Technical Handbook

2013 Energy distribution

Technical Handbook 2013

The partner for smart solutions you can trust Hager is a full-range supplier of electrical installation systems for building, residential and commercial properties. For decades, Hager has been synonymous with an extensive and complete offering. Highest quality, cutting-edge products, modularity, ease of installation, ease of use, excellent service and sophisticated design are the features that distinguish Hager.

Hager: a brand exceeding your expectations As a specialist in • power distribution • cable management • wiring accessories and smart building automation Hager the supplier for professionals – is synonym with top quality, innovative technology & reliability. All of which make Hager the partner for smart solutions, you can trust.

New ideas for the customer’s benefit

A flourishing group

Innovations and the systematic enhancement of the products and systems are key features of the Hager brand. It has always been our goal to use new designs and improvements to stay ahead of developments.

Hager Group is a family owned business with a more than fifty-years of tradition. As a global player, the company has about 11,400 employees and a turnover of more than 1.62 billion euros in 2012. Today, the Hager Group offers more than 74,000 items.

The use of innovations and new technologies at Hager is always customer-driven. Every year, Hager evaluates thousands of customer contacts, resulting in detailed knowledge of its customer’s needs in order to work efficiently and successfully. Based on this knowledge, Hager develops the innovative solutions that are so characteristic for the Hager brand. Ease of installation, ease of use, intuitive user interfaces, modularity and durability are brand values that guarantee highest quality throughout in Hager systems. 65 percent of Hager products and systems are less than three years old. This high degree of innovation enables the users to meet various new challenges effectively. The strong demand for innovations and enhancements is a good indicator for the customer-oriented policy of the Hager brand resulting in a high turnover at wholesalers..

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First Aid in case of Electric Shock Which factors cause an electric shock? Contact with live wires is often fatal. The intensity of a shock depends on • Voltage • Type of current • Length of exposure time • Path it takes through the body (heart or head are the most dangerous routes) What can happen if you get an electric shock? • Heart Failure (cardiac arrest) • Burns • Nerve, Muscle, and Organ Damage Human body's reaction to electric shock When excessive electrical currents pass through the human body, the nervous system is thrown out of gear. This causes the body to react to the passage of current through it as follows : 3 mA - A tingling sensation is felt

10-15 mA - Muscle spasm and tightening occurs

20-30 mA - The heart may fibrillate; severe shock is felt

>50 mA - Lethal. Fibrillation of the heart occurs

DO’s in case of electrical shock : To treat a person who has sustained electrical injury: Unplug the appliance and/or turn off the MCB (at the fuse box) - (Merely turning the switch off will not necessarily stop the flow of current) Call an ambulance If the victim is not breathing, immediately begin mouth-tomouth resuscitation 2

First Aid in case of Electric Shock To prevent shock: - Place the victim's feet higher than the head by about a foot - Cover person with a blanket or coat if available Check for indications of shock: - Cold, Moist Skin - Fast Heartbeat - Paleness - Feeling Faint Check for burns, which may not be visible from the outside. Sites to inspect in particular are: - The fingers and toes - Skin touching against metal accessories like jewellery or a belt buckle Take off any clothing over the burn-but only if it comes away without pulling skin along with it As long as the skin is unbroken, you can rinse the burn in cool, running water to ease pain Cover any surface burns with a sterile dressing or clean cloth Separate burnt fingers or toes with the dressing Take the victim to the emergency room-even if the person is breathing, is conscious, and insists that he is all right Don’ts in case of electrical shock : Do not touch the person with your bare hands before you are certain there is no live electricity WARNING: Never move the person if they are touching a power line or other source of high voltage. Under such circumstances keep a distance of at least 20 feet. The above precautions are for your own safety CAUTION: For the safety of the victim, do not move him/her if spinal injury is possible from an explosion or fall associated with the accident. Do not remove clothing that is stuck to the wound - Never put ice on a burn - Do not apply ointments or grease to burned skin (as with burns from flames)

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First Aid in case of Electric Shock Do not bandage with a towel, blanket, or cotton dressing that will stick to the wound. (Instead, use a sheet for large area) Take care not to break any blisters that have formed Shield the burned area from chafing What should you do if not sure if the power is off? If turning off the electricity is impossible or you can't tell whether it is off (unless it is high-voltage current), then to approach the victim: Stand on a mat (preferably rubber, but piled up newspapers/ magazines could be used if necessary), and Extend a wooden or cloth object, such as a - Broom handle - Chair - Piece of clothing, or - Rope

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Basic faults in an electrical system Types of Fault

Reason

Consequences

Protective Device to be used

Overload

It is mainly caused when one tries to use a equipment beyond its rated capacity, or there is a fault in the equipment E.g When you keep a heater on without any water in it.

