 - Types of CTs
Figure 2.4.1.2 - Working principle of CT
The current transformer should never be open-circuited or operated with no-load attached when
the main primary current is flowing. If the ammeter is to be removed, a short circuit should be
placed across the secondary terminals first. This is because when the secondary is open-circuited
it will produce a large secondary voltage. Current transformers are available in Ring type,
Bushing type, square type, bar type and etc.
Accuracy decreases with increased burden (load) or low line current. Accuracy Class of
Metering CTs:
Class
0.1 To 0.5
1
3
5
Metering Class CT
Applications
Precision measurements or protection
General industrial measurements more sensitive
General industrial measurements
Approximate measurements
Table 2.4.1 - Metering Accuracy Classes of CTs
My Experience
When I was connecting the CT, the ratio of the CT was not matched to the panel current
value.
The CT ratio was 150/5A. But the panel MCCB was 63A.
So I used the double turns for reduce the CT ratio as explain below.
Increasing the number of primary turns can decrease the turns ratio. A current transformer with
a 300 to 5 turns ratio can be changed to a 150 to 5 turns ratio by passing the primary twice
through the window. Also the turns ratio can be either increased or decreased by wrapping wire
from the secondary through the window of the current transformer.
Figure 2.4.1.3 - CT connection
2.4.2. Core Balance Current Transformer

The Core Balance Current Transformer is a current transformer is used for earth fault protection
in grounded three phase systems. It is also known as the zero-sequence current transformer. Each
phase conductor and neutral should pass through the core balance current transformer. It is
essential that each conductor passes through the device in
the same direction.
Figure 2.4.2 - Core Balance Current Transformer
Working principle of Core Balance CT

The net resultant flux being zero does not induce any current in the secondary of the transformer.
Thus the secondary current of the core balance current transformer when all the three phases are
healthy is zero. When an earth fault occurs in one of the phases, the zero-sequence fault current
which flows is not cancelled by the flux of the other two phases and hence induces a current in
the secondary. The core balance current transformer can be connected to an earth fault relay
which can be used to generate the tripping signal.
2.4.3. Indicator
Indicators are used to get information about states of equipment such as ON (Green), OFF (red),
TRIP (Orange). Indicators are available in read yellow blue and orange and 12V to 230V.
2.4.4. Ammeter
An ammeter is a measuring instrument used to measure the electric current in a circuit. Current
transformers and ammeters are used together as a matched pair in which the design of the current
transformer is such as to provide a maximum secondary current corresponding to a full-scale
deflection on the ammeter. For most current transformers the primary and secondary currents are
expressed as a ratio such as rated current : 5A.
2.4.4.1. Connecting process of an Ammeter
I was able practice connecting process of the Ammeter in to the panels.
In 3 phase system, 3 position selector switch was used to select the 3 phases R, Y or B.
CTs were connected in to the selector switch.
The selector switch was connected with the Ammeter A1 and A2.
Figure 2.4.3 Connecting diagram of an Ammeter
2.4.5. Voltmeter
A voltmeter is an instrument used for measuring electrical potential difference between two
points in an electric circuit. Analog voltmeters move a pointer across a scale in proportion to the
voltage of the circuit. The voltmeter selector switch is used to select the two phases or phaseneutral in 3 phase system.
Figure 2.4.4 voltmeter and selector
2.4.6. KWH Meter (Energy meter)

KWH Meter is used to measure the kW power. Mainly we use two types of KWh meters. Those
are single-phase kWh meters and three phase kWh meters. These three phase & single-phase
meters are can be dividing again like this C/T type and direct type. Mostly we use C/T type
energy meters. In some panels, used digital KWH meters.
2.4.7. Digital Power Analyzer

