Product Description

K- ePower- Marine Switchboards

K-ePower
Marine Switchboards
Main & Emergency Switchboards

Product Description

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K- ePower- Marine Switchboards

Revisions

Rev. Written by Checked by Approved by

Date Sign. Date Sign. Date Sign.
A 2009-08-18 KM 2009-08-18 GWJ 2009-08-19 DGL
B 2009-11-04 DGL

Document history

1. prod. Issue relase

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1 Technical description

1.1 General mechanical characteristics

1.1.1 Framework

The switchboards are manufactured in multi-cubicle, self-supporting, and dead-front type. They
comprise several individual panels and complete with necessary fittings and instruments. The right
and left side of the switchboard are covered with remove-able steel plates. On the front, the doors
are hinged on the left side of the frame (left opening if not otherwise specified) which can be
opened in an angle more than 90° without disturbing the meters, pilot lamps and etc. mounted on
them. The doors are equipped with arrestors to keep the door in opening position. All doors are
earthed to the frame with yellow/green wires. On the rear, the lift-off covers are arranged as
standard (the hinged doors are optional. In case of the switchboard is inaccessible from back side,
the screw-fixed cover plates are installed instead). The protection degree applicable for
switchboards is IP23, if not otherwise specified.

The framework of the switchboards is of maintenance-free welded construction which is designed

based upon the basic grid dimension of E=25mm, have horizontal girders on front and rear side at
approximately half height of the frame. The frames of switchboard are made of 3mm cold-rolling
steel sheet and doors/cover plates are made of 2mm. Switchgears/ components are arranged on
equipment compartment with associated mounting plates/ brackets, which are fastened with
self-tapping screws to the frames at flexible intervals following the design grid dimension. The
frames can be constructed for almost every requirement, depending of its application the
three-dimension of the frame can be selected in steps of 50mm (W: 300-1000mm, H:
1800-2400mm, D: 400-1000mm).

The incorporation of individual panels for switchboard is normally arranged in a row, it can also be
arranged in right-angled or back-to-back according to the special requirement.

Depending of the intended use of the panels, they are respectively designed and equipped into e.g.
generator control panel, feeder panel, motor starter panel and etc. The individual panels are
partitioned with steel sheet plates between each other.

Non-conductive handrails can be provided on the front and/or rear. If the switchboard abuts against
the back wall, then the handrail will not be arranged on the rear.

Option: Canopy lighting in front and/or rear of the switchboards are of the fluorescent type,
sockets for interior working light can be arranged on the back side, the power is supplied from the
switchboard itself. (To be designated in the Scope of Supply)
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1.1.2 Surface treatment

The complete steel construction including all steel profiles, partitions, top covers, doors are
protected against corrosion by acid washing, phosphating process followed by priming and final
textured powder coating. The standard colour of the framework is RAL 7024 (graphite grey). The
front doors and covers are in standard colour RAL 7035 (light grey). Other colours are available
on request. Refer to colour system, RAL, Munsell or NCS and the specific colour ID number. The
assembled mounting plates/brackets inside the panel are of zinc-galvanized steel.

To prevent the blur on surface during installation onboard, the doors and cover plates are
independently protected with transparent plastic membrane, so that they can be properly opened/
closed for handling or inspection under the packaged condition without unpacking.

1.1.3 Cable entry

Entry of external power cables and control cables in switchboards can be from bottom and top as
per requirement. For insertion and stripping of the cables sufficient space inside the switchboard is
provided. Connection of power cables to the switchgear will be done directly without intermediate
terminals. For fastening of power cables inside the switchboard, necessary numbers of perforated
angle bars or cable trays will be fitted inside each panel for allowing sufficient fixing strength.

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1.1.4 Transport division

The switchboard is normally split into several transportable divisions (less than 3000mm
recommended). Each such division is equipped with hoisting angle steel on its canopy for
transportation and installation purposes. All interconnecting wiring between switchboard divisions
is provided with plug connectors, which allow easy assembly after transportation and setting up.

The switchboards are equipped with foundation frame (standard 100mm channel steel), which
allows to either directly weld or bolt on vessel deck (Material for fastening is not included in the
scope of supply).