It can lead to reduction in life of equipment, ultimately leading to failure of insulation and hence damaging the equipment.

MCB / RCBO

Short Circuit

Insulation Failure, Shorting of the Phase to Phase or Phase and Neutral Wires.

High Inrush Current, MCB causing permanent damage to equipment and may lead to a Fire.

Eath Fault

Short circuit between Phase and Earth Conductor.

Can result in Fire due to sparking.

Earth Leakage Human Body Touching Live Wires. Insulation failure Over Voltage

RCBO / RCCB

Severe shock, causing RCBO / injury or even death. RCCB Consistent Earth Leakage can also cause a Fire.

Opening of Neutral Damage to Connection increase in sensitive Electronic Ph-Ph voltage of 440V, Equipment. Surge through Lighting or transients, Over voltage from Utility.

OV protection Device

Under Voltage Drop in supply voltage, Damage of Equipment, UV relays starting of heavy loads. Flickering of Lights. The above faults are basic faults experienced in most of the cases in an electrical system. There are many more faults that may be more severe, or have worse consequences, however, these are in exeptional cases and are not discussed above

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Selection chart for typical domestic loads S.No. 1 2 3 4

5 6 7 8 9 10 11

12 13 14

15 16 17 18 19

20 21

Items

Load/Wattage

Fan Lamp, Tubelight Room Heater Water Heater 8 ltrs 15 ltrs 60 ltrs Immersion Heater Hot Plate-single Iron-Non-automatic Automatic Mixer / Juicer TV / VCR / VCP Music system Refrigerator 165 ltrs 285 ltrs 350 ltrs Toaster Vacuum Cleaner Washing Machine without heater with heater Water Cooler Desert Cooler Oven Electric Kettle Air Conditioner 1 ton 1.5 ton 2 ton Hair Dryer Microwave

MCB rating

60W 40W 200W

* * 1A

1200-2000W 3000-4000W 4000-6000W 1000W 1000W 500W 1000W 300W 200W 200W

10 A 20 A 32 A 6A 6A 3A 6A 2A 1A 1A

400W 600W 750W 500W 400W

3A 4A 6A 3A 3A

300-1300W 5000-6300W 700W 300W 750W 1500W

10 A 32 A 6A 2A 6A 7.5 A

1000W 1500WA 2000W 1000W 800W

10 A 16 A 16 A 7.5 A 6A

Formula for Calculations : Incomer Rating : Single Phase = Total Load in Watts 230 volts Three Phase =

Total Load in Watts 3x415 volts

• The given data is only for guidance and may vary for different manufacturers

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Max. Short Circuit current as per Transformer kVA Transformer Rating

Full Load Current at 415 V

Max. Short Circuit Current (kA)

kVA

A

4% impedance

5% impedance

25

35

0.875

0.7

40

56

11.4

1.1

63

88

12.2

1.8

100

139

13.5

2.8

125

174

14.4

3.5

160

223

15.6

4.5

200

278

17

5.6

250

348

18.7

7.8

315

438

11

8.8

400

560

14.2

11.3

500

695

17.4

13.9

630

876

21.9

17.5

800

1112

27.8

22.2

1000

1390

34.8

27.8

1250

1740

43.5

34.8

1600

2230

55.8

44.5

2000

2780

69.5

55.6

2500

3480

87

69.6

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Selection table for motor application Recommended back-up MCB

Full load current approx.

Relay range

kW

amp.

amp.

