L.T.

SWITCHGEAR
• Low Tension (LT) switchgear refers to electrical equipment designed to control, protect,
and isolate electrical circuits operating at low voltages (typically up to 1000V AC or
1500V DC).

• LT switchgear is commonly used in industrial, commercial, and residential applications

to manage electrical power distribution and ensure the safe operation of electrical
systems.

• Main Components of LT Switchgear are:

a. Switch Fuse Unit (SFU)

b. Miniature Circuit Breaker
c. Earth Leakage Circuit Breaker
d. Moulded Case Circuit Breaker
e. Switches etc.

SWITCH FUSE UNIT

Key Components of a Switch Fuse Unit are:

a. Fuse Element
b. Switch Mechanism

a. Fuse Element:

A fuse provides protection against overcurrent or short-circuit conditions. When

excessive current flows through the fuse element, it melts, breaking the circuit and
preventing damage to downstream equipment. The fuse element typically consists of a
metal wire or strip with a specific current rating.

b. Switch Mechanism:
The switch part of the unit allows manual disconnection of the circuit from the power
supply. It is designed to make or break the current under no-load conditions.

Fig. Switch-Fuse Unit

Working Principle of SFU

• Normal Operation:

In normal conditions, the switch is closed, allowing current to flow to the connected load.
The fuse is intact and provides protection against any overload or short-circuit conditions.
• Overload or Short Circuit:

In case of an over-current or short-circuit condition, the fuse blows, disconnecting the

circuit and preventing damage to the downstream equipment. The switch mechanism
does not operate automatically; it simply remains in the closed position.

Types of Switch Fuse Units:

Switch Fuse Units are classified based on,

Type of Fuse: HRC (High Rupturing Capacity) Fuse, Rewireable Fuse

Mounting Type: Panel-Mounted, Floor-Mounted

Number of Poles: Single-Pole, Three-Pole, Four-Pole SFU

Applications of Switch Fuse Units:

Industrial Electrical Distribution: SFUs are used to protect motors, generators, transformers,
and other critical equipment.
Residential Electrical Systems: In some residential or commercial setups, SFUs are used to
protect individual circuits.
Feeder Protection: SFUs are often used as a disconnecting means for feeder circuits supplying
loads.

Lighting and Power Circuits: Used to protect circuits in buildings, lighting installations, and
distribution boards.

Advantages of Switch Fuse Units:

Over-current Protection: Protects the circuit from overloads and short circuits, ensuring
safety.
Isolation: Provides a safe method of isolating the circuit for maintenance or servicing.

Compact and Economical: Combines two functions (switching and protection) in a single
unit, making it cost-effective and space-saving.
Reliability: A well-designed SFU is reliable and ensures quick protection against faults.

Simplicity: The SFU is simple to operate and maintain, making it user-friendly for both
installation and troubleshooting.

MINIATURE CIRCUIT BREAKER (MCB)

MCB is a safety device used in electrical circuits to automatically disconnect the power supply
when an overload or short circuit occurs. It provides protection for both the electrical circuit
and the devices connected to it, preventing potential damage from electrical faults such as
overheating or fire.
Key Features of MCBs:
Overload Protection: MCBs trip (or open) when the current flowing through the circuit
exceeds the rated current for a certain period. This helps to protect the wiring and connected
devices from overheating.

Short Circuit Protection: In the event of a short circuit (where current flows through an
unintended path), the MCB trips instantly, preventing any damage from excessive current.

Manual Reset: After an MCB trips, it can be manually reset once the issue (overload or short
circuit) is resolved. This is in contrast to fuses, which need to be replaced after they blow.

Current Rating: MCBs come in various current ratings, typically ranging from 1A to 100A or
more, depending on the application.

Types of MCBs:

B-type MCB: Trips when the current exceeds 3-5 times the rated current. Suitable for
residential use where devices like lights and fans are connected.

C-type MCB: Trips when the current exceeds 5-10 times the rated current. Ideal for circuits
with inductive loads (e.g., motors, transformers).

D-type MCB: Trips when the current exceeds 10-20 times the rated current. These are used for
circuits with high inrush currents, such as large motors.

Breaking Capacity: This refers to the maximum fault current that the MCB can safely interrupt
without causing damage. It's a critical specification to ensure the MCB can handle possible
fault conditions without posing a risk.

Poles: MCBs are available in different pole configurations:

Single Pole (1P): For single-phase circuits.

Double Pole (2P): For 220V circuits.

Triple Pole (3P): For three-phase circuits.

