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What is Low Voltage Switchgear?
Low voltage switchgear is a versatile system to distribute power safely and effectively either for a building or other type of structure that requires power.
Customers buy our switchgear for two reasons; primarily because we produce high quality, bespoke switchboards built to the latest industry standards and secondly for our customer service.
At AF Switchgear, we design and manufacture 400V three-phase equipment for both industrial and commercial use. In addition to 400V three phase circuits, 220V single phase circuits can be tapped off these systems but must be factored in during the design stage.
What is the Purpose of Low-Voltage Switchgear?
Switchgear or switchboards as they are commonly known are essentially the ‘brains’ behind all of the power going into and then around a building or structure. Power is fed into the switchboard and then distributes the power wherever it is needed via cables or bus bar systems.
When we say switchgear, we are always referring to ‘low-voltage’ switchgear’ (low voltage being 400V AC usually). Power is taken from the DNO (Distribution Network Operator) usually via an incoming transformer into a switchboard. The power is then distributed through devices known as circuit breakers, isolators or fused switches. Devices are situated in the same switchboard as the incoming supply and in sub-boards downstream if required.
Device sizes are determined by the size of the load or current needed to make a piece of equipment or system work. Note that circuit breakers and fused switches are protective devices whereas isolators are not because they do not trip in an overload or fault condition. Isolators are usually used when manual switching is required to completely isolate the supply to or from equipment i.e., an output of a UPS unit for example.
There is usually at least one main LV Switchboard, which is fed by a mains transformer. The largest transformer that can be used to feed an AF Switchgear manufactured switchboard @ 400V is 4MVA, which can deliver up to 6300A and absorb a 100kA fault current. However, if different power streams are needed for resilience purposes, several transformers and/or main LV Switchboards can be utilised. Power is distributed through these boards and if required via sub-boards through a system called sub-distribution.
Sub-boards are used to carry the power to the point of use or as near to it as it can get. In any event, for a new project a power discrimination study should be carried out by an electrical engineer to determine the sizes of cable/bus bars/circuit breakers etc to ensure equipment and conductors are appropriately sized to carry the current required for normal use and for prospective fault currents in the event of a short circuit. This is a very important factor for safety purposes.
To conclude, LV switchgear is an engineered solution constructed of a steel housing, containing copper conductors and a combination of circuit breakers and isolators used to control, protect, and isolate electrical equipment or systems to allow work to be done and clear faults quickly and safely when required. In this context, ‘low-voltage’ always refers to systems that feature voltages of 1000VAC (or less) or 1500VDC (or less).
Here’s how they work:
- A mains transformer or backup generator supplies the switchboard via cables and/or busbars to an 'incoming' circuit breaker/device, which is usually an ACB (Air Circuit Breaker) or an MCCB (Moulded Case Circuit Breaker).
- On the output side of the incomer devices, power is distributed around the switchboard via internal copper bars that feed smaller rated circuit breakers, again ACB's or MCCB's. These devices are referred to as outgoing ways.
- Power is distributed from these smaller devices directly to equipment or to sub-boards which feature even smaller rated ACB’s; MCCB's or even smaller MCB's (Miniature Circuit Breakers).
- Most of the time, voltages fed into switchboards in the UK and Europe for commercial or industrial applications are three-phase supplies at 400VAC.
- All ratings for circuit breakers or isolators are rated in Amperes (Amps).
When is Switchgear Used?
Switchgear is used when there is a certain power requirement identified that needs to be controlled and distributed safely.
In a residential property like a house, switchgear wouldn’t be necessary simply because the power requirements are too small unless the building is very large! Residential buildings usually feature a Consumer Unit which is a mini version of a switchboard and normally limited to a 100A @ 220V single phase supply. Commercial or Industrial switchgear can be rated up to 6300A @ 400V three phase so quite a difference!
Is Low-Voltage Switchgear Safe?
Large power users like data centres can consume up to 100 Megawatts (1ooMW) of power – that’s 100 million Watts of power available to be used per hour (in comparison an electric kettle is about 3000 Watts (3kW)).
Whether you have this amount of power available or a smaller power requirement, it’s crucial to have a system that can distribute power safely and effectively. If designed and installed incorrectly, power systems can be dangerous or even worse lethal to equipment and people.
A correctly engineered low-voltage distribution system allows a building to deliver electrical supply safely. In the event of a fault, electricity can potentially damage equipment and endanger life. Electrical faults can also cause devastating injuries including severe burns or in the worst-case, death. All equipment manufactured and installed by AF Switchgear is designed to detect, isolate and clear electrical faults very quickly to protect life and equipment as much as practically possible.