Power analyzers accurately measure electrical power characteristics of the system. Power
analyzers, also called power meters or watt meters, provide precise measurements of power
supply system. This is useful for getting to power consumption and many more values of the
system.
I was able to refer metering performed of Schneider PM 700 digital analyzer,
Current - (per phase/ neutral) min/max Current demand: present
Voltage - (line-line/ line-neutral) per phase, min/max
Power: - real (kW), reactive (kvar), apparent (kVA), per-phase, total
Energy: - real (kWh), reactive (kvarh), apparent (kVAh)
Signed power factor:- total, min/max
Frequency: - present, min/max
2.5. Switching Devises Used in the Panels
2.5.1 Relay
A relay is a switching device. Relays are used where it is necessary to control a circuit by a lowpower signal with complete electrical isolation between control and controlled circuits or where
several circuits must be controlled by one signal.
Figure 2.5.1 relay and relay base
Relay consists with coil, normally open and normally closed contact points. When current starts
flowing through the control coil, the electromagnet starts energizing and contact points are
changed their position.
Coil voltage can be 12V to 230V AC or DC. Also contact current rating is important factor.
According to the contact pin arrangement, relays are categorized as 8 pins, 11 pins, 14 pins and
etc. relay is fixed with its base.
2.5.2. Contactor
I was able to identify the contactor construction and usages, because contactor was used in every
motor control panel. It was used for the high power application switching on power circuit. Also
I connected timers, auxiliary contact points (side and top), timers and mechanical interlock to the
contactors according to the requirement. In Orange Electric workshop I had used ABB,
Schneider and LS brands contactors.
Contactor is also a type of relay. The contactor consists with normally Open contacts and also
auxiliary contact points. Also it can connect auxiliary contact points (side and top), timers and
mechanical interlock.
Figure 2.5.2.1 - ABB contactor
Figure 2.5.2.2 Auxiliary
A contactor consists of mainly 2 parts-Fixed and movable jaws. the fixed jaws are firmly
connected with the circuit and is a provided with a coil having movable jaw as soon as current is
allowed to flow from the circuit the coil gets charged and due to electromagnetic effect it attracts
the movable metal jaw, thus the circuit is complete with the contact provided by the movable
jaw. This is the functioning of contactor. When current through the coil loss, coils demagnetize
and open the contacts. The coil consist with shaded pole core, because of avoiding the current
zero position of the AC supply.
The current rating of the contactor is depending on its category. The categories in standard are
described as:
AC-1 - Non-inductive or slightly inductive loads, resistance furnaces
AC-2 - Starting of slip-ring motors: starting, switching-off
AC-3 - Starting of squirrel cage motors. (Inductive and resistive loads)
AC-4 - Starting of squirrel-cage motors with inching and plugging duty.
2.5.3. Timer Relay

Timer relays are simply control relays with a time delay built in. Their purpose is to control an
event based on time. The difference between relays and time delay relays is when the output
contacts open & close: on a control relay, it happens when voltage is applied and removed from
the coil; on time delay relays, the contacts can open or close before or after some time delay.
Figure 2.5.3.1- Timers
Figure 2.5.3.2 - Analog timer internal connection
The timers are divided into many categories according to their performance,
ON delay
Upon application of input voltage, the time delay begins. At the end of the time delay, the output
is energized. Input voltage must be removed to reset the time delay relay & de energized the
output.
OFF delay
Upon application of input voltage, the time delay relay is ready to accept a trigger. When the
trigger is applied, the output is energized. Upon removal of the trigger, the time delay begins. At
the end of the time delay, the output is de-energized..
According to the requirement, Timer relay characteristics are selected according to fallowing
parameters.
Input coil current range - 12v to 440V (DC / AC)
Time settings - seconds, minutes, hours, days, month, years
Analog, digital, 24 hours, programmable, star-delta, etc.
Pin configuration - 8 pin, 11 pins, and 14 pins etc.
2.5.4. Push Buttons

The push-buttons & selector Switches are momentary contact device used for giving the ON and
OFF commands. Push button has normally open (NO) contacts and normally closes (NC)
contacts. Some selector switch has 2-stay part and some has 3-stay part and also spring return
selector switches are available. Emergency Push Button is another type of push button. Those
push buttons can connect auxiliary contact points.
Figure 2.5.4 Push button and emergency button
2.5.5. Selector Switches

