Dorman Smith PowerForm

Low Voltage Factory Built Assemblies

 Contents
Introduction to the PowerForm Switchboard System 1 Dorman Smith Switchgear Introduction
PowerForm Specification 2
Continuous product development
2500A Switchboard Specification 4 including new uprated
specifications have provided the
opportunity for Dorman Smith to
6300A Switchboard Specification 6 update their low voltage factory
built assembly range.
Cast Resin Transformers 9 This publication gives detailed
information on Dorman Smith’s
Packaged Substations 9 extensive range of low voltage
factory built assemblies and is
Loadline ACBs 10 intended to assist the design
engineer and installer in the
Microprocessor Based Overcurrent Releases 10 selection of equipment to meet
today's stringent specifications.
Loadline HP Circuit Breakers 11
Loadswitch Fused Devices 11
Switchboard Standards 12
EN60439-1:1999 (IEC 60439-1:1999) Switchboard Standard 12
Internal Separation of Assemblies 14
UK National Annex Table NA1 16
Forms of Separation 17
Form 1 – 4 17
Degrees of Protection 19
EN60529:1991 (IEC 60529-1:1989) Degrees of Protection 19
Energy Management 20
Power Factor Correction 20
Dorman Smith's world class
manufacturing facilities are
dedicated to answering the
individual needs of customers
using the company's own unique
refinement of ‘Just In Time’
techniques to achieve total
manufacturing flexibility.
Such is the efficiency of the
Dorman Smith UK plant, it won a
Britain’s Best factory award, and
has been chosen by the DTI as a
manufacturing reference plant for
the UK and was also the subject
of an Open University video on
manufacturing. Dorman Smith's
ability to design and manufacture
reliable, durable products and to
give advice on complex electrical
1
3
circuit protection, has firmly
established a Worldwide
reputation for high quality and
expertise.
Located in Preston, Lancashire,
Dorman Smith occupies a
purpose built site totalling
19,000m2 and is one of Britain’s
largest and most well respected
manufacturers of low voltage
switchgear, systems and
associated distribution
equipment.
In addition, there are also
manufacturing plants in Dubai
and Riyadh, which service the
Middle East markets.
 PowerForm Specification PowerForm Specification

Certification 2500A Busbar System

4
2 • Rated voltage 415V a.c. 5
3
The PowerForm Switchboard System has been fully tested and ASTA certified. • Rated insulation voltage 690V a.c.
• Dielectric test voltage 2.5kV
• Nominal frequency 50 Hz
• Fully ASTA certified Busbar System
Standards
• Busbar Ratings
- 1000A
PowerForm is a fully type tested switchboard fully complying with
- 1250A
• IEC 60439-1:1999 - 1600A
• EN 60439-1:1999 - 2000A
• BSEN60439-1:1999 - 2500A
• Busbar supports are flame
retardant and high temperature
glass reinforced.
Mechanical Characteristics
Max Horizontal Phase Busbar 2500A
• Degree of protection to EN 60529 • Steel pre-treatment involves iron Max Horizontal Neutral Busbar 2500A
(IEC 60529) is minimum IP3X with phosphate process for degreasing Max Vertical Phase and Neutral Busbar 1600A
higher protection available. • Paint finish in (Light Grey) Powder Max Short Time Current Busbars 50kA - 3 secs
• Internal degree of protection Coated polyester, colour RAL 7035 Max Peak Current 105kA
exceeds IP2X • Standard frames available are
• Functional unit interconnections as shown below
PVC insulated 6300A Busbar System
• All doors manufactured from
1.6mm steel and hinged • Rated voltage 415V a.c.
• All rigid busbar partitions made • Rated insulation voltage 690V a.c.
from perforated 1.5mm steel • Dielectric test voltage 2.5kV
• Nominal frequency 50 Hz
Frame Frame Widths (mm)
• Fully ASTA certified Busbar System
Range Cable Access Steel (mm) Height (mm) 500 550 600 650 800 850 1000 1300
PowerForm 25 Front 2 2356 • • •
• Busbar Ratings
Rear 2 2356 • • •
- 3200A
PowerForm 63 Rear 3 2356 • • • • • • •
- 4000A
- 5000A
- 6300A
• Busbar supports are flame
retardant and high temperature
glass reinforced.