As a class leading manufacturer, AF Switchgear must ensure the products it manufactures meets all relevant safety standards including statutory requirements such as BS EN 61439-2. To meet the latest standards, we carry out independently witnessed tests under laboratory conditions simulating electrical fault scenarios. This is called Type Testing and is a very expensive but necessary process.
Is Low-Voltage Switchgear Easy to Use?
You can’t buy large electrical switchgear systems from a wholesaler (unless in exceptional circumstances) or DIY store and is not intended for use by the general public.
As a switchgear manufacturer, we build bespoke switchgear that is designed to the specification of the building or application it is intended for and is usually situated in a ‘controlled environment’ like a plant room or switch room.
Some systems are easy to use and some systems are very complex. We always advise personnel to undertake training before operating any LV Switchgear as making a mistake can be costly or have catastrophic consequences if used incorrectly. We recommend that only a skilled, trained and suitably qualified person should operate live switchgear and that personal protective equipment (PPE) should be worn when switching devices for one’s own safety.
Why Choose AF Switchgear?
AF Switchgear is one of the UK’s leading manufacturers of specialist switchgear systems. Everything we produce is designed and built in-house to the latest industry standards. We also pride ourselves on the fact that each switchboard we build is bespoke and tailored to each customer. That means, for every customer, we design a solution that perfectly fits their specific applications with regards to both the physical size and electrical requirements.
We manufacture a variation of switchgear types and every customer we work with has a different set of requirements. For example, hospitals may require a system that can never suffer a loss of power at the point of use as this may endanger life. Other applications however may not need this level of resilience.
Here are some examples of specific requirements we would usually need to understand as a minimum when designing a switchboard:
- Prospective Fault Current Levels in kA
- Voltage (V), Frequency (Hz) and Current (A) rating of the incoming supply
- Number of incoming and outgoing circuits required
- 3 or 4 pole Circuit Breakers/Isolators/Fused Switches required
- Front or Rear Access to the board (for maintenance purposes)
- Logistical, installation and spacing restraints/requirements
- Energy Metering needs
- Thermal imaging again for maintenance purposes
- Cable or bus bar entry requirements
- Form Factor desired
- Circuit identification needs
- Is Restrictive Earth Fault required (protects the Transformer)
- Is Surge Suppression needed
- Any Power Factor Correction equipment required
If you require bespoke high-quality Low Voltage Switchgear for your project contact us today.
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Ever wondered how our switchboards are manufactured?
Today in our ‘In Focus’ series, we look at a short video clip of a particular piece of kit we use in our in-house fabrications facility.
The machine featured today is an automated punch machine manufactured by #TruPunch, which we have two in use currently.
The machine uses Radan CAD/CAM software and our Fabrication Engineers/Operators have to be specially trained to program the software and operate it correctly.
Once programmed the TruPunch machine can self-load and run for 24hrs a day if required.
It is very efficient in its operation and produces very little waste so all in all a great piece of kit.
Remote Factory Acceptance Tests
During these changing and challenging times we have all had to adapt our usual way of doing business in many areas.
One such change has been the introduction of Remote Factory Acceptance Testing with the use of Zoom and Microsoft Teams.
Our engineers have been tasked with hosting the events via live streaming using mobile cameras and stabilising equipment.
The tests to date have been extremely successful with excellent feedback from clients who were not only keen to praise Test Teams for their efforts but also to point out the huge steps in reducing all of our carbon footprints
APPRENTICE OF THE YEAR AWARD 2020
In partnership with our training provider, West Notts College it was with pleasure that we were once again able to present this prestigious annual award.
Despite all the challenges thrown at our apprentices, not least those of virtual classrooms we are very pleased to announce that we had two outstanding candidates whom the awarding authority voted for to receive the award.
Both having demonstrated excellent qualities in a number of key performance-related categories in regard to their individual training plans.
So on behalf of all staff at AF Switchgear, congratulations to:
Jack Glebocki – Fabricator and Welder Apprentice
Kai Lancashire – Electrical Apprentice
Presented by Managing Director, Ian Foster and Operations Manager, Mike Ratcliffe both received a trophy, a £250 tool voucher from our sponsor Protrade Tools and Fixings plus a box of our very own AF Switchbeer!
Take a look at our Solar installation!
Installing a State of the Art Solar Farm
AF Switchgear made a decision to install a Photovoltaic array a couple of years ago, therefore our very own Solar Farm and we are delighted with the results.