Selector switch has 2 parts or 3 parts. It is used to select the power path.
2.6. Cables
In panel wiring we used Orange Cable and Kalani Cable for requirements. I was able to refer
the cable current caring capacity table and selected the wires for panel wiring. In panel wiring
normally we used PVC insulated type single core copper wires.
The selection of cables for panel wiring was best done with reference to the latest and specific
manufacturers cable data and application guides with tables giving cable dimensional, and
current rating information.
The cross-sectional area of the conductors chosen should be of the optimum size to carry the
specified load current or short circuit short term current without overheating and should be
within the required limits for voltage drop.
Figure 2.6 PVC insulated cable
2.6.1. Cable Insulation Materials
PVC (Polyvinyl Chloride) is the most commonly used thermoplastic insulator for cables. It
is cheap, durable and widely available. PVC Normal operating temperatures are typically
between 750C and 1000C (depending on PVC type)
PE (Polyethylene) is part of a class of polymers called polyolefin. Polyethylene has lower

dielectric losses than PVC and is sensitive to moisture under voltage stress (i.e. for high
voltages only).
2.6.2. Cable Lug

Lugs were use to connect the wire to terminals. Cable lug was connected with connecting end
of the cable using wire crimping tool. Suitable Cable lug sizes depend on the wire cross
section area. In our workshop were so many types of lug. Such as Normal lug, U lug, and O
lug.
Figure 2.6.2 cable Lugs
2.6.3. Cable Numbering Tube

Numbering tubes are used to identify the cable in control circuit. Tube Printer is used to
print the numbers.
Figure 2.6.3 - Cable Numbering Tube
2.6.4. Current ratings of single core PVC insulated cable

Cross sectional
area (mm2)
Nominal conductor
size
(mm)
1 phase Current
carrying capacity
(A)
3 phase Current
carrying capacity
(A)
1.0
1/1.13
13.8
12
1.5
1/1.38
18
16
1.5
7/0.50
18
14
2.5
7/0.67
24
21
7/0.85
32
28
7/1.04
41
37
10
7/1.35
57
51
16
7/1.70
76
70
25
19/1.35
104
90
35
19/1.53
128
113
50
19/1.78
151
138
70
19/2.14
192
175
95
37/1.78
232
210
120
37/2.03
269
245
150
37/2.35
300
260
185
37/2.52
351
305
240
61/2.25
412
360
300
61/2.52
472
410
400
61/2.85
562
468
500
61/3.20
595
520
Table 2.6.4 - Current ratings of single core PVC insulated cable
2.7. Bus bars

The bus bar is a strip or bar of copper brass or aluminum that conducts electricity within a
switchboard, distribution board, substation, battery bank, or other electrical apparatus. Its main
purpose is to conduct a substantial current of electricity. The cross-sectional size of the bus bar
determines the maximum amount of current that can be safely carried
Figure 2.7 Bus bars
2.7.1. Bus bar sizes and current capacity

Size (inch)
Current capacity (A)
width x height
3/4 x 1/4
239
Copper tape 1x1/8
161
1 x 1/4
320
1 x1/4
399
1 1/4 x 3/8
602
1 x 1/4
479
1 x 3/8
722
2 x 1/4
640
2 x 3/8
965
2 1/4 x 1/4
718
2 x 1/4
798
3 x 1/4
960
4 x 1/4
1280
Table 2.7.1 - Bus bar current capacity
2.8. Distribution Panels

2.8.1 Main Distribution Panel
Main Distribution panel Board (MDB) is a panel or enclosure is used to distribute electrical
power to numerous individual circuits or consumer points, is taken in from the transformer or an
upstream panel. An MDB typically has a single or multiple incoming power sources and includes
main circuit breakers and residual current or earth leakage protection devices. A MDB is
comprised of a free standing enclosure, a bus bar system, MCCB's, metering and support
equipments and required current transformers. Panels are assembled in a systematic manner such
as incomer section and outgoing section.
Figure 2.8.1 - Main Distribution panel
2.8.2. Sub Distribution Panel

