THREE PHASE ELECTRICAL INSTALLATION

This electrical wiring installation tutorial explains how to do a Three Phase

Consumer Unit Installation from Utility Pole to a 3-Phase Energy Meter & 3-
Phase Distribution board and then How to connect Single Phase & Three Phase
Loads in a Three Phase Wiring Distribution System in home electric
Three Phase & Single Phase Power
In power generation plants, Three Phase power is generated by electrical generator
or alternator. In an alternator, the generated voltage and current by three
independent coils in stator are apart by 120 degree from each other. The generated
power from alternators then transmitted and distributed through transmission and
distribution lines to the sub distribution.

 In industrial and commercial buildings, they need high power. So they are
connected to the three phase Delta connection (3 Phase – 3 Wire System –
No Neutral Wire) before distribution transformer and then manage the
required voltage and current according to their needs in three phase and
single phase supply.

 On the other hands, buildings that need high power in three phase and
single phase, they are connected to the secondary of distribution
transformer. This way, they get three phase Star connection (3-Phase, 4
Wire System with Neutral Wire). In the Star connection, Three Phase Line
to Line (Phase to Phase) voltage are 415V AC (in US, 208V) and Single
Phase Line to Neutral (Phase to Neutral), there are 230V AC (120V in
US).

 In Three Phase Supply, motors and large electric heaters can be directly
connected to the Three Phases while in in Single Phase, load (Light, fan etc)
can be connected in between Phase and Neutral through proper protective
devices.
Why We Need Three Phase Power Supply?
To operate high power equipment and appliances such as electric motors and and
high power rated air compressor etc, we need Three Phase Power supply instead of
Single Phase Power supply. In ordinary homes, we mostly use Single Phase power
supply to operate lighting load, fans, washing machines etc, but in some cases as
well as industries offices high torque motors, multi-storey & large buildings, Three
Phase power supply needs to operate and maintain the system.
In our previous posts, we did it for Single Phase electrical wiring installation in
home and already know that what are MDB, DB, Final Sub Circuit, MCB, MCCB,
CB and RCD etc.
Requirements for Three Phase Wring Installation

In this tutorial, we need the following wiring accessories to wire three phase power
in home.

1) Three Phase Energy meter 1 No

2) Three Pole MCCB, 63A, 1 No
3) Double Pole, 63A, 30mA Trip Current RCD, 3 Nos
4) Double Pole MCBs, 63A, 3 Nos
5) Single Pole, 20A, MCB, 6 Nos
6) Single Pole, 16A, MCB, 3 Nos
7) Single Pole, 10A, MCB, 6 Nos
8) Distribution board cases, 3 Nos
9) Bus bar Link for Neutral Cable Connections
10) Copper strips for MCB common connection, 3 Nos (Cu Busbar segment)
11) Copper strip Busbar for Earth & Ground Link

How to Wire There Phase Main Distribution Board?

