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chap5 | Transformer | Power Supply
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5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Medium-voltage Switchgear Pressure Development in Switchgear Rooms Distribution Transformers (GEAFOL) Oil-immersed Distribution Transformers Low-voltage Switchgear Busbar Trunking Systems Distribution Boards for Sub-distribution Systems Uninterruptible Power Supply System (UPS) Standby Power Supply 60 69 70 75 79 96 102 104 108
5 Dimensioning of the Main Components for the Power Supply
It is essential to specify the main components for power supply at an early stage in order to estimate the necessary project budget and dimension the technical equipment rooms required for electric installations correctly. Based on the specific project targets and the established demand, steadfast decisions must already be made at this very stage. Wrong specifications can only be corrected at great expense at a later stage.
5.1 Medium-Voltage Switchgear
Depending on the local power supply network operator and the required transformer power, there are certain standards for medium-voltage switchgear which must be observed for the planning / sizing of utility substations. These standards are described in the Technical Supply Conditions of the respective network operator.
Photo 51/1: Extendible 8DJH medium-voltage switchgear in modular design
Totally Integrated Power – Dimensioning of the Main Components for Power Supply
Installation site / altitude (above sea level)
Room / door dimensions
c Wall installation c Stand-alone
c . . . . . . . . . kV
c 12 kV
c 24 kV
c 20 kV
c . . . . . . . . kV
Rated operating current of the busbar
c 630 A
c ..... A
c 16 kA
c 20 kA
c . . . . . . . . kA
Accidental arc qualiﬁcation
c IAC (Internal Arc Classiﬁcation)
Type of pressure relief
(pay attention to room height) c Pressure relief downward c Pressure relief to the rear / top c Pressure relief upward with pressure absorber
(as top unit for protective devices, instrumentation …) c 600 mm c 900 mm
Number of switchgear panels expandable
c No 61
Further points that should be considered when planning / dimensioning medium-voltage switchgear:
Operating voltage Rated short-time current Neutral-point connection Load ﬂow, power to be distributed Cable / overhead system Overvoltage protection Power quality (instable loads) ................................................................. ................................................................. ................................................................. ................................................................. ................................................................. ................................................................. .................................................................
Integration in the system protection concept of the responsible power distribution network operator .................................................................
Operating area accessibility (for qualiﬁed personnel only yes / no) Installation: – Arrangement, space required (=> panel width) – False ﬂoor / cable routes – Operating / installation corridor Access ways Pressure relief of the switchgear room
Operator control (handling, clarity …) Operator protection Switchgear expansion capability Operator control (monitoring and switching) Control and monitoring Interlocking system Measuring and metering
Ambient temperature Climatic conditions (pollution, salt, humidity, aggressive gases) Installation altitude (note derating factor for altitudes greater than 1,000 m above sea level)
Integration in the supply system control and the production process
Regulations of the power supply network operator (technical supply conditions) Electrotechnical standards (IEC / VDE)
Sector-speciﬁc application
Switching duty Switching frequency of the consumer Availability Service / maintenance
Association guidelines (VDEW / VDN) Statutory regulations Internal regulations
5.1.1 Medium-Voltage Switchgear – Examples
Figures 51/2 to 51/4 show examples of medium-voltage switchgear together with their dimensions and weights. Matters such as to which version would be suitable, and could the energy demand be supplied from the regional network, must be clarified with the responsible power supply network operator during the planning stage. Measurement procedures, protective technology, interlocking with the low-voltage switchgear, room layout and the scope of performance should also be dealt with.
Component Ring-cable feeder Transformer feeder Circuit-breaker feeder Metering panel Weight approx. 180 kg approx. 220 kg approx. 300 kg approx. 350 kg Working load approx. 600 kg / m2 Table 51/1: Average weights of individual medium-voltage switchgear components 10 kV (12 kV) / 3~50 Hz 20 kA (1 s) / 630 A -A51
-Q1 630 A
-Q1 630 A -F1 -A51 200 A -T11 3
110 V DC -A51
-T16 3
Transfer transformer
Manual operation of ground function
1400 310 310 430 1890 64 WxD 350 x 610 WxD 230 x 610 WxD 270 x 610 WxD 760 x 610 310 310 430 1890 840 61 650 840
60 Fig. 51/2: Example of a utilities substation with a transformer up to 630 kVA (minimum requirement) 775 15 1460
10 kV (12 kV) / 3~50 Hz 20 kA (1 s) / 630 A -Q0 630 A
110 V DC -Q1
-Q1 200 A 630 A -T11 3 -F1
-Q1 200 A -F1
-T11 3
600 310 310 500 840 2820 MS 1** MS 2** 64 WxD 230 x 610 WxD 270 x 610 WxD 420 x 610 WxD 760 x 610 WxD 350 x 610 WxD 390 x 610 310 310 500 840 2820 430 430 15 775 430 430 Fig. 51/3: Example of a utilities substation with one or several transformers using switch-disconnector and fuse assemblies
Manual operation of ground function Modular spacing
-A51 -Q0 630 A
-Q0 630 A
110 V DC -Q1 630 A -T11 3
110 V DC -Q1 630 A 630 A
-T11 3 -T21 Ring
-T21 3 Transformer
840 2820
430 MS 2**
MS 1**
1400 WxD 230 x 610 WxD 270 x 610 WxD 420 x 610 WxD 760 x 610 WxD 350 x 610 WxD 350 x 610 64 310 310 500 840 2820 430 430 61 650 Fig. 51/4: Example of a utilities substation with one or several transformers using circuit-breakers 775 15
5.1.2 Medium-voltage Switchgear Design
Gas-insulated switchgear should be used for the mediumvoltage utilities substation. The advantages of gas-insulated switchgear are: Low space requirements (up to approx. 70 % savings with 20 kV) compared to air-insulated switchgear Smaller transportation size and consequently easier shipping Increased safety of operation due to hermetically sealed primary switchgear section (adverse impact such as dirt, small animals, contact, condensation are excluded due to the encapsulation) Maintenance-free primary section (no lubrication and readjustment necessary) Better eco balance than air-insulated switchgear with regard to the service life
Installation site: The switchgear is to be used indoors in compliance with IEC 61936 (Power installations exceeding 1 kV a.c.) and VDE 0101. A distinction is made between: Switchgear in locations with no access from the public, outside closed off electrical operating areas. Switchgear enclosures can only be removed with the aid of tools and operation by unqualified personnel must be prevented. Closed electrical operating areas: A closed electrical operating area is a room or location used solely for the operation of electrical switchgear and is kept locked. Access is only to electrically skilled persons and electrically instructed persons; unqualified personnel however only when accompanied by electrically skilled or instructed persons. Operating and maintenance areas These are corridors, connecting passages, access areas, transportation and escape routes. Corridors and access areas must be sufficiently dimensioned for work, operation and transportation of components. The corridors must have a minimum width of 800 mm. Corridor width must not be obstructed by equipment protruding into the corridor, such as permanently installed drives or switchgear trucks in disconnected position. The width of the escape route must be at least 500 mm, even if removable parts or fully open doors protrude into the escape route. Switchgear panel or cubicle doors should close in the escape direction. For mounting and maintenance work behind enclosed units (stand-alone), a passage width of 500 mm is sufficient. A minimum height of 2,000 mm below ceilings, covers or enclosures, except for cable basements is required. Exits must be arranged in such a way that the escape route in the room has a width ≥ 1,000 mm and does not exceed 20 m for rated voltages up to 52 kV. This requirement does not apply to walk-in busbar or cable conduits or ducts. If operator corridors do not exceed 10 m, one exit is sufficient. If the escape route is longer than 10 m, an (emergency) exit is required at both ends. Fixed ladders or similar facilities are permissible as emergency exits in escape routes.
Operator protection: The gas-insulated switchgear is safe to touch thanks to its grounded metal enclosure. HV HRC fuses and cable terminations are only accessible if branch circuits are grounded. Operation is only possible if the enclosure is fully sealed (and any doors closed). Maintenance-free pressure absorption system, laid out as “special cooling system” reduces pressure-related and thermal impacts of an arc fault so that personnel and building will be safe (Fig. 51/5). Extendibility: The switchgear should be extendible with a minimum time expense. A modular system with ordering options for busbar extensions on the right, left or both sides provides the best prerequisite for this: Individual panels and panel blocks can be mounted sideby-side and extended as desired – no gas work required on site Low-voltage compartment is available in two heights, wired to the switchgear panel by means of plug connectors All panels can be replaced at any time
8DJH switchgear Rated voltage Ur Rated insulation level Rated short-duration power-frequency withstand voltage Ud Rated lightning impulse withstand voltage Up Rated frequency fr Rated operating current Ir Rated short-time current Icw Rated surge current Ip Rated short-circuit making current Ima Ambient temperature T without secondary equipment with secondary equipment for branch circuits for busbar for switchgear with tcw = 1 s for switchgear with tcw = 3 s (option) [up to kA] [kA] [up to kA] [up to kA] 20 20 50 50 25 – 63 63 20 20 50 50 25 – 63 63 [kV] [kV] [kV] 60 75 95 50 / 60 Hz up to 400 A or 630 A up to 630 A 20 20 50 50 25 – 63 63 20 20 50 50 25 – 63 63 20 20 50 50 95 125 7.2 20 12 28 15 36 17.5 38 24 50
– 25 / – 40 to + 70 °C – 5 to + 55 °C
Table 51/2: Electrical data of the gas-insulated 8DJH switchgear
1 Low-voltage compartment Switchgear room ≥ 2400 1 ≥ 1000 4 2000 2300 775 ≥ 1000 5 890 ≥ 2400 2 3 ≥ 1000 Switchgear room 1 2 9 10 – Standard for circuit-breaker panels – Option for every other panel type 2 Pressure-relief opening 3 Room height 4 Panel depth 5 Access corridor 6 Cable space cover 7 Cable 7 115 2 Cable basement Side view ≥ 15 > 600 8 9 834 Cable basement Side view 300 ~200 12 11 8 Height of cable basement corresponding to cable bending radius 9 Direction of pressure relief 10 Pressure absorption canal 11 Height of pressure absorption canal base beneath the switchgear panel ≥ 15 12 Depth of pressure absorption canal behind the switchgear panel ≥ 200 620 ≥ 200
Switchgear arrangement with standard panels
Switchgear arrangement with rear pressure absorption canal (option)
Fig. 51/5: Room layout for switchgear with pressure relief downward (left) and with pressure absorption canal
Single-row installation at the wall ≥ 1000 Operation and supervision Two-row installation at the wall ≥ 50 ≥ 1000 ≥ 1000 Dimensions in millimeter Low-voltage panels ≥ 50 Medium-voltage panels ≥ 50 Operation and supervision ≥ 50
Stand-alone, back to back Operation and supervision
Fig. 51/6: Examples for the arrangement of panels and corridors (acc. to AGI Worksheet J 12)
Transportation using manual lift truck w/o pallet
Rod diameter 40 mm (observe switchgear weight) Pallet Transportation by fork-lift truck, object hanging from platform
Transportation using crane and pallet Crane hook
Rod diameter 40 mm
Transportation by fork-lift truck, object standing on platform
Transportation using crane and rod Fig. 51/7: Transportation methods
5.2 Pressure Development in Switchgear Rooms
In case of a fault within a gas-insulated switchgear station, an arcing fault can occur which strongly heats the surrounding gas resulting in an extreme rise in pressure. The extent of the pressure rise depends on the room geometry, the pressure relief openings and arcing fault energy. The consequences of such a (rare) fault can be extremely serious not only for the operating personnel, but also for the room. For this reason, appropriate measures must be taken for pressure relief, such as pressure relief openings, canals, absorbers or coolers (Fig. 52/1, Fig. 52/2). The actual pressure load capability of the building as well as its structural characteristics must have been inspected and approved by the statics engineer. There is a simplified pressure calculation according to Pigler for the 8DJH switchgear (Fig. 52/3). It provides a good approximation for closed rooms when the pressure increases uniformly throughout the room. However, the result of the pressure calculation does not provide any information on the pressure load capability of the building and its structural components (e.g. doors and windows). They must be designed by the statics engineer. Responsibility cannot be assumed for any damage resulting from arcing fault.
Definitions The free building volume corresponds to the volume of the room in which pressure relief takes place minus the volume of the switchgear itself and any other interior fittings. If pressure is relieved into the cable basement, the free building volume corresponds to the cable basement volume. If there is a pressure compensation opening from the cable basement into the switchgear room, both room volumes may be combined as an approximation. In this case, the opening for compensation between the two room volumes must be equal to the pressure relief opening to the outside. In case of highly complex geometries or higher short-circuit powers, it is necessary to perform a detailed pressure calculation with 3D finite elements which also takes the dynamic pressure development into account.
Fig. 52/1: Pressure relief downward
Fig. 52/2: Pressure relief upward with pressure absorber
Pressure calculation according to Pigler for the 8DJ/H switchgear type without absorber 12 10 8 6 4 2
Excess pressure [p] in hPa
400 50 1 16
Room volume [VR] in m3: Cross section of pressure relief opening [Arel] in m2: Short-circuit current [IK“] in kA:
900 Time [t] in ms
Maximum pressure [Pmax]: 10.9 hPa after 99 ms
Fig. 52/3: Example of stationary excess pressure resulting from internal arcing faults
5.3 Distribution Transformers (GEAFOL)
Selection of the transformer version Requirements of the installation site in accordance with DIN VDE 0101 (water protection, fire protection and functional endurance) suggest the use of cast-resin dry-type transformers (e.g. GEAFOL). Compared to oil-immersed transformers using mineral oil or silicone oil or diester oil, dry-type transformers place the lowest demands on the installation site while fulfilling the highest requirements in terms of personal protection and low fire load. Cast-resin dry-type transformers should at least meet the requirements C2 (Climate Category), E2 (Environment Category) and F1 (Fire Safety Category) as defined in IEC 60076-11. How many transformers are required? Depending on the application, the use of several transformers operated in parallel may be useful. GEAFOL transformer require almost no maintenance. For this reason, a back-up transformer for maintenance work needn’t be considered. Caution! Make sure that the two transformers to be operated in parallel have the same technical characteristics (including their rated short-circuit voltages). Reference value for dimensioning of two transformers operated in parallel: Rated power of each transformer = (power demand / 0.8) / 2. Additional transformer ventilation for more power The output of GEAFOL transformers up to 2,500 kVA, in degree of protection IP00, can be increased to 140 % or 150 % when cross-flow fans are installed. Efficient blowing can, for example, raise the continuous output of a 1,000 kVA transformer to 1,400 kVA or 1,500 kVA. However, the short-circuit losses are also twice or 2.3 times the value of the power loss for 100 % nominal load. Additional ventilation is a proven means for covering peak loads as well as compensating a transformer failure, when transformers are operated in parallel. Guideline: The price for efficient additional ventilation is about 15 % of the transformer price.
