CHAPTER 1 1.

0 Introduction

The project is designed for three phase power supply applications. It involves automatic changeover between the main power supply and an auxiliary power supply, such as a generator. The project implements an automatic switching between the two power sources, whenever one fails. The circuit of the project consists of the power unit and the control unit, with electronic relay switches. The design of the project takes into consideration practical or real life situations, even though it is a prototype design. Irrespective of that fact, a lot of precautions were put in place, to its performance acceptable. The basic operation of the project is to automatically change from public power supply when there is power failure to an auxiliary power supply (e.g generator). This operation connects the power supply from the generator to the load after a predetermine time interval. Switching is possible through the use of electronic relay. The system was also designed to automatically change the auxiliary power supply back to the main supply moment, after the AC mains are restored. 1.1 Background Due to the irregularities in power supply and incessant fluctuations in the supplied voltage, a lot of people are being faced each day with the challenge of power quality problem and how to acquire a stable and regular power supply in the country. It was as a result of this the invention of automatic power changeover system came into play and hence this project. But in order to make this project more robust, we have incorporated electronic switching facility into it.
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1.2 Statement of the problem The problem of power failure or outage in general cannot be over stressed, as it does not promote development to public and private sector. The investors do not feel secure to come into a country with constant or frequent power failure. These limit the development of industries. In addition, there are processes that cannot be interrupted because of their importance, for instance surgery operation in hospitals, transfer of money between banks and lots more. This project has gone a long way to solve the problem. 1.3 Objective of the project The objective of this project is meant to relieve people of the burden of having to monitor the restoration of the public power supply and also to manually changeover from public supply (PHCN) to auxiliary supply (GEN). 1.4 Scope of study This project had been designed for both single phase and three phase power supply, which can carry a maximum load of 60A and can be operated with approximately a 15kVA generator. However, the calculated value was 14.4kVA and can work under the ambient temperature of 35oC.

CHAPTER 2 2.0 Overview Of The Principle Of Electromagnetism Electromagnetism is the main driving element in electrical machines, instruments and other electrical apparatus. An electromagnet consists of a magnetic core and a coil. When electric current is passed through a conductor (coil) a magnetic field is set around that conductor, a phenomenon discovered by Oersted in 1820. From this, it was discovered that if a coil is wound on an iron rod, and connected to an emf source, the iron becomes magnetized and behaves like a permanent magnet. The magnetic field of the electromagnet is represented by dotted lines and its direction is as shown by the arrow heads according to the diagram below. It will be seen that the field due to the electromagnet is similar to that of the bar magnet.

Fig. Description of electromagnetism 2.1 Overview Of Electronic System The subject of electronic is one that is difficult to define, since it refers to an extremely wide range of electrical technology having only the unifying aspect that electronics deal principally with the communication of information and/or data handling. Electronic systems fall into two broad categories:

a. Analogue b. Digital In analogue systems, the information of data is given as an electrical signal that varies in direct proportion to the information of data. It follows that the variation must be continuous and, between the limits of operation of the system. Unlike analogue systems, digital systems can have signals that have one of a limited number of discrete values. The most common digital systems are binary systems in which the signals can have only one of two values. These values are referred to as o and 1 being the absence and presence of the sypply current or voltage respectively. Digital systems are most commonly associated with data handling devices such as calculators, computers, watches and microprocessors. However,digital systems are also increasingly used in conjunction with analogue systems. 2.2 Brief Description Of The Components Used 2.2.1 The Enclosure of The Panel This is a steel structure in form of a box with dimension [450 x 350x 170]mm which houses all the electrical and electronic components and some other accessories used for this project. It is a wall- mounting type with hangers for mounting and a door with key lock mechanism. 2.2.2 Timers Timers are used in control circuit to facilitate current operating sequence of the circuit by providing delays. There are different types, which are stated below: a. Pneumatic
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b. Clock work c. Synchronous d. Electronic In this project, electronic timers have been adopted, the tiner consist of in-built four Ics with two timing Ics, ne flip flop and one gate. The outputs of which are used to energize an associated relay coil and hence the contact. 2.2.3 Contactor The contactor is a solenoid-operated switching device which is generally held closed by a reduced current through the closing slenoid[Although various mechanicallylatched types exist for specific duties]. Contactors are designed to carry out numerous closed/open cycles and are commonly controlled remotely by on/off push buttons. In addition, contactor is a monostable device with two conditions: 1 and 0. The contactor requires a continous control signal to stay in condition 1. As soon as the control signal is disabled, the contactor will return to its stable condition 0. Application of contactors can be found in Utility Consumer Units, Industrial Panels, mostly feeding a number of lamps, a heater or a ventilator. Standard switches or other controlling devices are not able to switch high loads. However, by the use of contactor, the high load can be easily switched on and off applying a low power control signal only. Contactors enable automatic switching when controlled for example by a timer, twilight switch or PLC.