Max Horizontal Phase Busbar 6300A

Max Horizontal Neutral Busbar 10,000A
Max Vertical Phase and Neutral Busbar 1600A
Max Short Time Current Busbars 100kA - 1 sec
Max Peak Current 220kA
 25 25
2500A Switchboard 2500A Switchboard
Specification Specification

PowerForm 25 Constructional Details Typical Arrangements

4 1. Typical arrangement 2500A
5
busbar system
• 2500A, 50kA/3sec Busbars
• Loadline HP changeover MCCBs
• Front access cabling
• High performance Loadline HP
outgoing MCCBs

2. Typical Controlgear Compartment

Horizontal Busbar Positions

2
 63 63
6300A Switchboard 6300A Switchboard
Specification Specification

25 Constructional Details
PowerForm 63 Typical Arrangements
6 3. Typical arrangement 6300A 7
busbar system
• 6300A 100kA/1sec Busbars.
• Selective forced air cooling to:
- Busbars.
- ACB Enclosure.
• 4 Pole withdrawable ACBs.
• Rear access cabling.
• High performance Loadline HP
outgoing MCCBs.

4. Internal view showing 6300A

Busbar
• Outgoing Connections.
• 800mm Main Cubicle.
• 500mm or 800mm
Cable Access Way.

5. View showing special

Busbar arrangements

Horizontal Busbar Positions

4 5
 63
6300A Switchboard
Specification
Special Arrangements
8 6. Insulated busbar components
Certain essential installations may
require insulated Busbars within
the Busbar enclosure to ensure
resilience of supply. To comply with
this Dorman Smith can offer a totally
insulated system.
To comply with EN 60439-1
(IEC 60439-1) Form 4, UK Annex
Types 1 and 4, the Busbar
separation is achieved using
insulated coverings.
• 6300A Busbar fully insulated.
• Joints also insulated using
shrouds.
• Insulation by means of a durable
polymeric coating.
7. Fan assisted cooling system
To assist with cooling, high current
switchboards, an option is to force
air cool the internal components.
• Fan will cool ACBs.
• Also can cool Busbars.
• Air flow adjusted to suit final
temperature requirements.
• Thermostatically controlled.
• Main and standby options.
7
Packaged Substations
Cast-Resin Transformers
Advantages and characteristics of
cast-resin transformers.
Excellent antipollution features and
maximum safety
All constructive materials and
especially the insulating resin are
self-extinguishing: they do not
develop, in case of fire, toxic gases
and they are moisture tolerant.
Performances
Cast-resin transformers are the best
solution for all technical installation
problems, thanks to their capability
to withstand network impulsive
voltage peaks,dynamic short-circuit,
and overloads, with the optional
addition of cooling fans for
increasing rated capacity.
Packaged Substations
Maintenance-free
The high stability of the physical
characteristics of the materials and
the state-of-the-art technology
reduce maintenance to the
minimum.
Where can cast-resin transformers
be used?
The electrical and physical
properties of cast-resin transformers
fit them for both civil and industrial
use: hospitals, theatres, airports,
subway, mines, off-shores platforms,
nuclear power plants, vessels,
industrial plants, etc. That is to say
wherever there are fire or
environmental pollution risks and
where safety is a must.
IEC 726
Maximum reliability 9
The product offers the maximum
reliability thanks to the computerised
control of thermal processes, to the
check of the chemical and the
physical characteristics and to the
measuring of the TG (Glass-
transition) temperature of resin.
Economy of installation
Elimination of sumps for oil
collection, reduced overall
dimensions and an excellent
distribution of weights allow cost
reduction of the plant.

