Proc.

of the 8th International Conference on Engineering and Emerging Technologies

(ICEET) 27-28 October 2022, Kuala Lumpur, Malaysia

Design and Simulation of a Versatile Three-Phase

Automatic Changeover Switch
2022 International Conference on Engineering and Emerging Technologies (ICEET) | 978-1-6654-9106-8/22/$31.00 ©2022 IEEE | DOI: 10.1109/ICEET56468.2022.10007253

Michael Ampofo Boateng Daniel Afriyie Joel Akorli

Engineering Department Engineering Department Engineering Department
Ashesi University Ashesi University Ashesi University
Accra, Ghana Accra, Ghana Accra, Ghana
[email protected] [email protected] [email protected]

Kojo Acquah Ambrose Dery

Engineering Department Engineering Department
Ashesi University Ashesi University
Accra, Ghana Accra, Ghana
[email protected] [email protected]

Abstract— The importance of a changeover/ transfer switch is based in Ghana, all parameters (e.g.: frequency of power
cannot be understated. When using a generator, this switch supply) were set to the country’s nominal standards. This was
attempts to provide a smooth transition. A transfer switch is acquired from the Electricity Company of Ghana’s (ECG)
created in this project for a college in Ghana, to enable it to switch repository. Furthermore, the Proteus software was utilized due
electricity from the utility to a different source. Previously, a
manual switch was used, which was activated by physically
to its uniqueness to vividly demonstrate circuit functionality.
moving a lever. However, with this newly improved switch, if it
deems the power to be out (due to heavy rains or an electrical
accident), it will instantly and safely change-over to the generator
or solar power. Ultimately providing electricity to critical
functions (set precedingly). The final circuit was carefully
designed and divided into two halves, for better explanation. The
starter circuits were specially designed to simulate how the auto
switch-over will be powered (either through a single or three phase
supply). The end circuits were utilized to show how the auto
switchover gives users feedback. The overall outcome of the
project is a combination of the start, and end circuit. This resulted Fig. 1. Ashesi University campus building (with solar power provision)
in the adaptable auto-transfer switch. The project has an
immediate impact on three Sustainable Development Goals II. LITERATURE REVIEW
(SDGs): 7, 9, and 11. This is due to the fact that it is an innovation
that promotes clean energy, while also contributing to smart cities. In [2], Arun Dev et al. designed a three-phase single mode
changeover controller. It possessed two dc relays that were
Keywords— Single/three phase, Solar, Generator, ATmega328, capable of switching the power source from the grid, to solar/
generator. The switching mechanism is very fast with the use
Uninterrupted power, Changeover-switch.
of the relays. However, this changeover switch does not display
the recent power source to the user, and it is impossible to
I. INTRODUCTION manually operate it aside from being automatic. Hence, users
Ashesi University is a four-year institution that emphasizes do not have the choice to switch to the preferred power source,
both engineering and the liberal arts. It focusses on training to save power at a particular time.
ethical and entrepreneurial leaders to better Africa, and the
world. This project investigates the design of a safe, efficient, A digital electronics-based changeover switch is designed
and fast changeover switch that allows automatic starting. It by Singh, et al in [3]. It is designed as a way to prevent the
further allows automatic power generation for the entire school, generator from starting – if the power has not gone out for more
as soon as the power received from the grid is terminated. One than two (2) seconds – to save cost from false starting the
could argue that manually operating the switch would reduce generator. This changeover nonetheless, does not allow users to
some level of cost, but the safety of Ashesi employees must be select between single and three phase, and does not show them
considered [1]. Any handling of a power source could have the current power source.
unfavorable consequences. Manually starting a generator could Durrani, et al., designed a changeover switch for a hybrid
be disastrous, especially at night. A transfer switch removes the system comprising of the national grid, solar and a generator in
dangers associated with an outage entirely [1]. The many [4]. This system makes use of efficient switching priorities, to
parameters required to design a suitable changeover switch for save cost. The national grid is highly prioritized followed by the
Ashesi University, was evaluated. Considering that the college solar, and when the solar is unavailable, the generator takes