The Main Distribution panel Board then feeds to the Sub distribution boards, which is installed
generally at the point where a large distribution cable terminates and several smaller sub-circuits
start. The voltages and current ratings are low. These are the switchboards that although similar
construction, are larger than a final distribution board circuit. The boards are installed midway
through the power distribution system, at the point in a large distribution cable ends, and several
smaller starting sub-circuits.
Figure 2.8.2 - Sub Distribution panel
My Experience
2.8.3. The pump house distribution panel wiring procedure
I was able to create an electrical design & wire the fallowing distribution panel in the orange
workshop
Figure 2.8.3 -The pump house distribution panel wiring diagram
This distribution panel was designed for pump house. In this pump house all the pumps will
not operate at the same time, some pumps are using as the standby pumps.
ABB 4 poles 125A MCCB was used as the main breaker.
DELB ELR with shunt release coil was used as the protection device and HOBUT
200/5A core balance CT is used to get current inputs.
According to the customer requirement, emergency stop switch was connected with shunt
coil.
The 35mm2 copper PVC insulated wires (Kalani cables) were used to wire from main MCCB
to bus bar chamber. Thence 16mm2 for 63A, 10mm2 for 40A and 4mm2 for 16A wires were
used.
R, Y, B incoming indicators were attached to the panel door through the 2A fuse.
Problems faced during this panel wiring
This panel box was designed 250x400x150 size. The 150mm was not enough for the
HOBUT 200/5A core balance CT. so that I had to cut the cover plate of the panel, before
the wired.
2.9. Changeover Panels

In Orange workshop I observed Manual type and Auto type changeover panels. In Automatic
Changeover Panels we used several types of Auto transfer Switches (ATS). MCCB type,
Contactor type and Changeover type were some of them.
A changeover panel is operating on a mains power failure system. There are two types of
changeover panels.
2.9.1. Manual Changeover Panel

In manual changeover panels rotary manual switch with centre off position is used to enable
selection of 2 different supplies. Most commonly a mains supply and a back-up generator
supply.
2.9.2. Automatic Changeover Panel (ATS panel)

The automatic panel, when the main supply is interrupted on one or all phases (after an
adjustable delay period) the generator sets will start-up automatically. After an initial warm-up
period (adjustable) the generators will synchronize with each other by means of motorized circuit
breakers or contactors onto a common bus bar. When the power will come, the motorized
change-over switch will be closed and the load will be connected to the main supply.
Figure 2.9.2 - Automatic Changeover Panel
My Experience
2.9.3. Automatic Changeover Panel wiring
I was able to wire the below control circuit of Automatic Changeover panel. The panel consisted
with Telegarn ATS changeover with motorized kit.
This circuit was designed to get continues power supply from CEB or generator. According to
this panel circuit it can automatically switch on the generator when CEB power failure.
Figure 2.9.3 - Automatic Changeover Panel control wiring diagram
Important points
The Telegarn ATS changeover unit was used separate auxiliary supply from CEB side
(used pin no 01 and 02) and generator (used pin no 03 and 04).
There was two selector switches, one was used to Auto-Manual selector other one was used
to select CEB or Generator in manual mode.
Phase Failure Relay (PFR) was used to detect the supply conditions in CEB and generator.
R2 relay was used to give a CEB ON signal to the 11th pin of changeover motorized kit
through open point (NO) of R2 63.
R3 relay was used to give a Generator ON signal to the 10th pin of changeover motorized kit
through open point (NO) of R363.
T4 timer was used to avoid the sudden change from generator supply to the CEB supply, if
CEB supply is changing quickly due to voltage fluctuation, T4 will keep generator supply
continuously.
12th pin of the motorized kit was used to give OFF signal in to the changeover.
For interlock purpose R3 15 and R2 15 closed points were used in the circuit.
T4
1
4
and R173 closed points were used in generator starting control supply for avoid the
generator start manual or auto when the CEB supply is connected in manual or auto mode.
2.10. Motor Control Panels

Motor Control panel consist of different motor starting methods such as Direct Online Starter
(DOL), Star-Delta Starter, Auto Transformers, Variable Speed Drives or Variable Frequency
Drives. Mainly used DOL and Star-Delta methods,
2.10.1. Direct Online Starter (DOL) panel

