Protective Devices_MV Panels upto 415V

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1 PROTECTIVE DEVICES

1.1 GENERAL

1.1.1 Scope
1 This Part shall specifies the requirements for protective devices.

1.1.2 General Reference

1 The work of this Part is integral with the whole of the Project Documentation and is not
intended to be interpreted outside that context.
2 Co-ordinate the work with all other services affecting the work of this Section.

1.1.3 Ratings
1 The ratings of the various overcurrent protective devices shall be, in general, as
indicated on the Project Drawings. However, the protective device ratings shall be
confirmed based on the equipment and items being provided by the Contractor.
Contractor shall provide calculation and justification for proposing any change in the
rating.

1.1.4 Standards
The following standards shall be complied with:

IEC 60947-2 ACB’s, MCCB’s

IEC 60947-2, IEC 60898 MCB’s
IEC 60144 Direct Acting Meters
IEC 60831-1 & 2 Power factor correction capacitor
IEC 60664 & IEC 1010-1 Power factor regulator
IEC 60070 & IEC 60831 Capacitor switching contactors
IEC 60289 & IEC 60076 Detuned reactors
IEC 60947-4 Motor Starters
IEC 60947-4 Contactors
IEC 60529 Degrees of protection of enclosures
IEC 60364 and IEC 755 Earth Leakage Relays
IEC 60947-1 and 60947-4 Overload Relays

1.1.5 Overcurrent Protective Device Co-ordination

1 The Contractor shall carry out and provide an overcurrent protective device. Co-
ordination study as part of his material submission, as outlined below:
2 Properly co-ordinated automatically operated overcurrent protective devices shall be
provided for this Project. The overcurrent protective devices shown on the Drawings
shall be co-ordinated for adequate continuous current and interrupting capacity to
assure proper overcurrent protective devices operation under normal and fault
conditions in the system.
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3 All overcurrent protective devices on this Project and the first upstream device of the
existing electrical system shall be co-ordinated so that they will perform as follows.
When two or more overcurrent protective devices (including the first upstream protective
device of the existing system) in series with each other experience current flow greater
than their rated current, the device with the lowest rated current shall trip and/or open
the circuit first and thereby prevent the higher rated devices from operating.
4 The Supplier of the overcurrent protective devices shall prepare a co-ordination study to
verify the above stated performance requirements. The study shall be documented by
the Supplier and the documents shall include but not be limited to the following:
a. a composite drawing or drawings (on full size, reproducible, log-log
paper) showing the entire new electrical system (including the first
upstream protective device of the existing system) showing all protective
device curves (including motor overloads), short circuit duties, motor
starting curves and damage curves for motors, equipment and
conductors. This drawing or drawings shall show that all protective
devices are properly co-ordinated to perform as stated above
b. manufacturer’s overcurrent operating curves (on full size, reproducible,
log-log paper) for each overcurrent device. In the case of fuses, both
minimum melt and maximum clearing time curves shall be included
c. reproducible copies of all Project single line diagrams so marked to show
short circuit duties at all switchboards and motor control centres, and
which operating curve applies to each overcurrent device on the diagram
(the operating curves shall also be correspondingly marked)
d. a tabulation of the short circuit duties at all switchboards and motor
control centres, sizes and ratings of all overcurrent protective devices
and the required settings of all of the adjustable overcurrent protective
devices so that the performance requirements are met. Protective
devices which have earth fault protection features are specifically
required to meet this performance requirement.
e. Breaker selection will be done for service breaking capacity (Ics) for
values indicated in drawings / specification.

5 This documented co-ordination study shall be submitted for review before the
overcurrent devices are supplied for the Project.

1.1.6 Quality Assurance

1 The suppliers manufacturing facility shall be certified to the ISO - 9001 series of
standards from the International Standards Organisation.

1.1.7 Acceptable Manufacturers

Siemens
Schneider Electric
Cutler Hammer

All major components (namely ACBs, MCCBs, MCBs etc) will be from one of the approved
supplier only for co-ordination and discrimination between upstream and downstream
products.

