FACULTY OF ELECTRICAL ENGINEERING - Welcome to...
Transcript of FACULTY OF ELECTRICAL ENGINEERING - Welcome to...
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
FACULTY OF ELECTRICAL ENGINEERING
AUTOMATED ELECTRICAL DISTRIBUTION PANEL NAME: MATRIC NUMBER: 1. MOHD SHARIZAN BIN ESTAR B010410181 COURSE: 4 BEKP 2 SUPERVISOR: DR MUSSE MOHAMUD AHMED DATE: 7th MAY 2008
“I hereby declare that I have read through this report and found that it has comply
the partial fulfillment for awarding the degree of Bachelor of Electrical Engineering
(Industrial Power)”
Signature : ………………………………………
Supervisor’s Name : Dr. MUSSE MOHAMUD AHMED
Date : ………………………………………
AUTOMATED ELECTRICAL DISTRIBUTION PANEL
MOHD SHAHRIZAN B. ESTAR
This Report Is submitted In Partial Fulfillment Of Requirement For The Degree of
Bachelor In Electrical Engineering (Industrial Power)
Fakulti Kejuruteraan Elektrik
Universiti Teknikal Malaysia Melaka
MAY 2008
“ I hereby declare that this report is a result of my own work except for the experts
that have been cited clearly in the reference.”
Signature : ……………………………………
Name : MOHD SHAHRIZAN B. ESTAR
Date : …………………………………...
i
ACKNOWLEDGEMENTS
Firstly, I am Thankful to Allah who has given me a chance to complete this
subject and also my final report for Projek Sarjana Muda 2 (PSM2) in this semester.
Secondly I want to thank to the Universiti Teknikal Malaysia Melaka
(UTeM) especially Faculty of Electrical Engineering (FKE) for giving me an
opportunity to do my Projek Sarjana Muda 2 (PSM 2) in fulfillment for Bachelor of
Electrical Engineering.
Thirdly thankful to my supervisor, Dr Musse Mohamud Ahmed for the
advices and also the material that he give to me. Without his guidance and advices,
maybe my project can’t be completed on time.
I also want to thank to Mrs SOO the master student for her advice and teach
about the principle of the programming and also about the software. Next, I want to
thank to my parent and my family in supporting me while doing the project. To my
coordinator, all lectures and my fellows friends who helped me to finish up this
project and report, thank you very much. To my PSM partner, thank you for your
cooperation. Lastly to mrs Umi Kalsum Tomiran for her support.
I hope what I have learned while doing this project will help me in the future.
I also hope that this report will become a guideline for all future students in UTeM.
THANK YOU.
MOHD SHAHRIZAN B. ESTAR
Bachelor in Electrical Engineering (Industrial Power)
Faculty of Electrical Engineering
Universiti Teknikal Malaysia Melaka
ii
ABSTRAK
Panel pengagihan automatik adalah panel yang di kawal oleh SCADA
(Kawalan Penyeliaan Dan Pemerolehan Data) dan Unit kawalan terminal (RTU).
SCADA seperti namanya, ia bukanlah mengawal sepenuhnya dalam sesuatu sistem,
tetapi lebih berfokus kepada kawalan penyeliaan. RTU pula sebagai pengantara
dimana ia akan mengumpulkan data dan menghantar ke system utama. Dari kedua-
dua ciri ini, SCADA dan RTU akan berkerjasama untuk mengawal beban. Sebagai
beban, ia boleh seperti lampu mentol, kipas, pengubah dan juga pelbagai lagi
peralatan elektrik yang dianggap selamat. SCADA akan menunjukan sebarang
permasalahan yang berlaku di dalam sesuatu system itu secara automatik.
Projek ini mengenai mengawal, memantau dan panel beban boleh beroperasi
setelah segala peralatan dipasang kedalam panel penghantar. Di dalam panel ini
mengandungi barang-barang yang digunakan oleh panel pengagihan biasa.
iii
ABSTRACT
Automated distribution panel is a panel that is being controlled by SCADA
(Supervisory Control and Data Acquisition) and RTU (Remote Terminal Unit).