Fig. 53/1: Transformer truck rollers can be swung around in two directions. The roller-to-roller center spacing (E) applies to lengthways and sideways travel accordingly
A-A Exhaust air (nat.)
GEAFOLtransformer Full-wall* Medium voltage Alternative exhaust air cutout Protection bar
Intake air * also see the section “Transformer casing“, page 71
Transformer 630
Rated short-circuit transformer voltage Normally, 6 % should be selected as a rated short-circuit voltage (uzr) for a rated power above 630 kVA in order to keep short-circuit currents as low as possible in the event of a fault. The switchgear installed at the secondary side of the transformer must be designed to withstand such short-circuit currents.
7500 Self-closing doors opening outwards, in ﬁre resistance rating F 30A DIN 4102 Fire resistance rating F 90A DIN 4102
Fig. 53/2: GEAFOL cast-resin transformers installed in an electric utilities room supplying an ofﬁce tower (arrangement acc. to DIN VDE 0108)
Metering Transfer
Example: A 1,000 kVA transformer with a rated short-circuit voltage of 4 % supplies the 0.4 kV secondary network with approx. 36 kA in case of a short circuit. The same transformer with a rated short-circuit voltage of 6 % only supplies the 0.4 kV secondary network with approx. 24 kA in case of a short circuit. Vector group DYN5 (standard vector group in Germany) DYN11 (frequently used vector group in Asia as well as in Europe) Note: Vector groups Dyn5 and Dyn11 have the same price.
Temperature monitoring Transformers are equipped with a temperature monitoring system. For a three-phase transformer, this system consists of three series-connected PTC sensors – one per phase – and a tripping unit. It is useful to provide for an additional temperature sensor loop for an alarm, which can be wired to the same tripping unit. Transformer casing The transformer casing serves as contact protection in electrical operating areas which are freely accessible. With IP23 or higher, it is possible to reduce the acoustic power level by up to 3 dB. Conditions for installation – room layout
No-load losses – reduced losses Following the guidelines for sustainable construction of the German Ministry for Traffic, Building and Residential Development and with regard to the energy passport, transformers with reduced losses should be preferred. The economic efficiency of such a transformer can be verified by means of a loss evaluation. Guideline: If the cost factor for a kilowatt hour exceeds 2,000 EUR per annum, the increased cost for a transformer with reduced losses pays off within five years. Noise – acoustic power level Noise caused by transformers can be reduced as follows: Use of transformers with reduced no-load losses; this reduces the acoustic power level by approx. 8 dB. Reduction of structure-borne noise by using metalrubber rails and special transformer bedding. (Note: The transformer noise itself is not changed by this). Decoupling of connected busbars to minimize structureborne noise (e.g. by using elastic tapes).
GEAFOL cast-resin transformers can be installed in the same room as medium- and low-voltage switchgear without any extra precautions. For switchgear that come within the scope of Elt Bau VO, the electric utilities room must be enclosed by fireproof walls and doors (walls in fire resistance rating F90A, doors in F30A).
No-load losses Power loss at maximum transformer power (150 %)1)
(approx. values for 25°C air temperature)1)
Primary rated voltage Acoustic power level2)
Short-circuit losses at 120 °C
(approx. values for 25 °C air temperature)
Power loss at rated transformer power [m3 / min] [kg] Pv (rated) [W] [m3 / min] Pv (max) [W] LWA [dB] (A) [mm] (B) [mm] (H) [mm] (E) [mm]
Air ﬂow rate required for cooling at rated transformer power
Air ﬂow rate required for cooling at maximum transformer power
Roller-to-roller center spacing
Ur OS [kV]
Ur US [kV]
uzr [ %]
Pk 120 [W]
Table 53/1: Transportation, dimensions, weights – GEAFOL cast-resin transformers, 100 to 500 kVA
4 4 6 6 4 4 6 6 4 4 6 6 4 4 6 6 4 4 6 6 4 4 6 6 6 4 4 6 6 4 4 6 6 6 4 4 6 6 4 4 6 6 6 4 4 6 6 4 4 6 6 6
440 320 360 290 600 400 460 340 610 440 500 400 870 580 650 480 820 600 700 560 1,100 800 880 650 1,300 980 720 850 680 1,250 930 1,000 780 1,450 1,150 880 1,000 800 1,450 1,100 1,200 940 1,700 1,300 1,000 1,200 960 1,700 1,300 1,400 1,100 1,900 1,900 1,900 2,000 2,000 1,750 1,750 2,050 2,050 2,600 2,600 2,750 2,750 2,500 2,500 2,700 2,700 3,200 3,200 3,300 3,300 3,200 3,200 3,400 3,400 4,000 3,800 3,800 3,900 3,900 3,900 3,900 4,100 4,100 5,170 4,400 4,400 4,900 4,900 3,800 3,800 4,300 4,300 5,500 5,900 5,300 6,400 6,400 4,900 4,900 5,100 5,100 6,000 2,530 2,410 2,560 2,490 2,530 2,330 2,720 2,600 3,470 3,300 3,530 3,430 3,620 3,330 3,620 3,450 4,340 4,120 4,330 4,190 4,620 4,320 4,620 4,390 5,700 5,160 4,900 5,140 4,970 5,540 5,220 5,510 5,290 7,140 5,990 5,720 6,390 6,190 5,630 5,280 5,930 5,670 7,750 7,790 6,830 8,240 8,000 7,090 6,690 7,010 6,710 8,500 8 8 8 8 8 7 9 8 11 10 11 11 11 10 11 11 13 13 13 13 14 13 14 14 18 16 15 16 15 17 16 17 16 22 18 18 20 19 17 16 18 17 24 24 21 25 24 22 20 21 21 26 5,140 5,020 5,310 5,240 4,930 4,730 5,530 5,410 7,050 6,880 7,310 7,210 7,060 6,770 7,330 7,160 8,740 8,520 8,870 8,730 9,020 8,720 9,300 9,070 11,200 10,390 10,130 10,500 10,330 10,900 10,580 11,150 10,930 14,250 12,040 11,770 13,130 12,930 10,860 10,510 11,840 11,580 15,310 15,900 14,120 17,040 16,800 13,830 13,430 14,020 13,720 16,750 16 15 16 16 15 15 17 17 22 21 22 22 22 21 22 22 27 26 27 27 27 27 28 28 34 32 31 32 31 33 32 34 33 43 37 36 40 39 33 32 36 35 46 48 43 52 51 42 41 42 42 51 59 51 59 51 59 51 59 51 62 54 62 54 62 54 62 54 65 57 65 57 65 57 65 57 67 67 59 67 59 67 59 67 59 69 68 60 68 60 68 60 68 60 69 69 61 69 61 69 61 69 61 70 600 720 570 720 620 740 610 730 820 960 690 850 790 920 780 860 1,010 1,250 960 1,130 1,070 1,230 1,020 1,190 1,190 1,120 1,400 1,130 1,260 1,370 1,590 1,350 1,450 1,460 1,290 1,500 1,230 1,390 1,470 1,710 1,380 1,460 1,590 1,490 1,620 1,420 1,540 1,550 1,700 1,500 1,670 1,810 1,210 1,230 1,200 1,280 1,220 1,260 1,250 1,280 1,270 1,260 1,220 1,290 1,280 1,320 1,320 1,350 1,330 1,340 1,340 1,390 1,370 1,420 1,390 1,430 1,450 1,340 1,400 1,360 1,400 1,490 1,520 1,490 1,520 1,410 1,370 1,390 1,400 1,430 1,460 1,520 1,490 1,500 1,560 1,410 1,420 1,450 1,490 1,460 1,490 1,530 1,560 1,560 670 675 680 685 740 745 750 750 690 685 690 700 745 755 760 770 700 700 710 720 730 740 740 745 825 820 820 820 820 835 835 835 840 915 820 820 820 820 830 835 840 840 925 820 820 820 820 840 845 855 860 925 840 845 810 890 925 945 920 940 1,025 1,100 990 1,010 1,060 1,060 1,040 1,050 1,055 1,190 1,060 1,070 1,115 1,130 1,110 1,130 1,365 1,130 1,195 1,160 1,170 1,145 1,205 1,180 1,205 1,445 1,230 1,330 1,220 1,230 1,285 1,305 1,260 1,260 1,500 1,315 1,340 1,245 1,265 1,365 1,370 1,275 1,290 1,615 without wheels without wheels without wheels without wheels without wheels without wheels without wheels without wheels 520 520 520 520 520 520 520 520 520 520 520 520 520 520 520 520 520 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670
0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
Power increase through extra ventilation
Without extra ventilation
Rated power Width Roller-to-roller center spacing Height
Primary rated voltage No-load losses Short-circuit losses at 120 °C
(approx. values for 25 °C air temperature) (approx. values for 25°C air temperature)1)
Secondary rated voltage Power loss at rated transformer power Pv (rated) [W] [m3 / min] [kg] 1,670 1,840 1,570 1,760 1,790 1,930 1,590 1,780 2,090 1,970 2,210 1,840 2,090 2,020 64 72 64 72 73 79 77 75 79 72 77 76 27,850 29,630 29,030 32,400 31,800 32,060 50 48 52 50 57 64 62 21,050 19,950 21,500 25,200 19,000 18,500 18,500 20,000 23,900 25,350 23,950 27,800 64 60 65 76 72 76 72 84 33,990 33,290 34,780 34,080 37,510 43,600 42,700 42,360 41,260 42,130 51,330 50,030 50,790 49,390 55,300 84 89 87 98 96 97 102 100 105 103 113 131 129 127 124 127 154 150 153 149 166 65 73 65 73 65 73 65 73 75 67 75 67 75 76 68 76 68 76 78 70 78 70 78 81 71 81 71 81 2,220 1,880 2,070 2,620 2,440 2,850 2,260 2,590 2,420 2,740 2,250 2,430 2,990 2,570 2,920 2,590 2,810 3,580 3,360 3,850 3,510 3,890 4,350 3,860 4,390 3,930 4,430 5,090 4,550 5,230 4,870 5,520 5,920 1,540 1,580 1,620 1,500 1,530 1,560 1,610 1,550 1,570 1,610 1,620 1,740 1,550 1,620 1,640 1,680 1,570 1,680 1,630 1,640 1,800 1,720 1,740 1,760 1,790 1,870 1,810 1,840 1,840 1,870 1,970 1,920 1,950 1,960 2,000 2,100 2,080 2,110 2,150 2,190 2,280 1,520 1,470 1,550 850 840 845 870 880 940 820 825 860 870 850 855 890 890 965 990 990 990 990 990 990 990 990 1,060 990 990 1,000 1,000 1,065 990 990 1,010 1,020 1,090 1,280 1,280 1,280 1,280 1,280 1,280 1,280 1,280 1,280 1,280 1,510 850 1,440 820 1,410 820 1,485 1,485 1,310 1,330 1,530 1,565 1,380 1,390 1,640 1,535 1,535 1,390 1,410 1,595 1,595 1,470 1,460 1,695 1,730 1,795 1,510 1,530 1,790 1,665 1,630 1,650 1,795 1,590 1,630 1,640 1,650 1,895 1,740 1,780 1,840 1,850 1,995 1,910 1,940 1,940 1,980 2,135 2,030 2,060 2,030 2,050 2,215 29 28 28 27 29 28 29 28 29 32 30 33 32 36 34 33 32 34 40 38 38 36 40 36 38 37 43 44 42 48 46 49 25,570 25,070 23,830 26,310 25,010 25,510 26,350 26,850 81 22,200 67 21,800 66 22,250 67 22,940 69 23,440 71 72 21,840 66 64 22,240 67 72 20,710 63 64 21,110 64 72 18,540 56 71 19,070 58 62 19,470 59 70 18,580 56 62 19,030 57 70 18,920 57 62 19,190 58 70 19,220 58 62 19,570 59 70 [m3 / min] 9,530 9,180 9,290 9,020 9,540 9,090 9,570 9,170 9,460 10,380 9,980 10,830 10,430 11,750 11,250 10,970 10,520 11,340 13,100 12,600 12,450 11,950 13,250 11,870 12,640 12,140 14,100 14,500 13,900 15,900 15,300 16,250 16,660 15,960 17,180 16,480 18,950 21,320 20,420 Pv (max) [W] (A) [mm] (H) [mm] (B) [mm] LWA [dB] (E) [mm] 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 670 820 820 820 820 820 820 820 820 820 820 820 820 820 820 1,070 1,070 1,070 1,070 1,070 1,070 1,070 1,070 1,070 1,070 1,070 1,070 1,070 1,070 1,070 Air ﬂow rate required for cooling at rated transformer power Air ﬂow rate required for cooling at maximum transformer power Total weight Length
Power loss at maximum transformer power (150 %)1)
Acoustic power level2)
Sr [kVA] Pk 120 [W] 7,300 7,300 7,200 7,200 6,900 6,900 7,200 7,200 6,600 7,800 7,800 8,300 8,300 8,500 8,500 8,200 8,200 7,900 10,000 10,000 9,500 9,500 9,500 8,700 9,400 9,400 10,000 11,000 11,000 12,000 12,000 11,500 12,600 12,600 12,800 12,800 13,500 16,200 16,200 15,500 15,500 15,000 19,000 4 4 6 6 4 4 6 6 6 4 4 6 6 4 4 6 6 6 4 4 6 6 4 4 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
Ur OS [kV] uzr [ %] 1,500 1,150 1,370 1,100 1,950 1,500 1,650 1,250 2,200 1,800 1,400 1,700 1,300 2,400 1,900 1,950 1,500 2,650 2,100 1,600 2,000 1,500 2,800 2,300 2,300 1,800 3,100 2,400 1,800 2,700 2,100 3,600 2,800 2,100 3,100 2,400 4,100 3,500 2,600 4,000 2,900 5,000 4,300 3,000 5,000 3,600 5,800 Po [W]
Table 53/2: Transportation, dimensions, weights – GEAFOL cast-resin transformers, 630 to 2500 kVA
GEAFOL distribution transformer
Besides the regulations, standards and guidelines listed in section 2.3, the international standard IEC 60076-11 for dry-type transformers and speciﬁcations made by the local power distribution network operator must be observed.
.................... .................... .................... .................... c Yes 50 Hz c 4 % c 6 % c No
kVA (from power demand calculation) (from power demand calculation) kV (speciﬁed by power supply company) kV (low-voltage level)
Secondary rated voltage (no-load)
Tapping of primary winding Rated frequency Rated short-circuit voltage Type Vector group Extra ventilation on the transformer Make-proof grounding switch on the transformer No-load losses and noise
Cast-resin dry-type transformers c DYN5 c Yes c Yes c DYN11 c No c No
c Reduced (useful) c Not reduced
c Systems for alarm and tripping c System for fan control
Insulation against structure-borne noise Transformer casing
c Yes (transformer bedding) c Yes
c IP20 degree of protection – indoors c IP23 degree of protection – indoors c IP23 degree of protection – outdoors c No High level of operational safety and long service life Maximum ambient temperature (standard 40 °C) 74 c Partial discharge less than 5pC at twice the rated voltage .......... °C
5.4 Oil-Immersed Distribution Transformers
Distribution transformers supply the power required for plants and buildings on the last transformation stage from the power plant to the consumer.