1.2 PRODUCTS

1.2.1 Air Circuit Breakers

1 To IEC 60947-2, suitable for triple pole service and shall have breaking capacity of 65
kA symmetrical for 1 seconds at 415 Volts. Ics=Icu=Icw=65KA.
2 The Air Circuit Breakers (the conventional type and not moulded case circuit breaker)

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shall be 500 V, 50 Hz, triple pole with neutral link for incoming and outgoing ACB or four
poles for bus tie ACB only with ratings as shown on the Drawings. They shall be air
break, trip free, draw-out type with mechanical and electrical ON/OFF indicators.
3 Where air circuit breakers are to be electrically operated by automatic motor wound
spring mechanism, a standby manual operating handle shall be provided for operating
the circuit breaker in case of power or motor failure.
4 The air circuit breaker shall be provided with over current, short circuit and earth fault
protection having the following characteristics:
a. adjustable long time delay current setting (40 % - 100 %) with varied
tripping time
b. adjustable short time delay current setting (1.5 to 10 times) with variable
tripping time
c. instantaneous tripping for heavier over current adjustable from 2 to 15
times of base current
d. adjustable earth fault trip current setting (20 % - 60 %) with variable
tripping time, if shown in the drawing.

5 The circuit breaker shall have three position on the draw-out mechanism, namely
service position where all main and auxiliary contacts are made, test position where
main contacts are open but auxiliary contacts are closed and isolated position where all
contacts are open. An indicator shall clearly show these positions and provisions shall
be made for locking the breakers in any position. ON/OFF indicator shall be provided.
6 Mechanical Interlocks shall be provided to prevent withdrawing or inserting of the
breaker when it is ‘ON’. Any attempt to do so shall trip the breaker automatically.
7 The withdrawable part of the circuit breaker shall be effectively connected to earth
through scraping contacts that shall make before and break after the main and auxiliary
contacts.
8 The moving contacts comprising the main and arcing contacts shall be of the spring
loaded, self aligning type. The arc contacts shall be arranged to make before and break
after the main contacts.
9 Each ACB shall be included but not limited with following components and accessories:
a. auxiliary Contacts
b. arc Chutes
c. folding Extension Rail
d. charging Handle
e. open and Close Push-buttons
f. over Current Trip Indicator
g. key lock on Trip Button
h. Spring Charge Condition Indicator
i. breaker Position Indicator
j. making Current Release
k. automatic Shutters for the B/B Terminal
l. carriage for every size of ACB exceeding 25 KG in Weight
m. operation Counter
n. shunt trip mechanism.

10 ACB’s shall be provided with solid state type microprocessor based over current & earth
fault relays with integral LCD display, which shall use digital programming techniques
for highest protection accuracy and be integrated as part of the circuit breaker. The
current transformers / sensors and the wiring shall be integrated within the case and
shall be self powered. The current sensors shall be located within the case of the circuit
breaker. The over current relay shall have a wide adjustment range to allow flexibility of
setting on site. The trip unit shall measure the true RMS value of any wave form of
current. The control unit shall be equipped with a push to reset mechanical indicator, for
anti-pumping function.

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Characteristics of the trip units shall be as given below :

Long time protection (LT)
– Adjustable (in steps of 4% ) from 0,4 to 1 of the sensor rating (In).
– Time delay adjustable from 0.5 to 24 seconds
Short time protection (ST)
– Adjustable from 1.5 to 10 times the long time protection setting (Ir).
– Time delay adjustable from instantaneous to 0.4 seconds.
– Time inverse characteristic (I2t) may be switched in order to improve
discrimination
Instantaneous (INST)
– Adjustable from 2 times up to at least 15 times the rated current.

Where indicated in the drawings, the trip unit shall be equipped with an earth fault
option.

All trip units for ACBs will have integral LCD display which will measure current, voltage
parameters. As a minimum the following parameters will be displayed on the integral
display unit:
Energy, Real Power, Apparent Power, Demand Power
Current for all three phases
Voltage
Power Factor

The integral LCD display will also contain Maintenance Indicators (contact wear,
Operation cycles etc) including last ten trips and alarms.

As an option, communication option will be provided which will read and set protection
parameters remotely, transmit all calculated indicators and measurements remotely
through Modbus protocol.

All Air circuit breakers will be provided with motor mechanism.

11 The Main Incoming Circuit Breakers shall be provided with cable terminal boxes to suit
the incoming cables from the transformer/source supply.
12 Circuit breakers shall be tropicalised to operate continuously in an ambient temperature
of 55 °C and high relative humidity.
13 Type test certificate for each size of circuit breakers and MCCB from an internationally
recognised testing authority acceptable to the Engineer shall be provided.