2.2.4 Relays A relay is an electromagnetic device that is used by varying the input in other to get a desired output. Relays are of two types: a normally closed and normally opened. The type used in this project is the normally opened relay. It is good and common practice to switch a relay with a transistor. The transistor is set in the common emitter configuration. 2.2.5 How Relays Work Relays are composed of a coil of wire around a steel core, a switch, and a spring that holds one or more contacts in place. When an electrical current flows through the coil. It becmes energized, acting like an electromagnet. The resulting magnetic field opens the cntact and closes the circuit. Thereverse is the case when the electrical current stops flowing. There are some factors that need to be borne in mind, when selecting the right relay to use. These include the voltage rating of the contact, the number and type of contact, the voltage of the coil and the current rating of the con tact. 2.2.6 Circuit Breaker A circuit breaker is an automatically or manually operated switchgear which is 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. However, a circuit breaker can be reset (either manually or automatically) to resume normal operation. Circuit breakers are made in varying sizes, from small device which protect an individual household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city.

2.2.7 Types Of Circuit Breaker There are many different technologies used in circuit breakers and they do not always fall into distinct categories. The following types are common in domestic, commercial and industrial applications for low voltage less than Ikv use. a. Miniature circuit breaker (MCB): This type of circuit breaker has adjustable trip characteristics. They have rated current not more than 100A. They also exhibit thermal or thermal magnetic operation. b. Moulded case circuit Breaker (MCCB): This type may also have adjustable trip current characteristics. They have rated current up to 1000A. They also exhibit thermal or thermal magnetic operation. c. Air circuit Breaker (ACB): This type of circuit breaker is mainly used for main power distribution in large industrial plant, where the breakers are arranged in draw out enclosures in case of maintenance. They have their rated current up to 10KA. They have fully adjustable trip characteristics, including configurable trip threshold and delays usually controlled electronically with programmable logic controller and some other automation tools. 2.2.8 Transistor This is a semi conductor device, which was invented by a team of three scientists at Bell Laboratories, USA in 1947. There are two basic types: The Bipolar Junction Transistor (BJT) and the Field Effect transistor (FET). The BJT is used in two broad areas of electronics: (a) as a linear amplifier to boost an electrical signal, and (b) as an electronic switch. But the one in this project is used as a switch.

2.2.9 Integrated circuit (IC) To put it very briefly, an Integrated circuit (IC) is just a packaged electronic circuit. It is a complete electronic circuit in which both the active and passive components are fabricated on a tiny single chip of silicon. Active components are those which have the ability to produce gain e.g. Transistors. Passive components are the ones that do not have this ability, e.g. resistors, capacitors, e.t.c. ICs are produced by the same processes as are used for manufacturing individual transistors and diodes, e.t.c. In such circuits, different components are isolated from each other by isolation diffusion within the crystal chip and are interconnected by an aluminium layer that serves as wires.

CHAPTER THREE 3.0 Methodology Of The ACO Panel The operation of the power unit was well organized and coordinated for an efficient performance. The operational process is outlined below: i.
ii.

The power circuit is not active when there is no supply from any of the sources. The response of the contractor K1 to mains is by simulating the presence of public supply, which will then energize the contactor K1 after a short delay of about 5 secs. The circuit will continue to engage the public power supply as long as it is available.

iii.

However, when there is a failure in the public supply, contactor KI is deenergized and the load is disconnected with the help of the breaker Q1 from K1. Thereafter, contactor K2 picks up the signal after the presence of auxiliary supply had been simulated. There is a delay of about 7 secs in the loading of the auxiliary supply so as to attain stability for a while. After the said delay, the auxiliary supply is loaded.

iv.

Power supply from the auxiliary is interchanged the moment the public supply is restored. Immediately, the generator is switched off. To avoid the danger of both contactors closing at the same time, should the

public supply (PHCN) be restored when the auxiliary supply (Generator) is on, an electric interlock system was incorporated in between the two contractors by supplying the coil of each contactor through normal closed contact of the other. Hence, one contactor will close at a time.

3.1

The Power Circuit This is the circuit that receives large electrical energy and feeds it into the

load or a power-consuming device. The line is operated by an associated control unit. The power circuit used in this project is three phase which is electrically isolated from the control circuit.

Fig. Power circuit single line diagram 3.2 Output Load Terminal This is the terminal that supplies the wiring of the various devices that will be connected to the ACO (e.g. the wiring of a building) with electricity from either the normal public power supply or the auxiliary power supply, such as a generator. For clarity, the expected power supply from the generator is intended as back up to the normal public power supply. A 60 W light bulb is connected to this terminal as the load and an MCB (Q1) is used to protect the load.