This is the most common method of starting low power induction motors, where the starter is
connected directly across the three phase of the supply. However, the starting current at the
moment of switching direct-on-line can be as high as 6-8 times the rated current.
A Direct Online Motor Starter (DOL) consists of following components.
o A Circuit Breaker or Fuse(F)
o A Contactor (K1)
o An Overload Relay (OL1)
o start button (S1)
o Stop button (S0)
Figure 2.10.1 - Power circuit and control circuit of DOL panel
Typically, the contactor of the DOL circuit is controlled by separate start and stop push buttons.
When the start push button is pressed, the current flow through the control circuit and the
contactor coil which will energize the contactor coil and then the NO contactor contact get
closed and self holding. So the current is passed to the motor. When the stop button is pressed or
the over load coil is operated, the control circuit get broken and the contactor drops out.
My Experience
2.10.2 Cooling tower panel wiring
I was able to wire the cooling tower panel according to the given details. This panel is consisting
with two 5.5kW pumps and a 1.5kW cooling fan motor. The two main motors are manually
selectable. All three motors are wired in DOL method.
Figure 2.10.2.1 - Power circuit of cooling tower panel
Figure 2.10.2.2 - Control circuit of cooling tower panel
Calculations
Main pump and standby pump
o Full load current
V 3 Cos
o pump over load
5.5 * 103
8.6 A
2.3 A
415 * 3 * 0.8
= 8A to 12A
o pump contactor = 12A

o MCB
rating
= 16A
Cooling fan motor

o Full load current
V 3 Cos
o over load
= 2A to 4A
o contactor
= 4A
o MCB
= 6A
rating
1.5 * 103
415 * 3 * 0.8
Important points
Main MCB was selected as 25A Orange MCB.
Main RCCB was selected as 32A-100mA Orange RCCB.
Two position selector switch was used to selector
Run and trip indicators were used, trip indicators were connected through normally open
point (NO 97-98).
The main motor and standby motor only work after the cooling fan is on. For that purpose,
the control circuit supply for the main and standby pumps were connected through the
normally open point (NO) of the cooling fan motor contactor (KM3).
1 x 1/8 cupper tape bus bar chamber was designed for distribute the MCBs.
All the power circuit wirings were going on 4mm2 CU/PVC wires.
2.10.3. Star-Delta Starter Panel
When very large (< 5HP) motors are started by DOL, they cause a disturbance of voltage on the
supply lines due to large starting current surges. To limit the starting current surge, large
induction motors are started at reduced voltage and then have full supply voltage reconnected
when they run up to near rotated speed. Star-Delta starter is the reduced voltage starting method.
This type reduces phase voltage to about 58% of the running voltage, which reduce the current
and the motors torque.
Figure 2.10.3 Power circuit and Control circuit of star delta panel
The Star/Delta starter is manufactured from three contactors, an on delay timer and a thermal
overload. The currents through the winding are 1/ 3 of the current in the line.
There are two contactors that are close during run, often referred to as the main contractor and
the delta contactor. These are AC3 rated at 58% of the current rating of the motor. The third
contactor is the star contactor and that only carries star current while the motor is connected in
star. The current in star is one third of the current in delta, so this contactor can be AC3 rated at
1/3 (33%) of the motor rating.
In the star-delta starting method, firstly the motor starts as star after 80% of its full speed it can run as
delta. The one delay timer is sated that time of 80% of its full speed.
Full load current =
P
V 3 Cos
Main over Load Relay (OL)= full load current x 1/3
Size of Main and Delta Contractor (K1 & K2)= full load current x 1/3
Star Contactor (K3) = full load current x 1/3
My Experience
2.10.4. Fire pump panel wiring
I was able to create electrical design & wire the fire pump panel.
Two main pumps of 37kW and a jockey pump of 2.2kW were used for the panel.
The 37kW pumps are connected as star-delta and 2.2kW pump as direct online
connection.
Calculation
For Main pumps
o Full load current
V 3 Cos
37 * 103
64.3 A
415 * 3 * 0.8
o Main & delta contactors = Full load current * 1/3 = 64.3 * 1/3 = 37.3 A
o Star contactor
= Full load current * 1/3
o Main pump over load
= 30A to 42A
o Main pump MCCB
=100A
= 64.3* 1/3
= 21.4 A
For jokey pump

o Full load current
V 3 Cos
2.2 * 103
3.8 A
415 * 3 * 0.8
o Jokey pump contactor = 4A