Loadline ACBs
10
Loadline Air Circuit Breakers and
their accessories conform to the
International Standards IEC 947,
EN 60947 (harmonised in the 17
CENELEC countries), CEI EN 60947
and IEC 1000, and conform to the
relevant CE directives:
• Low Voltage Directives
(LVD) No. 73/23EEC
• Electromagnetic compatibility
Directive” (EMC) No. 89/336EEC
Microprocessor Based Overcurrent Releases
Protection PR111 PR112
Functions
Overload protection
L to the traditional protection functions,
with inverse long
time-delay trip
Selective short-circuit
S Current
protection with inverse
or definite short time
delay
Instantanious short
I circuit protection with
adjustable trip current
setting
Earth Fault Protection
G technical characteristics and
RESIDUAL
SOURCE GROUND
RETURN
Thermal memory
for functions L and S
LV Protective Devices
The apparatus complies with the
specifications of the regulations for
on-board installations and is
approved by the following Naval
Registers:
• RINA (Italian Naval Register)
• Det Norske Veritas
• Bureau Veritas
• Germanischer Lloyd
• Lloyd’s Register of Shipping
• Polskj Reiestr Statkow
The constant increase in the
technological and functional
complexity of electrical installations
makes it essential for every
component - particularly those such
as protection circuit breakers which
are crucial to safety - to offer the
highest levels of continuity of service
and reliability combined with
minimal maintenance requirements.
Loadline Air Circuit Breakers were
designed in line with the advanced
plant engineering requirements, and
features high resistance to
The circuit breakers fitted with
microprocessor-based releases offer
load control, self-test and information
transmission capabilities in addition
enabling them to be interfaced with
centralised control and supervision
systems. Loadline offers all the
components needed to build systems
that are tailored to each installation,
from field units to front ends (with
standard communication protocols),
from actuators to control systems.
As a result, the work of specifiers and
designers is considerably simplified
when it comes to choosing the
performance required.
LV Protective Devices
Loadline High Performance MCCBs
mechanical, electrical and thermal Loadline HP circuit breakers and ensure high reliability, precise 11
stresses. their accessories conform to the tripping and immunity to the
Loadline Air Circuit Breakers International Standards IEC 947-2, influence of ambient conditions. The
represent the logical functional EN 60947 (harmonised in the 17 power supply required for correct
complement to the Loadline HP CENELEC countries), CEI EN 60947 operation is supplied directly by the
moulded case circuit breakers and and IEC 1000, while also conforming releases’s current transformers with
have, like them, been designed for to the following EC directives: one phase current ≥ 15% of their
integration and perfect co-ordination • Low Voltage Directives (LVD) rated curents, even with only one
phase powered. Just one adjustment
with the different lines of low voltage No. 73/23 EEC
products. is required for all the phases and
• Electromagnetic Compatibility
neutral, and tripping of the release is
Loadline Air Circuit Breakers are Directive (EMC) No. 89/336 EEC
simultaneous for all the poles of the
available in five different models: Loadline HP S4, S5, S6 and SX7 circuit breaker with operating
E1, E2, E3, E4 and E6, each of circuit breakers for alternating characteristics that are unaffected by
which benefits from the current protection can be fitted with ambients conditions. Operation of
interchangeability of the various overcurrent releases PR211/P and the release can be checked using a
different versions of moving parts PR212/P featuring mircoprocessor- TT1 portable test device powered
(with different breaking and rated based electronic technology. This using normal batteries.
current capacities) for the same makes it possible to obtain
fixed part. The rated uninterrupted protection functions which
currents range from 800 to 6300 A.
The breaking capacities range from
40kA to 150kA (380/415 V a.c.).
Loadswitch Fuse Combination Units
All this is thanks to the fact that the Loadswitch fuse Combination Units category of AC23A and short-circuit
selection criteria are common to both conform to EN 60947-3 (IEC 60947- capacity of 80KA enables Loadswitch
families of circuit breakers and use 3). 80kA RMS Fused Short Circuit to be installed with confidence on
intuitive and easy-to-read codes and Current any inductive or resistive load.
symbols.
• 415V ac Rated Voltage The door handle can be padlocked
The new circuit breakers continue a • Current ratings 32A to 800A off as standard. Up to three padlocks
tradition of switchear designed and can be attached with ease.
• 80kA RMS Fused Short-Circuit
manufactured paying particular
attention to use and user interface-
related aspects, with obvious • AC23A Utilisation Category
Loadswitch has been designed to
advantages in terms of ergonomics,
clarity and speed of identification. exceed the requirements of
EN 60947-3 (IEC 60947-3) and to
offer solutions demanded by our
customers where ease of installations
and ever increasing cable sizes are
required.
A full uninterrupted duty ensures
that the unit can maintain full rated
load indefinitely. A utilisation