1.2.2 Moulded Case Circuit Breakers

1 Shall have a combination of thermal and magnetic tripping giving an inverse time delay
protection against sustained overloads and instantaneous tripping under heavy
overloads and short circuits. Unless otherwise stated in the particular specification or
drawings, MCCB shall have a minimum short circuit rating of 36 kA Ics values.
2 Breakers shall have a quick make, quick break over-centre switching mechanism that is
mechanically trip free from the handle so that contacts cannot be held closed against
short circuits and abnormal current.
3 Tripping due to overload or short circuits shall be clearly indicated by the handle
assuming a position mid-way between the manual ON and OFF position.
4 Latch surfaces shall be polished.
5 Poles shall be constructed to open, close and trip simultaneously.
6 Ampere ratings shall be clearly visible.
7 Breakers shall be completely enclosed in a moulded case to IEC No. 157 - 1A, suitable
for installation inside switchboards.
8 Non-interchangeable trip breakers shall have the trip unit sealed.

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9 Breakers with earth leakage relay protection shall be provided with shunt trips.
10 Frame sizes shall be as per manufacturer’s standard size and as approved by the
Engineer, however minimum frame size will be 200A for standardisation.
11 For breakers up to and equal to 250 Amps equipped with thermal trip units
 Adjustable (from 80% to 100% of the current rating) thermal protection.
 Fixed magnetic protection for current ratings up to 200 A
 Adjustable (from 5 to 10 times the current rating) for current ratings greater
than 200 A. It shall be possible to ensure neutral protection. The tripping
threshold shall be equal to that of the phases, or to a reduced value (generally
half of that of the phases).
For breakers above 250 Amps equipped with electronic trip unit.
long time protection (LT)
 Selectable Ir threshold with fourty-eight settings from 40 to 100% of the trip
unit rating.
short time protection (ST)
– Im threshold shall be adjustable from 2 to 10 times the thermal setting Ir.
– the time delay shall be fixed at 40 ms.
instantaneous protection
 the threshold shall be fixed (between 12 and 19 times In, depending on the
rating)
For MCCBs above 250A, a thermal memory (in the event of repeated overloads, the
electronic trip units shall optimize protection of cables and downstream devices by
memorizing temperature variations). A load monitoring function shall be an integral part
of the electronic trip units indicating four loads levels (60%, 75%, 90% and 105%) by
LED's (with flashing LED for 105%). It shall be possible to install with the electronic trip
unit, a high threshold earth fault protection, a load monitoring remote indication or a set
of four fault indicating LED's in front to indicate the cause of tripping.

1.2.3 Miniature Circuit Breakers

1 These shall be type C for general purpose uses, suitable for the load they feed, and
shall have short circuit rating Icn of 10 kA, unless specified otherwise in the Project
Documentation.
2 They shall be fault rated so that fuse backup protection is not required.
3 They shall be rated in accordance with IEC 60898.
4 They shall include the following minimum features:
a. magnetic and thermal trip elements
b. trip-free mechanisms
c. locking of facilities with detachable proprietary brackets and clearly
marked ratings.

1.2.4 MCB/ELCB
1 Combined MCB/ELCB units shall be provided for final circuits supplying socket outlets,
water heaters and water pumps.
2 The units shall have a trip sensitivity of 30 mA.

1.2.5 Earth Leakage Circuit Breakers (ELCB)

1 Current operated earth leakage circuit breakers shall provide accident protection by
interrupting dangerous contact with voltage which may be present in faulty electrical
equipment as a result of frame faults, insufficient insulation or misuse.
2 The ELCB shall also provide a high degree of protection against earth leakage, fires
and electric shock and can withstand at least 6 kA (with upstream short circuit
protection device) or as specified in the Project Documentation. The breakers shall

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generally comply with IEC 61008 and the recommended specification CEE 227 of the
IEC on Rules for the approval of electrical equipment.
3 The breaker shall consist of a core balance transformer, a tripping coil with contact
assembly, main supply contacts, ON/OFF switch, a test button and a trip free
mechanism all enclosed in a robust body of all insulated material.
4 Degree of Protection against earth leakage throughout the electrical installation shall be
as indicated on the Drawings. Unless otherwise indicated, ELCB shall have 30 mA trip
settings.
5 The breaker protecting lighting and or power circuits shall be mounted in the panel
board enclosure.