Four Pole (4P): For a 3-phase, 4-wire system.

Applications of MCB: MCBs are commonly used in residential, commercial, and industrial
applications to protect electrical systems and ensure safety by interrupting power during fault
conditions.

Advantages of MCBs:
Instant Protection: Provides immediate disconnection in case of overload or short circuit,
ensuring that damage is minimized.

Resettable: Unlike fuses, MCBs do not need to be replaced after they trip; they can be reset
manually.

Compact Size: They are small and take up less space compared to older types of circuit
breakers, making them suitable for modern electrical panels.

Durable: MCBs can endure multiple trips without degrading, which makes them more reliable
for long-term use.
Cost-effective: MCBs are generally affordable, especially for residential applications.

How MCBs Work:

Overload Condition: When the current exceeds the rated value for a prolonged period, the
MCB's thermal mechanism (a bimetallic strip) bends due to heat, which trips the circuit.
Short Circuit Condition: When a short circuit occurs, the current increases almost instantly.
The MCB’s magnetic mechanism quickly trips the breaker to disconnect the circuit before
damage can occur.

Fig. Miniature Circuit Breaker (MCB)

EARTH LEAKAGE CIRCUIT BREAKER (ELCB):

An ELCB (Earth Leakage Circuit Breaker) is a safety device used in electrical systems to
prevent electric shocks and fires caused by leakage currents. It detects and interrupts leakage
currents, which may arise when electrical current flows through unintended paths, such as
through a person or a damaged insulation, potentially causing harm.

Types of ELCBs:
1. Voltage ELCB (Old type):

 This type detects leakage voltages between the earth (ground) and the electrical system.
If the earth potential rises beyond a certain threshold, the ELCB will trip to disconnect
the supply.
 Voltage ELCBs are less commonly used today due to their limitations in detecting small
leakage currents.

2. Current ELCB (Modern type, also called RCD or RCCB):

 This type detects the current leakage between the live (phase) wire and the neutral
wire, comparing the incoming and outgoing currents. If there is an imbalance between
the currents (i.e., some current is leaking to the ground), it trips the circuit to stop the
flow.
 These are more common and effective in protecting against electric shocks and fire
hazards.
  It works on the principle of differential current and is more sensitive to small leakage
currents.

Working Principle of a Current ELCB:

 The ELCB uses a current transformer (CT) to monitor the current flowing through
the live and neutral wires. Under normal conditions, the current entering the live wire
is equal to the current leaving through the neutral wire.
 If any current leaks to the earth, the imbalance causes a difference in the current
between the live and neutral wires. The ELCB detects this difference (typically around
5–30 mA) and trips the circuit.
 When this imbalance is detected, the ELCB disconnects the electrical supply,
preventing potential electric shock or fire hazards.

Fig. Circuit diagram of ELCB

Key Features of ELCB:

Safety: Protects people from electric shocks by detecting leakage currents, which could be due
to insulation failure, grounding issues, or other faults.

Sensitivity: ELCBs are sensitive to small leakage currents, usually in the range of 5 to 30 mA,
which is the threshold that could cause harm to the human body.

Instant Action: ELCBs can detect leakage currents and trip the circuit in milliseconds, offering
quick disconnection to prevent accidents.

Applications of ELCB:
Residential Wiring: To protect against electrical hazards in homes.
Industrial and Commercial Electrical Systems: For machinery and electrical installations
where leakage currents can occur.

Outdoor Installations: Where earth leakage is more likely due to environmental factors.

Difference Between ELCB and RCCB:

 ELCB (Voltage type): Detects voltage between earth and the electrical system. Less
commonly used.
 RCCB (Residual Current Circuit Breaker): Detects current imbalance between the
live and neutral wires and is more commonly used today.
Advantages of ELCB:
Enhanced Safety: ELCBs improve safety by disconnecting the power in case of leakage
currents.

Fire Protection: Prevents electrical fires that could result from leakage currents.
Prevents Electric Shocks: Cuts the current when a leakage current is detected, reducing the
risk of fatal shocks.

Limitations of ELCB:
False Tripping: If the grounding system is not properly connected, or in certain situations, an
ELCB may trip unnecessarily.

Not a Substitute for Overcurrent Protection: ELCBs do not provide protection against
overcurrent or short circuits; they only detect leakage currents. Overcurrent protection devices
like circuit breakers or fuses are also necessary.