Introduction
12 This International Standard applies
to low voltage switchgear and
controlgear assemblies (type-tested
assemblies (TTA) and partially type-
tested assemblies (PTTA)), the rated
voltage of which does not exceed
1000 V a.c. at frequencies not
exceeding 1000Hz, or 1500V d.c.
Type Tested Assemblies (TTA)
Section 2.1.1.1
A low voltage switchgear and
controlgear assembly conforming to
an established type or system
without deviations likely to
significantly influence the
performance, from the typical
assembly verified to be in
accordance with this standard.
Partially Type Tested Assemblies (PTTA)
Section 2.1.1.2
A low voltage switchgear and
controlgear assembly, containing
both type-tested and non-type-tested
arrangements, provided that the
latter are derived (e.g. by
calculation) from type-tested
arrangements which have complied
with the relevant test.
Type Tests Section 8.2
Type tests include the following:
a) verification of temperature-rise
limits (8.2.1):
b) verification of the dielectric
properties (8.2.2);
c) verification of the short-circuit
withstand strength (8.2.3);
d) verification of the effectiveness of
the protective circuit (8.2.4);
Switchboard Standards
This standard applies to assemblies
intended for use in connection with
the generation transmission,
distribution and conversion of
electric energy, and for the control of
electric energy consuming
equipment.
e) verification of clearances and
creepage distances (8.2.5);
f) verification of mechanical
operation (8.2.6);
g) verification of the degree of
protection (8.2.7).
EN60439-1:1999
The object of this standard is to lay
down the definitions and to state the
service conditions, construction
requirements, technical
characteristics and tests for low-
voltage switchgear and controlgear
assemblies.
Section 2.1.1.1
Section 2.1.1.2
Section 8
Switchboard Standards
Fundamentals of Separation
In accordance with the Standard, separation of the
various elements of an Assembly: busbars, functional
units, terminals, can be claimed providing one or more
of the following criteria are met:
1. Protection against contact with live parts belonging
to adjacent functional units. The degree of protection
shall be at least IP2X or IPXXB.
As a minimum, finger contact with live parts in adjacent
functional units is prevented. With Assemblies supplied
by Dorman Smith Switchgear this is extended to include
protection against finger contact between: functional
units, adjacent busbars and busbar connections, and
terminals as required for the particular form of
separation being considered.
The requirement is proven with the standard test finger.
Typical Applications
Form 1 - No separation
Typical applications are places where the switchboard is
in a secure location and where failure of the switchboard
will cause little or no additional disruption to other areas
being fed by the switchboard.
Form 2 - Separation of busbars from functional units.
Applications may well be the same as Form 1 but where
it is important that a fault in the switchboard need not
affect all functional units being fed from the same
busbar system.
Methods of Construction
Dorman Smith have considerable experience in
designing and constructing low voltage switchboard
assemblies from the simplest panelboard to the
most complex multi-cubicle control and distribution
switchboard including HV/LV transformer to provide
a packaged substation.
The various methods of separation and construction
offered by Dorman Smith from Form I through to
Form 4 are illustrated in detail on pages 14-15 can
be seen from these diagrams a modular approach
2. Protection against the passage of solid foreign 13
bodies from one unit of an Assembly to an adjacent
unit. The degree of protection shall be at least IP2X.
The minimum requirement is proven by the standard
test finger not being able to touch live parts in adjacent
units and a 12mm ball not being able to pass between
units.
In practice a higher degree of protection may be
required for horizontal partitions to prevent small objects
form falling between compartments and should be
identified in the contract specification.
These two fundamental criteria are interrelated. Dorman
Smith Switchgear will therefore ensure all these are fully
met in respect of the particular form of separation
offered.
Form 3 - Separation of busbars from functional units
and the functional units from one another but not
their terminations.
Should be applied where it is important to provide
protection from internal live parts and where failure of
functional units being fed from the same busbar would
cause unacceptable disruption.
Form 4 - Separation of busbars from functional units
and the functional units from one another including
their terminations.
Should be applied where it is important to provide
protection from internal live parts and where failure of
functional units being fed from the same busbar would
cause unacceptable disruption. Because all the
terminations are separated it is possible to isolate and
work on a single functional unit.
has been employed which enables the maximum
number of permutations to be achieved within a highly
cost effective frame work.
If you would like more information on Dorman Smith Low
Voltage Switchgear Systems our technical Sales Team
will be pleased to assist and can upon request organise
educational seminars and training for your staff on
EN 60439-I and the UK National Annex.
 Switchboard Specification Switchboard Specification