5.4.1 Distribution Transformers with Cooling and Insulating Liquid
The requirements alone determine the design of a distribution transformer. The various parameters are based on this – from the rated output to the connection system, from the cooling liquid to the tapping. Oil-immersed distribution transformers from Siemens fulfill these requirements for sealed and expansion tank transformers. Fig. 54/1 provides a view of the inside of a sealed oil-immersed distribution transformer; technical data is listed in Table 54/1.
Standard: Rated output: Rated frequency: Rated high voltage: Taps on the high-voltage side: Low voltage: Connection system: IEC 76, EN 60076, EN 50464 30–4,000 kVA 50 Hz Up to 36 kV ± 5 % or ± 2 × 2.5 % 400–720 V (special versions for up to 12 kV can be constructed) Coils on the high-voltage side: Delta connection Coils on the low-voltage side: Star connection 4 % (only for rated high voltage 24 kV and < 630 kVA) or 6 % (for rated output > 630 kVA or for rated high voltage > 24 kV) ONAN IP00 RAL 7033 (available in other colors) Iron core and windings Both are held together by a clamping frame and bolted to the tank cover. The entire module can be lifted out of the tank. Iron core High-quality electric sheet steel, the latest core construction and optimized laminates ensure operation with minimum noise and power loss. Windings Construction and materials guarantee a long operating life. Off-circuit tap changer It is used to adapt the transformation ratio to the local voltage conditions. Can be set from the outside in zero voltage state. Low-voltage bushings High-voltage bushings Thermometer well Important accessory for temperature monitoring. Tank The TUMETIC design shown here is hermetically sealed. Elastic corrugated walls accommodate the change in volume of the liquid coolant. Truck Smooth rollers can be aligned for lengthways or sideways travel. Corrosion protection The surface has several layers of paint in the standard cement gray color (RAL 7033). Special colors or zinc plating are possible.
Cooling: Degree of protection: Paint ﬁnish: Table 54/1: Technical data
Fig. 54/1: Sealed oil-immersed 630 kVA distribution transformer – view of the interior
Various protective and monitoring devices are available as accessories for sealed and oil-immersed distribution transformers (Table 54/2). Sealed Hermetically sealed distribution transformers are filled with oil as a cooling and insulating liquid and are suitable for a power range of 30 to 4,000 kVA and operating voltages up to Um = 36 kV (Fig. 54/2). Expansion tank Oil-immersed distribution transformers with expansion tank can be used for power ranges of 30 to 4,000 kVA and operating voltages up to Um = 36 kV (Fig. 54/3). The following liquids are available as cooling and insulating liquid for oil-immersed distribution transformers: Mineral oil, which fulfills the international standards for insulating oils, IEC Publication 60296 – for distribution transformers without special requirements. Silicone oil, which is self-extinguishing when a fire occurs. Due to its high fire point of over 300 °C, it is classified as K-liquid according to IEC 61100. Diester oil, which does not pollute water and is bio-degradable. Diester oil also has a fire point of over 300 °C, a high level of safety against fires and is also classified as K-liquid according to IEC 61100. The design of the transformers depends on the requirements. For example, double-tank versions are available for special requirements in protected water catchment areas and versions with extreme radiation reduction for use in EMC-sensitive areas. Data on standard transformers is listed in Table 54/3.
Protective and monitoring devices Main characteristics and operating factors Dial thermometer: For 100–2,500 kVA on request Temperature of the cooling liquid DGPT2 relay: Full protection device for Gas formation Oil pressure Oil temperature (2 contacts) Sealed protection: Switch according to the oil level R1 gas relay: Monitoring of the gas formation (2 contacts) Pressure relief valve in sealed types: The excess pressure is relieved above the set value 2-ﬂoat Buchholz relay: 2 systems in expansion tank types Monitoring of the gas formation, the oil loss and the oil ﬂow rate – between 1,000 and 2,500 kVA standard version – between 400 and 630 kVA on request Desiccant breather for expansion tank types: (on request) Desiccant 0.5 kg / 1 kg Magnetic oil level indicator: Expansion tank types, ﬂoat movement is transmitted to the indicator via magnets
Further accessories on request: Vibration dampers – 4 items (transformer bedding), ﬂexible connection elements Table 54/2: Sealed and expansion tank – accessories
A = length; B = width; H = height E = roller-to-roller center spacing 8 7
2N 2U 2V 2W 1U 1V 1W
4 1 E 5 E
6 3 A 5 Ground connections 6 Pulling lug, Ø 30 mm 7 Lashing lug 8 Filler tube
1 Oil drain 2 Thermometer well 3 Adjuster for off-circuit tap changer 4 Rating plate (moveable)
Fig. 54/2: Sealed – dimensions
A = length; B = width; H = height E = roller-to-roller center spacing 1 5 3 10 H
7 8 E E 9
6 Adjuster for off-circuit tap changer 1 Oil level indicator 7 Rating plate (moveable) 2 Oil drain 8 Ground connections 3 Thermometer well 9 Pulling lug, Ø 30 mm 4 Buchholz relays (on request) 5 Desiccant breather (on request) 10 Lashing lug
Fig. 54/3: Expansion tank – dimensions
Losses p0 pk [W] 4,200 4,200 6,000 6,000 8,400 8,400 3,250 3,250 4,600 4,600 6,500 6,500 8,500 8,500 10,500 10,500 13,500 13,500 17,000 17,000 2,350 2,350
Dimensions A/B/H [mm] 1,060 / 770 / 1,307 1,060 / 770 / 1,307 1,210 / 860 / 1,462 1,210 / 860 / 1,462 1,250 / 890 / 1,577 1,250 / 890 / 1,577 1,060 / 770 / 1,307 1,060 / 770 / 1,307 1,080 / 840 / 1,472 1,080 / 840 / 1,472 1,250 / 890 / 1,577 1,250 / 890 / 1,577 1,580 / 950 / 1,585 1,580 / 950 / 1,585 1,610 / 1,000 / 1,730 1,610 / 1,000 / 1,730 1,690 / 1,000 / 1,830 1,690 / 1,000 / 1,830 1,880 / 1,150 / 1,947 1,880 / 1,150 / 1,947 1,060 / 770 / 1,307 1,060 / 770 / 1,307
Weight Oil [kg] 200 195 260 260 365 365 195 195 265 260 345 340 440 435 505 500 640 640 755 755 205 205 Total [kg] 955 955 1,255 1,260 1,710 1,720 970 985 1,360 1,370 1,775 1,795 2205 2,210 2,655 2,655 3,085 3,095 3,670 3,675 885 890 58 58 63 63 66 66 51 51 56 56 59 60 59 59 63 63 66 66 68 68 52 52
Noise LWA / LPA 1 m / LPA 0.3 m [dB(A)] 44 44 50 50 52 52 38 38 43 43 45 46 45 45 48 48 51 51 53 53 39 39 51 51 55 55 56 56 43 43 48 48 50 50 49 49 52 52 55 55 56 56 45 45
[kVA] 1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 3.1 3.2 250 250 400 400 630 630 250 250 400 400 630 630 800 800 1,000 1,000 1,250 1,250 1,600 1,600 160 160
[V] 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 10,000 ± 4 or ± 5 % / 400 20,000 ± 4 or ± 5 % / 400 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5 Dyn5
[ %] 4 4 4 4 4 4 4 4 4 4 4 4 6 6 6 6 6 6 6 6 4 4
[W] 530 530 750 750 1,030 1,030 425 425 610 610 860 860 950 950 1,100 1,100 1,350 1,350 1,700 1,700 375 375
Table 54/3: Oil-immersed distribution transformers – standard transformers
Rated power .................... .................... .................... .................... c Yes .......... kVA (from power demand calculation) (from power demand calculation) kV (speciﬁed by power supply company) kV (low-voltage level) c No
Secondary rated voltage (no-load) Tapping of primary winding Type
c Sealed
c Expansion tank c Diester oil
Insulating liquid Rated frequency Rated short-circuit voltage Vector group No-load losses and noise Accessories and monitoring equipment
c Mineral oil 50 Hz c 4 % c Dyn5
c 6 % c Dyn11 c Other ..........
c Not reduced
c Sealed protection c Dial thermometer with 2 contacts c Transformer protection block c Pressure switch, 2 contacts c Pressure relief valve c Buchholz relay (expansion tank) c Desiccant breather (expansion tank)
c Standard (125 µm) c Hot-galvanized c Hot-galvanized and additional coating
c Standard porcelain bushings c Outside cone – device connection
Secondary connection (standard according to DIN 50386)
c With transformer connection terminals and covers for indoor installation c With transformer connection terminals and covers for outdoor installation
Maximum ambient temperature (standard 40 °C) 78
5.5. Low-voltage Switchgear
When planning low-voltage switchgear, knowledge of the conditions at the location of use, the switching duty and the availability requirements are the basis for economic dimensioning. As no major switching functions have to be considered in the planning of power distribution systems in commercial buildings and no major extensions are to be expected, a performance-optimized technology with high component density can be used. In these cases, mainly fuse-protected equipment in fixed-mounted design is used. However, in a power distribution or motor control center for a production plant, replaceability and reliability of supply are the most important criteria in order to keep the
downtimes as short as possible. The use of withdrawableunit design in not only circuit-breaker-protected, but also in fuse-protected systems is an important basis. The prevention of personal injury and damage to equipment must, however, be the first priority in all cases. When selecting appropriate switchgear, it must be ensured that is a type-tested switchgear assembly (design verification according to IEC 61439-1 / -2 DIN VDE 0660-600-1 / -2) with extended testing of behavior in the event of an internal arcing fault (IEC 61641, VDE 0660-500, Addendum 2). The selection of the switchgear and the protective devices must always be made under consideration of the regulations that have to be observed with regard to the requirements for the entire supply system (full selectivity, partial selectivity) (Photo 55/1).
Photo 55/1: SIVACON S8 low-voltage switchgear
Project name ....................................................... ....................................................... Owner / developer ....................................................... ....................................................... Planning engineer ....................................................... ....................................................... Installation c ...................
c Wall installation c Back to back Room dimensions (sketch)
c ≤ 2,000 m c > 2,000 m
c Double-front installation
Room height: . . .................... mm
Degree of protection Ambient temperature (24 hour average) 80 c IP30 c 35 °C c IP31 c IP40 c IP41 c IP . . . . . . . .
c . . . . . . . . °C
Supply system / feed-in data
Power supply system c TN-S c TN-C c TT Number of transformers / power Rated operating voltage Ue Rated frequency f Rated feed-in current Ie c TN-S (EMC-friendly) c TN-C-S c CGP
c IT ukr c 4 % c 6%
. . . . . . . . item / . . . . . . . . . kVA, ........ V c 50 Hz ........ A c . . . . . . . . . Hz
Rated current of main busbar NPS / SPS section Ie Rated short-time withstand current of main busbar NPS / SPS section Icw PEN / N conductor cross section ........ A/........ A
. . . . . . . . kA (1 s) / . . . . . . . . kA (1 s) / c 50 % c 100 %
Type-tested modules according to IEC 61439-1 / -2 Protection against accidental arcing IEC / TR 61641 (VDE 0660-500, Addendum 2) c Yes
c Operator safety c Operator and system safety c Busbar insulation
Connection of incoming / outgoing feeders > 630 A c Busbar trunking system c SIVACON LDA / LDC c SIVACON LXA / LXC c Other Connection direction to switchgear c Top c Bottom c Top / bottom c Cable
Incoming feeders Couplings Outgoing feeders > 630 A Outgoing feeders ≤ 630 A Type of outgoing feeders ≤ 630 A c Fixed mounting c Fixed mounting c Fixed mounting c Fixed mounting c Withdrawable-unit design c Withdrawable-unit design c Withdrawable-unit design c Withdrawable-unit design c Fuse-protected 81 c Plug-in design
c Circuit-breaker protected
5.5.1 Planning Notes for Low-voltage Switchgear
Installation – clearances and corridor widths The minimum clearances between switchgear and obstacles specified by the manufacturer must be taken into account when installing low-voltage switchgear (Fig. 55/2). The minimum dimensions for operating and servicing corridors according to VDE 0100 Part 729 (IEC 60364-7-729 Draft) must be taken into account when planning the space requirements (Table 55/1, Fig. 55/3, Fig. 55/4). Caution! If a lift truck is used to insert circuit-breakers or withdrawable units, the minimum corridor widths must be adapted to the lift truck!
Manufacturer Dimensions of the lift truck e. g. Kaiser + Kraft Height Width Depth Minimum corridor width about 1,500 mm 2,000 mm 680 mm 920 mm
Space requirements Height: Width: Depth: Rated current of the main busbar Busbar position 2,000 mm and 2,200 mm (optionally with 100 mm or 200 mm base) For data required for the addition of panels please refer to the panel descriptions Cable / busbar entry Top & bottom Top & bottom Top & bottom Top & bottom Bottom Bottom Top & bottom B C Front A: 100 mm from the rear side of the installation B: 100 mm from the side side panels C: 200 mm from the rear panels with back to back installation Fig. 55/2: Clearances to obstacles A Type of installation Single front Single front Double front Double front Single front Single front Single front
600 mm 800 mm 1,000 mm 1,200 mm 500 mm 800 mm 1,200 mm
Rear Rear Rear Rear Top Top Top
4,000 A 7,010 A 4,000 A 7,010 A 3,270 A 6,300 A 3,270 A
Table 55/1: SIVACON S8 switchgear dimensions
Transportation units Depending on the access routes available in the building, one or more panels can be combined into transportation units (TU). The max. length of a TU should not exceed 2,400 mm. The transportation unit length results from the sum of the panel widths per TU + 200 mm (230 mm), however at least 1,400 mm (1,430 mm). The dimensions for the transportation unit heights result from the switchgear height plus 190 mm for the transport base. The relevant depth of a transportation unit depends on the depth of the switchgear.
Depth 500 mm 600 mm 800 mm 1,000 mm 1,200 mm Transportation unit depth 1,050 mm (1,060 mm*) 1,050 mm (1,060 mm*) 1,050 mm (1,060 mm*) 1,460 mm (1,490 mm*) 1,660 mm (1,690 mm*) Front B Front
* Values in brackets = export packaging for shipping by sea
Weights The panel weights as listed in Table 55/2 (Page 84) should be used for the transportation and dimensioning of building structures such as cable basements and false floors.