Our PV array is made up of hundreds of Polycrystalline panels, each rated at 260W covering our factory roofs. The DC power is converted to AC through 25kW inverters into a bespoke built Switchgear and Monitoring System.
In total we have generated over 275,000 kWh to date, contributing greatly to our power usage.
Derby Velodrome
Installing Twin Package Substations at the Derby Velodrome
AF Switchgear supplied several twin package substations for the Derby Arena and Velodrome, one of the largest projects undertaken in the East Midlands.
The 5,000-seat arena features a 12-court sports hall, a gym, group exercise space and a cafe. As well as cycling, the venue hosts sports including basketball and doubles up as a concert venue. The indoor Velodrome is one of only five in the UK. The others include the:
- National Cycle Centre in Manchester
- Wales National Velodrome in Newport, South Wales
- London Olympic Velodrome in Stratford City
- Sir Chris Hoy Velodrome in Glasgow
The project at the Derby Arena and Velodrome required fast-track manufacturing to enable a quick ‘power-on’ date. The substation needed to facilitate the heating and ventilation aspect during construction, purely to maintain a controlled ambient temperature to allow the wooden track to be laid and then settled.
In addition to manufacturing the numerous substations for Derby Arena and Velodrome, AF Switchgear also supplied substations and final circuit distribution boards for the Sir Chris Hoy Velodrome in Glasgow, the host venue for the Glasgow Commonwealth Games.
The indoor arena section features a hydraulically operated 200m running track, jumping and throwing areas, and sports halls. The Velodrome houses a 250m high-banked cycle track with a multi-use infill area. The scheme also includes a community sports centre, four floodlit outdoor sports pitches and a 1km outdoor cycle track.
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JCB Academy
Providing JCB Academy With Engineering for LV Switchboards and Control Panels
AF Switchgear worked on the JCB Academy project, which was undertaken in partnership with a long-standing client called Imtech.
To promote UK engineering and education, JCB decided to sponsor an academy opening its doors to Year 10, 11 and 12 students, accommodating up to 540 people. For the project, AF Switchgear manufactured the LV switchboards and control panel.
The control panel was designed to run a modern version of one of the world’s oldest engineering wonders: an Archimedes Screw.
The device, which was shaped like a giant corkscrew, was used to create a fully functional water turbine. Weighing in at 13.3 tonnes, the screw generated up to 85% of the centre’s electricity, saving up to 64 tonnes of CO² compared to using mains electricity.
Approx. 50% of the water is derived from the River Dove, which runs through the site, with the weight of the water forcing the screw to rotate, generating electricity to act as an asynchronous generator. This in turn, powers the local site load and can export to the grid when needed.
Situated adjacent to JCB’s headquarters in Rocester, Staffordshire, the academy is part housed in the Grade II listed Tutbury Mill, with a new annexe housing the main classrooms. Built in 1871 by Industrial Revolution entrepreneur Richard Arkwright, renovation of the picturesque site began in December 2009.
In addition to the main LV switchboards and control panel, AF Switchgear were called in to provide specialist engineering assistance.
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No.20 Fenchurch Street
AF Switchgear was selected to supply the complete Power Distribution Unit for No 20. Fenchurch Street (also known as the Walkie Talkie Building) in the City of London.
The Walkie Talkie building was designed by the Uruguayan architect, Rafael Viñoly. Canary Wharf Management and Land Securities set up a joint venture to construct the £200m building, which is 525ft tall and consists of 38 floors plus a high-level Sky Garden.
AF Switchgear’s contract was to supply and install 13no.Package Substations, 51no. Switchboards and a complete Energy Management System.
A substation helps to regulate high voltages, reducing them so that power can be easily and efficiently distributed to home and businesses.
A Power Distribution Unit (PDU) helps to control the electrical power in data centres by providing standard electrical outlets.
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2021 has seen a record number of applications for our Panel Building Apprenticeship Scheme.
Spokesman Lee Speed from West Nottinghamshire College states, “Interest this year has been unprecedented in the electrical sector, with over one hundred applications for apprenticeship positions within AF Switchgear”.
Following a series of college assessments, interviews and practical assignments we are delighted to announce five new apprentices who start their 4-year Level 3 BTEC and NVQ qualifications.
Panel Building is an ideal entry into the electrical industry, giving successful candidates the opportunity to develop their electrical engineering careers.
From all at AF Switchgear, we wish them all every success for the future.
#apprenticeships #careerdevelopment #futureengineers
From left to right – Alexander Peeters Weem, Joel Harrison, Holly Parker-Tinklin, Spencer Whittle & Harry Russell