Internal Separation of Assemblies Section 7.7 Form 3a Criteria

14 15
Symbols used in Diagrams
Separation of busbars from the functional units
and separation of all functional units from one
Barrier another. Separations of the terminals for external
conductors from the functional units, but not
from each other.
Terminal Device Busbar
Terminals for external conductors not separated
from busbars.
Form 1 Criteria

No Separation. Form 3b Criteria

Separation of busbars from the functional units

and separation of all functional units from one
another. Separations of the terminals for external
conductors from the functional units, but not
from each other.

Terminals for external conductors separated from

busbars.

Form 2a Criteria
Form 4a Criteria
Separation of busbars from the functional Units.
Separation of busbars from the functional units
Terminals for external conductors not separated and separation of all functional units from one
from busbars. another, including the terminals for external
conductors which are an integral part of the
functional unit.

Terminals for external conductors in the same

compartment as the associated functional unit

Form 2b Criteria
Form 4b Criteria

Separation of busbars from the functional Units.
Terminals for external conductors separated from
busbars.
Separation of busbars from the functional units
and separation of all functional units from one
another, including the terminals for external
conductors which are an integral part of the
functional unit
Terminals for external conductors not in the
same compartment as the associated functional
unit, but in individual, separate, enclosed
protected spaces or compartments.
 Switchboard Standards Switchboard Standards

UK National Annex Table NA.1 Form 2b Type 2 Internal Separation of Assemblies Section 7.7
16 The internal separation of of construction, based on typical However, in order to achieve 17
Assemblies by barriers or partitions practice in the United Kingdom. agreement between manufacturers
is specified in 7.7 and is subject to Other types of construction are not and users, it is recommended to
agreement between the precluded, and it is not essential to adopt one of the listed types of Incoming
Unit
Outgoing
Units
Outgoing
Units
Outgoing
Units
manufacturer and the user. adopt any of the listed types in order construction.
Table NA.1 gives additional to comply with the requirements of
information regarding different types the Standard.