Generally, Electric supply and service providers install a single phase energy
meter when load is less than 7.5kW (10HP) in domestic areas (consumer unit for
home).
If the limit is exceeded, then it’s recommended to install a 3-phase energy
meter for consumer units when load is exceeds from 7.5 kW, then 3-phase
electrical wiring is recommended in domestic areas (homes).
In this tutorial, We assume that we will only connect single phase load (Light
points, fans, TV, Power Socket, AC etc.) in this three phase electrical wiring
installation. In other words, we will not power up 3 phase motors because in our
homes, we haven’t that kind of (three phase) loads. If three phase load exists in
your home, then you can do so. As we can see that the total load is exceeded the
limit of single phase electrical wiring installation as we will be feeding different
rooms and areas in home, that’s why we have to wire our distribution in three
phase system.
Practical Procedure of Three Phase wiring of distribution board &
installation
We have learned the basic electrical wiring of bulb, fans etc (i.e. Sub-circuits and
final sub circuits) in our previous posts, so follow the steps below to do the same
as mention below..
1) First of all, connect the three-phase energy meter as shown in fig below
2) Connect the MCCB (Moulded Case circuit Breaker) as main switch to the
incoming three phases (R, Y, B) from 3-phase energy meter. (Check the
wiring colour code for different areas in below section)
3) Now connect the outgoing three phases (R, Y, B) from MCCB (Moulded
Case circuit Breaker) to the DP (Double Pole MCB , RCD, SP (Single Pole
MCBs and load) as shown in fig below)
4) Now connect the RCD from DP with Phase (Line) and Related Neutral
Link. The Out going Phase lines should be connected to the final and final
sub circuits. The same can be done for Neutral Wires. (RCD – Residual –
current device – is a device that quickly breaks an electrical circuit to prevent
serious harm from any ongoing electric shock)
5) Finally, Connect the electrical appliances with the Earth link terminal which
leads to earth electrode in the earthing and grounding system as shown in fig
below.
6) Do the the same steps for all three distribution boards for different rooms
and areas.
You may also use a Four Pole MCCB instead of Three Pole MCCB. Simply
connect the Neutral wire in the last slot of that MCCB (Incoming and Outgoing
like other phases) and then connect the outgoing Neutral to copper strip (i.e. Earth
Link) as shown in fig.
Wiring Diagram of Three Phase Distribution Board
 CIRCUIT BREAKERS

A CB (Circuit breaker) is a device which:

 Control (make or break) a circuit manually or by remote control under normal

and fault conditions.
 Break a circuit automatically under fault conditions (like over current, Short
circuit, etc).

Circuit breakers are installed and used for safety purposes in both residential as
well as commercial and industrial areas. In power distribution, we need circuit
breakers at different levels. Depending on the current carrying capacity, breaking
capacity and other functions, we select a suitable circuit breaker according to our
needs i.e. VCB, ACB (Air Circuit Breaker), MCCB and then MCB , this is common
hierarchy being followed in power distribution system.
 Air Circuit Breaker

 Operates in air (where air-blast as an arc quenching medium) at atmospheric

pressure.
 It has completely replaced by oil circuit breaker.
 No chance of oil fire like in oil circuit breaker.
 Rated Current up to 10k A.
 Trip thresholds and delays are adjustable.
 Electronically and microprocessor controlled.
 It is used in large industrial plant for main power distribution.

Miniature Circuit Breaker (MCB)

 MCB stands for “Miniature Circuit Breaker”.

 Rated current under 100 amps.
 Interrupting rating of under 18,000 amps.
 Trip characteristics may not be adjusted.
 Working principle based on thermal or thermal magnetic operation.
 Suitable for low current circuits (low energy requirement), i.e. home wiring.
 Generally, used where normal current is less than 100 Amps.

.
Moulded Case Circuit Breaker (MCCB)

 MCBB stands for “Molded Case Circuit Breaker“.

 Rated current in the range of 10-2500 amps.
 Thermal operated for overload and & magnetic operation for instant trip in SC
(short circuitconditions).
 Interrupting rating can be around 10k – 200k amps.
 Trip characteristics is adjustable.
 Suitable for high power rating and high energy i.e. commercial and industrial use.
 Generally, used where normal current is more than 100 Amps.

Main Difference between MCB and MCCB

 The main different between MCB and MCCB is the interrupt current rating
which is up to 1800 amperes for MCB and 10k – 200k Amperes for MCCB.

 both MCB and MCCB are classified as low voltage circuit breakers and the
operation principle is based on thermo-magnetic for both devices.
The following table shows the difference and comparison between MCB and
MCCB.