Double-front installations In the double-front installation, the panels are positioned in a row next to and behind one another. The main advantage of a double-front installation is the extremely economic design through the supply of the branch circuits on both operating panels from one main busbar system. The "double-front unit" system structure is required for the assignment of certain modules. A double-front unit (Fig. 55/5) consists of at least 2 and a maximum of 4 panels. The width of the double-front unit is determined by the widest panel (1) within the double-front unit. This panel can be placed on the front or rear side of the double-front unit. Up to three panels (2), (3), (4) can be placed on the opposite side. The sum of the panel widths (2) to (4) must be equal to the width of the widest panel (1). The panel combination within the double-front unit is possible for all technical installations with the following exceptions. Exceptions The following panels determine the width of the doublefront unit and may only be combined with an empty panel. Bus sectionalizer unit 5,000 A incoming / outgoing feeder 6,300 A incoming / outgoing feeder Environmental conditions for switchgear The climate and other external conditions (natural foreign substances, chemically active pollutants, small animals) may affect the switchgear to a varying extent. The effect depends on the heating / air-conditioning systems of the switchgear room. If higher concentrations are present, pollutant-reducing measures are required, for example: Air-intake for operating room from a less contaminated point Slightly pressurizing the operating room (e.g. by blowing uncontaminated air into the switchgear) Switchgear room air conditioning (temperature reduction, relative humidity< 60 %, if necessary, use air filters) Reduction of temperature rise (oversizing of switchgear or components such as busbars and distribution bars) Power losses The power losses listed in Table 55/3 (Page 84) are approximate values for a panel with the main circuit of functional units to determine the power loss to be discharged from the switchgear room.
height of passage under covers or enclosures
Fig. 55/3: Reduced corridor widths within the area of open doors
Min. corridor width 700 or 600 mm
Min. free passage 500 mm 1)
With switchgear fronts facing each other, the space requirements only account for obstruction by open doors from one side (i.e. doors that don’t close in escape direction) Take door widths into account, i.e. door can be opened at 90 ° minimum Full door opening angle = 125 ° (Sinus 55 °)
Fig. 55/4: Minimum corridor width according to VDE 0100 Part 729
Double-front installations – top view
Double-front installations only with main busbar system at the rear
Double-front units Fig. 55/5: Panel arrangement of double-front installations
Rated current [A] Size 630–1,600 Circuit-breaker design with 3WL (withdrawable unit) 2,000–3,200 4,000 Size I Size II
Installation depth [mm] 500 / 600 500 / 600 600 / 800 800 500 600 800 600 800 500 600 800 500 600 800
Panel width [mm] 400 600 600 800 800 1,000 1,000 600 800 1,000
Approx. weight [kg] 340 390 510 545 770 915 400 470 590 360 470 415 440 480 860 930 1,050
4,000–6,300 Universal mounting design panel (incl. withdrawable units, ﬁxed mounting with front doors) 3NJ4 in-line-type switch-disconnector panel (ﬁxed mounting)
3NJ6 in-line-type switch-disconnector design panel (plugged)
Reactive power compensation panel Table 55/2: Average weights of the panels including busbar (without cable)
Circuit-breaker design with 3WL (withdrawable unit)
Circuit-breaker type 3WL1106 630 A 3WL1108 800 A 3WL1106 1,000 A 3WL1106 1,250 A 3WL1106 1,600 A 3WL1106 2,000 A 3WL1106 2,500 A 3WL1106 3,200 A 3WL1106 4,000 A 3WL1108 5,000 A 3WL1106 6,300 A Size I Size I Size I Size I Size I Size II Size II Size II Size III Size III Size III
Universal mounting design panel (incl. withdrawable units, ﬁxed mounting with front doors) 3NJ4 in-line-type switch-disconnector panel (ﬁxed mounting) 3NJ6 in-line-type switch-disconnector design panel (plugged) Fixed-mounted type panel with front covers Reactive power compensation panel Table 55/3: Power loss generated per panel (average values)
5.5.2 Low-Voltage Switchgear – Example
Circuitbreaker design
2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 600 400 200 0
A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B A B
Plug-in 3NJ6 in-line switch-disconnector design
Fixed-mounting with front cover
Fixed 3NJ4 in-line Reactive power switch-disconcompensation nector design
4800 Boring 4 x Ø 14,8 mm Threaded hole M12 Installation front 75 W–150 Boring 4 x Ø 14,8 mm Threaded hole M12 Depth 500, 600, 800 (depth 800 only for main busbar at rear) W D Panel width Panel depth Free space in the fastening plane for cable and busbar penetration
Installation front 75 W–150
D–350 D
Fig. 55/6: SIVACON S8, busbar position at rear 2,200 × 4,800 × 600 (H × W × D in mm)
Universal mounting design Fixed mounting Plug-in design Withdrawable-unit design Cable outlets Motor feeders Up to 630 A / Up to 250 kW Front and rear side 600 / 1,000 / 1,200 2b, 4a, 3b, 4b Rear / top
3NJ6 in-line switchdisconnector design
W–100 W
Depth 800, 1000, 1200 (depth 800 only for main busbar at top)
Fixedmounted design Fixed-mounted design with front covers
3NJ4 in-line switchdisconnector design
Fixed mounting Withdrawableunit design Incoming feeder Outgoing feeder Coupling Up to 6,300 A Front and rear side 400 / 600 / 800 / 1,000 / 1,400 1*, 2b, 3a, 4b Rear / top
Central compensation of the reactive power Up to 600 kvar Front side 800 1*, 2b Rear / top / without
Current In Connection Panel width [mm] Internal compartmentalization Busbars
Up to 630 A Front side 1,000 / 1,200 1*, 3b, 4b Rear / top
Up to 630 A Front side 1,000 / 1,200 1*, 2b, 4a, 3b, 4b Rear / top
Up to 630 A Front side 600 / 800 1*, 2b Rear
* Alternative form 1 plus main busbar cover for shock protection
Table 55/4: Various mounting designs according to panel types
5.5.3 Planning Notes – Panel Types Circuit-breaker design
Field of application: Incoming feeders Couplers (sectionalizer and bus coupler) Outgoing feeders Design options: Air circuit-breaker (ACB) Molded-case circuit-breaker (MCCB) Panel dimensions: Height: 2,000 or 2,200 mm Width: Refer to Table 55/5 Depth: 500, 600, 800, 1,000, 1,200 mm Degrees of protection (according to IEC 60529): Ventilated ≤ IP41 Non-ventilated ≤ IP54 Form of internal compartmentalization: Form 1, 2b (panel-height door) Form 3a, 4b (3-part door) Cable / busbar connection direction: Busbar position at rear: Panel depth 600, 800 mm: Connection from: Top or bottom Access: Front side Panel depth 1,000, 1,200 mm: Connection from: Top or bottom Access: Front side Busbar position at top: Panel depth 500, 800 mm Connection from: Bottom Access: Front side Panel depth 800, 1,200 mm Connection from: Top or bottom Access: Front or rear sidePanel design Clearly separated functional areas with separate auxiliary device compartment for each circuit-breaker, large cable or busbar connection compartment and centrally arranged circuit-breaker.
2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 A BA B CA B DA B EA B A F B GA B HA B J A B KA B L A B MA B NA B P A B QA B RA B S A B T A B UA B V
Fig. 55/7: Circuit-breaker design Rated circuitbreaker current Min. panel width, incoming / outgoing feeder / bus coupler [mm] 400 600 800 1,000 Min. panel width, sectionalizer Short-circuit breaking capacity Icu [kA] 65 100 100 100
[A] 630 … 1,600 6301) … 3,200 4,000 5,000 … 6,300
[mm] 600 800 1,000 1,400
630 A with rated current module (rating plug)
Table 55/5: Panel dimensions
Field of application: Motorized loads up to 250 kW Cable feeders up to 630 A Incoming feeders up to 630 A Design options: Circuit-breaker protected or Fuse-protected design Arbitrarily combinable function module in: Fixed-mounted design Plug-in design Withdrawable-unit design Panel dimensions: Height: 2,000 or 2,200 mm Width: 600, 1,000, 1200 mm Depth: 500, 600, 800, 1,000, 1,200 mm Degrees of protection (according to IEC 60529): Ventilated ≤ IP41 Non-ventilated ≤ IP54 Form of internal compartmentalization: Fixed-mounted design Form 2b, 3b, 4a, 4b Withdrawable-unit / plug-in design Form 3b, 4b Possible combinations Figs. 55/8 and 55/9 show possible combinations. Cable connection direction: Busbar position at rear: Panel depth 600, 800 mm: Connection from: Top and / or bottom Access: Front side Panel depth 1,000, 1,200 mm: Connection from: Top and / or bottom Access: Front side Busbar position at top: Panel depth 500, 800 mm Connection from: Bottom Access: Front side Panel depth 800, 1,200 mm Connection from: Top and / or bottom Access: Front or rear side Panel design: Height of device compartment: 1,600 mm* / 1,800 mm Width of device compartment: 600 mm Width of cable connection compartment: Either 400 mm or 600 mm
* Panel height 2,000 mm
2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 A BA B CA B DA B EA B A F B A GB HA B J A B KA B L A B MA B NA B P A B QA B RA B S A B T A B UA B V
Fig. 55/8: Universal mounting design – possible combination
600/400* mm 600 mm 2200/2000 mm 1800/1600 mm 600 mm
Withdrawable-unit design Fixed-mounted design Plug-in in-line switchdisconnector design
Fig. 55/9: Universal mounting design – possible combination
Rated currents of vertical panel busbar The rated operating currents for various cross sections are listed in Table 55/6. Vertical panel distribution busbar: Contact protection (IP20 B) Covers at the front with tap openings spaced at 50 mm as option Contact protection with phase separation (IP20 B) Arcing-proof embedding Shutter for normal and miniature withdrawable units Withdrawable-unit design Module sizes: Miniature withdrawable units (MU) Normal withdrawable units (NU) 4 × MU ¼ = height 150 / 200 mm 2 × MU ½ = height 150 / 200 mm 1 × NU = height 100 to 700 mm Three module sizes are shown in Photo 55/10. Utilization of the single branch circuit: Motor starters: In ≤ 0.8 × InC Cable feeders: In ≤ 0.8 × InC The total current of all branch circuits must not exceed the rated current of the vertical distribution busbar in the panel. Module heights of miniature withdrawable units Table 55/7 contains guide values for direct starters and cable feeders. Module heights of normal withdrawable units Table 55/8 contains guide values for direct starters and cable feeders.
Rated operating current for ambient temperature of 35 °C [A] Ventilated (e.g. IP40) Non-ventilated (e.g. IP54)
Shaped copper 400 650 Flat copper 400 800 895 1,120 820 1,000 905 1,100 830 1,000
Table 55/6: Rated operating currents according to cross section
Photo 55/10: ¼ size, H150; ½ size, H200; size H150 mm
Size of withdrawable unit ¼, height 150 mm ¼, height 200 mm ½, height 150 mm ½, height 200 mm
400 V / direct starters Up to 11 kW Up to 15 kW Up to 22 kW Up to 30 kW
Cable branch circuits Up to 35 A Up to 35 A Up to 63 A Up to 63 A
Table 55/7: Module heights of the miniature withdrawable units
Size of withdrawable unit 100 mm 150 mm 200 mm 300 mm 400 mm 500 mm 600 mm 700 mm
400 V / direct starters Up to 11 kW Up to 22 kW Up to 45 kW Up to 75 kW Up to 132 kW Up to 160 kW Up to 250 kW YD 250 kW
Cable branch circuits Up to 25 A Up to 125 A Up to 250 A Up to 630 A – – – –
Table 55/8: Module heights of the normal withdrawable units
Fixed-mounted design with front doors
Utilization of the single branch circuit: Cable feeders: In ≤ 0.8 × InC Module heights in fixed-mounted design: The module heights listed in Table 55/9 should be taken into account for the fixed-mounted design.
Type Type Rated switch current [A] Module height [mm] 3-pole Switchdisconnector with fuse 3KL50 3KL52 3KL53 3KL55 3KL57 3KL61 Circuitbreaker 3RV1.3 3RV1.4 3VL1 3VL2 3VL3 3VL4 3VL5 63 125 160 250 400 630 50 100 160 160 250 400 630 150 250 250 300 300 450 150 150 150 150 200 250 250 4-pole 250 250 250 350 350 500 – – 200 200 250 300 350
Table 55/9: Characteristics of switch-disconnectors and circuitbreakers
Fig. 55/11: Plug-in 3NJ6 in-line switch-disconnector design
Field of application: Cable feeders up to 630 A Incoming feeders up to 630 A Design options: Fuse-protected design Switch-disconnector with fuses with double interruption With or without current measurement Integrated current transformer and retrofit accessories Panel dimensions: Height: 2,000 or 2,200 mm Width: 1,000, 1,200 mm Depth: 500, 600, 800, 1,000, 1,200 mm Degrees of protection (according to IEC 60529): Ventilated ≤ IP41 Form of internal compartmentalization: Form 1, 3b, 4b
3NJ6 in-line switch-disconnector design module heights: The module heights listed in Table 55/10 should be taken into account for the in-line switch-disconnector design. Component mounting rules for ventilated panels with 3-pole or 4-pole in-line switch-disconnectors: Component mounting in the panel from the bottom to the top decreasing in size from size 3 to size 00 Recommended maximum component density per panel approx. ⅔ including reserve Distribute in-line switch-disconnectors of size 2 and 3 to different panels, if possible The total current of all branch circuits must not exceed the rated current of the vertical distribution busbar in the panel: – Rated currents of component sizes = 0.8 × IN of the largest fuse-link – Rated currents of smaller fuse-links sizes = 0.8 × IN of the fuse-link
Module height of the in-line switchdisconnectors [mm] 3-pole 4-pole 100 150 250 250
3NJ6203 3NJ6213 3NJ6223 3NJ6233
Compartments with module door Can be freely equipped Can be freely equipped Can be freely equipped Can be freely equipped Table 55/10: Module heights of the various types
Module height 100 200 300 400
Cable connection direction: Busbar position at rear: Panel depth 600, 800 mm: Connection from: Top and / or bottom Access: Front side Panel depth 1,000, 1,200 mm: Connection from: Top and / or bottom Access: Front side Busbar position at top: Panel depth 500, 800 mm Connection from: Bottom Access: Front side Panel depth 800, 1,200 mm Connection from: Top and / or bottom Access: Front side Panel design: Height of device compartment: 1,550 mm* / 1,750 mm Width of device compartment: 600 mm Width of cable connection compartment: Either 400 mm or 600 mm
Rated operating current for ambient temperature of 35 °C [A] Ventilated (e.g. IP40)
Flat copper 600 800 1,500 2,100
Table 55/11: Rated operating currents according to cross section
Rated currents of vertical panel busbar The rated operating currents for various cross sections are listed in Table 55/11. Vertical distribution busbar in panel: Contact protection (IP20 B) Covers at the front with tap openings spaced at 50 mm
Fixed-mounting design with front cover
Field of application: Cable feeders up to 630 A Modular devices Design options: Circuit-breaker-protected or fuse-protected design Single / multiple branch circuits Panel dimensions: Height: 2,000 or 2,200 mm Width: 1,000, 1,200 mm Depth: 500, 600, 800, 1,000, 1,200 mm Degrees of protection (according to IEC 60529): Rack cover Ventilated ≤ IP31 Additional viewing or panel door Ventilated ≤ IP41 Non-ventilated ≤ IP54 Form of internal compartmentalization: Single branch circuits Form 1, 2b, 3b, 4a, 4b Multiple branch circuits Form 1, 2b Utilization of the single branch circuit: Cable feeders: In ≤ 0.8 × InC Cable connection direction: Busbar position at rear: Panel depth 600, 800 mm: Connection from: Top and / or bottom Access: Front side Panel depth 1,000, 1,200 mm: Connection from: Top and / or bottom Access: Front side Busbar position at top: Panel depth 500, 800 mm Connection from: Bottom Access: Front side Panel depth 800, 1,200 mm Connection from: Top and / or bottom Access: Front side
Fig. 55/12: Fixed-mounting design with front cover 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 A BA B CA B DA B EA B A F B A GB HA B J A B KA B L A B MA B NA B P A B QA B RA B S A B T A B UA B V
Table 55/12: Rated operating currents according to cross section
Panel design: Height of device compartment: 1,600 mm* / 1,800 mm Width of device compartment: 600 mm
p Width of cable connection compartment: Either 400 mm or 600 mm* Panel height 2,000 mm
Fixed-mounted 3NJ4 in-line switchdisconnector design
Rated currents of vertical panel busbar: The rated operating currents for various cross sections are listed in Table 55/12. Module heights in fixed-mounted design The module heights listed in Table 55/13 should be taken into account for the fixed-mounted design.