1

0.75

12.1

1.4 - 12.3

NC306N

ND303N

1.5

1.1

12.7

2.0 - 13.3

NC310N

ND304N

2

1.5

13.5

3.0 - 15.0

NC310N

ND306N

2.5

1.8

14.8

4.5 - 17.5

NC316N

ND306N

3

2.25

15

4.5 - 17.5

NC316N

ND306N

4

3

16.4

4.5 - 17.5

NC316N

ND310N

Motor Rating 415V, 3 phase hp

‘C’ Type amp.

‘D’ Type amp.

5

3.7

17.9

6.0 - 10.0

NC320N

ND310N

6

4.5

19

6.0 - 10.0

NC325N

ND316N

7.5

5.5

11.2

9.0 - 15.0

NC332N

ND316N

Chart for Star-Delta starting Motor Rating 415V, 3 phase hp

kW

Full load current approx.

Relay range

amp.

amp.

Recommended back-up MCB ‘C’ Type amp.

‘D’ Type amp.

11

0.75

12.1

0.95 - 11.5

NC303N

ND303N

11.5

1.1

12.7

1.45 - 12.3

NC304N

ND302N

12

1.5

13.5

1.45 - 12.3

NC304N

ND303N

13

2.25

15

2.05 - 13.3

NC306N

ND303N

14

3

16.4

3.05 - 15.0

NC310N

ND304N

15

3.7

17.9

4.55 - 15.0

NC310N

ND306N

16

4.5

19

4.55 - 17.5

NC316N

ND306N

17.5

5.5

11.2

4.55 - 17.5

NC316N

ND310N

10

7.5

14.8

6.05 - 10

NC320N

ND310N

12.5

9.3

19

9.05 - 15.0

NC325N

ND316N

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Cable selection chart Single core cable (Flexible) voltage grade 1100 V, conforming to IS : 694-1990 Nominal area of conductor

Current carrying capacity as per IS:3961

Max. Resistance per km. at 20°C

Sq. mm

Amp.

Ohms

1.0

11

19.50

1.5

14

13.30

2.5

19

07.98

4.0

26

04.95

6.0

31

03.30

10

42

01.91

16

57

01.21

25

71

00.78

Standard Colours : Red, Green, Blue, Yellow, Black. * As per IS: 3961 (Part V) - 1968 Above data is indicative. Hager will not be liable for damage arising from incorrect applications.

Color identification of cables Purpose

Color of cable

R phase of 3 phase AC circuit

Red

Y phase of 3 phase AC circuit

Yellow

B phase of 3 phase AC circuit

Blue

Neutral of single / 3 phase AC circuit

Black

Earthing

Green

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SPN Distribution Board Wiring Diagram

Neutral link To load

MCB

2 Pole RCCB/ RCBO/MCB/ Isolator

Earth link Shorting link

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TPN Distribution Board with SP Outgoing Wiring Diagram

Neutral link

O/G MCB

Earth link LED indication

Shorting link

4P MCB/ RCCB/RCD

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TPN Horizontal PPI Wiring Diagram

To load

2P RCD Neutral link

O/G MCB

Shorting link

Indicating lamps 4P MCB/ RCCB/ RCD

PPI - Per Phase Isolation Incase of a fault in one circuit only the relevant circuit trips and balance remains connected

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TPN Tier Type Distribution Boards Wiring Diagram

To load

Shorting link

MCB O/G

2P RCD

Earth link Neutral link

4P MCB / ISO

LED indication/ or OV device

13

TPN DBs - Phase Segregated DBs Wiring Diagram

To load

MCB O/G Shorting link

2P RCD

x160 MCCB or 4P MCB/ISO

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Indicating lights or over voltage device

RCCBs RCCB is a current operated voltage independent device. They provide protection even when the voltage is dip or neutral conductor is interrupted. In a healthy circuit, the vector sum of all the currents in 3 phases and neutral is equal to zero. In case of current leakage to earth, the device senses the imbalance between incoming and outgoing currents in the system and provides automatic disconnection from supply. Why use an RCCBs? RCCBs are devices which protect the user from the harmful effects of electric shocks. These function by detecting the residual current, comparing the value with the rated residual operating value and opening the protected circuit when the residual current exceeds this value. RCCBs are an efficient means for ensuring people’s protection against electrical shocks resulting from direct and indirect contact. RCCBs are used for various applications depending upon different current sensitivities. RCCBs