1.1.5 Bus bars

The bus bars are made of electrolytic copper with high conductivity which has sufficient
current-carrying capacity for continuous operation and feeder’s power distribution. Standard bus
bars are of bare copper- not insulated and not coated. Insulated bus bars tin-coated bus bars are
optional (to be specified in Scope of Supply for actual project). Bus bars and bus bar isolators are
designed for withstanding mechanical strains created by electromagnetic forces during maximum
peak short currents. Bus bar isolators are of moisture resistant type. For safety, the PVC
transparent plates are provided to shelter the bus bars from where the electroshock hazard possibly
happens, and the warning labels are stick on the protective plates.

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The bus bars are divided into sections corresponding to the switchboard transport sections. At the
joining position of the transport sections, mechanical bus connectors (screwed copper links) are
installed. Earth bus bar is provided inside the panels for connecting the cable’s armour and
grounding cables. They are fitted throughout the whole switchboard in conductive contact to the
panel frame.

The phase mark of AC system is R-S-T (or U-V-W, L1-L2-L3), the bus bar is respectively
distinguished with green-yellow-brown labels. The polarity identification of DC system is P-N, the
bus bar is distinguished with red-blue labels. Earthing bar is marked with yellow/green label. The
bus bar phase R-S-T and polarity P-N is arranged from left to right, top to below and front to rear.

1.1.6 Nameplates and labels

The manipulative and indicative components on the doors are distinctly marked by engraved
nameplates, which are made of laminated PVC plate in flame retardant type, with black text on
white background. For any nameplates used for emergency or warning purpose, white text on red
background is applicable. The text on nameplates is in English, alternatively in English/Chinese
All the nameplates are fastened by miniature screws.

For circuit breakers, the following information is marked on its nameplates:

- Item letter code number (identical to drawings and in accordance with IEC 750)
- Service name (feeder designation or name of appliance)
- Setting current / frame rated current (A)

In case of any feeder breakers equipped with emergency stop or preferential trip function, the
colour coded labels are additionally added above its nameplate. For the distinguishing purpose, the
colour identification nameplate will be accordingly arranged nearby.

The components located on the front doors such as change-over switches, measuring meters, pilot
lamps & pushbuttons, are marked with item letter code number (identical to drawings and in
accordance to IEC 750) and its service name. Other components located inside the switchboard,
such as terminal blocks, transformers, relays, contactors, etc. are provided with item letter code
number labels according to actual drawings.

1.2 General electrical characteristics

The switchboard structure is environmentally type-tested by authorized institutions SEARI in

compliance with IEC 60439-1, IEC 60068 and IEC 60529 of following technical parameters:
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- Rated insulation voltage 1000 V AC

- Rated maximum operating voltage Up to 690 V AC
- Rated frequency 50 or 60 Hz, +/-5%
- Rated insulation level 3000 V rms (one min. 50Hz withstand voltage)
- Impulse withstand voltage 8 kV peak (1,2/50 micro-sec. wave)
- 1 second withstand current Up to 100 kA
- Peak withstand current 220 kA
- Bus bar rated current Up to 5000 A

The environment test is carried out by SMERI which is including: High temperature test (70ºC),
Low temperature test (-55ºC), Temperature and Humidity test (55 ºC, RH 95%), Salt spray test,
Fungus test, Inclination test (±10 º, ±15 º, ±45 º), Vibration test (0-100 Hz, ±5 m/m2) and
Enclosure protection test (IPX4)

1.2.1 Internal wiring

All wiring inside the switchboards is of flame retardant types and Ship Class Type approved. They
are flexible copper-strand insulated conductors with minimum cross section of 1.0 mm2 (2.5 mm2
For CT) unless otherwise required by certain component manufacturer. For the secondary control
circuitry, voltage grade of the wires is >400 V. For power source wires and cables connected to
mains, voltage grade of >750 V is used. For data-bus line, the suitable screen-shield multi-core
cables are used. All the wires and cables used are of tinplated cu types to avoid oxidation.

The control wires are fitted in slotted cable ducts of flame retardant type to prevent abrasion,
cutting of its insulation, excessive motion caused by vibration and for easy maintenance. All
internal wires are address marked in each end by use of printed PVC sleeve tubes. As per the
component terminal shape, suitable connecting ferrules or sleeves are used on wire and cable ends.