2200 2000 1800 1600 1400 1200 A BA B CA B DA B EA B A F B GA B HA B J A B KA B L A B MA B NA B P A B QA B RA B S A B T A B UA B V
Number per line 3-pole / 4-pole 1 4 1 3 1 1 1 1 9 1 9 7 6 4/3 4/3
Rated switch current [A]
Module height [mm] 3-pole / 4-pole 150 / – 300 / – 200 / – 300 / – 250 / – 300 / – 300 / – 100 / – 200 / – 100 / – 200 / – 250 / – 300 / – 350 / 450 350 / 450
Fuse-switchdisconnector
3NP40 10 3NP40 10 3NP40 70 3NP40 70 3NP42 70 3NP43 70 3NP44 70
160 160 160 160 250 400 630 12 12 25 25 50 100 160 160
3RV101 3RV101 3RV1.2 3RV1.2 3RV1.3 3RV1.4 3VL1 3VL2
Fig. 55/13: Fixed-mounted 3NJ4 in-line switch-disconnector design
Field of application: Cable feeders up to 630 A Incoming feeders up to 630 A Design options: Fuse-protected design Fuse-switch-disconnector With or without current measurement Integrated current transformer and retrofit accessories Panel dimensions: Height: 2,000 or 2,200 mm Width: 600, 800 mm Depth: 600, 800,1,000, 1,200 mm Degrees of protection (according to IEC 60529): In-line switch-disconnectors through the door: Ventilated ≤ IP31 In-line switch-disconnectors behind the panel door Ventilated ≤ IP41 Non-ventilated ≤ IP54 Form of internal compartmentalization: Form 1, 2b
For data on single branch circuits with 3KL switch-disconnectors with fuses and 3VL molded-case circuit-breakers, see "Fixedmounted design with front doors", Page 89 Table 55/13: Characteristics of fuse-switch-disconnectors and circuit-breakers
3NJ4 in-line switch-disconnector module heights The module heights listed in Table 55/14 should be taken into account for the in-line switch-disconnector design. Component mounting rules for panels with 3-pole 3NJ4 in-line switch-disconnectors: Arrangement of the in-line switch-disconnectors in the panel: 3NJ4 in-line switch-disconnectors decreasing in size either from left to right or from right to left. Permissible utilization of the branch circuits: The specified 3NJ4 rated currents apply for 3NJ4 in-line switch-disconnectors equipped with the largest possible LV HRC fuse-links. If smaller LV HRC fuse-links are used, the same proportionally smaller utilization is permitted. Example: 3NJ414 in-line switch-disconnector in non-ventilated panel equipped with 500 A LV HRC fuse-links, ambient temperature ≤ 40 °C: Max. permissible continuous operating current = (370 A / 630 A) × 500 A = 290 ACable connection direction: Busbar position at rear: Panel depth 600, 800 mm: Connection from: Top or bottom Access: Front side Panel depth 1,000, 1,200 mm: Connection from: Top or bottom Access: Front side Panel design: Width of device compartment: 500 mm* / 700 mm
* Panel width 600 mm
Fig. 55/14: Reactive power compensation
Rated currents of vertical panel busbar The rated operating currents for various cross sections are listed in Table 55/15.
Type Rated current [A] Size Module height of the in-line switchdisconnectors [mm] 3-pole 50 100 100 100
Field of application: Closed-loop controlled reactive power compensation with connection to the main busbar or separate installation up to 600 kvar (Fig. 55/14). Design options: Non-choked Choked: 5.67 %, 7 %, 14 % With / without AF suppression circuit With / without upstream switch-disconnector module as cut-off point between main and distribution busbar Panel dimensions: Height: 2,000 or 2,200 mm Width: 800 mm Depth: 500, 600, 800, 1,000, 1,200 mm Degrees of protection (according to IEC 60529): Ventilated ≤ IP41 Form of internal compartmentalization: Form 1, 2b
3NJ410 3NJ412 3NJ413 3NJ414
Table 55/14: Module heights of the various types Cross section [mm²] Rated operating current for ambient temperature of 35 °C [A] Ventilated (e.g. IP40) Flat copper 6001) 1,0002)
Non-ventilated (e.g. IP54)
1,560 2,180
1,430 1,790 Panel width 800 mm
Panel width 600 mm
Table 55/15: Rated operating currents according to cross section
Selection table for direct connection to main busbar Table 55/16 Cable connection direction: Busbar position at rear Panel depth 600, 800 mm: Connection from: Bottom Access: Front side Panel depth 1,000, 1,200 mm: Connection from: Bottom Access: Front side Busbar position at top Panel depth 500, 800 mm Connection from: Bottom Access: Front side Panel depth 800, 1,200 mm Connection from: Bottom Access: Front side Panel design: Height of device compartment: 1,600 mm* / 1,800 mm Width of device compartment: 800 mm
Reactive power per panel [kvar] 50 100 150
Choking possible
Installation option Busbar position at the rear Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 1) Yes 1) No Busbar position at the top Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No
[kvar] 2 × 25 4 × 25 6 × 25 4 × 50 5 × 50 6 × 50 7 × 50 8 × 50 8 × 50 9 × 50 10 × 50 12 × 50 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 1) Yes 1) No
< 2,200
200 250 300 350 400 400
Can only be implemented with IP30 / IP31 degree of protection
Table 55/16: Installation options for reactive current compensation
Reactive power per panel [kvar] 50 100 150 200 250 300 350 400 450 500 600
Back-up fuse [A] 100 250 355 500 630 2 × 355 2 × 400 2 × 500 2 × 500 2 × 630 2 × 630
Cable cross section [mm²] 35 120 2 × 70 2 × 120 2 × 150 2 × 185 4 × 95 4 × 120 4 × 120 4 × 150 4 × 185
Selection table for back-up fuse and connecting cable for separate installation, see Table 55/17. Calculation and determination of required capacitor power: 1. The electricity bill of the power supply company shows the consumption of active work in kWh and reactive work in kVArh; the company demands a cos φ of 0.9 ... 0.95; in order to cut costs, reactive work shall be compensated to a value approximating cos φ = 1.
Determination of tan φ1: Reactive work kvarh tan φ1 = ―――――― = ―― kWh Active work
2. Refer to Table 55/18 for the conversion factor "F" and multiply it with the mean power consumption Pm. With tan φ1, cos φ1 shows the power factor prior to compensation, cos φ2 shows in factor "F" the desired power factor for compensation. The required compensation power is specified in kVAr. Determination of the required compensation power: The required compensation power can be determined with the values of Table 55/18.
Table 55/17: Back-up fuse and cable cross section
Mean power consumption:
Reactive work Wb = 19,000 kvarh per month Active work Ww = 16,660 kWh per month
16,600 kWh Active work ―――――― = ―――― = 92.6 kW Working hours 180 h
Reactive work 19,000 kvarh tan φ1 = ―――――― = ――――― = 1.14 16,600 kWh Active work
Power factor cos φ1 = 0.66 (for tan φ1 = 1.14) Power factor cos φ2 = 0.95 (desired) Conversion factor „F“ = 0.81 (from tan φ1 and cos φ2) Compensation power = mean power × factor „F“ = 92.6 kW × 0.81
Required compensation power: 75 kvar
Fig. 55/15: Sample calculation
Actual value (versus) tan φ1
4.90 3.87 3.18 2.68 2.29 2.16 2.04 1.93 1.83 1.73 1.64 1.56 1.48 1.40 1.33 1.27 1.20 1.14 1.08 1.02 0.96 0.91 0.86 0.80 0.75 0.70 0.65 0.59 0.54 0.48 0.43 0.36 0.29 0.20
Conversion factor “F” cos φ2 = 0.70
3.88 2.85 2.16 1.66 1.27 1.14 1.02 0.91 0.81 0.71 0.62 0.54 0.46 0.38 0.31 0.25 0.18 0.12 0.06 –
0.20 0.25 0.30 0.35 0.40 0.42 0.44 0.46 0.48 0.50 0.52 0.54 0.56 0.58 0.60 0.62 0.64 0.66 0.68 0.70 0.72 0.74 0.76 0.78 0.80 0.82 0.84 0.86 0.88 0.90 0.92 0.94 0.96 0.98
cos φ2 = 0.75
4.02 2.99 2.30 1.79 1.41 1.28 1.16 1.05 0.95 0.85 0.76 0.68 0.60 0.52 0.45 0.38 0.32 0.26 0.20 0.14 0.08 0.03 –
cos φ2 = 0.80
4.15 3.12 2.43 1.93 1.54 1.41 1.29 1.18 1.08 0.98 0.89 0.81 0.73 0.65 0.58 0.52 0.45 0.39 0.33 0.27 0.21 0.16 0.11 0.05 –
cos φ2 = 0.82
4.20 3.17 2.48 1.98 1.59 1.46 1.34 1.23 1.13 1.03 0.94 0.86 0.78 0.71 0.64 0.57 0.50 0.44 0.38 0.32 0.27 0.21 0.16 0.10 0.05 –
cos φ2 = 0.85
4.28 3.25 2.56 2.06 1.67 1.54 1.42 1.31 1.21 1.11 1.02 0.94 0.86 0.78 0.71 0.65 0.58 0.52 0.46 0.40 0.34 0.29 0.24 0.18 0.13 0.08 0.03 –
cos φ2 = 0.87
4.33 3.31 2.61 2.11 1.72 1.59 1.47 1.36 1.26 1.17 1.08 0.99 0.91 0.84 0.77 0.70 0.63 0.57 0.51 0.45 0.40 0.34 0.29 0.24 0.18 0.13 0.08 0.03 –
cos φ2 = 0.90
4.41 3.39 2.70 2.19 1.81 1.68 1.56 1.45 1.34 1.25 1.16 1.07 1.00 0.92 0.85 0.78 0.72 0.65 0.59 0.54 0.48 0.42 0.37 0.32 0.27 0.21 0.16 0.11 0.06 –
cos φ2 = 0.92
4.47 3.45 2.75 2.25 1.87 1.74 1.62 1.50 1.40 1.31 1.22 1.13 1.05 0.98 0.91 0.84 0.77 0.71 0.65 0.59 0.54 0.48 0.43 0.38 0.32 0.27 0.22 0.17 0.11 0.06 –
cos φ2 = 0.95
4.57 3.54 2.85 2.35 1.96 1.83 1.71 1.60 1.50 1.40 1.31 1.23 1.15 1.08 1.00 0.94 0.87 0.81 0.75 0.69 0.63 0.58 0.53 0.47 0.42 0.37 0.32 0.26 0.21 0.16 0.10 0.03 –
cos φ2 = 0.97
4.65 3.62 2.93 2.43 2.04 1.91 1.79 1.68 1.58 1.48 1.39 1.31 1.23 1.15 1.08 1.01 0.95 0.89 0.83 0.77 0.71 0.66 0.60 0.55 0.50 0.45 0.40 0.34 0.29 0.23 0.18 0.11 0.01 –
cos φ2 = 1.00
Table 55/18: Conversion factors “F”
5.6 Busbar Trunking Systems
When a planning concept for power supply is developed, it is not only imperative to observe standards and regulations, it is also important to discuss and clarify economic and technical interrelations. The rating and selection of electric equipment, such as distribution boards and transformers, must be performed in such a way that an optimum result for the power system as a whole is kept in mind rather than focusing on individual components. All components must be sufficiently rated to withstand normal operating conditions as well as fault conditions. Further important aspects to be considered for the creation of an energy concept are: Type, use and shape of the building (e.g. high-rise building, low-rise building, multi-storey building)
5.6.2 Planning Notes
Considering the complexity of modern building projects, transparency and flexibility of power distribution are indispensable requirements. In industry, the focus is on continuous supply of energy as an essential prerequisite for multi-shift production. Busbar trunking systems meet all these requirements on efficient power distribution by being easily planned, quickly installed and providing a high degree of flexibility and safety. The advantages of busbar trunking systems are: Straightforward network configuration Low space requirements Easy retrofitting in case of changes of locations and consumer loads High short-circuit strength and low fire load Increased planning security Power transmission Power from the transformer to the low-voltage switchgear is transmitted by suitable components in the busbar trunking system. These components are installed between transformer and main distribution board, then branching to sub-distribution systems. Trunking units without tap-off points are used for power transmission. These are available in standard lengths. Besides the standard lengths, the customer can also choose a specific length from various length ranges to suit individual constructive requirements. Power distribution Power distribution is the main area of application for busbar trunking systems. This means that electricity cannot just be tapped from a permanently fixed point as with a cable installation. Tapping points can be varied and changed as desired within the entire power distribution system. In order to tap electricity, you just have plug a tap-off unit on the busbar at the tap-off point. This way a variable distribution system is created for linear and / or area-wide, distributed power supply. Tap-off points are provided on either or just one side on the straight trunking units. For each busbar trunking system, a wide range of tap-off units is available for the connection of equipment and electricity supply.