Application

30 mA

personal protection domestic installation / direct contact

100 mA

limited personal protection / indirect contact

300 mA

building / fire protection

IEC 61008 defines RCCBs as per following class : • Class AC-for normal AC supply networks having no harmonics • Class A-for disturbed AC supply networks having harmonic disturbances • Class B-class A + for DC networks

Connection diagram 3 phase 4 wire system suppy

3 phase 3 wire system suppy

1 phase system suppy

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RCCBs Why Hi RCCBs? RCCB being a very sensitive device may trip due to some electrical disturbances in the system, which deforms the sine wave. These disturbances can be: • External Disturbance - HV network disturbance, lightening • Internal Disturbances - Switching surges, harmonics, non linear loads like VFD, thyristor, electronic loads, pulsated DC loads These disturbances may interfere with the operation of RCCBs connected to network, apart from other electronic devices connected to system. These disturbances can have following effects on the working of residual current device: Nuisance Tripping • RCCB may trip without a genuine earth leakage • Continuity of supply is affected, though no compromise in people’s safety Blinding • RCCB may not trip on a genuine earth leakage • People’s safety is no longer guaranteed In both of the above cases, either continuity of supply or people’s safety is compromised which is not desirable. Technical details : • Protects a circuit automatically in the event of an earth leakage • Conforms to IEC 61008 IS12640-1 • With earth fault indicator & positive contact indication

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Hi-RCCBs Hager “Hi RCCB” (Class A) can withstand the increasingly frequent disturbances which causes nuisance tripping or blinding in normal (class AC) RCCBs. Hager Hi RCCB has • Specially designed torroids which solves the problem of non-activation of relay in case of leakage of pulsated DC current • Electronic filter circuits for treatment of electrical signals to improve the performance compared to standard RCCBs • Earth leakage tripping band of 80 - 100% of sensitivity which is higher than normal RCCBs Selection / installation tips for RCCBs / RCBOs Careful selection of RCCBs is required for ensuring optimum protection to human life & installation. 1. The current rating of RCCB should not be less than circuit design current 2. Select 2P RCCBs for single phase supply distribution and loads 3. Select 4P RCCBs for three phase supply distribution and loads 4. Select the correct trip sensitivity as per following table: • For protection of human life against direct contact – 30mA • For protection of human life against indirect contact – 100mA • For protection of installation against electrical fires – 300mA 5. Neutral wire should not be looped. Looping of neutral may cause unwanted tripping of RCCBs 6. RCCBs must be tested regularly (once in a month) by pressing “Test” trip push button to check its healthiness 7. Use IP65 enclosures for installation of devices in dusty and humid outdoor area 8. RCCBs shall only be connected downstream of MCB 9. Ensure correct earthing throughout the installation. Periodically check that all earthing points are healthy 10. Wire shall be terminated tightly on the device terminals to ensure proper connection Technical details : • For electrical networks with high harmonics / pulsated DC currents and transients • Conforms to IEC 61008 & EMC standard EN 61543 • With earth fault indicator & positive contact indication 17

MCBs Correct selection of MCBs Correct selection of MCBs is very important to ensure optimum protection to installations. Generally in any installation, we have different kinds of loads like incandescent lights, HPMV lamps, Fluorescent Lights, Motors, Fans, Pumps, Electronic loads like UPS, Servers, Computers and Printers etc. which all have different electrical characteristics. It is very important to choose right kind of MCBs to protect each type of load, depending upon load characteristics. B curve MCBs are used for : • Protection of resistive loads that have starting current equal to their running current • Protection of DG sets (since DG sets have low short-circuit capacity) • B curve MCBs have magnetic threshold setting between 3 – 5 x Ir C curve MCBs are used for : • Slightly inductive loads with moderate (below 5 Ir*) starting current • General houseload loads like lights, fans & household electrical appliances • C curve MCBs have magnetic threshold setting at 5 – 10 x Ir D curve MCBs are suitable for : • Inductive loads with a high (5-10 x Ir) inrush current • Suitable for UPS, small motor & pumps, small transformers etc. • D curve MCBs have magnetic threshold setting at 10 – 20 x Ir which does not give nuisance tripping while starting the load • Ir – rated current Following are some of the main points which should be kept in mind while selecting MCBs for a particular application. • The current rating of MCBs should be more than load current in the circuit; For example, if the load current in a circuit is 9A, the minimum MCB rating should be 10A. • The current carrying capacity of wire should be more than MCB current rating; For example – if we select MCB of 10A, then current carrying capacity of wire should be more than 10A. • MCBs are available in B, C & D tripping category. They should be selected as per load characteristics as shown in table on next page.