In summary, an ELCB plays a crucial role in ensuring electrical safety by detecting leakage
currents and preventing electrical shocks or fire hazards. The RCCB (Residual Current Circuit
Breaker) is a more modern version of the ELCB and is widely used in modern electrical
systems.

MOLDED CASE CIRCUIT BREAKER (MCCB):

An MCCB (Molded Case Circuit Breaker) is a type of electrical protection device used to
protect electrical circuits and equipment from overcurrent conditions, such as overload and
short circuits. It is designed to automatically interrupt the flow of electricity in case the current
exceeds safe levels, preventing damage to the electrical system.

Key Features of MCCB:

Overload Protection: MCCBs are capable of detecting overloads (when the current exceeds
the normal rated capacity for a period of time). This protection ensures that the circuit is not
subjected to excessive heat that could damage wires, equipment, or cause fires.
Short Circuit Protection: MCCBs are designed to detect and protect against short circuits
(where current takes an unintended low-resistance path, such as in a fault condition). In such
cases, the MCCB quickly trips the circuit to prevent damage to the system.

Adjustable Trip Settings: Unlike standard circuit breakers, many MCCBs allow the user to
adjust the trip settings, making them versatile for different applications and protecting circuits
with varying current ratings.

Rated Current: MCCBs come in a range of current ratings, typically from 10 A to 2500 A.
This allows them to be used for protecting both low and high-capacity circuits.

Molded Case Design: The breaker mechanism is housed in a molded plastic or thermosetting
case, which offers electrical insulation, durability, and protection from environmental factors
like dust and moisture.

Trip Mechanism: MCCBs generally use an electromechanical trip mechanism (thermal and
magnetic) to detect overcurrent conditions:
Thermal Trip Mechanism: This operates based on the heating effect of the current, which
causes a bimetallic strip to bend and trip the breaker when there is an overload for an extended
period.

Magnetic Trip Mechanism: This detects high-speed surges of current, such as those caused
by short circuits, using an electromagnetic coil to trigger the trip mechanism almost
instantaneously.

Resetting Capability: After the MCCB trips, it can be manually reset, allowing the user to
restore the circuit once the problem (such as an overload or short circuit) has been resolved.

Fig. Working of MCCB

Applications of MCCBs:
Industrial Power Distribution: Used in industrial plants and factories to protect large
electrical systems and heavy machinery.

Commercial Buildings: Used to protect circuits in commercial installations such as office

buildings, shopping malls, etc.

Residential Electrical Panels: In larger residential installations, an MCCB may be used to

protect high-power circuits (e.g., for air conditioners, water heaters, etc.).
Motor Protection: MCCBs are commonly used in motor protection circuits, as they can handle
the large inrush current that motors experience when starting.

Advantages of MCCBs:
High Current Handling: MCCBs can handle a wide range of currents, from low to very high,
making them suitable for various applications.

Customizable Settings: Adjustable trip settings allow for fine-tuning based on the specific
needs of the circuit.

Reliable and Durable: Molded case design provides durability and reliable operation in harsh
environments.

Thermal and Magnetic Protection: The combination of thermal and magnetic trip
mechanisms provides a comprehensive safety solution for both overload and short circuit
conditions.
Resettable: After tripping, the MCCB can be reset, reducing the need for replacement and
improving overall cost-effectiveness.

Disadvantages of MCCBs:
Size: MCCBs are generally larger than other types of circuit breakers like MCBs (Miniature
Circuit Breakers), which can make them less suitable for very compact applications.

Cost: MCCBs can be more expensive than smaller, simpler breakers like MCBs due to their
higher current ratings and additional features.

Complexity: The settings for MCCBs may require proper understanding and adjustment,
which could require technical knowledge.

In conclusion, an MCCB is a highly effective protection device for electrical systems, designed
to safeguard against overcurrent conditions (both overloads and short circuits). It is used in
both low and high-power applications and is essential for ensuring the safety and longevity of
electrical equipment.

Comparison of various LT Switchgear components:

EARTHING
EARTHING, also known as grounding, is a safety measure that protects people and electrical
appliances from electric shock, fire, and damage. It's a process that connects the non-current-
carrying parts of an electrical system to the earth through a low resistance wire or electrical
cable.

NECESSITY OF EARTHING:
Safety: Earthing provides a safe path for electrical current to flow to the ground in the event of
a fault, reducing the risk of electrocution and fire.

Voltage stability: Earthing helps maintain a stable voltage level in the system, which is
especially important for sensitive equipment.

Protective devices: Earthing ensures that protective devices like circuit breakers, fuses, and
surge protection devices function properly.