Forms of Separation Table NA.1

Main criteria Sub criteria Form Type of Construction
No separation Form 1
Terminals for external
conductors not separated Form 3b Type 2 Internal Separation of Assemblies Section 7.7
Separation of busbars from the from busbars.
functional units. Form 2 Type 1 Busbar separation is achieved by insulated covering,
Terminals for external e.g. sleeving, wrapping or coatings
conductors separated from
busbars. Type 2 Busbar separation is by metallic or non-metallic rigid
barriers or partition. Incoming Outgoing Outgoing Outgoing
Unit Units Units Units
Separation of busbars from the Terminals for external
functional units and separation conductors not separated Form 3a
of all functional units from one from busbars.
another. Separation of the
terminals for external Type 1 Busbar separation is achieved by insulated coverings,
Terminals for external e.g. sleeving, wrapping or coatings
conductors from the functional
conductors separated from Form 3b
units, but not from each other. Type 2 Busbar separation is by metallic or non-metallic rigid
busbars.
barriers or partitions.
Type 1 Busbar separation is achieved by insulated coverings,
e.g. sleeving, wrapping or coatings. Cables may be glanded elsewhere.
Terminals for external
conductors in the same Type 2 Busbar separation is by metallic or non-metallic rigid barriers or
compartment as the partitions. Cables may be glanded elsewhere. Incoming Outgoing
Cables
Cable
associated functional unit. Outgoing
Type 3 Bushbar separation is by metallic or non-metallic rigid barriers or partitions. Cables
Separation of busbars from the The termination for each functional unit has its own integral glanding facility.
functional units and separation
of all functional units from one Type 4 Busbar separation is achieved by insulated coverings,
another, including the terminals Form 4a e.g. sleeving, wrapping or coatings. Cables may be glanded elsewhere. Form 4a Type 2 Internal Separation of Assemblies Section 7.7
Terminals for external
for external conductors which Type 5 Busbar separation is by metallic or non-metallic rigid barriers or partitions.
conductors not in the same Terminals may be separated by insulated coverings and glanded in common
are an integral part of the
compartment as associated cabling chamber(s).
functional unit.
functional unit, but in
individual, separate, Type 6 All separation requirements are by metallic or non-metallic rigid barriers or
enclosed protected spaces partitions. Cables are glanded in common cabling chamber(s). Incoming Outgoing Outgoing Outgoing
Unit Units Units Units
or compartments. Type 7 All separation requirements are by metallic or non-metallic rigid barriers or
partitions. The termination for each functional unit has its own integral
glanding facility.

Incoming Outgoing
Cable Cables
Outgoing
Cables
 Switchboard Standards Degrees of Protection

Form 4b Type 5 Internal Separation of Assemblies Section 7.7 EN 60529 : 1991

18 EN 60529 : 1991 describes a system for The first characteristic numeral designates enclosures and protection of the 19
classifying degrees of protection provided the degree of protection with regards to equipment inside the enclosure
by enclosures of electrical equipment with a solid objects. against the ingress of solid foreign
Incoming Outgoing Outgoing Outgoing rated voltage not exceeding 1000V ac and The second numeral designates the degree objects.
Unit Units Units Units
1500V dc. of protection against the ingress of liquid. b) Protection of the equipment
The markings used to indicate the degree of It is intended to provide indication of: inside the enclosure against
protection consist of the letter IP (Ingress harmful ingress of water.
Protection) followed by two characteristic a) Protection of persons against
numerals. access to hazardous parts inside

First Number - Protection Against Solids Second Number - Protection Against Liquids
Protection of persons Protection against
Protection against solid against access to IP Example Liquids - Tests Protection from water
Outgoing
IP Example foreign objects - Tests hazardous parts with:
Incoming
Cable Cables
Outgoing 0 No protection. non-protected 0 No protection No protection
Cables

Full penetration of 50mm diameter Protection against

sphere allowed. Protection against
Form 4b Type 6 Internal Separation of Assemblies Section 7.7
II IIIII
III

1 vertically falling drops

II
1 50

IIIIIIIIIIIIIIIIIIIII
back of hand

IIIIIIIIIIIIIIIIIIIIIII
Contact with hazardous parts not vertically falling drops of water.
of water.