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Types of MCBs to be used for different loads Type of Load

Residential

Commercial

Suitable MCB curve

Resistive Loads • Incandescent lights • Incandescent lights • Geyser

• Boilers

• Heater

• Heaters

• Fan blower heaters • Oil radiator heaters Slight Inductive Loads

• Florescent Lights

B curve

• Florescent lights

• Small motors (FHP) • High pressure mercury vapour lamps • Fans & small pumps • Sodium vapour lamps • Window / Split ACs • Lights with ballasts C curve

• Microwave • Refrigerators • General household equipment Inductive Loads Water lifting pumps

Florescent lights • ID & FD fans

• UPS

• Small control transformers

D curve

• Medium size motors • Refrigerators for commercial use * Above table is only indicative and not an exhaustive list Technical details : • Curve B & C 10 kA as per IEC 60898 • Conforms toIS/IEC 60898 - 1:2002 IEC 60898 - 1995 IEC 60947 - II 19

Over-voltage release-MZ209 Over-voltage in residential & commercial installation is a common problem which can cause serious damage to household electronic & electrical devices. Over-voltage not only reduces the operating life of equipment, it also increases running & maintenance cost.

Causes of over-voltage : • Neutral break in system • Faulty connections during installation / maintenance work • Poor voltage regulation • Over-compensation by capacitors (in industries) Neutral break is shown below, is the most common phenomenon:

In the case of the neutral being broken, houses 2 and 3 are supplied by an artificial neutral, created by the downstream network. One of them shall experience over-voltage and the other, under-voltage due to difference in their instantaneous loading conditions. Problems due to over-voltage : • Sudden failure of electronic devices • Reduction in useful life of equipment • Increased failure, high running & maintenance cost • Heating in systems • Insulation failure Hager offers Over-voltage release MZ209, which continuously monitors voltage between phase & neutral. It breaks the supply by opening the circuit breaker in case the voltage between phase and neutral conductor increases from the pre-determined level (280V AC) and thus prevents damage to household devices. 20

Over-voltage release-MZ209 The over voltage auxiliary prevents re-closing until the voltage comes back within the normal threshold. Indication that the protection device has tripped due to over voltage is provided by a flag on the auxiliary. The flag indicator appears Red if the tripping is caused due to an over voltage.

Over-voltage release MZ209 can be used with hager MCBs, RCCBs & RCBOs to provide total protection to installation against overload, short-circuits, earth-leakage & over-voltage faults in a system.

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Changeover switches Changeover switches are used to shift from one source of supply to another source, and vice versa.

Hager modular changeover switch is a compact device which can be mounted on a standard DIN channel inside an enclosure. Its design is compatible with all other hager modular devices, such as MCBs and RCCBs. The changeover switch comes in 2P and 4P versions, for single and three phase applications, respectively. It has three positions (I - O - II) with centre-off position. The incoming side must be protected against short circuits. For isolation, use it with an appropriate MCB. Technical details: • • • • •

Conforms to IEC 60947 Part I Ratings - 25A & 40A No. of poles - 2P & 4P 3 positions (I - O - II) with centre OFF Utilization category - AC 21A

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Isolators The simple and safe-to-install switch disconnectors (isolators) from Hager help to make your work easier and ensure absolute safety of electrical installations. All devices are manufactured in compliance with the latest IEC standards and are CE marked. They are particularly easy and safe to install.

Technical details : • • • • •

Conforms to IEC 60947 - Part III Ratings - 25A, 32A, 40A, 63A & 100A No. of poles - 2P, 3P & 4P Utilization category - AC 22 IEC & approved

Contactors Used for remote switching and control of power circuits.