o Jokey pump over load = 3A to 8A
o Jokey pump MCCB
= 6A
Figure 2.10.4 Control circuit of Fire pump panel
Important points
The panel was designed with two pressure sensors, when sensor 1 will gives signal to the
panel, main pump1 will operates. If pump1 will overload, the pump 2 will operates. The
Pump 1 or pump 2 needs more power, sensor 2 will gives signal to jokey pump operation.
ABB MCCBs, over loads and contactors were used.
Omron 11 pin relays and ANLY 8 pin timers are used.
The panel was designed as auto and manual operation.
Two position selector switches were used for auto manual selector and pump selector.
Problems faced during this panel wiring
The ABB contactor has only one external normally open (NO) contact point and no any
normally close (NC) contact point. I had to fallowed one of below way to solve this,
o Can connect auxiliary contact points to the contactor.(side contact or top contact)
o Can use mechanical interlock instead to the contact point interlock.
o Can connect another relay with parallel to the contactor.
I was able to connect auxiliary contact points. Other solutions are not suitable for this panel.
When the panel was being tested, the one timer didnt operate correctly.
o According to the 8 pin timer connection, point 1 and point 8 are act as common. If
point 1 is connected to the incoming side, the point 8 must be connected to the
incoming side. Otherwise timer will not operate correctly.
Figure 2.10.4.1 Timer connection of fire pump panel
2.11. Power Factor Correction Capacitor Bank
Various industries and power system loads are inductive that take lagging current which decrease
the system power factor. The poor power factor increases the current flowing in conductor and
thus copper loss increases. Further high reactive power flows through the line, the apparent
power (KVA) and cost of electricity bill is high.
The power factor of a circuit may also be defined as the ratio of active power (KW) to the
apparent power (KVA). The lagging reactive power is responsible for the low power factor. It is
clear from the power triangle that smaller the reactive power component, the higher is the power
factor.
Figure 2.11 Power factor triangle

Figure 2.11.1 Capacitor Bank
The power factor can be improved by connecting capacitors in shunt with the system operating at
lagging power factor. These static capacitors provide leading current. A number of capacitor
units are combined to capacitor bank arrangement. Capacitor bank connected in shunt with load.
They improve the electrical supply quality and increase the efficiency of the system. Also reduce
reactive power and cost effective. Power factor correction is an investment that helps to improve
companys profit performance. The capacitor bank with automatic regulation offers the most
economical solution.
Capacitor bank offers several advantages over other methods of power factor improvement.
Losses are low in static capacitors.
There is no moving part, therefore need low maintenance.
They are lightweight so it is can be easy to install.
2.11.1. Components used in Capacitor Bank

Power factor correction capacitors
Capacitors are made in metalized polypropylene film (PFC). For
three-phase loads, three-phase capacitors are used. Normally threephase capacitor is interconnected three capacitors in delta.
Capacitors are rated in kVAR. Common factors of the capacitor are
Rated Voltage, kVAR Range, frequency, temperature, and harmonics.
Figure 2.11.1.1 Power capacitor
Capacitor Switching Contactor

When we were selecting contactor, consider about Rated current (Ie),
Reactive power (kVAR), voltage category and Thermal current (Ith).
Capacitor switching contactors consist with contacts and damping
resistors. The capacitor switching contactor designed switch the
capacitor first through contact block of three contacts in series with
quick discharge damping resistor to limit to inrush current. Normally
rated current is carried by main contacts, which after closing after
Figure 2.11.1.2 Capacitor
switching contactors
about 5 ms, effectively bypass the damping resistor.
Automatic power factor controller