SCADA as the name indicates, is not a full control system, but rather focuses on the
supervising level. RTU as a device is located at a remote site to collect data and
transmit the data back to a central station (or master). An RTU also collects
information from the master device and implements of processes the data and this is
directed by the master. From this particular feature, SCADA and RTU will be
interfaced to control the loads. As the loads could be lamps, fans, relays, motors and
other equipment with security features. All the equipment will be installed in the
panel and the data processes will be delivered at the control centre system by local
input output device. SCADA will detect the entire problem during the current flow to
the loads in the computer, if any problem arises; it will automatically show on the
computer.
This project is about to monitor, control and operate electrical loads and
equipment connected to the panel. The panel consist the real equipment of an
ordinary distribution panel.
iv
TABLE OF CONTENT
CHAPTER CONTENT PAGE
TABLE OF CONTENT iv
LIST OF TABLE vi
LIST OF FIGURE vii
LIST OF ABBREVIATION viii
LIST OF APPENDIX Ix
1 INTRODUCTION 1
1.1 Automated Distribution Electrical Panel Definition 1
1.2 Problem Statement 2
1.3 Experiment Objective 2
1.4 Scope Of Project 3
2 LITERATURE REVIEW 4
2.1 Distribution panel 4
2.2 Equipments characteristic 5
2.2.1 Miniature Circuit Breaker (MCB) 5
2.2.2 Relays 8
2.2.3 ICP- Controller i-7188XG 10
2.2.4 I/O Module i-7058D 13
2.2.5 DC Power Supply 15
2.2.6 Supervisory Control and Data Acquisition
(SCADA)
18
2.2.7 Remote Terminal Unit (RTU) 20
2.3 Summary 22
v
CHAPTER CONTENT PAGE
3 METHODOLOGY 23
3.1 Project Methodology 23
3.2 Summary 24
4 RESULT AND DISCUSSION 25
4.1 Designing the Distribution Panel 25
4.2 Distribution Panel Concept 26
4.3 Miniature circuit breaker ( MCB ) Rating Calculation 30
4.4 Result 31
4.5 Discussions 31
4.6 Summary 32
5 CONCLUSION 33
5.1 Conclusion 33
5.2 Suggestion 33
REFERENCE 34
APPENDIX 35
vi
LIST OF TABLE
CHAPTER CONTENT PAGE
1 Table 1. the spefication of the ICP – Controller i -
7188XG
11-12
vii
LIST OF FIGURE
NO CONTENT PAGE
1 Figure 1. The connection between the electrical panel to
the loads panel and computer.
5
2 Figure 2. Photo of inside of a circuit breaker 6
3 Figure 2.1 Molded case circuit breaker (MCCB) 7
4 Figure 3. The normal condition of the relay and the relay
that is use inside the panel
9
5 Figure 4.1 The controller model and the cable for
interfacing to computer.
10
6 Figure 4.2 1xRS-232, 4 DI & 4 DO Board, for I-
7188XG/XB
12
7 Figure 4.3 Support I/O Expansion Board: X-Board series 13
8 Figure 5. the connection inside the controller 15
9 Figure 6. Solomon S-35-24 single power supply 16
10 Figure 7. the example of the SCADA application in
industry
20
11 Figure 8. An example of RTU application in industry 22
12 Figure 9. The basic concept of the automated electrical
distribution panel
26
13 Figure 10. Single line diagram of the electrical
distribution system
28
14 Figure 11. Installation of the electrical panel and loads
panel
29
15 Figure 12. the dimension of the electrical distribution
panel
30
viii
LIST OF ABBREVIATION
DC - Direct current
V - Volt
AC - Alternating current
PSM - Projek Sarjana Muda
KV - Kilo Volt
HV - High Voltage
Ω - Ohm
mA - mili Ampere
nF - nano Farad
pF - piko Farad
M - Mega
Hz - Hertz
W - Watt
Mm - mili meter
Kg - kilogram
LV - Low Voltage
ix
LIST OF APPENDIX
NO CONTENT PAGE
1 Indusoft Web Studio 35
2 ISAGRAFT 38
3 Datasheet_7188xg.pdf 44
1
CHAPTER 1
INTRODUCTION
1.1 Automated Electrical Distribution Panel Definition
Automated means the system can operate by its own. The definition of the
distribution panel is the main electrical control center, which contains switches or
circuit breakers, is connected to the service wires and delivers current to the various
branch circuits. Automated Electrical Distribution Panel means, the system of the
distribution panel can operate automatically using SCADA and RTU programming,
to control the loads. By using this programming, when there is a problem, such as
short circuit, the panel can be repaired by itself by monitoring from the control room.