III
III

permitted.
III
III III

Protection against vertically falling dripping up to 15° from

Full penetration of 12.5mm 2 drops of water with enclosure
III
II IIIIIIIIIIIIIIIIIII
II
diameter sphere not allowed. The tilted 15° from the vertical. the vertical

I
IIIIIIIIIIIIIIIIIIIII

II
III
IIII
2 12.5

II IIIIIII
jointed test finger shall have finger
Protection against sprays to 60° from

III
III
I
adequate clearance from

II
III
IIIIIIIIIIIIIIIIIIIII
Incoming Outgoing Outgoing Outgoing II

Unit Units Units Units 3 the vertical - limited ingress limited spraying
hazardous parts.
permitted.
The access probe of 2.5mm Protection against water splashed
3 tool splashing from all
diameter shall not penetrate. 4 from all directions - limited ingress
permitted. directions
Compartment The access probe of 1.0mm
for future use 4 wire Protected against low pressure jets of hosing jets from all
diameter shall not penetrate. 5 water from all directions - limited
ingress permitted. directions
Limited ingress of dust permitted
5 wire Protected against strong jets of strong hosing jets from
(no harmful deposit). 6 water, eg. for use on shipdecks
limited ingress permitted. all directions
Totally protected against ingress of
6 wire 15cm min.
Protected against the effects of
dust. 7 temporary immersion
Incoming Outgoing immersion between 15cm and 1m.
Cable Cables
Outgoing
Cables
Protected against long periods of
8 continuous immersion
immersion under pressure.

Form 4b Type 7 Internal Separation of Assemblies Section 7.7

EN 60529 : 1991
For switchboard assemblies intended for indoor use IP00 IP2X IP3X IP4X IP5X
Incoming Outgoing Outgoing Outgoing EN60439-1 : 1999 states that there is no requirement for protection
Unit Units Units Units
against ingress of water (clause 7.2.1.1) and that the IP references Where some degree of protection against ingress of water is required the
preferred for assemblies designated for indoor use are: following table gives the preferred IP combination numbers:-

List of Preferred IP References

Compartment
for future use

First Characteristic Numeral Second Characteristic Numeral

Protection against contact and protection Protection against harmful ingress of water
against ingress of solid foreign 1 2 3 4 5
2 IP21
3 IP31 IP32
Incoming Outgoing
Cables
4 IP42 IP43
Cable
Outgoing 5 IP53 IP54 IP55
Cables
6 IP64 IP65