978-1-6654-9106–8/22/$31.00 ©2022 IEEE

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control. The system also has a charge controller that protects B. System Block and Flowchart Diargam
the battery (for solar) from overcharging, and from complete Figure 3 displays the block diagram of the proposed design.
drainage. This design however, does not give feedback to users
on the power source operating at any given time. It also does
not allow users to switch between manual and automatic modes.
Herath, et al., also designed an intelligent changeover
solution for a domestic hybrid power system in [5]. With the
help of a microcontroller, this system is able to sense the power
demand of the house at that moment and select the appropriate
power source (either solar or the grid), to supply power. This
changeover switch allows the generator to be added when there
is no grid power, and the battery for the solar is below 25% of Fig.3. System block diagram
its full capacity. At any point in time, the power source is The block diagram considers rectification and filtering of the
displayed on an LCD. Even so, this changeover system does not input voltage. The Proteus software was instrumental in
allow users to select between a single and three phase input. displaying a virtual terminal, and LED indicators, to signal
The four models ([2], [3], [4], and [5]) were reviewed, and their power in certain parts of the circuit. Proteus also helped explain
critiques displayed on a Pugh chart. The proposed model seeks two important starter-circuit methods. The flowchart of the
to reach the full 16 marks criteria-score. entire system is displayed in Figure 4.
TABLE I. PUGH CHART OF RELATED MODELS

Description M1 [2] M2 [3] M3 [4] M4 [5]

Sketch

Weight Model 1 Model 2 Model 3 Model 4

Criteria
Fully Automated 5 + + + +
Provides users 4 – – – +
with feedback
(LCD display)
Allows user to 4 – – – +
switch between
manual or
automatic mode
Enables users to 3 0 – – –
select between a
single/ three
phase input
Fig.4. Flowchart for the automatic changeover switch
Net Score (out of 16) –3 –6 –6 10

C. Important Considerations and Calculations

III. DESIGN METHODOLOGY
Calculations were made to provide accurate inputs into the
A. Computer Aided Design Model of Control Panel respective components in Proteus. It was presumed that the
This is the Computer Aided Design (CAD) model of the switch is applied on a 220V/415V configuration, and with a 12-
control panel, for the three-phase automatic switch. It was kilo ampere generator, operating at 50 hertz – along with a
power factor of 0.8.
designed using Solidworks. It contains components like relays,
contactors, push buttons, connecting wires, and circuit Using Ghana’s electricity standards:
breakers. The importance of using these, will be further Apparent Power = 12kVA
elaborated in the component justification section. Line Voltage (VL)= 415V
Phase Voltage (VS) = 240V
Active power = Apparent power x Power factor (1)
= 12 x 1000 x 0.8 = 9.6 kW
*For a balanced load
P = 3IpVPcosǾ (2)
9600 = 3 x Ip x 240 x 0.8
Ip = 9600 /(3 x 220 x 0.8)
Ip = 18.3 A
Fig. 2. Complete CAD design of the circuit and its casing For better efficiency, the minimum current rating is given
25% more tolerance.