Available from 20 A to 63 A for AC 1 Utilization Category. No. of Poles 2 NO, 3 NO, 3 NO + 1 NC, 4 NO Rating 25 A, 40 A, 63 A Utilization Category-AC 1 (switching of resistive loads only) Technical details : • For remote switching & control of power circuits. • All contactor ratings are for AC 7A load only (Coil voltage 230V 50Hz)

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Time switch Hager offers a comprehensive range of modular time switches in electro-mechanical, digital & astronomical versions to meet the basic to the most advanced applications.

Time switches are used to automatically switch on-off electrical circuits according to real time of day e.g. street lights, glow sign boards, fountains, etc. They enhance user comfort and save valuable energy. They give us the freedom from repeated manual switching and ensure that loads are operated according to time schedule without fail. This helps in saving energy by switching off the circuits and avoiding unnecessary energy consumption when devices are not required. Hager recommends time switches to control air-conditioning, heaters, water pumps, street lights, water sprinklers, periphery, security lights, etc. Electro-mechanical time switch – for simple daily routine applications. For e.g. daily water pump operation. Digital Time Switch – offers more flexibility in operation, suitable for different settings for each day of the week. e.g. Office lights and A/C control, School bell automation. Astro Time Switch – Most advanced technology which adjusts On-Off time based on sunrise & sunset times. Typical applications – Street lights, Shop window lights, External lights of buildings. Technical details : Astronomical time switches are used to control various loads according to sunrise and sunset time. Example street light, neon sign etc.

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Movement & presence detectors Hager movement and presence detectors are suitable for indoor and outdoor residential & commercial applications. PIR detectors monitor human movement / presence in detection zones & automatically switch on the lighting when movement is detected. They are very useful for application in offices, schools, cafeteria, wash rooms, parking lots, conference rooms, etc. PIR detectors will automatically switch off the lights after preset time delay if no movement is detected for the set time. Technical details: IP55 wall mounted movement detectors suitable for outdoor applications Comfort range: Adjustable lux level 5 to 1000 lux. Time delay upto 15 mins. Vertical / horizontal head adjustment. Detection area control by shutters Enhanced range: All features of comfort range plus adjustable sensitivity control via potentiometer. Infra red remote control for remote setting (accessory).

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Dimmers & Dimming System Modular devices used for control of lighting levels in domestic premises, software offices, large corridors, conference halls and hotels. Control is localized. Remote is possible by associated Push Buttons.

Separate dimmers are available for control of incandescent or halogen with standard or electronic ballast and fluorescent lamps. Stand - alone dimmers for 600 W and 1000 W. Control of 3000 W can be possible by using master and slave combination.

Dimmers They are compact devices and can be fitted inside distribution boards along with other modular devices to control the lighting output as per users need. Main features of hager dimmers: • • • •

Soft start (progressive start) to increase the lamp life Memorization of last dimming level Protection against over-heating Can be controlled by several push buttons

Technical details: These devices are used for control of lighting levels in domestic & professional premises

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Time Lag Switch A time lag switch allows you to switch ON the lights during an adjustable time. After the time lag, the lights switch OFF automatically. Hager staircase time lag switch works with any bell push switch available in the market. The time lag switch is suitable for staircase, corridor, lift lobbies for saving energy in lighting.

Technical details: A staircase time lag switch allows you to switch on the light during an adjustable time. After the time lag it switches off automatically.

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Notes

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Notes

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Hager Electro Private Limited Sales & Marketing office : Office 2A, First Floor North Court Building Opposite Joggers Park Kalyani Nagar Pune-411006 India

Tel: +91 20 41477500 Fax: +91 20 41477510 Toll free no.: 1800 103 5440 Email: [email protected] Website: www.hager.co.in

Delhi Sales Office : B 217 Tower B DLF Towers, Jasola New Delhi-110025 India

Tel: +91 11 49677500 Fax: +91 11 49677555

Mumbai Sales Office : Office # 1301A, Tower 3 Indiabulls Finance Centre Elphistone Road Mumbai, India

Tel: +91 22 71813200

Hager Electro SAS: 132 Boulevard d` Europe BP 78 F-67212 OBERNAI FRANCE