Load centers and possible power transmission routes and locations for transformers and main distribution boards Building-related connection values according to specific area loads that correspond to the building’s type of use Statutory provisions and conditions imposed by building authorities Requirements of the power distribution network operator The result will never be a single solution. Several options must be assessed in terms of their technical and economic impacts. The following requirements are the main points of interest: Easy and transparent planning Long service life High availability Low fire load Flexible adaptation to changes in the building Most applications suggest the use of suitable busbar trunking systems to meet these requirements. For this reason, engineering companies increasingly prefer busbar trunking to cable installation for power transmission and distribution. Siemens offers busbar trunking systems ranging from 25 A to 6,300 A.
Characteristic Planning, calculation Expansions, changes Space requirements Temperature responses and derating Free from halogen Fire load Type-tested switchgear assembly
Cable High determination and calculation expense, the consumer locations must be ﬁxed High expense, interruptions to operation, calculation, risk of damage to the insulation More space required because of bending radiuses and the spacing required between parallel cables Limits depend on the laying method and cable accumulation. The derating factor must be determined / calculated PVC cables are not free from halogen; halogen-free cable is very expensive Fire load with PVC cable is up to 10 times greater, with PE cable up to 30 times greater than with busbars The operational safety depends on the version
Busbar Flexible consumer locations, only the total load is required for the planning Low expense as the tap-off units are hot pluggable Compact directional changes and ﬁttings Type-tested switchgear assembly, limits from catalog Principally free from halogen Very low, see catalog Tested system, non-interchangeable assembly
Table 56/1: Cable / busbar comparison
Benefits System CD-L up to 40 A The multi-purpose busbar trunking system for the areawide power supply of lighting systems: Multi-purpose application thanks to high IP55 degree of protection Reduction of planning costs thanks to easy configuration Time-saving installation thanks to plug-in rapid connection Variable changes of direction Optimal utilization of the busbar line through tap-off points on both sides Even current load on all conductors through division of the connected tap-off plugs to the different phases
140 I e [%] 120
Ie =100 80 60 40
15 10 25 20 25 30 35 40 45 50 55 60 65 Ambient temperature [°C]
Fig. 56/1: Comparison of temperature response and derating
70 60 50 40 30 20 10 0 Fig. 56/2: Comparison of ﬁre load at a rated current of 2,000 A
7 × 3 × 185/95 9 × 3 × 120/70
Fast and flexible change of consumer locations through tap-off plugs System BD01 to to 160 A The busbar trunking system for power distribution in trade and commerce: High degree of protection up to IP55 Flexible power supply Easy and fast planning Time-saving installation Reliable mechanical and electrical cables and connections High stability, low weight Small number of basic modules Modular system reduces stock-keeping
Depending on type 10 to 30 times higher
(see Catalog LV 70 for data)
PE/EPR (halogen-free) 7 × 3 × 185/95 9 × 3 × 120/70 2–4 × PVC
Variable changes of direction Multi-purpose tap-off units Forced opening and closing of the tap-off point System BD2 up to 1,250 A The busbar trunking system for power distribution in the aggressive industrial environment: High degree of protection up to IP55 Easy and fast planning Time-saving and economic installation Safe and reliable operation Flexible, modular system providing simple solutions for every application Advance power distribution planning without precise knowledge of device locations
System LR The busbar trunking system for power transmission in extreme environmental requirements (IP68). Detailed information on this system is available in your local Siemens AG office. Communication-capable busbar trunking system Communication-capable functional extensions to be combined with known tap-off units: For use with the systems BD01, BD2, LD and LX Applications: – Large-scale lighting control – Remote switching and signaling in industrial environments – Consumption metering of distributed load feeders Interfacing to KNX / EIB, AS-Interface and PROFIBUS bus systems Easy contacting of the bus line with insulation displacement method Easy and fast planning Flexible for extension and modification Modular system Retrofitting to existing installations possible Further information Busbar trunking system selection guide (MobileSpice) You can order busbar trunking systems up to 1,250 A with the selection guide. The following configurators are available: SIVACON 8PS system CD-L, 25 … 40 A SIVACON 8PS system BD01, 40 … 160 A SIVACON 8PS system BD2, 160 … 1,250 A This selection guide is available via the A&D Mall and contained on DVD in Catalog CA 01. This DVD is available free-of-charge from your Siemens sales office. Manual Planning with SIVACON 8PS – Busbar Trunking Systems up to 6,300 A German: Order no. A5E 01541017-01 English: Order no. A5E 01541117-01 Brochure Busbar Trunking Systems for Safe and Flexible Power Distribution up to 6,300 A German: Order no. E20001-A220-P309-V2 English: Order no. E20001-A220-P309-V2-7600
Ready to use in no time thanks to fast and easy installation Innovative construction: expansion units to compensate for expansion are eliminated. Tap-off units and tap-off points can be coded at the factory Uniformly sealable System LD up to 5,000 A The perfect busbar trunking system for power distribution in industrial environments: High IP54 degree of protection Easy and rapid installation Safe and reliable operation Space-saving, compact design, up to 5,000 A in one casing Load feeders up to 1,250 A Type-tested connection to distribution board and transformers System LX up to 6,300 A The busbar trunking system for power transmission and distribution in buildings: High degree of protection up to IP55 Easy and rapid installation Safe and reliable operation Load feeders up to 1,250 A Type-tested connection to distribution board and transformers
CD-L system up to 40 A BD01 system up to 160 A BD2 system up to 1,250 A
LD system up to 5,000 A LX system up to 6,300 A Communication-capable busbar trunking systems
Fig. 56/3: Overview of busbar trunking systems
Frequency Number of active conductors Degree Ambient Mounting of pro- temperature, position tection min / max Length Tap-off points Tap-off units Material Fire load Combinable with communicationcapable tapoff units for – [V AC] 400 50 … 60 One side: 2, 4, 6 Both sides: 2 × 2 1×4+1×2 2×4 2×6 (PE = casing) 4 (PE = casing) Up to IP55 −5 / +40 On edge, ﬂat (tapoff points downward) 2 3 One side: Every 0.5 or 1 m Up to 63 A Insulated Al or Cu conductor, painted sheet-steel casing Al or Cu busbars, painted sheet-steel casing 0.76 IP55 −5 / +40 On edge 1.5 2 3 One side: Every 0.5, 1 or 1.5 m Both sides: Every 0.5, 1 or 1.5 m Up to 16 A Insulated Cu conductor, painted sheet-steel casing One side: 0.75 Both sides: 1.5 [Hz] [ °C] [m] [kWh / m] 400 50 … 60 Lighting control 690 50 … 60 5 Up to IP55 −5 / +40 On edge, ﬂat and vertical 0.5 … 3.25 Without Both sides: Every 0.25 or 0.5 m offset Up to 630 A 0.6 … 0.67 (without tap-off points) Lighting control, remote control and signaling and consumption metering Without One side: Every 1 m Both sides: Every 1 m Up to 1,250 A Insulated Al or Cu busbars, painted sheet-steel casing Horizontal, on edge and vertical 0.35 … 3 Without One side: Every 0,5 m Both sides: Every 0.5 m Up to 1,250 A Insulated Al or Cu busbars, painted aluminum casing −5 / +40 Horizontal, on edge and vertical 0.5 … 3 Without One side: Selectable Up to 630 A Epoxy resin system, Cu busbars 4.16 … 8.83 (without tap-off points) Remote control and signaling and consumption metering 1,000 50 … 60 4 or 5 Up to IP54 −5 / +40 Horizontal, on edge and vertical 0.5 … 3.2 1,000 50 … 60 3, 4, 5, 6 (PE = casing) Up to IP55 −5 / +40 1.95 … 11.07 (without tap-off points) Remote control and signaling and consumption metering 1,000 50 … 60 4, 5 IP68 – –
25 40 2 × 25 2 × 40
BD2A BD2C
160 … 400 630 … 1,250
LDA1 … LDA8 LDC2 … LDC8
1,100 … 4,000 2,000 … 5,000
LXA01 … LXA10 LXC01 … LXC10
800 … 4,500 1,000 … 6,300
LRC01 … LRC29
630 … 6,300
Table 56/2: Rating data overview for busbar trunking systems
Project name ....................................................... ....................................................... Owner / developer ....................................................... ....................................................... Planning engineer .......................................................
Rated operating voltage Rated current (depending on degree of protection and laying method) Ambient temperature Degree of protection
c TN-S c TN-C
c TN-S (EMC-friendly) c TN-C-S c TT c IT
Type-tested connection to LVMD
Conductor conﬁguration
c L1, L2, L3 c PE
c 2N c PE = casing
c . . . . . . . . PE
Maximum voltage drop (from supply to busbar to the ﬁnal load feeder) Number of ﬁre barriers (wall lead-through bushings) Proportion of busbars with ﬁre barriers (in m) Fastening / routing of busbar Busbar layout drawing (incl. lengths and loads)
5.7 Distribution Boards for Subdistribution Systems
Distribution boards are available in flush-mounted or surface-mounted design and as floor-mounted distribution boards. Sub-distribution boards are often installed in
Distribution board for max. current carrying capacity up to [A] 1,250 1,250 1,250 1,250 1,250 630 630 630 Cabinet depth Outer dimensions HxW Inner dimensions HxW
confined spaces, recesses or narrow corridors. This often results in a high device packing density. In order to prevent device failures or even fire caused by excess temperatures, special attention must be paid to the permissible power loss in relation to the distribution board size, its degree of protection and the ambient temperature.
Modular widths Degree of protection IP Safety class Permissible device power losses Pv of built-in devices at overtemperature 30 K, ambient temperature 35 °C [W] 55 55 55 55 55 55 55 55 55 55 43 43 43 43 43 55 55 55 55 55 55 55 55 55 55 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 158 309 414 478 550 129 182 324 410 466 110 124 278 384 440 155 262 384 448 514 155 262 384 448 514 50 78 109 130 158 60 90 118 150 194 68 102 131 176 239 77 107
[mm] 400 400 400 400 400 250 250 250 250 250 210 210 210 210 210 320 320 320 320 320 320 320 320 320 320 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210
[mm] 1,950 x 300 1,950 x 550 1,950 x 800 1,950 x 1,050 1,950 x 1,300 1,950 x 300 1,950 x 550 1,950 x 800 1,950 x 1,050 1,950 x 1,300 1,950 x 300 1,950 x 550 1,950 x 800 1,950 x 1,050 1,950 x 1,300 1,950 x 300 1,950 x 550 1,950 x 800 1,950 x 1,050 1,950 x 1,300 1,950 x 300 1,950 x 550 1,950 x 800 1,950 x 1,050 1,950 x 1,300 650 x 300 650 x 550 650 x 800 650 x 1,050 650 x 1,300 800 x 300 800 x 550 800 x 800 800 x 1,050 800 x 1,300 950 x 300 950 x 550 950 x 800 950 x 1,050 950 x 1,300 1,100 x 300 1,100 x 550
[mm] 1,800 x 250 1,800 x 500 1,800 x 750 1,800 x 1,000 1,800 x 1,250 1,800 x 250 1,800 x 500 1,800 x 750 1,800 x 1,000 1,800 x 1,250 1,800 x 250 1,800 x 500 1,800 x 750 1,800 x 1,000 1,800 x 1,250 1,800 x 250 1,800 x 500 1,800 x 750 1,800 x 1,000 1,800 x 1,250 1,800 x 250 1,800 x 500 1,800 x 750 1,800 x 1,000 1,800 x 1,250 600 x 250 600 x 500 600 x 750 600 x 1,000 600 x 1,250 750 x 250 750 x 500 750 x 750 750 x 1,000 750 x 1,250 900 x 250 900 x 500 900 x 750 900 x 1,000 900 x 1,250 1,050 x 250 1,050 x 500
[pcs.] 144 288 432 576 720 144 288 432 576 720 144 288 432 576 720 144 288 432 576 720 144 288 432 576 720 48 96 144 192 240 60 120 180 240 300 72 144 216 288 360 84 168
630 630 630 630 630 630 630 630 630 630 630 630 630 630 630 630 630 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400
Table 57/1: Guide values for device power losses at an ambient temperature of 35 °C
Distribution board for max. current carrying capacity up to [A] 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160
Outer dimensions HxW
Inner dimensions HxW
Modular widths
Permissible device power losses Pv of built-in devices at overtemperature 30 K, ambient temperature 35 °C [W]
[mm] 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 210 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140
[mm] 1,100 x 800 1,100 x 1,050 1,100 x 1,300 1,250 x 300 1,250 x 550 1,250 x 800 1,250 x 1,050 1,250 x 1,300 1,400 x 300 1,400 x 550 1,400 x 800 1,400 x 1,050 1,400 x 1,300 950 x 300 950 x 550 950 x 800 950 x 1,050 950 x 1,300 1,100 x 300 1,100 x 550 1,100 x 800 1,100 x 1,050 1,100 x 1,300 1,250 x 300 1,250 x 550 1,250 x 800 1,250 x 1,050 1,250 x 1,300 1,400 x 300 1,400 x 550 1,400 x 800 1,400 x 1,050 1,400 x 1,300 500 x 300 500 x 550 500 x 800 650 x 300 650 x 550 650 x 800 650 x 1,050 800 x 300 800 x 550 800 x 800 800 x 1,050 950 x 300 950 x 550 950 x 800 950 x 1,050 1,100 x 300 1,100 x 550 1,100 x 800 1,100 x 1,050
[mm] 1,050 x 750 1,050 x 1,000 1,050 x 1,250 1,200 x 250 1,200 x 500 1,200 x 750 1,200 x 1,000 1,200 x 1,250 1,350 x 250 1,350 x 500 1,350 x 750 1,350 x 1,000 1,350 x 1,250 900 x 250 900 x 500 900 x 750 900 x 1,000 900 x 1,250 1050 x 250 1,050 x 500 1,050 x 750 1,050 x 1,000 1,050 x 1,250 1,200 x 250 1,200 x 500 1,200 x 750 1,200 x 1,000 1,200 x 1,250 1,350 x 250 1,350 x 500 1,350 x 750 1,350 x 1,000 1,350 x 1,250 450 x 250 450 x 500 450 x 750 600 x 250 600 x 500 600 x 750 600 x 1,000 750 x 250 750 x 500 750 x 750 750 x 1,000 900 x 250 900 x 500 900 x 750 900 x 1,000 1,050 x 250 1,050 x 500 1,050 x 750 1,050 x 1,000
[pcs.] 252 336 420 96 192 288 384 480 108 216 324 432 540 72 144 216 288 360 84 168 252 336 420 96 192 288 384 480 108 216 324 432 540 21 34 49 25 41 58 75 30 47 66 81 34 54 68 87 39 60 73 102 43 43 43 43 43 43 43 43 43 43 43 43 43 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 1+2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
148 208 290 85 114 168 247 338 94 122 194 288 378 68 102 131 176 219 77 107 148 208 290 85 102 168 247 338 96 132 194 288 378 34 57 80 42 68 96 124 49 78 109 133 56 89 112 144 64 100 121 168
5.8 Uninterruptible Power Supply (UPS)
Relevant guidelines and descriptions of UPS systems as well as further references can be found in the following standards: IEC 62040-1 General requirements and safety requirements for UPS IEC 62040-2 Requirements on electromagnetic compatibility (EMC) IEC 62040-3 Methods for the specification of performance and testing requirements Note that the above standards cannot substitute detailed expert planning and are by no means complete. Planning notes for UPS systems The classification of static UPS types is described in the international standard IEC 62040-3. A UPS meets the highest requirements according to the VFI-SS-111 classification of this standard. This requirement is usually met by a permanent double transformation of alternating voltage (single- or three-phase) with fusing in a DC link. These UPS types, known as on-line UPS, are used today for an output power above 10 kVA mainly in the professional sector and are considered in the following. For double-transformer UPS types, a description of the four essential system groups and their requirements with regard to installation and availability may present a straightforward planning aid. Construction and installation Supply network input DC link with battery system UPS output for load supply Signaling and communication Redundancy and availability The mutual interrelations and numerous other details, not mentioned here, are not taken into consideration. Their consideration and integration in the overall project are planning tasks. Construction and installation 230 V floor-mounted models are only used for single PC terminals or small computer networks in one room, or for single applications up to a power demand of about 20 kVA. If one server cabinet provides enough space, a suitable 19-inch UPS version may be installed. Special attention must here be paid to sufficient ventilation, noise and EMC requirements. 19-inch solutions for power demands above 20 kVA hardly make sense, as the built-in devices and batteries would use up a lot of precious cabinet space.