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1.2.2 Connection Terminals

All terminal blocks for secondary circuit are of spring-clamped type without screws. Terminals at
least enable the single wire in 2.5 mm2 cross section easily connected. The terminals used for
power incoming/ outgoing cables whose cross section > 6 mm2 will be screw fastening type.

1.2.3 Measuring indicators

Measuring indicators are provided in standard DIN 43700/IEC 61554 sizes 96x96 mm and 72x72
mm (or 48x48mm) for starters , with black frame, white scale background, black pointers (rotating
angle 90 ), black text and red-mark on nominal value. The precision class is of 1.5 and the scale
of the indicators normally has the following measuring range:

- Voltmeter 0 ~120 % of rated voltage

- Ammeter 0 ~130 % of rated current (over-current withstanding type for starters)
- Watt-meter -15 % (reverse) to approx. 130 % of rated wattage

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- Frequency meter 55-60-65 Hz (alternatively 45-50-55Hz)

1.2.4 Air Circuit Breakers (ACB’s)

Three-pole Air Circuit Breakers (630A~6300A, frame size current) may be used as power
incoming breakers, outgoing feeders or bus-ties, in fixed or withdraw-able type. Manual operation
of the breakers (by operating handle) is possible from the front. The electrical motorised operation
can be furnished, particularly for remote controlled power incoming breakers or bus-ties. The
ACB’s are equipped with electronic releases which can be configured with adjustable long time
over-current inverse time trip, short time delay trip, and electromagnetic instantaneous trip for
short current.

The flexibility for adding accessories such as microprocessor-controlled over current release, shunt
releases, under-volt releases, lock and interlocks, etc. creates a lot of possibilities for tailoring the
system to fit a wide range of applications. The actual configuration of ACB’s is defined hereinafter
Scope of Supply.

Above pictures show three different brands of ACBs mounted in our switchboards.

1.2.5 Molded Case Circuit Breakers (MCCB’s)

Three-pole Molded Case Circuit Breakers (100A~1600A, frame size current) may be designed as
power incoming breakers, outgoing feeders or bus-ties in fixed, plug-in or withdraw-able type.
Normally for outgoing feeder breakers, the operation is achieved manually by means of rocker arm
on its front if no otherwise specified. The electrical motorised operation can be furnished,
particularly for remote controlled power incoming breakers.

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The feeder breakers are normally equipped with pyromagnetic release (inverse time thermal
over-current trip and/or magnetic instantaneous trip devices). Depending of factual application, the
electronic release may be used for more precise protection. Feeder breaker for steering gear motor
is equipped with instantaneous trip only.

The flexibility for adding accessories such as auxiliary contacts, shunt releases, under-volt releases,
lock and interlocks, etc. creates a lot of possibilities for tailoring the system to fit a wide range of
applications. The actual configuration of MCCB’s shall be defined in Scope of Supply.

1.2.6 Motor Starters

All motor starters combined in the switchboards or MCC’s are of fixed mounting type. According
to the respective usage and requirement, starters are available for the following functions:

- Direct on line starting (DOL)

- Star/delta starting (Y/Δ)
- Reversible running
- Double speed running
- Auto-transformer starting
- Soft starting control
- Frequency converter start

The motor starters can be configured with 2 options: either Basic type or Intelligent type.

Option 1: Basic motor starter

Basic motor starters are integrated by traditional circuit breakers, contactors & thermal relays with
a basic protection on the motors. The control functionality on the motor is locally achieved by
various relay circuits, the remote control and alarm monitoring can be transmitted by separate I/O
modules which are the integral part of Automation System by communication cables.