MCB and MCCB Selection

Now the question is that for a situation, where standard current carrying capacity
needed is 100A with breaking capacity of 15KA, what should be used? An MCB or
MCCB? We assume cost is not very different.
 Both are in moulded case and having almost similar features especially when
we are comparing with fixed thermal setting option of MCCB and they are
classified as low voltage circuit breakers. For magnetic setting, we can select
MCB as per curve and MCCB will have either fixed setting or can be
adjusted.
 So what is the criteria to make a selection of MCB or MCCB? Space can
be a point of consideration as MCBs are more compact but it doesn’t make
a big point as bigger size of MCCB brings many advantages too like better
fault clearing mechanism. keep in mind that both MCB & MCCB are low
 voltage circuit breakers and created to respond to IEC 947 standards (We
are going to discuss these standards below)
 Actually there is difference in standards they follows. An MCB is supposed
to function in accordance to IEC 60898-1 (Unless mentioned otherwise)
and so is tested accordingly. While an MCCB is tested in accordance
with IEC60947-2. So to understand the difference between MCB and
MCCB we need to get a brief idea of these two standards.
Difference between IEC 60898-1 and IEC 60947-2

IEC60898-1
It defines behaviour of circuit breaker having rated operational voltage not
exceeding than 440V (between Phases), Rated current not exceeding than 125A
(We have range 0.5A-125A) and rated short circuit capacity not exceeding than
25KA (Usually it is 10KAin MCB). This is designed for unskilled user (or say
uninstructed user) and for devices not being maintained consequently. Also
pollution degree covered is zero pollution to maximum pollution (degree 2). These
are the circuit breakers we find in residential homes, shops, school & offices
electrical distribution switchboards.
IEC60947-2
This standard applies to circuit-breakers, the main contacts of which are intended
to be connected to circuits, the rated voltage of which does not exceed 1000 V a.c.
or 1500 V d.c. It also contains additional requirements for integrally fused circuit-
breakers. It covers very high range of standard current carrying capacity (We have
range of 6A-6300A) and meant for skilled user. The device is also supposed to be
maintained properly. Also pollution degree is to be 3 or more. These circuit
breakers are industrial applications and protect the power distribution of up to
1000 volts AC. and 1500 volts DC. (For MCBs, MCCBs & ACBs)
So it is clear that these items are different in their fundamentals. An MCB designed
for indoor, pollution-free conditions and would not be suitable for harsh, outdoor
applications that require pollution degree 3.
Typically, IEC 60898-1 certified Circuit Breakers meet minimally required
performance to proof proper protection of household installations: Pollution
degree 2, impulse voltage 4kV, isolation voltage is the same as nominal voltage
440V. That is the reason why usually we meet limited number of technical
information printed on Circuit Breakers.
It is not necessary that Circuit breakers certified with IEC 60898-1 can’t be
certified with IEC 60947-2, but for sure any manufacturer need to obtain
 certification. Rating of same MCB can be different for different standards, so, it is
highly recommended to check the data properly printed on it.
So, the application and needs will decide that which device is to be used or
selected.
Comparison Between IEC 69896-1 & IEC 60947-2

MCB Characteristic IEC 60898-1 IEC 60947-2

Rated Current: In 6 – 125A 0.5 – 160A
SC Breaking Capacity <25kA <50kA

Rated Voltage: Ue 400V 440V, 500V, 690V

Impulse Voltage: Uimp 4kV 6kV – 8kV
Pollution Degree 2 3
Curves B,C,D B,C,D,K,Z,MA
Application Current AC AC or DC
Electrical Auxiliaries No Monitoring Control

How to select MCB or MCCB at Different Circuit Levels

Well, as we have cleared everything in the above sections as well as, the MCB
nameplate rating data also give an appropriate information, but the choice of MCB
or MCCB is based on certain factors and conditions like;

 ICS as a % from ICU. (See Difference between ICS & ICU in term of Circuit
Breakers)
 Maximum Operating Voltage
 Insulation voltage
 Mechanical operation ( endurance and durability)
 Breaking Capacity for each Operating Voltage

Below are types of MCBs which shows the magnetic fault protection. Also, to
prevent the accidental overloading of the cable at no fault, there is a thermal device
in MCB to eliminate the chances of unwanted tripping operation of MCB. For
short circuit protection in home appliances, the current rating is about to 6kA
while for heavy and industrial operation, it is above the 10kA.
What is an RCD?
An RCD, or residual current device, is a life-saving device which is designed to
prevent you from getting a fatal electric shock if you touch something live, such as
a bare wire. It can also provide some protection against electrical fires. RCDs offer
a level of personal protection that ordinary fuses and circuit-breakers cannot
provide.