Digital power factor controller is used to control to capacitor bank.
Measurement of the required reactive power and control the
capacitor switching according to the power factor desired or preset value. Also indication of power factor, display the number of
capacitors steps switched into the system and preset parameters of
the system. Disconnect the capacitors when a system voltage drop
Figure 2.11.1.2- Automatic
power factor controller
occurs. Power factor controller is selecting according to number of

switching steps.
Discharge resistor
Capacitors should be discharged to <10% of the rated voltage prior to being re-energized. For
this purpose, special discharge resistors are offered which can be selected in accordance with the
applied operating voltage and the desired discharge period. Standard IEC 831 requires a
discharge to 75V or less within 3 minutes.
My Experience
2.11.2. 6- steps Capacitor bank panel wiring
I was able to create electrical design & wire the capacitor bank according to the given details and
requirements.
Active Power is 260kW
Current power factor (cos1) = 0.7
Needed to improve up to (cos2) = 0.95. (0.95 is the default value)
Calculations
Current Apparent Power = 140kW / 0.7 = 200 kVA
Target Apparent Power = 140kW / 0.95 = 147.36 kVA
Current Reactive Power = 140 x tan(1)= 142.8 kVAR
Target Reactive Power = 140 * tan(1)= 46.01 kVAR
Needed capacitor bank = {Current Reactive Power - Target Reactive Power}

= 142.8 46.01 = 96.79 kVAR
Capacitor bank was designed for 97 kVAR
Used 6 EPCOS PFC Capacitors (7.5kVAR x 3 , 25kVAR x 3)
According to the EPCOS capacitor ratings,
7.5kVAR
7500/ (230*3) =10.8A
HRC fuse rating is 20A

Wire gauge is 2.5mm2
25kVAR
25000/ (230*3) =36.2A HRC fuse rating is 63A

Wire gauge is 16mm2.
Important points
Seven steps LOVATO DCRK7 Automatic power factor controller was used.
1000 x 2000 x 600 powder coated panel box was used.
According to rated values power and control circuit drawings were designed.
Figure 2.11.2 - Capacitor Bank power circuit drawing
Figure 2.11.3 - Capacitor Bank control circuit drawing
100A MCCB (ABB) was used as main breaker & 35mm2 wires are used.
1 x 1\8 copper bus bar chamber was used to distribute power to capacitors.
100/5 rated CT was used for current supply.
R1 relay was used in protection purpose, when generator will switched on, capacitors are
disconnected.
LS brand capacitive switching contactors with discharging resistors were selected

according to kVAR value & current value.
Control circuit was wired by using auto cable.
Temperature was one of the main stress factors for polypropylene type capacitors, an
average temperature of EPCOS PFC Capacitor is 45 C, so that two 230V cooling fans
are included in to the panel.
Panel was checked according to stranded.
At the first power up, the unit in manual mode and press the MODE key and set CT
primary current, Smallest step kVAR, Rated capacitor voltage, required cos2 value.
2.12. Electrical Panel Testing

I was able to test the several panels according to the IEC stranded in the testing section of
Orange Electric Workshop. The following testing equipments were used to check the conditions
of the panels.
2.12.1. Testing equipment

Low voltage test lamp
I used test lamp for find simple faults or detect and presence or absence of voltage at each point.
The test lamp was an electric lamp connected with two insulated wire leads. Also it was used for
identification the approximate voltage (230 or 415V) by using the brightness of the lamps.
Figure 2.12.1.1 - Test Lamps
Clamp meter
Clamp meter is an electrical device having two jaws which open to allow clamping around an
electrical conductor. This allows properties of the electric current in the conductor to be
measured, without having to make physical contact with it, or to disconnect it for insertion
through the probe.
Figure 2.12.1.2 - Clamp meter

Continuity tester
A continuity tester is an electrical test equipment used to determine if an electrical path can be
established between two points that is if an electrical circuit can be made. The circuit under test
is completely de-energized prior to connecting the apparatus.
The tester consists of an indicator in series with a source of electrical power - normally a battery,
terminating in two test leads. If a complete circuit is established between the test-leads, the
indicator is activated.
Figure 2.12.1.3 - Continuity tester
Megger tester
The Megger tester is a method of testing making use of an insulation resistance meter that will
help to verify the condition of electrical insulation. The tester generates a high DC voltage of
around 500V to 5KV or more. In distribution panels, insulation resistance more than 5 M, it has
enough insulation resistance.
Figure 2.12.1.4 - Megger tester
2.12.2. Panel tests