All the data will be monitored by SCADA. The RTU will collect the data and
transfer it to the SCADA to be monitored. This automated distribution panel can use
single phase or the three phase system. The distribution panel is usually used by
Tenaga Nasional Berhad (TNB) when the new residential areas are created. This
system will make the work more easily because everything will be monitored by
computer by know where the place that have a problem, and can know either the
system can automatically repair or not. By using this panel, it should be repaired
automatically.
With this panel also, we can use in manual way. Everything can be done in
front of computer. By clicking the manual button and the system will run in manual
way. This system also can be use inside the building to determine the problem in
every level, or it can be use in the house, so that the owner can switch on the light at
the bed.
2
1.2 Problem Statements
Each of the projects has their own problem to be discussing before starting
the project. By stating the problem statement it easy to know the purpose of doing
this project and what are the problem to be solved. Below are the problem statements
for this project.
• Currently, all the electrical panels used by the consumers are designed in
conventional way, if any problem arises from the supply or from the
equipments connected to the panel, it is solved by manual way
• This panel is designed to function in an automated manner instead of
manual practice
1.3 Project Objectives
Before conducting or doing the project, the objectives of the project are the
main focus in this project. At the last of this report from the conclusion the objective
are stated where it succeed or not. Below are the objectives of this project.
• To design and fabricate an automated electrical panel using SCADA and
RTU.
• Study about the equipment characteristic.
• To design the wiring diagram, installing all the equipment to the panel.
• To operate and test the panel with SCADA and RTU and control the load
connected to it.
3
1.4 Scope of Project
This project report consists of five chapters, chapter one is introduction,
chapter two literature review, chapter three methodology, chapter four results and
discussion and chapter five is the conclusion. Chapter one will be explain about an
automated Electrical Distribution panel and its applications. This chapter also states
the problem for the project, objective and scope of the project report.
Chapter two will discuss about the electrical panel and the equipment that
will be use in this project, there are eight important material including the hardware
and software will be discuss in this chapter. First equipment about the miniature
circuit breaker (MCB), second equipment relays, third equipment bulb, fourth
equipment is ICP-Controller i-7188XG and its characteristic, fifth equipment is input
output module i-7058D and its characteristic, sixth is about DC power supply for the
controller, seventh and eighth is about the programming part, there are SCADA and
RTU.
Chapter three is the methodologies for the whole processes of project from
PSM I until PSM II. In project methodology will explain the whole project procedure
from starting finding and research the topic until choose the best circuit. For PSM 1
is about the analysis according to the panel and also the equipment. It is necessary to
know because if the wrong rate of material being use, the panel cannot run smoothly.
Then in PSM 2 is about installation and testing part.
In chapter four is discussing about the project result, this chapter consist of
analysis of the panel that being use nowadays and its type. In this chapter also the
panel characteristic will be discuss and also its principle. Finally the last is chapter
five about the conclusion of the whole project report and suggestions.
4
CHAPTER 2
LITERATURE REVIEW
2.1 Distribution panel
Distribution panel is the main electrical control center, which contains
switches or circuit breakers, is connected to the service wires and delivers
current to the various branch circuits. A distribution panel (known in the
United State as a (circuit) breaker panel, panel board, or loads center) is a
mounting enclosure for multiple electric circuit breakers. The distribution
panel is installed to the consumer units. Distribution boards typically found in
central location inside building and often serve as the point at which
electricity is distributed within a building. Circuit breakers can be used to
manually de-energize electrical circuit when the downstream wiring is being
serviced.
The equipments the being install in the automated distribution panel
are circuit breaker, relays, DC power supply, ICP-controller and wires.
Circuit breaker panel are always dead front, which is the operator of the
circuit breakers cannot contact live electrical parts. During servicing of the
distribution boards itself, though, when the cover has been removed and the
cables are visible, some breaker panels commonly have live parts exposed.
This distribution panel will be connected to the computer and also to
the loads board. In the loads board has lamps delegating the consumers. This
distribution panel is ring system and it use three phase four wire system to
supply the distribution board and the loads board.
5
Figure 1. The connection between the electrical panel to the loads panel and
computer
Figure 1 show the connection between the electrical panel to the loads and
computer. From the computer, the RTU programming must be burn out to the ICP-
Controller first, then after finish burn out, run the SCADA programming. The
programming will interface automatically.