What does an RCD do?

 An RCD is a sensitive safety device that switches off electricity automatically
if there is a fault.
 An RCD is designed to protect against the risks of electrocution and fire
caused by earth faults. For example, if you cut through the cable when
mowing the lawn and accidentally touched the exposed live wires or a faulty
appliance overheats causing electric current to flow to earth.

How does it work?

An RCD constantly monitors the electric current flowing through one or more
circuits it is used to protect. If it detects electricity flowing down an unintended
path, such as through a person who has touched a live part, the RCD will switch
the circuit off very quickly, significantly reducing the risk of death or serious injury.
What are the main types of RCD?
RCDs can help protect you from electric shock in potentially dangerous areas like
bathrooms and gardens, and there are various types of RCDs that can be used to
make sure you are always as safe as possible.
A) Fixed RCDs
These are installed in the consumer unit (fuse box) and can provide protection to
individual or groups of circuits. A fixed RCD provides the highest level of
protection as it protects all the wiring and the sockets on a circuit, and any
connected appliances.
B) Socket-Outlet RCDs
These are special socket-outlets with an RCD built into them which can be used in
place of a standard socket-outlet. This type of RCD provides protection only to
the person in contact with equipment, including its lead, plugged into the special
socket-outlet.
C) Portable RCDs
These plug into any standard socket-outlet. An appliance can then be plugged into
the RCD. They are useful when neither fixed nor socket-outlet RCDs are available
but, as with socket-outlet RCDs, they provide protection only to the person in
contact with the equipment, including its lead, plugged into the portable RCD.

Are RCDs reliable?

We’ve found that fixed RCDs are about 97% reliable. This improves if they are
tested regularly. If you have fixed RCD protection, it will reduce the risk of electric
shock to you and your family. It can also protect your home against the risk of fire
caused by faulty wiring or appliances.
 Remember – Although RCD protection reduces the risk of death or injury
from electric shock it does not reduce the need to be careful. Have your
wiring checked at least once every 10 years to ensure the safety of you, your
family and your home. If you find a fault with your wiring, or an appliance,
stop using it immediately and contact a registered electrician.
 Don’t forget to test – You should test all fixed and socket RCDs about
every three months. Manufacturers recommend that portable RCDs are
tested every time you use them.
 Beware – If you hold the test button in for a long time and the RCD does
not switch off the electricity supply, then get advice from a registered
electrician.
 The UK standard for safety – Since July 2008 virtually all circuits in new or
rewired homes have been required to include an RCD under the latest
edition of BS 7671.
How do I check whether I already have fixed RCD protection?
To check if you have fixed RCD protection, go to your consumer unit and have a
look to see if there is a device with a pushbutton marked ‘T’ or ‘Test’. This ‘test’
button is part of an RCD. If an RCD is fitted, there should also be a label on or
near the consumer unit stating ‘test quarterly’

WIRING COLOR CODES OF IEC AND NEC

 We have used Red for Live or Phase, Black for Neutral and Green for
Earth Wire.

 You may use the specific area codes i.e. IEC – International Electro-
technical Commission (UK, EU etc) or NEC (National Electrical
Code [US & Canada] where;
Wiring Colour Code:
NEC
Single Phase 120V AC:
Black = Phase or Line, White = Neutral and Green/Yellow = Earth Conductor
Three Phase 208 AC:
Black = Phase 1 or Line1, Red = Line 2, Blue = Line 3,
White /Gray = Neutral and Green/Yellow= Earth Conductor
IEC:
Single Phase 230V AC:
Brown = Phase or Line, Blue = Neutral and Green = Earth Conductor