For a power demand of 10 kVA and more, as is well in reach for modern computer and server rooms up to veritable data centers, central solutions are typically configured, featuring a 400 V three-phase connection. USP and battery installation in an air-conditioned and ventilated room of its own is to be preferred. The data provided by the manufacturer on power loss and air flow through the UPS as well as the required ambient temperature for battery blocks must be observed for air conditioning. A battery with 11 min buffering time can be integrated in a 20 kVA UPS (total weight 390 kg) (Fig. 58/1). Separate battery cabinets are required for 100 and 500 kVA. Their dimensions and weights for approx. 11 min buffering time for 100 kVA approx. 800 mm × 650 mm with approx. 1,200 kg and for 500 kVA approx. 7,000 mm × 800 mm with approx. 9,700 kg. Supply network input Depending on the power demand, a UPS with 230 V input voltage should be chosen for a demand up to about 10 or 15 kVA, or 400 V for a higher demand. Owing to the rectification of the alternating input voltage by the UPS, there will be system perturbations on the input network. Stable supply networks as in Germany permit a relatively high input current total harmonic distortion (VDEW recommends THDI < 30 %). In weaker networks, the impact of high UPS system perturbations may significantly affect the environment in the input network. This is also true for a redundant standby power supply (RPS) which is to take over supply in the event of a power failure. For this case, a harmonization of the RPS output to the input conditions at the UPS must be ensured, or alternatively a UPS with a special reduction method for system perturbations, e.g. by means of filters, 12-pulse rectifier circuits or a transistor-controlled rectifier, should be selected. DC link with battery system In order to buffer switching faults in the input network, a battery is still preferred today. The dimensioning of the battery depends on the DC link voltage of the UPS, the required buffering time in the event of a power failure, the desired service life of the battery blocks and the room conditions for ventilation and checking the battery blocks.
500 kVA 2575 kg
100 kVA 390 kg
20 kVA 145 kg 804 mm 830 mm 838 mm
500,8 mm 845 mm
Fig. 58/1: Base diagrams for UPS units without batteries of various power ratings
Single-block monitoring can reduce service overheads on the one hand and increase the reliability of battery power availability on the other. UPS output for load supply Besides the required active power, the load-side power rating for a UPS system also takes the phase interrelations between output voltage and current into account. By means of suitable filtering measures to improve the output voltage quality, UPS output currents may be emitted phase-delayed towards voltage waves. Many of the power supply units nowadays integrated in computers and servers show this power input quality which is characterized by a so-called “inductive power factor” (for lagging current wave) between 0.6 and 0.9. However, modern power supply units are provided with a “power factor compensation” so that phase displacement does not occur any more and pure active power is taken in by the UPS. If loads requiring large capacitors, e.g. for filtering, are connected to the UPS, the entire load system may also have a socalled capacitive load performance factor (current wave leading voltage wave), which must be taken into account for UPS sizing. The possibilities for selective protection upstream and downstream of the UPS, and the short-circuit behavior of the UPS have an impact on power distribution in the load network. What is important for UPS engineering is that the option of a bypass for safe triggering of a short-circuit fuse is also included in the planning. Signaling and communication For a decentralized UPS in an office, an LED display and an acoustic signal meets the essential requirements on signaling UPS status, load requirements and alarms. A serial interface (possibly a USB port) should be provided for PC-based monitoring and parameterization. In a central UPS arrangement, the monitoring unit is rarely in the installation room, so that interfacing to a data network, such as Ethernet per SNMP, or an industrial network like PROFIBUS must be possible. The same applies to emergency signaling using floating contacts with suitable connections. When UPS telemonitoring is outsourced to the UPS manufacturer or its representative, the UPS can communicate with the service center via a separate telephone line. Active “messaging” – in which the UPS immediately signals problems and faults upon occurrence, informing competent authorities, such as the service center, technician and the data center operator, if necessary, by a sequence of measures – would be the optimal solution. Redundancy and availability In addition to the quality of the individual components, the availability can be increased through redundancy. The redundancy can be distributed among the component or device redundancy and the system or route redundancy. If
several components or devices can perform a function and this function is not impaired when a fault occurs in an individual component or device, then the redundancy is called (N+1), as N components or units are required to ensure availability. Redundancy of components in a device is called "internal redundancy". In a "mirrored" arrangement for high-security applications, the complete UPS system is built in parallel, as (N+N) redundancy. (N+1) redundancy for the individual system can also be provided here, for example, (N+1)+(N+1) redundancy. Systematic errors and faults in routes and supplies can also result in the failure of the UPS protection. With the N+N redundancy, two separate systems provide a high level of availability as when a failure occurs in one system route or in a component, the task can be taken over by the second system without a problem. (N+1)+(N+1) redundancy can be selected for component or device redundancy in addition to the system redundancy. An important feature when considering redundancy in detail is "diversity". It is better when devices and components use different operating principles so that when there is a systematic malfunction, both systems do not fail simultaneously. One example is the different stored energy features for the UPS DC link. The battery is a chemical storage module, while the flywheel uses rotational energy and the super capacitor stores the electric charge. The following must be taken into account when planning the UPS: Power system configuration for the input network; power quality and input power factor System perturbation problem at the UPS input Load on safe busbar; planned reserve for rated power Parallel connection; centrally operated, manual bypass for servicing Power factor of the connected loads Battery: buffering time, service life, maintenance, location Ventilation, air conditioning, cable sizing Communication link and shutdown functionality
Basic specifications for the UPS system
Rated power, load-side
Active power required Apparent power required Load power factor required (cos φ) Voltage and frequency, system conﬁguration .................... .................... .................... .................... kVA kW cap. / ind. V , Hz
Power supply source (generator, transformer), number of inputs Permissible system perturbations Voltage and frequency, system conﬁguration .................... .................... .................... % THDi V , Hz
c Central installation in separate room (dimensions) c Decentralized, 19-inch computer, network, server cabinets c Decentralized, ﬂoor-mounted in the computer or ofﬁce room
Electromagnetic compatibility Noise Climatic conditions (room temperature, ventilation, …) Buffering time, shutdown and monitoring
e.g. Class C1, C2, C3 dBA in 1 m
°C, m3 air ﬂow
Battery buffering time at 100 % load Battery service life Battery capacity DC link voltage Signaling
.................... .................... .................... .................... c Serial c USB
min years Ah V c Ethernet c Modbus / JBus
c Contacts Shutdown
c PROFIBUS
c Single system
c Parallel / redundancy systems
c Central monitoring of several separate systems Alarm and messaging system Telemonitoring c c
No redundancy Redundancy of the devices Redundancy of the systems Redundancy for devices and systems c N (sufﬁcient to supply load) c N+1 (N devices are sufﬁcient for load supply) c N+N (2 separate systems that independently supply the load) c (N+1) + (N+1) (2 separate systems, each of which contains one more device than necessary)
5.9 Standby Power Supply
The use of a redundant power supply for the purpose of supplying power when the public supply fails may be required for several reasons, for example: To fulfill statutory regulations for installations for gathering of people, hospitals or similar buildings Official or statutory regulations for the operation of high-rise buildings, offices, workplaces, large garages or similar buildings To ensure operation of safety-relevant systems such as sprinkler systems, smoke evacuation systems, control and monitoring systems or similar systems To ensure operation of IT systems To safeguard production processes in industry To cover peak loads or to complement power supply system
Standby state and version The standby state of power generation stations or redundant power supplies differs according to systems without defined interruption time and systems with a defined, permissible interruption time. If there is no requirement with regard to the period between the power demand and the standby state or energy output, then a system without defined interruption time is used. Manual start of the redundant power supply is usually sufficient in this case. A maximum interruption time between the demand for power and the supply can be defined when required for production processes or by statutory regulations (DIN VDE 0100-710 or -718). These systems are usually started automatically. The different permissible interruption times determine the generator unit variant. In most cases this is a standby generator unit, whereby the unit or system is started from standstill upon demand. The maximum permissible interruption time is 15 s, for example. In certain cases, a shorter interruption time is permitted.. Specially configured generator units must be used in order to be able to implement this shorter interruption time. Criteria for use The only distinction made here is between use on land and marine use. Marine use can be disregarded here. For use on land, appropriate variant classes are defined for the various application options.
5.9.1 Basic Terms
General First, a distinction is made between a power generating unit and a power generating station. The power generating unit is only the actual machine unit comprising drive motor, generator, power transmission elements and storage elements. The power generating station also contains the auxiliary equipment such as exhaust system, switchgear and the installation room. This is then a complete redundant power supply. The purpose of use and the design have not been taken into account yet. Operating modes A distinction is made between continuous operation, time-limited continuous operation and pure emergency operation during the operation or use of redundant power supplies. The unlimited continuous operation enables the operation of a redundant power supply, theoretically for an unlimited time and without interruption. This operating mode is only very rarely used in regions supplied throughout by power supply companies. Equipment that enables long maintenance intervals for the redundant power supply or the continuous operation system must also be taken into account for this mode. Continuous operation for a limited time is the most frequent application for redundant power supplies. The maximum operation time of the system and, in particular the drive motor, is limited. This operating mode is useful for most applications, whereby an operation time of 1,000 h / a with a power reserve of 10 % is available (see DIN / ISO 3046 and 8528). Pure emergency power operation permits operation up to 500 h / a, but it is not possible to overload the system.
5.9.2 Dimensioning of the Generator Units
DIN ISO 8528 applies for the dimensioning and manufacturing of redundant supply generator units. The variant class of the generator unit results from the load demands (Table 59/1). The following factors are important for the dimensioning of the generator units' rated power: Sum of the connected loads = load capacity Simultaneity factor Turn-on behavior of the consumers Dynamic response and load connection response of the generator unit Environmental conditions at the installation site of the generator unit Reserves for expansions Short-circuit behavior
Load capacity The load capacity results from the sum of the individual loads to be supplied. However, the electric apparent power must be used as the basis for the generator unit dimensioning. If necessary, only selected loads may be included in a generator unit supply in order to reduce the generator unit output. Simultaneity factor So-called simultaneity factors are used to determine the actual or realistic consumer load. The generator unit output is reduced by this factor. For values valid for the preliminary planning, see chapter 3. Turn-on and operating behavior of consumers The start-up and turn-on behavior of electric motors, transformers, large lighting systems with incandescent or similar lamps has a major effect on the generator unit output. Especially when there is a large proportion of critical consumers in relation to the generator unit output, an individual test must be performed. The possibility of connecting loads or load groups in stages significantly reduces the required generator unit output. All the available possibilities of reducing the start-up loads of installed consumers should be fully exploited. The operation of some consumer types can also have a major effect on the generator unit output and variant. A special test must be performed when supplying consumers with power electronic components (frequency converters, power converters, UPS systems). Dynamic response The dynamic response of the generator unit at full load connection and for the load changes to be expected must be adapted to the permissible values of the consumers. The variant class of the generator unit in accordance with DIN ISO 8528 is determined by the consumer type or the relevant regulations. Fulfilling the required values can result in an overdimensioning of the engine, generator or both components. As a rule, modern diesel engines with turbochargers and possibly charge air cooling are mostly not suitable for load connections of approx. 60 to 100 % in one load impulse. If no particular consumer-related requirements are made of the generator unit, the load connection must be performed in several stages. Environmental conditions
1 Static frequency deviation ± [ %] Dynamic frequency deviation ± [ %] Static voltage deviation ± [ %] Dynamic voltage deviation [ %] Sustained short-circuit current × In 8 15 5 – –
Variant class 2 5 10 2.5 +22 / –18 3 3 3 7 1 +20 / –15 3
Table 59/1: Generator-unit-speciﬁc operating values in accordance with DIN ISO 8528
The reference conditions for diesel motors must be taken into account here. According to DIN 6271, an ambient or air-intake temperature of 27 °C, a max. installation altitude of 1,000 m above sea level and a relative humidity of 60 % apply. If less favorable conditions are present at the installation site of the generator unit, the diesel engine must be overdimensioned or the engine-specific derating factors must be taken into consideration. Short-circuit behavior If no particular measures are taken, the unit generators supply a three-pole sustained short-circuit current of approx. 3 to 3.5 × In at the generator terminals. If the respective generator unit system supplies large or comprehensive networks, a larger short-circuit current may be required, e.g. for selectivity reasons. An overdimensioning of the generator is required in this case. As the active power may exceed the value of the rated generator unit power when a short-circuit occurs, the diesel engine may also have to be overdimensioned in this case.