2.2 Equipments characteristic
In this project, there are eight material that being use including for the
hardware and software. For the software material, indusoft and isagraft is use to
determine SCADA and RTU programming. For the hardware, the material that being
installed, are miniature circuit breaker (MCB), relays, DC power supply, ICP-
Controller, input output module, and bulb. For this project, 1.5mm2 cable size is
being use to connect all the equipment.
2.2.1 Miniature Circuit Breaker (MCB)
All circuit breakers have common features in their operation, although details
vary substantially depending on the voltage class, current rating and type of the
circuit breaker. The circuit breaker must detect a fault condition; in low-voltage
circuit breakers this is usually done within the breaker enclosure. Large high-voltage
6
1. Actuator lever - used to manually trip and reset the circuit breaker. Also indicates the status of the circuit breaker (On or Off/tripped). Most breakers are designed so they can still trip even if the lever is held or locked in the on position. This is sometimes referred to as "free trip" or "positive trip" operation.
2. Actuator mechanism - forces the contacts together or apart.
3. Contacts - Allow current to flow when touching and break the flow of current when moved apart.
4. Terminals 5. Bimetallic strip 6. Calibration screw - allows the
manufacturer to precisely adjust the trip current of the device after assembly.
7. Solenoid 8. Arc divider / extinguisher
circuit breakers have separate devices to sense an over-current or other faults. Once a
fault is detected, contacts within the circuit breaker must open to interrupt the circuit;
some mechanically stored energy within the breaker is used to separate the contacts,
although some of the energy required may be obtained from the fault current itself.
When a current is interrupted, an arc is generated - this arc must be contained,
cooled, and extinguished in a controlled way, so that the gap between the contacts
can again withstand the voltage in the circuit. Finally, once the fault condition has
been cleared, the contacts must again be closed to restore power to the interrupted
circuit.
A circuit breaker is an automatically-operated electrical switch designed to
protect an electrical circuit from damage caused by overload or short circuit. Unlike
a fuse, which operates once and then has to be replaced, a circuit breaker can be reset
(either manually or automatically) to resume normal operation. Circuit breakers are
made in varying sizes, from small devices that protect an individual household
appliance up to large switchgear designed to protect high voltage circuits feeding an
entire city. [1]
Figure 2. Photo of inside of a circuit
breaker
7
When closing DC circuits, the current reaches about 95% of its final steady
state value after time 3τ, where τ is the time constant. Similarly, when an alternating
current is closed, the current reaches a steady value after a transient process. The
time depends upon the resistive, inductive and capacitive elements of the circuit. The
highest switching current is achieved if switching is effected at zero voltage (very
high peak currents can develop if the switch is closed on short circuit conditions).
Below a threshold voltage, any circuit can be opened without any arc formation. In
practice, however, the commonly used switches do produce an arc while interrupting
the current. The arc must be either kept limited or extinguished at the earliest in order
not to damage the contacts.
Copper is by far the most widely used contact material. But since non-conducting
layers are formed on copper contacts as a result of switching, a wiping action is
provided while designing copper contacts. These are also plated with a layer of silver
in many applications. In low voltage circuits, silver is also in use as contact material.
Since switching almost invariably gives rise to arcing, extinguishing such arcs
assumes vital importance to prolong contact life.
The following methods are employed:
• Lengthening of the arc till it extinguishes
• Intensive cooling (in jet chambers)
• Division into partial arcs
• Zero point quenching
• Connecting capacitors in parallel with contacts in DC circuits
• Use of vacuum
• Use of air
• Use of oil
Figure 2.1 Moulde case circuit breaker (MCCB)
8
The contacts need to be kept properly insulated from other metal parts including the
body. Different insulating materials are in use. The most commonly used material is
cast epoxy. Besides, PVC, polystyrene, polycarbonate and ceramics are also in use.
Figure 2 show the photo of inside of circuit breaker. Small circuit breakers
are either installed directly in equipment, or are arranged in a breaker panel. The 10
ampere DIN rail mounted thermal-magnetic miniature circuit breaker is the most
common style in modern domestic consumer units and commercial electrical
distribution boards throughout Europe.
In this project, the function of MCB is to cut off the supply to the load and
also to the panel. So it will be easy to do the maintenance or repairing if there any
problem occurred to the system.