Lightning, static electricity, and short circuits: Earthing protects against electrical hazards
caused by these.

Types of Earthing:

A. Plate Earthing

B. Pipe Earthing

C. Rod Earthing
D. Strip or Wire Earthing

PLATE EARTHING
PLATE EARTHING is a method where a plate made of galvanized copper or iron is buried
vertically at least 3 meters below ground level. This plate connects all conductors to the earth,
providing a path for electrical discharge.

PROCEDURE FOR PLATE EARTHING:

Earth Pit: An earth pit is excavated at a suitable location, with a minimum size of 900mm
x900mm and a depth of 3m below the surface.

Plate Electrode: A GI plate of minimum size 600mm x600mm and thickness of 6.3 mm is
used. If a copper plate is used, a minimum thickness of 3.15mm is required. The plate is
surrounded by alternating layers of charcoal and salt.
Earthing Connection: Galvanized Iron strips are fixed and welded to the plate at two different
locations. Loose earthing can adversely affect the electrode system resistivity, so these
connections are made strong.

Water Connection: A pipe is fixed at the top to maintain moist conditions around the earth
plate. The pipe is covered with a wire mesh, and water is poured through it. The excavated pit
is then filled with stone-free soil.
Inspection Chamber: A brick chamber is built over the earth pit on a P.C.C (Plain Cement
Concrete) layer. The top cover is placed with cast iron hinges to a CI frame.

Fig. Plate Earthing

PIPE EARTHING
In pipe earthing, a galvanized steel perforated pipe is buried underground vertically, connecting
all the electrical conductors to the earth. The depth of pipe in pipe earthing depends on the
conditions of the soil. This method is affordable and requires low maintenance.

Procedure for Pipe Earthing

a. Identify the ideal location for earthing, an earth electrode should not be closer than 1.5
m from any building.
b. Excavate an earth pit with the required depth considering the soil type and resistivity.

c. The tapered end of the GI pipe should go vertically deep into the soil, not less than 3m.
 d. The pit is to be filled with charcoal and salt alternatively to increase the moisture-
holding capacity of the soil and thus maintain its conductivity.

e. The top end of the pipe should not be less than 20 cm below the ground level, and a
chamber of size not less than 30 cm x 30 cm x 30 cm is built over it for maintenance.

f. A watering funnel with mesh is to be installed at the top opening end. This is for
maintaining the moisture content by watering during summer or dry seasons.

g. Earthing wires are connected to the pipe at the terminal clamps available, using nuts-
bolts and washers.

h. Usually, an 8SWG earth wiring is used for high tension connections and, a 10SWG wire
is used for low tension connections.

COMPARISION OF VARIOUS EARTHING METHODS

Feature Plate Earthing Pipe Earthing Rod Earthing Wire Earthing

Definition Uses a metal Uses a metal Uses a metal Uses a metal

plate (usually pipe (typically rod (usually wire buried in
copper or steel) buried in copper or the earth or laid
galvanized the ground. galvanized along the
iron) buried in iron) driven surface.
the ground. into the earth.
Material Used Copper, Steel, Copper, Copper,
galvanized galvanized galvanized aluminum, or
iron, or steel. iron, stainless galvanized
stainless steel. steel. steel.

Size/Shape Flat rectangular Circular pipe Long, Flexible wire

or square plate. (usually 25mm cylindrical rod (usually 8 to
to 50mm (usually 2.5m 10mm thick).
diameter). to 3m long).

Installation Buried Buried Driven Typically laid

Depth vertically, vertically or vertically into horizontally or
usually 3-5 feet horizontally, the earth vertically in
deep. usually 3-5 feet (usually 3m to trenches, or in
deep. 5m deep). shallow pits.

Cost Relatively high Medium, Moderate, Low to

due to material depending on depending on moderate, due
and installation the pipe size rod length and to the wire
complexity. and material. material. material cost
and simplicity
of installation.

Maintenance Requires Low Minimal Very low

periodic maintenance, maintenance maintenance;
inspection and but prone to but can corrode however, wire
cleaning of the rusting if not over time, corrosion can
plate to ensure properly requiring affect
good treated. periodic conductivity.
conductivity. inspection.

Earth Low resistance Moderate Low to Higher

Resistance if installed resistance, moderate, resistance
properly. especially if depending on compared to
pipe is soil conditions. other methods
corroded. due to smaller
cross-sectional
area.