5.9.3 Cooling of the Generator Unit Engines
Diesel engines can be cooled in various ways. The basic motor cooling variant depends on the manufacturer-specific equipment of the respective diesel engine. As different cooling methods and principles result in different building requirements, the cooling system should be firmly established. On the other hand, the engine cooling system variant is affected by the conditions at the installation site of the redundant power supply. Air cooling Cooling air is directed over a suitably constructed engine surface by a blower. This cooling method is only found on diesel engines up to approx. 100 kW. Closed-circuit water cooling with built-on radiator and fan Water-cooled diesel engines dissipate the waste engine heat via a water-glycol mixture that is led through the respective separate engine cooling system. The cooling water heated in the engine is cooled in a radiator. Diesel engines that have been designed for a built-on or frontmounted radiator have a fan driven directly by the engine. The required amount of air is blown through the radiator by this fan. The radiant heat of the motor is dissipated by the air flow produced by the fan. The built-on radiator can also be equipped with a charge air cooler. Modern diesel engines are often equipped with turbochargers and charge air coolers. Depending on the design concept of the manufacturer, the charge air circuit of a diesel engine can be designed for air or water cooling. Separate installation of engine and cooling unit Conditions in the building may require the radiator to be installed separately from the generator unit. In this case, the radiator fan is driven by an electric motor. Depending on the distance between the generator unit and the cooling unit, additional devices such as coolant pumps, intermediate heat exchangers, etc. may be required.
5.9.4 Room Layout and System Components
When planning the generator unit room, the local building regulations must be taken into account The planning of the generator unit room can also have a significant influence on the acquisition costs of a redundant power supply. The installation room should be selected according to the following criteria: Short cable routes to the supply point (LVMD) The room should be located as far away as possible from residential rooms, offices, etc. (offending noise) Problem-free intake and exhaust of the required air flow rates Arrangement of the air inlets / outlets taking into account the main wind direction Problem-free routing of the required exhaust pipe Easy access for moving in the components The later generator unit room must be selected so that is it large enough to easily accommodate all the system components. Depending on the installation size, there should be 1 to 2 meters of access space around the generator unit. The generator unit room should always have a temperature of at least + 10° C in order to prevent condensation and corrosion forming and to reduce the engine preheating (Fig. 59/1). Foundation Generally a flat, oil-resisting base with adequate load carrying capacity is sufficient for the installation of generator units. Separate foundations are usually only required for larger generator units or when there are special requirements because of the building structure. Ventilation Appropriate air flow rates are required for the ventilation and cooling depending on the size of the generator unit and the engine cooling method (Fig. 59/2). The flow speed throughout the entire ventilation system should not exceed 6 m / s in order to avoid flow noise. The size of the air inlets and outlets or the entire air circulation is calculated from the required air volume and the flow speed.
The openings should be arranged so that warm exhaust air cannot be drawn in again (thermal short-circuit). The ventilation openings are closed with automatic or motordriven shutters and with weather shields outdoors. If the required air flow rate cannot be achieved, the engine cooling may have to be moved out of the generator unit room (see Section "Cooling of the Generator Unit Engines"). Exhaust system Exhaust systems should be as short and with as few changes of direction as possible. Further statutory regulations, technical guidelines and specifications must be taken into account for the arrangement of the exhaust system, for example, within a building well or for free-standing outdoor chimneys. The design of the actual exhaust pipe with regard to the required cross section results from the planned total length, the maximum exhaust volume and the permissible exhaust back-pressure. Fig 59/3 can be used as a rough guide to determine the pipe cross section. Tank facilities Diesel fuel or fuel oil can be used for diesel generator units. However, the customs and tax regulations must be taken into account when fuel oil is used. There must be sufficient fuel storage capacity available when operating a redundant power supply with a diesel motor. In Germany, the regulations for setting up tank facilities and the regulations for storing flammable liquids must be observed – in particular the water resources management law (WHG), technical rules for waterendangering substances (TRwS 779) and the directive for facilities handling waterendangering substances (VAwS). Each generator unit tank facility should have enough fuel for 8 hours of operation at full load (Fig. 59/4). Facilities that are subject to DIN VDE 0100-710 must be dimensioned for at least 24 hours of operation at full load. In tank facilities for emergency power supply, the fuel level must be at least 0.5 m above the injection pump of the diesel engine. In many cases, in particular for systems in continuous operation. it may be better to divide the tank facilities into a 24-hour tank and a storage tank. The 24-hour tank then remains in the generator unit room with capacity to suit the available space. The storage tank can then be installed in another room or designed as overground tank for outdoor installation or as underground tank. The 24-hour tank is refueled by means of an automatic filling device.
160 140 m3 120 100 80 60 40 20 0 0 400 800 1200 1600 kVA 2000
Fig. 59/1: Space requirements of a complete redundant power supply including soundprooﬁng
30 m3/s 25 20 15 10 5 0 0 400 800 1200 1600 kVA 2000
Fig. 59/2: Estimated air ﬂow rate required for cooling, room ventilation and combustion in relation to the rated power
600 DN 500 400 300 200 100 0 0 400 800 1200 1600 kVA 2000
Fig. 59/3: Rough determination of the pipe cross section in relation to the rated power
Fig. 59/4: Hourly fuel consumption in relation to the rated power
Soundproofing The various sound sources of a generator unit system cause a noise level that is impermissible in nearly every field of application. Highly effective soundproofing is indispensable here. The legally permissible immission values in the various fields of application are specified in the German "TA-Lärm" (technical directive on noise pollution) (see 5.9.5 "Effects on the Environment"). Soundproofing measures: Spring insulator to avoid the transmission of structureborne noise Sound absorbers in the air intake and exhaust circuits as silencers to reduce the ventilation and machine noise. High-performance exhaust mufflers or muffler combinations in the exhaust pipe Noise insulating covers for the generator unit Sound absorbing cladding of the generator unit room
This applies especially to the sound absorbers in the air intake and exhaust circuits as their size results from the required noise level reduction, the air flow rate and the free conduit cross section. The space required for the exhaust muffler, preferably mounted below the ceiling, must be taken into account when specifying the room size and height. A reduced noise level is already achieved in the generator unit room through the use of a noise insulating cover and this results in lower noise values in the adjacent areas. The noise level is also reduced in adjacent rooms through the use of sound absorbing room cladding by a similar extent, but only slightly in the generator unit room itself. System design and installation As a rule, stationary redundant power supplies are installed in separate rooms. The system components described in the previous sections are brought into the generator unit room individually, assembled and completed there. If a suitable generator unit room is not available, a redundant power supply can also be provided as compact unit in a container, or for smaller systems with a soundproof enclosure. All system components are installed ready for operation in an ISO container or soundproof enclosure (Fig. 59/5).
Noise insulating covers for engine radiator when installed separately The soundproofing measures must be dimensioned or designed for the required reduction in noise level. In some cases, the substantial space requirements of the soundproofing equipment must be taken into account in the room layout.
24-hour tank with oil sump
Air intake mufﬂer
Fig. 59/5: Typical arrangement of a stationary redundant power supply
5.9.5 Effects on the Environment
A distinction must be made between emissions and immissions when considering the effects of a redundant power supply on the environment: Emissions come from a device and affect the environment. Immissions are environmental effects at a certain location. A redundant power supply therefore represent a source of emissions. With regard to a certain location or measuring point, the immissions caused by the redundant power supply must be taken into account. Noise Depending on the power output, the noise emitted by diesel generator units lies between 90 and 110 dB(A) measured at one meter in an open area. Under the same conditions, the exhaust noise without muffler is approx. 100 to 120 dB(A). Refer to the valid regulations for the permissible immissions. Exhaust gas The exhaust gases from diesel engines contain pollutants in various proportions and concentrations. The pollutants and their limits relevant for diesel units (internal combustion engines) are specified in the respective valid regulations. Heat Heat is radiated into the installation room by the generator unit engine, the generator and, if present, also the exhaust system. This heat must be dissipated by the ventilation system, In systems with a radiator and fan in the generator unit room, this heat is partly dissipated by the air flow of the engine or radiator fan. If there is no radiator and fan in the generator unit room, the room ventilation must be adapted to the radiant heat the is produced. Vibrations An insulation level of approx. 95 to 97 % is achieved through the use of highly-effective vibration dampers between the engine, generator and the base frame. The remaining vibrations which are transferred to the building structure can usually be ignored. In buildings with more stringent requirements (e.g. hospitals), the generator unit can be installed with double anitvibration mountings.
5.9.6 Electrical Switchgear
Operation of a power supply unit always requires the use of switchgear for the control and monitoring of the unit (Table 59/3, Page115). Fully automatic redundant power supply Automatic operation of the generator unit system during a power failure is implemented. The switchgear has the following components and performs the following major functions: Power supply monitoring Automatic start and stop of the generator unit at power failure and power restoration Power unit for the supply / generator switchover Generator protection and measurement Supply of the auxiliary drives and equipment Battery charging unit and monitoring Control system equipment Additional equipment in accordance with DIN VDE, VdS, etc. Equipment and protective devices for possible parallel operation with the power system or other generators Manual operation The generator unit is started manually by a qualified operator. Apart from that the configuration and the functions of the switchgear are similar to automatic operation. Manual systems are used, e.g. for isolated supplies without any special safety requirements. Start and control supply voltage Diesel engines that are used in the power range relevant for redundant power supplies are usually started with electric starters. The required voltage is supplied by appropriate batteries. For stationary redundant power supplies, these batteries must be configured as Planté-plate batteries in accordance with DIN 6280-13. The battery voltage is also used as control supply voltage. For large systems, it may be better to use separate starter and control batteries.
Rated current The rated current of the power unit of generator-unit switchgear corresponds to the rated current or rated power of the generator unit. Protective measures The local power supply conditions must be taken into account when specifying the "Protection against electric shock" measure in accordance with DIN VDE 0100-410. It must be ensured that the generator sustained short-circuit current is large enough for the protection through automatic shutdown. With large systems, a power supply or short-circuit calculation may be required here. All system components must be included in the equipotential bonding in accordance with the valid regulations. Power cable The appropriate DIN / VDE regulations must be taken into account when selecting the power cable cross section and type for a generator unit. Allowances may have to be taken into account for increased ambient temperatures, laying method and total length. Parallel operation A distinction must be made between parallel operation with other generator units or with the power system.
In parallel operation of generator units, the generator unit itself and the switchgear must be equipped for parallel operation or have the required equipment (Fig. 59/6). In parallel operation with the power system, a further distinction can be made between short-term parallel operation and continuous parallel operation. The shortterm synchronization of power system and generator is used for emergency power systems, e.g. for uninterrupted switchback after power restoration or for uninterruptible load test operation. Continuous parallel operation with the power system is used, e.g. for peak load systems or unittype cogenerating stations, to complement the existing power supply. In parallel operation with the power system, the requirements of the power supply company on the protective devices must be taken into account and agreed upon. If parallel operation of a generator unit is intended, the switchgear must be equipped with a suitable control. Generally, automatic synchronization equipment is used here, which is often just an extension of the actual generator unit control and monitoring unit. If a redundant power supply or emergency power supply is made up of several generator units, a common higher-level control must be provided. This controls the parallel operation of the generator units.
Power unit Instrumentation and control Controller
Fig. 59/6: Schematic representation of the electrical system of a generator unit
Power at cos φ 0.8
Air rate required
Generator unit weight
Required opening for air intake and exhaust width / height [mm] 800 / 1,000 1,000 / 1,500 1,200 / 1,500 1,200 / 1,500 1,200 / 2,000 1,200 / 2,000 1,400 / 2,000 16,00 / 2,000 1,600 / 2,000 1,800 / 2,000 2,000 / 2,500 2,200 / 2,500 2,200 / 2,500 2,200 / 2,500 2,200 / 3,000 1,600 / 2,000 1,600 / 2,000 1,800 / 2,000 1,800 / 2,500 1,800 / 2,500 1,800 / 2,500
Required room dimensions without storage tank length / width / height [mm] 5,000 / 3,000 / 2,500 6,000 / 3,000 / 2,700 6,000 / 3,000 / 2,700 6,000 / 3,000 / 2,700 6,500 / 3,000 / 2,700 6,500 / 3,000 / 2,700 6,500 / 3,000 / 2,700 7,000 / 3,500 / 3,000 7,000 / 3,500 / 3,000 7,000 / 3,500 / 3,000 8,000 / 4,000 / 3,000 8,000 / 4,000 / 3,000 9,000 / 5,000 / 3,500 9,000 / 5,000 / 3,500 9,000 / 5,000 / 3,500 9,000 / 5,000 / 3,500 9,000 / 5,000 / 3,500 11,000 / 5,000 / 4,000 11,000 / 5,000 / 4,000 12,000 / 5,000 / 4,500 12,000 / 5,000 / 4,500
[kVA] 20 60 80 100 160 200 250 300 400 500 630 700 820 920 1,000 1,650 1,850 2,100 2,600 2,900 3,100
[kW] 16 48 64 80 128 160 200 240 320 400 504 560 656 736 800 1,320 1,480 1,680 2,080 2,320 2,480
[m3 / h] 2,700 10,600 11,500 12,000 22,500 22,600 22,800 23,000 23,500 28,000 31,500 51,500 64,000 64,000 81,000 118,800 118,800 171,700 198,000 198,000 198,000
[m3 / h] 320 720 850 950 1640 1,800 1,980 3,680 4,900 5,100 6,100 9,000 10,300 11,400 13,000 18,700 20,200 26,700 27,700 30,300 31,700
[V / Ah] 12 / 54 12 / 90 12 / 90 12 / 90 24 / 54 24 / 54 24 / 54 24 / 90 24 / 90 24 / 104 24 / 104 24 / 160 24 / 192 24 / 192 24 / 224 24 / 640 24 / 640 24 / 640 24 / 1280 24 / 1280 24 / 1280
[kg] 650 900 1,000 1,100 1,400 1,600 1,900 2,300 2,700 3,200 4,100 5,500 6,300 6,400 7,200 10,800 11,300 13,400 16,100 16,900 18,400
Table 59/3: Generator units for stationary use or permanent installation in buildings as emergency power systems – technical data
Project name ....................................................... ....................................................... Owner / developer ....................................................... ....................................................... Planning engineer
Generator unit output Power that must be substituted immediately after power failure Notes on consumers (heavy starting or special features, e.g. UPS) UPS load Rated voltage, rated frequency Power factor, number of phases Power supply system
. . . . . . . . . . . . . . . . . . . . kW . . . . . . . . . . . . . . . . . . . . kW
. . . . . . . . . . . . . . . . . . . . VA .................... V .................... Hz
. . . . . . . . . . . . . . . . . . . . (cos φ) c TN-S c TN-C
c TN-S (EMC-friendly) c TN-C-S c TT c IT c Gas
Fuel Required operating time at rated power without refueling Type of cooling for combustion engine Operating mode
c Diesel fuel
.................... h c Air cooling c Liquid cooling c Emergency power unit
c Time-limited operation c Peak load unit
c Stand-alone
c Parallel operation with other power generating units Expected operating hours Installation Effects of weather Ambient temperature, installation altitude (above sea level) Air pollution Noise limit (maximum level) Emissions Exhaust gas emission limits 116 . . . . . . . . . . . . . . . . . . . . hours per annum c Stationary c Indoor c Transportable c Mobile
c Open air installation .................... m
. . . . . . . . . . . . . . . . . . . . °C c Sand / dust
c Chemicals dB
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