2.2.2 Relays
A relay is an electrical switch that opens and closes under the control of
another electrical circuit. In the original form, the switch is operated by an
electromagnet to open or close one or many sets of contacts. Because a relay is able
to control an output circuit of higher power than the input circuit, it can be
considered to be, in a broad sense, a form of an electrical amplifier.
When a current flows through the coil, the resulting magnetic field attracts an
armature that is mechanically linked to a moving contact. The movement either
makes or breaks a connection with a fixed contact. When the current to the coil is
switched off, the armature is returned by a force approximately half as strong as the
magnetic force to its relaxed position. Usually this is a spring, but gravity is also used
commonly in industrial motor starters. Most relays are manufactured to operate
quickly. In a low voltage application, this is to reduce noise. In a high voltage or high
current application, this is to reduce arcing.
If the coil is energized with DC, a diode is frequently installed across the coil,
to dissipate the energy from the collapsing magnetic field at deactivation, which
would otherwise generate a spike of voltage and might cause damage to circuit
components. Some automotive relays already include that diode inside the relay case.
Alternatively a contact protection network, consisting of a capacitor and resistor in
series, may absorb the surge. If the coil is designed to be energized with AC, a small
9
copper ring can be crimped to the end of the solenoid. This "shading ring" creates a
small out-of-phase current, which increases the minimum pull on the armature during
the AC cycle. [2]
By analogy with the functions of the original electromagnetic device, a solid-state
relay is made with a thyristor or other solid-state switching device. To achieve
electrical isolation an optocoupler can be used which is a light-emitting diode (LED)
coupled with a photo transistor.
In this project, the functions of the relays are as a switch to the loads. The
relay will be installed in normally open condition. So when coil energize, the relay
will change from normally open to normally close. To energize the coil, the input of
the coil will be connected to the 24V DC from the DC power supply, then the output
of the coil is connected to the ICP-Controller i-7188XG.
Figure 3 show the condition of the relays either it on normally open or in
normally close condition. Another picture show the relays that will are use to
installed in the panel.
Figure 3. The normal condition of the relay and the relay that is use inside the panel
10
2.2.3 ICP- Controller i-7188XG
The I-7188XG is a series of expandable embedded controllers
designed for industry applications and can be used to replace PC or PLC devices in
harsh environments. The I-7188XG also has support for an input output expansion
bus, which can be used to implement various input output functions, such as D/I,
D/O, A/D, D/A, UART, Flash memory, battery backup SRAM, AsicKey and other
INPUT OUTPUT functions. Most types of input output function can be implemented
using this bus. ICP DAS offers more than 20 types of input output Expansion Board
for the I-7188XG , which can be used to expand the features of the controller.
Depending on the type of embedded firmware programs that are being developed,
and which input output Expansion Board, the I-7188XG can be used as a single
versatile controller.[4]
This controller will be connecting with the panel and the computer. At the
panel, the controller is connected with the relay so give signal either to energize the
coil or not. This controller is very important because without it the panel cannot
operate automatically and the panel cannot have interfacing with the computer. The
controller is connected using DB 9 COM1. Figure 4 show the controller model and
the cable that must be use to connected to the computer.
Figure 4.1 The controller model and the cable for interfacing to computer.
11
CPU module
CPU 80188 CPU, 40MHz or compatible
SRAM 256K bytes for I-7188XB
512K bytes for I-7188XB/512
Flash 512K bytes
EEPROM 2K bytes
NVRAM 31 bytes
RTC (Real Time Clock) Yes
Hardware Serial Number Yes
Build-in Watchdog Timer Yes
Communication Interface
COM 1 RS-232/RS-485 (Default is RS-232)
COM 2 RS-485 (can be upgraded to 3000V
isolated for OEM)
COM 3 No
COM 4 No
Ethernet Port No
Digital Input
Input Channels 1
On Voltage Level +1V/DC Max. (Connect to GND)
Off Voltage Level +3.5V/DC to +30V/DC Max.
Digital Output
Output Channels 1
Output Type Open-collector
Max Load Current 100mA
Load Voltage +30V/DC Max.
LED Display
1 LED as Power/Communication Indicator
5-digit 7-segment LED (for I-7188XBD only)
Dimensions
123mm x 72mm x 33mm
Operating Environment