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 Ip = 125% x 18.3 Accordingly, if the phase 2 line is faulty, the phase 3 comes ON.
Ip = 22.9 A When the phase 1 returns, power supply is automatically
In order to avoid any accidents, the cable carrying this rerouted to phase 1, followed by phase 2 – in that order.
current (Ip = 18.3A) was made to handle a current that is about The circuit also enables users (Ashesi) to select if they want
50% more than the calculated primary current (which is the automatic changeover to switch to the generator in any kind
approximately 38A). Transformer calculations: of fault (as explained above). The user could also be able to
!"
= 𝐶𝑃$$#
$"
(3) switch between phases (if the problem is not a power outage,
!# but perhaps just a single faulty wire). In so doing, users would
where CP =coupling factor = 1.0 ; have a constant supply of power. This will reduce generator
Vs = Secondary coil voltage = 12V(rms) maintenance cost by a considerable degree.
Vp = primary coil voltage = 220V (rms) With the only disadvantage being that any 3-phase appliance
Lp = primary coil inductance = 4H would not be powered if the user selects the phase switching
!" ! % $# capabilities of the circuit. Using the concept of digital
𝐿𝑠 = '(! % !#! (4)
electronics, the logic for a 3 input AND gate and OR gate, was
)** % * purposefully designed. Users may select the full three phase
𝐿𝑠 = *+*,,
= 0.0119 H
option by simply pushing the AND gate button. The OR gate
For the primary and secondary dc resistances, Rp and Rs button/ transistor circuit, triggers the single-phase selector
respectively capability. Table II shows a truth table for the AND and OR
!# .., gates outputs when the input phases are either high or low. The
Rp = = = 220Ω (5)
-# ) highs and lows are registered as binary inputs at the end circuit.
For current on the secondary coil,
TABLE II. LOGIC GATES TRUTH TABLE
!# % -# .., % )
Is = = = 18.33𝐴 (6) Input (Phase 1, 2, and 3) Output (AND gate) Output (OR gate)
!" ).
!" ). 000 0 0
Hence, Rs = = = 0.655Ω (7) 001 0 1
-" )+.00
010 0 1
011 0 1
IV. PROTEUS DESIGN
100 0 1
A. Implementation 101 0 1
After calculating for the primary-secondary inductance, as 110 0 1
well as the primary-secondary dc resistance for the transformer 111 1 1
with two primary and two secondary windings, assembly of the B. Component Justification
starter circuit began. For this project, the primary task was to
assemble together a circuit capable of switching from a three- The components and their functionalities, are displayed in
phase input grid supply to a three-phase generator, Table III below.
automatically. To take the research, and final solution to the TABLE III. COMPONENTS USED IN PROTEUS CIRCUIT
next level, some additional considerations were made:
Components Functions
• In the likely occurrence that 1 or all of the 3 phase lines Transformers (x3) Steps down 230V mains to 12V for
are faulty, the automatic 3 phase transfer switch testing.
activates the generator/solar to serve the load. That is, Timer 555 (x3) Used as an ON/ OFF delay for other
fans and other components in Ashesi. single phases not in use
(e.g.: b or c).
• Another alternative considered was: what if a fault is in LEDs (x3) To serve as indicators that a phase
just 1 line of the 3-phase supply, and the school deems is in use.
it a good idea to simply change to either second or third 3 input AND gate 4075 (x1) This implements the full 3 phase
phase (if, for example, the first phase got damaged). option.
3 input OR gate 4073 (x1) This implements a single-phase
After the voltage has been stepped down by the
option.
transformer externally, it is rectified into an output dc Motor (x1) To mimic a load fan.
waveform by the full wave bridge rectifier. This dc output is IRF3205 NPN MOSFET (x3) The MOSFET upon receiving a
then filtered by an electrolytic capacitor before being fed into minimal gate voltage of 2V,
the voltage regulator. The linear voltage regulator then keeps switches ON the power supply -
the voltage at a constant level before feeding into the timer, the through coils that closes the relay.
MOSFET, and then the relay [1]. This circuit works such that, 7812, 12V regulator (x3) Regulates the input voltage from
one phase is ON at a time. When phase 1 goes OFF, that is when output of transformer, into steady
there is a fault in line 1, the starter circuit switches to phase 2 12V.
automatically, after a 5 second delay (using the timer 555).

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 Capacitors (x9) Stores energy and enables delay as V. RESULTS AND DISCUSSION
it is involved in the T=RC (time
constant equation). Considering the tests conducted, the operation of the system
Resistors (x6) Resists current to LEDs and also is very effective and coordinated for efficient performance. The
enables delay as it is involved in the behavior and operation process which covers the design is
T=RC (time constant equation).
outlined below:
1N4007 diode (x3) Diodes used as freewheeling to
make sure entire current flows 1) All load relies primarily on the main power supply from
through coil. ECG.
AC supply input (x3) Voltage input into transformer, AC.
BC 557 PNP transistor (x4) Works as an alternative to the logic
2) In the proteus design, a dip in power automatically results
gates (this is method 2). With a in a (three) phase switch, and the load is automatically
specific gate current, it switches disconnected from the mains, and transferred to the standby
OFF other relays (for other phases), generator source.
when 1 other phase is ON.
3) The design’s response to the mains power failure is to
12V relay | contactors (x3) Relay coils are essential, and
coordinates the auto switches to switch ON the starting mechanism of the generator, then the
connect to different power supply solar supply subsequently.
options (phase 1, 2 or 3). 4) There is a delay in the loading of the generator so as to
ATmega328 (x1) Microcontroller used as the central
attain stability for a while. After the delay, the generator is fully
brain. It was coded with C++ to
control most components in the end loaded.
circuit (when conditions are met). 5) Once the main power supply from ECG is restored, power
Push buttons (permanent) (x2) In case of extreme emergencies, the supply from the generator is immediately cutoff. Thus, allowing
user can interact with the system for the reuse of mains power.
manually.
Virtual terminal / LCD (x1) To display feedback to the user.
A. Starter Circuit Simulations using Proteus
1) Relays are initially NO (Normally open), (See Figure 5).
C. Starter Circuit Methods
This extensive project also covers two variations of the
starter circuit’s functionality. One uses logic gates, and the
other uses power electronics (most predominantly BC557
transistors).
1) For Method 1 of the starter circuit, logic gates are used.
The AND gates would mean that if phase 1, 2 and phase 3 are
all ON (upon the user pressing the AND gate’s enable push
button), then a 3-phase auto changeover mode gets activated. If
the user presses the push button for the OR gate, it activates the
mode of switching between phase lines in case of a fault in a
single line [1]. Fig. 5. Starter circuit method 1: phase 1 input activated