Depending on individual functions, typically a basic motor starter consists of, but not limited to
following components:

1 pc MCCB with instantaneous tip, or motor protective C/B as per capacity

1 unit Magnetic contactor(s) & thermal relay
1 unit Ammeter & current transformer (normally for vital pumps or where required)
1 pc Hour counter (where required)
1 pc Control transformer
1 pc “Start” push button (green)
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1 pc “Stop” push button (red)

1 pc “Power source” indicating light (white)
1 pc “Running” indicating light (green)

1 pc Operation mode switch (Auto/Hand or Local/Remote, where applicable)

1 pc “Heating” indicating light (blue, where applicable)
1 pc “Heater on” switch (where applicable)
1 lot Fuses for control circuit
1 lot Control relays (as per function)

1 pc I/O module for remote control & alarm monitoring

(DPU module of Kongsberg, can be common used for several motor starters)

Option 2: Intelligent motor starter

Except 2 necessary components: circuit breaker (or fuse switch) and contactor(s), there is only
another component so called Motor Control Unit (MCU) which is essential to make up of an
intelligent motor starter. The MCU is a microprocessor based intelligent module which provides
full motor control, protection and monitoring functions. It can transmit real-time data upward to
control centre and receive operating command in reverse via communicating with up-level
Automation System.

Depending on individual functions, typically a basic motor starter consists of, but not limited to
following components:

1 pc MCCB 3P with instantaneous tip, or Fuse Switch

1 pc MCU with correlating operating panel
1 unit Magnetic contactor(s)

1 pc Operation mode switch (Auto/Hand or Local/Remote, where applicable)

1 pc “Heating” indicating light (blue, where applicable)
1 pc “Heater on” switch (where applicable)
1 lot Fuses for control circuit

1 pc Control transformer (can be common used for several motor starters)

1 pc Common used 24VDC power supply unit (for all motor starters in the MCC)

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2 Supplier list for main components

If there is no otherwise specified, the recommended brands of components used for switchboards are as follows:

Components Manufacture
 Air circuit breakers (ACBs) ABB or Schneider
 Moulded case circuit breakers (MCCBs) ABB or Schneider
 Contactors & Thermal over-load relays ABB or Schneider
 Instruments & gauges Deif
 PMS modules Kongsberg
 I/O modules (DPUs) for motor starters Kongsberg
 Motor Control Units (MCUs) for motor starters ABB
 Voltage transformers Moeller
 Current transformers Local maker
 Auxiliary relays Idec
 Control fuses Woehner
 Terminal blocks Phoenix
 Change-over switches Kraus & Naimer

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 Push buttons/ signal lamps Moeller

3 Mode of operation

3.1 Main switchboard

3.1.1 Automatic operation

The automatic functions can be performed by K-Chief 500 Power Management System either
integrated or as stand alone system in the switchboard. The Function Description of the PMS to be
negotiated additionally.

The following automatic functions are performed by PMS which is configured and furnished in the
main switchboard:

- Diesel generator monitoring and control

- Diesel engine safety protection and start/stop
- Circuit breaker synchronize & connect
- Bus line voltage and frequency control
- Generator voltage and frequency control
- Generator load limitation in kW and %
- Symmetric or asymmetric load sharing
- Load control with load shedding
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- Separation of alarm, control and safety protection

- Single or multiple switchboard control
- Heavy consumers start logic
- Automatic start and connect after blackout
- Automatic line frequency adjustment
- Control of diesel electric propulsion
- "Take me home mode”, control of PTI with clutches etc.
- "One touch auto sequence" automatic mode control

3.1.2 Manual operation

In normal situation the main switchboard is used in automatic operation. The manual operation is
equipped as the back-up of the automatic operation. In manual operation all the essential function
can be carried out by hand such as generator start and stop, connecting, synchronising and load
sharing (by means of synchroscope and governor switches).

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3.2 Emergency Switchboard

In normal situation, the Emergency switchboard is energized from Main switchboard. When the
voltage of the MSB fails the tie-breaker between MSB and ESB is automatically disconnected, the
emergency generator set is automatically started and the emergency switchboard is energized
automatically after a total delay of max. 45 seconds (allowing for stand-by generator to connect
first). When MSB voltage restored, the emergency generator will be automatically disconnected,
and then stopped with time delay. The ESB will be renewably energized by MSB via the
reconnection of the bus tie-breaker.

Normally there is now power feed-back to the main switchboard in any occasion. Alternatively the
emergency generator can be also used as harbour generator when required. In this case a select
switch “Normal / Harbour” will be additionally furnished. In “Harbour” mode, the emergency
generator is able to inversely supply the power to main switchboard.

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