Power Factor Correction
20
Introduction
Electrical installation sizing must be
carried out according to the apparent
power S which, defined as the
product of the voltage and the
current (V x I) is expressed in [VA].
When there are ohmic loads, the
apparent absorbed power is utilised
completely as active power and is
dissipated in heat, whereas when
there are other loads, such as
motors. welders, fluorescent lamps.
transformers. etc., a part of the
apparent absorbed power, called
reactive power Q, is utilised only to
energise the magnetic circuits. It
cannot therefore be used as active
power to carry out work.
Types of Power Factor Correction
Distributed power factor correction
Distributed power factor correction
is, in fact, the best technical solution
since capacitor and user equipment
follow exactly the same path during
daily service of loads, so the cosφ
setting becomes automatic and
systematic.
Apart from this, with local power
factor correction it is not only the
supply authority which benefits from
reactive energy saving, but also the
whole internal distribution system of
the user. ln industrial installations,
for example, the saving which can be
made with distributed power factor
correction, is not just a question of
tariffs, but is also noted in sizing all
the MV/LV substations with the
The ratio between the active power
and the apparent power expresses
the power factor (cosφ) or the
dephasing between voltage and
current when the user absorbs
reactive power.
The power factor is equal to 1 when
all the apparent absorbed power is
active, whereas it is less than 1 when
the apparent absorbed power
consists of partly active power and
partly reactive power.
This means that user equipment with
a low power factor requires more
apparent power from the network
(and therefore more current) than a
corrected loads
Another advantage with regard to
distributed power factor correction, is
its simple and cost-effective installation
since the capacitor and load are
connected and disconnected
simultaneously and can use the same
protections against overloads arid
short-circuits.
Centralised power factor correction
Centralised power factor correction is
cost-effective in the case of installations
with several heterogenous loads
operating on an occasional basis, so
there is high installed power and fairly
Iow average energy absorption by loads
in simultaneous service. With
centralised power factor correction, the
bank power is notably less than the
Energy Management
user with a higher power factor.
Therefore the voltage drops and
energy losses are higher, the lower
the power factor.
To keep down voltage drops and
power losses it is therefore necessary
to size the installations considering
the higher current due to the low
power factor, and this is to the
detriment of the installation’s cost-
effectiveness.
For these reasons, companies
supplying electrical energy increase
the price of electricity for users with
a low power factor.
overall power which would be required
for distributed power factor correction,
taking into account, too, that the kVAR
cost of a high-powered capacitor is less
than that of small capacitors.
The bank can be connected
permanently only if the reactive
energy absorption is fairly regular
during the day, otherwise it must be
switched to prevent having cosφ in
advance.
When the reactive power absorption
is highly variable during operation of
the installation, automatic regulation
is required with the bank split up
into several steps.
Energy Management
Harmonics
Introduction
Manufacturers are increasingly being
asked to provide for oversized neutral
capabilities in their products. This is
to cater for all anticipated increased
current in the neutral system.
The increased current is a result of
harmonics being introduced onto the
system, by modern day equipment
such as, variable speed drives, static
Recommendations
• Obtain information about the
harmonic current for all equipment
to be installed;
• Consider the effect of source
impedance of ups and standby
generator systems - they can be
much higher than the impedance
of the main transformer and cause
more severe voltage distortion;
• Eliminate the source of harmonics
by specifying low harmonic
versions of switch mode power
supplies, variable speed drives and
high frequency ballasts;
The Effects of Harmonics
The effects of harmonic voltages are
malfunctions in sensitive equipment
such as the sensing circuits of circuit
breakers and ups switches. The
effects of harmonic current are
overheating in conductors,
transformers, motor coils and
capacitors.
When harmonic loaded single phase
circuits on different phases are
brought together in a distribution
board, the third harmonic
components and all the odd
rectifiers, microwave ovens, personal
computers, etc. This can result in
severe overheating e.g. in cabIes,
busbar, enclosures, transformer coils,
etc.
Therefore, Industry, commercial
premises, offices and homes, may all
be affected, and with the growth of
use of such equipment, the problem
will escalate.
• Calculate the harmonic voltage and • Specify transformers and filters to
current at critical parts of the
system, phase and neutral • Follow guidelines for identification
conductors;
• Design the installation, including
proper sizing of neutral
conductors, to accommodate • Safety considerations are
harmonic currents where they
occur;
• Separate circuits supplying
harmonic generating loads from
those supplying loads which are
sensitive to harmonics;
multiples (triplen harmonics) add
together in the neutral. In severe
cases the neutral current can exceed
twice the phase currents. In such
cases a double size neutral busbar is
often specified.
However, it may be necessary to
double rate busbar and circuit
breakers in the main distribution
board as well. In a large installation
the main circuit breaker could be
rated at 4000 A. Finding an acb to
take an 8000A neutral conductor
can be difficult.
21
BSRIA (Building Services Research
Association) has been working with
the industry to find the extent and
severity of power quality problems
related to harmonic currents. It has
found widespread problems and
believes that unless designers and
operators are more aware of the
problems, and take action to avoid
them, they will become critical.
remove harmonics;
of harmonic problems including
surveys, measurement methods
and diagnosis;
paramount and the correct choice
of instruments is also emphasised
so that they will measure harmonic
frequencies.
Fortunately, diversity of the harmonic
loads leads to a certain amount of
cancellation since the harmonic
currents of different loads are rarely
in perfect phase. The solution may
require modelling software to predict
the neutral current. A range of
solutions is available, from U.P.S. to
avoid interruptions, through isoIating
and phase shift transformers to
passive and active filters.
All of the above information, including drawings, illustrations and graphic designs, reflects our present understanding and is to the best of our knowledge and belief correct and reliable. Users, however, should
independently evaluate the suitability of each product for the desired application. Under no circumstances does this constitute an assurance of any particular quality or performance. Such an assurance is only
provided in the context of our product specifications or explicit contractual arrangements. Our liability for these products is set forth in our standard terms and conditions of sale.
© Tyco Electronics EPP-0891-3/01

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