2) For Method 2 of the starter circuit, no logic gates are

2) When one phase is ON (say phase 2), and the others are
used. The delay circuit is used in conjunction with the
transistor. After 5 seconds of phase 1 being OFF, the circuit OFF, if the single-phase mode is selected, the motor will be
switches to phase 2 and so on [1]. So, this method is another powered from phase 2. Phase 2 relay closes, and the motor spins
way to apply a single phase for Ashesi University, in case of a (See Figure 6).
fault in any wire (at least one wire must be functional).
Engineer disclaimer: The single-phase selector capability is
optional, and is most suitable for homes, hostels and
appliances on campus that use single phase.
• Single phase option: When phase 1 is OFF, phase 2 is
next, if phase 3 is OFF or all are OFF, then the
automatic switch triggers the generator to come ON and
power the load.
• Three phase option: When all three phases are off (most
probably due to a power cut) or even one single phase
shuts down, the switch automatically redirects to the Fig. 6. Starter circuit method 1: phase 2 input activated
available 3 phase generator/solar (as Ashesi has both).

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 3) When all three phases are ON, should the three-phase 2) When Grid input from starter circuit is HIGH, that is “1,”
mode be selected, the motor will be powered ON. Relays close the LCD screen prints “Grid (Priority).” The circuit switches
now, and the motor spins. All LEDs are HIGH (See Figure 7). ON the relay for the grid automatically, while shutting down
the Solar or Generator power. Notice that the LEDs shows
which system is prioritized at the moment (See Figure 10).

Fig. 7. Starter circuit method 1: all 3 phase inputs are activated

4) Starter method 2, using PNP transistors instead of logic

gates, with OFF delays (See Figure 8).

Fig. 10. Grid input – 1, solar input – 0, hence grid relay activated (closed)

3) When the grid shuts down, the microcontroller triggers the

solar or generator pin input to HIGH, then the solar panels’
relay coil is closed (See Figure 11). When there is a fault in our
internal circuit such that both the generator/ panel and the grid
pin input is connected and are on, the code recognizes this and
puts OFF the relay to the grid. Whiles switching ON the
available solar energy. Please note the microcontroller can
easily be configured to prioritize the grid instead of the
generator in case of a fault.
Fig. 8. Starter circuit method 2: transistor configuration used

B. End Circuit Simulations using Proteus

1) The final circuit is the combination of two halves. Here is
the end circuit with full connections, and a 1 or 0 representing
the state of the grid and the panel / generator (See Figure 9).
The following circuits required an Arduino code to simply
activate the relays based on the input of the grid or solar power.
There is also an option to use the manual changeover switch.
This is done by pushing the AUTO/MANUAL button down,
and then pushing the GRID/SOLAR BUTTON. By default, the
end circuit registers as AUTO (automatic).

Fig. 11. Grid input – 0, solar input – 1, hence solar relay activated (closed)

C. Important Links
1) Starter circuit video:
https://drive.google.com/file/d/1o5llD95Ym59ZBjSyZJLVku4
v6hiAUl6m/view

2) End circuit video:

https://drive.google.com/file/d/1A1ZG8trRXqSbL-EiCd6i5-
eh4HoWARm_/view

Fig. 9. Grid input – 0, solar input – 0

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 Fig. 12. Completed three phase selector/auto changeover switch in Proteus (start and end circuit)

VI. CONCLUSION AND FUTURE WORKS REFERENCES

[1] T. Kume and M. Swamy, "A quick transition electronic winding
The objective of this project was to move one step closer to changeover technique for extended speed ranges," 2004 IEEE 35th Annual
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facility like Ashesi, a sudden power outage could be 2004, pp. 3384-3389 Vol.5, doi: 10.1109/PESC.2004.1355073.
tremendously disruptive to the normal operation of the school. [2] M. A. Dev, P. F. Beevi, K. Abhinshan, K. S. kumar and K. M. Safvan,
This abrupt power fluctuation could result in the loss of crucial "Three Mode Single Phase Automatic Changeover Controller," 2020.
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between the main power source and the generator/solar (when [3] Uneet Kumar Singh, "Automatic Phase Changeover
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[4] S. Durrani, H. Ali, A. Zahir, and S. Khan, "Prototype Designing of
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for better efficiency and functionality, as opposed to the and Renewable Energy Technologies (PGSRET), 2018.
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used to establish a meaningful connection between the high Alahakonn and R. Hirshan, "Intelligent changeover solution for a
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(at the end circuits). 215, doi: 10.1109/SCSE49731.2020.9313063.

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