2.12.2.1. Visual inspection procedure
The visual inspection of any installation was as important as any testing that was carried out
on an installation.
Before Visual Inspections was done, the relevant document of the testing panel was observed
by inspector.
The first part of a visual inspection was to ensure that the system was safe to test and that you
have enough information to be able to carry out the further test safely.
Followings were the main visual inspection area which aimed to check in the orange panel
testing process by us.
Figure 2.12.2.1 - Visual inspection test report
2.12.2.2. Insulation Resistance Testing Procedure

This test was done to ensure the insulation of the cable has not been damaged, and has no short
circuit faults present. Results were recorded in Meg Ohms (It must be more than 5M).
Before I was doing the test, the panel power supply was disconnected.
The Megger tester test probe was connected to the live and neutral of the cable that requires
testing, then press the test button. Repeat the procedure between the live and earth, and the
neutral and earth. Voltage range of the tester voltage was 1000Vdc for 415V and 500Vdc for
230V.
The test was done according to the fallowing inspection test report requirements.
Neon lights will cause false readings, as will emergency or discharge lighting, so ensure
these are all disconnected prior to commencing tests. Also capacitors must disconnect from
the circuit.
Figure 2.12.2.2 - Insulation Resistance test report

2.12.2.3. Functional tests

All equipments were tested to ensure that it operates correctly. All switches, isolators, analyzers,
EFR, ELR, PFR and circuit breakers must be manually operated and checked the connectivity to
ensure that they function correctly, also that they have been correctly installed and adjusted
where adjustment is required.
Figure 2.12.2.3 Functional tests reports

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HIGHER NATIONAL DIPLOMA IN

ADVANCED TECHNOLOGICAL INSTITUTE

: ELECTRICAL ENGINEERING (POWER)

Industrial training is an important experience in the learning procedure of an Engineering student

Higher National Diploma in Engineering six months Industrial Training is coordinated by

Higher National Diploma in Engineering [HNDE]- Electrical 23-batch

Higher National Diploma in Engineering [HNDE]- Electrical 23-batch

1.0. CHAPTER 01- INTRODUCTION

1.1. Introduction of OREL Corporation Private Limited ..................................... 10

1.2. Safety Practices ...... 15

2.1. Orange Industrial Electrical workshop 17

2.2. Tools & Machines used in workshop ..... 20

2.3. Electrical Protective Devises Used in the Panels ......... 24

Higher National Diploma in Engineering [HNDE]- Electrical 23-batch

2.3.2.2. MCB Distribution Box designing ... 26

2.4. Measuring Devises Used in the Panels... 34

2.5. Switching Devises Used in the Panels 38

Higher National Diploma in Engineering [HNDE]- Electrical 23-batch

2.6.4. Current ratings of single core PVC insulated cable ... 42

2.7. Bus bars ... 43

2.8. Distribution Panels .... 44

2.9. Changeover Panels .... 47

2.10. Motor Control panels . 50

2.11. Power Factor Correction Capacitor Bank 57

2.12. Electrical Panel testing ..... 62

3.0. CHAPTER 03 - CONCLUSION

3.3. References ...... 69

Higher National Diploma in Engineering [HNDE]- Electrical 23-batch

Orange Electric factory

OREL Corporation businesses

Orange Electric Logo

Electrical Safety Signs

Standard Panel Design

Pneumatic Pop-Rivet Gun

Nuts and bolts

Wire End Caps

HRC Fuse with holder

Standard dimensions of MCBs

MCB Distribution Box wiring diagram

Internal connection of RCCB

2 poles and 4 poles RCCB

MCCB and its auxiliary components

Auxiliary contacts and Tripping Coil arrangement

Installation of MCCB internal accessories

Higher National Diploma in Engineering [HNDE]- Electrical 23-batch

wiring diagram of OBO SPD device

ANLY PFR and its connection diagram

LS Overload relay and symbol

DELAB EFR and its connection

Core Balance Current Transformer

Connecting diagram of an Ammeter

Voltmeter and selector

Relay and relay base

Analog timer internal connection

Push button and emergency button

PVC insulated cable

Cable Numbering Tube

Main Distribution panel

Sub Distribution panel

The pump house distribution panel wiring diagram

Automatic Changeover Panel

Automatic Changeover Panel control wiring diagram

Power circuit and control circuit of DOL panel