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

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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