Durability Highly durable Moderate, can Fairly durable, Less durable,

if made from corrode over but can degrade especially in
copper or time. over time due high-moisture
stainless steel. to corrosion. environments
or where
corrosion is
rapid.
 Space Requires a Takes up less Takes up less Very compact,
Requirement relatively large space than plate space than plate especially when
area for earthing, more or pipe laid in shallow
installation. compact. earthing. trenches or
attached to
structures.

Application Commonly Suitable for Common in Commonly

used for large residential small-scale used for light
installations, buildings, installations residential,
industrial small and residential telecom
plants, and industries, and earthing. installations, or
substation pipelines. as an auxiliary
earthing. earthing
system.

Best Suited Areas with high Areas where Areas with Areas where
For soil resistivity space is limited normal soil compact, cost-
and where large or where pipes resistivity, effective
surface area are already where space is earthing is
grounding is available. not a constraint. needed, or as a
needed. supplementary
method.

BATTERIES
A battery is a device that stores electrical energy in chemical form and releases it as electrical
energy when needed. It consists of one or more electrochemical cells that convert chemical
energy into electrical energy.

The main components of a battery are:

1. Anode (negative terminal): The electrode where oxidation occurs.

2. Cathode (positive terminal): The electrode where reduction occurs.

3. Electrolyte: A substance that allows ions to move between the anode and cathode.

4. Separator: Prevents the anode and cathode from coming into direct contact while
allowing ions to pass through.

Types of Batteries:
Batteries can be broadly classified into two categories:

1. Primary (non-rechargeable) batteries

2. Secondary (rechargeable) batteries.
1. Primary (Non-Rechargeable) Batteries
These batteries can be used only once and cannot be recharged. Once the chemical
reaction inside the battery is exhausted, it must be disposed of.

2. Secondary (Rechargeable) Batteries

These batteries can be recharged and used multiple times, making them more cost-
effective over the long term.

PRIMARY (NON-RECHARGEABLE) BATTERIES

Battery Description Applications

Alkaline Most common primary battery. Uses zinc Remote controls, toys,
Battery and manganese dioxide as electrodes. flashlights, clocks, radios.

Zinc-Carbon Older type, uses zinc and carbon Low-power devices like
Battery electrodes. Slightly less efficient than flashlights, clocks, and
alkaline. radios.

Lithium Uses lithium metal as the anode and a Watches, cameras, hearing
Battery variety of cathode materials. High energy aids, medical devices.
(Primary) density and long shelf life.

Silver Oxide Uses silver oxide as the cathode and zinc Watches, hearing aids, and
Battery as the anode. Known for stable voltage and small electronic devices.
compact size.

Mercury Uses mercury oxide as the cathode and Used in hearing aids,
Battery zinc as the anode. High energy density but cameras, and other small
toxic and less common today. electronics (rare today due
to environmental concerns).
SECONDARY (RECHARGEABLE) BATTERIES

Type of Battery Description Applications

Lead-Acid Uses lead and lead oxide as electrodes, Automotive, uninterruptible

Battery with sulfuric acid as the electrolyte. power supplies (UPS),
One of the oldest rechargeable battery electric vehicles.
technologies.

Nickel- Uses nickel oxide hydroxide and Power tools, cameras,

Cadmium cadmium as electrodes. Known for medical equipment, and
good cycle life but suffers from portable devices.
(Ni-Cd)
memory effect.

Nickel-Metal An improvement over Ni-Cd, uses a Hybrid vehicles, digital

Hydride hydrogen-absorbing alloy instead of cameras, portable
cadmium. Has higher capacity and is electronics.
(Ni-MH)
more environmentally friendly.

Lithium-Ion Uses lithium-based compounds for the Smart phones, laptops,

anode and cathode. High energy electric vehicles, power
(Li-Ion)
density, lightweight, and has no banks.
memory effect.

Lithium- A variation of Li-Ion, uses a polymer Drones, portable

Polymer (Li-Po) electrolyte instead of a liquid electronics, electric
electrolyte, making it flexible and vehicles.
lighter.

Sodium-Sulfur High-temperature battery using molten Grid energy storage,

Battery sodium and sulfur. Known for high renewable energy storage.
energy efficiency but requires high
operational temperatures.

Zinc-Air Battery Uses oxygen from the air and zinc as Hearing aids, medical
the anode. Typically has a higher devices, and other small
energy density than other primary electronics.
batteries.

Flow Battery Uses two chemical components Large-scale energy storage

dissolved in liquids and separated by a systems, renewable energy
membrane. They store energy in integration.
external tanks.