1.2.6 Overload Relays

1 Thermal overload relays shall be used for motors ratings up to and including 11 kW,
giving protection against:
a. overcurrent unbalance
b. single phase
c. earth fault

2 Solid-state electronic protection relays shall be used for motors rated above 11 kW,
having the following protection features:
a. overload
b. overcurrent
c. single phase
d. earth fault
e. under-voltage
f. over-voltage
i. digital indication for above values
3. Documentary evidence must be produced showing the current/time characteristic of each
overload at its setting (hot/cold for the thermal overload) overlaid on the motor
manufacturers thermal stability time/current characteristic for comparison.

Consideration must be given as to the requested method of starting (DOL, star delta,
etc.).

1.2.7 Fuses
1 Fuses shall be the High Breaking Capacity (HBC) type to BS 88.
2 The fuse shall either include a suitable fuse carrier or it shall be capable of isolation. If
the fuse carrier is included it shall be such that when it is being withdrawn normally or
when it is completely withdrawn the operator is completely protected from accidental
contact with any live metal of its fuse link fuse contacts and fixed contacts.
3 If the fuse is capable of isolation it shall be so interlocked with the switch that isolation is
complete before the fuse enclosure can be opened further. The switch shall be
prevented from closing while the fuse-cover is open.

1.2.8 Fuse Switches

Generally
a. to be metal clad, unless otherwise specified in the particular specification, with
front operated handles interlocked with enclosure door to prevent opening the
door with the switch in the “ON” position
b. switch shall have the door with “ON/OFF” indication and means of pad locking
in the “OFF” position

2 Fuse Switch and Switch Fuses:

a. to BS EN 60967-3

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b. fuses: to BS 88 bolted type, class Q1, 415 V and switches certified for AC-23A
duty, unless specified otherwise in the Project Documentation, rating as
indicated in the Project Documentation,
c. fused switch carriages: withdrawable type
d. fuse switches: ASTA certified to 50 kA, or as otherwise indicated on the
drawings.

1.2.9 Isolating Switches

1 Isolating switches shall be:
a. same design as fuse switches and switch-fuses, with solid copper links in place
of fuses
b. single pole and neutral, or triple pole and neutral, as indicated
c. ratings, as indicated.

1.2.10 Stop Lock-off Push Buttons

1 Stop lock-off push buttons for motors shall be the mushroom headed red stay-put type
with automatic latching, the units having to be key operated to be released. 2 Push
buttons shall be housed in a surface mounting weatherproof enclosure to IP 65. 3 Push
buttons shall be UV stabilised.

1.2.11 Control Relays/Auxiliary Relays/Interposing Relays

1 Relays shall be suitable for operation on nominal 240 or 110 V AC supply or in special
cases 24 V AC or DC (i.e. low voltage application), as per the Project Documentation.
Relays shall be suitable for operation at plus 10 % and minus 25 % of their nominal
rated voltage. Relays and contactors shall be selected for category AC 3 duty.
2 Relays shall be of the plug-in type only complete with plastic cover and shall be fitted
with normally open/normally closed or changeover contact combinations as necessary.
3 The contact material shall be suitable for their specific application and the Contractor
must supply this information during the mobilisation period.
4 Mixed voltages must not be used on the different output contacts of a particular relay. If
necessary additional relays shall be used.
5 Coils shall be vacuum impregnated or guaranteed suitable for the local climatic
conditions.
6 Terminations to the relay bases shall be of the front connected screw clamp type. The
relay mounting panel shall be drilled and tapped to accept future spare bases.
7 Relays shall be secured to their bases by retaining bar or clip to prevent malfunction
due to the relay loosened in its base.
8 Care shall be taken to ensure that relay contacts and associated wiring are suitably fuse
protected.
9 AC operated relays shall have a neon indicator mounted within their clear covers which
shall be connected directly across the relay coil to indicate when supply is connected.
These indicators shall be easily seen when the relay compartment door is opened.
10 Relays having different contact configurations or different coil voltage shall under no
circumstances be interchangeable.
11 A permanent means of identification shall be affixed to both relay and base in line with
the circuit diagram reference.
12 Where remote supply voltages are used then care shall be taken to ensure that all
relays and any other equipment involved (terminals fuses etc.) are completely shrouded
and where possible segregated. A warning label engraved in English and Arabic shall
be fitted onto or adjacent to any such equipment. Similarly where voltages exceeding 55
V to earth are employed in relay compartments or non door-interlocked sections then
shrouding segregation and warning labels shall be applied.

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END OF PART

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