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3.3

The Control Circuit The control circuit is based on sequential timing. It is an auxiliary circuit

associated with the line. The control circuit does not carry the load current. It is concerned with the switching of low current logic signal to an associated contactor coil or to other control devices. Essentially, this is the circuit that does the change over from one power supply to the other. It also effects the visual indications as reflected by the pilot lamps on the panel door, which show the status of the contactors. The control circuit contains some integrated circuits (ICS) which are incorporated into the switching mechanism. The circuit also consists of relays that provide external switching. These devices are quite robust for efficiency and reliability. The diagram below shows the control circuit in a simplified form.

Fig. Control diagram for public supply (PHCN)

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Fig. Control diagram for generator

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Fig. Internal wiring of the electronic IC timer

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3.4

Logic Representation Of The ACO Panel According to the table below, 0 is used to indicate no supply and 1 is

used to indicate supply. The table shows the possible combination of the input supplies to give a desired output. Step 1 3 Input1 (PHCN) Input2 (GEN) 0 0 0 1 Output load Observations and comments No supply gets to the load The bulb lights up after a period of about 7 secs. During this period, the generator builds up voltage and maintains stability after which 2 1 0 1 the load is connected. The bulb lights up after a period of 5secs, powered by the public 4 1 1 1 supply. The bulb lights up, after a period of 5secs, powered by the public supply and Gen is switched off. Fig. Logic representation of the circuits operation, using simple OR gate truth table. Description Of The Above Steps With The Visual Alerts (Pilot Lamps): Step 1: Public supply off, Generator Off. All the pilot lamps will be off. Step 2: Public supply ON, Generator OFF The yellow lamp will first light up indicating public supply ready. Thereafter, after 5 secs, the yellow lamp will be off and the green lamp will light up indicating load connected. 60 W bulb 0 1

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Step 3: Public supply OFF, Generator ON The yellow lamp for generator ready will be on for about 7 secs and then is switched off so that green lamp is switched on showing load connected. Step 4: Public supply ON, Generator On In this situation, the public supply is restored, when the generator is still on. The yellow lamp (PHCN ready) will be on for about 5 secs and then green lamp is on, while the yellow lamp is off, the load will be disconnected from the generator and transferred to the public supply (PHCN) and the generator switched off. 3.5 Calculations of the control logic unit.

The control logic unit operation is based on sequential timing. The main component of the unit is the control IC to determine the time to switch. The device has 8 control terminals. Only two are used for DC power supply. Pins 2 and 7 are the inputs, while pins 1,3,4,5,6 and 8 are the outputs. The device works with 28V DC supply. The six outputs are derived from a main frequency. The main frequency of oscillation is given by (Horowitz and Hill 1995; Thomas 1997; Theraja and Theraja 2002): Fm = 1/(2.3RtcxCtc), Where 6Rtc >R5 > 2Rtc. The typical values of R5, Rtc, and Ctc are 10k, 33k, and 0.001microfarad. Therefore, Fm = 1/(2.3x33x103x0.001x10-6), Fm = 13.2kHz. The output frequencies are based on the following formula: Fqx = Fm/2x (ii) (i)

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These signals are used for switching or controlling two latches which deal with changeover control. 4013B IC contains two independent latches. They work with active high input signals.

CHAPTER 4
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4.0

Symbols and their meaning.

K1 Contactor for public supply (PHCN) K2 Contactor for auxiliary supply (Genenrator) Q1 4pole Miniature Circuit Breaker (MCB) for the load H1 Pilot lamp for PHCN ready (yellow) H2 pilot lamp for PHCN connected to load (green) H3 pilot lamp for GEN ready (yellow) H4 pilot lamp for GEN connected to load (green) T1 electronic timer with an inbuilt IC for PHCN T2 electronic timer with an inbuilt IC for GEN RA electronic latch for PHCN RB electronic latch for GEN Rc electronic relay for lamp test S1 push button for lamp test. F1 miniature circuit breaker, 1pole for PHCN control circuit. F2 - miniature circuit breaker, 1pole for GEN control circuit.

4.1

Conclusion
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An automatic power changeover switch has been designed and constructed. The prototype of the automatic power change over switch worked according to the specification and quite satisfactorily. The device is quite cheap, reliable and easy to operate. Whenever there is power outage, it reduces stress for manpower changeover. 4.2 Recommendation The panel could be produced in mass for the Nigerian market since the components used are easy to come by in the market. This panel can be modified to suit different load requirement by changing the main contactors and the miniature circuit breakers considered appropriate for the load.

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REFERENCES Jonathan Gama Kolo 2007. Design and construction of an automatic power changeover switch. Eaton Holec Electric BV 2007. Description of automatic transfer system for Gbaran Ubie oil project, Bayelsa State. Theraja, B.L; and Theraja, A.K. 2007. A textbook of electrical technology, 21st edition.

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