The document outlines specifications and construction details for various power control and motor control center panels, including features such as fully bolted trolleys, modular design, and robust safety mechanisms. It includes dimensions, operational ratings, and material specifications relevant to low voltage switchgear products. Additionally, it provides a cost analysis for equipment and panel assembly pertinent to a project by Ahluwalia Contracts in New Delhi.

1. © 2004 Xilinx, Inc. All Rights Reserved
SWITCHBOARDS

2. MANUFACTURING FACILITIES- NOIDA

3. • Power motor control centers (PMCC)
• Motor Control Centers (MCC)
• CLOSE DOOR PANELS / HIGH DENSITY
• Power cum Motor control centers
• Intelligent MCC’s
• APFC Panels
• Control Desk
• Soft starter, Drive & Automation Panel
• Feeder Pillars
• DG Synchronizing & Load Sharing Panels
• Crane Control Panels
PRODUCT RANGE

4. LV SWITCHGEAR PANEL
Specifications
And beyond

5. MOTOR CONTROL CENTER
Specifications
And beyond

6. PANEL ASSEMBLY

7. SALIENT FEATURES – DRAWOUT TROLLEY
1. FULLY BOLTED TROLLEY WITH MS RIVET
2. TROLLIES ASSEMBLED THRU’ JIGS & FIXTURES
3. RIGID CONSTRUCTION
4. TOTALLY STANDARDIZED HAVING 50mm PITCH
5. TROLLEY SIZES 150,200……….. 700mm
6. LIBERAL SPACING OF COMPONENTS
7. POWER CONTACTS PRECISELY DESIGNED AND AVAILABLE IN 125A, 250A, 400A & 630A
8. HOUSED IN A VERY STEADY MATERIALS MICROLON – 9312
9. CONTROL TERMINALS PLUG IN TYPE RATING FOR 25A, INSULATION LEVEL

8. Important design features
• Main Busbar/Horizontal busbar chamber at the top of cubical
(Busbars at the bottom can also be supplied on request).
• Vertical busbars/droppers chamber behind the equipment
modules.
• Auxiliary Busbar chamber at the top front side in front of main
busbar chamber.
• Equipment modules or withdrawable Trolleys.
• Cable alley covering full height of each MCC cubicle for
termination of power and control cables.
The MCCs are available in SINGLE FRONT and DOUBLE FRONT
or BACK to BACK execution to meet any specific requirement.
Therefore, Flexi module provide complete solution for modern
industrial applications and power distribution.
MOTOR CONTROL CENTER

9. 9
CUBE – CLOSE DOOR DESIGN

10. MECHANISM

11. MECHANISM

12. All units combined and in function
Movable contacting module with mechanical-
interlocking for Test- Disconnected- and Operate-
position
Rotating contacting bolts get
under pressure with the VBS and
cable- module installed in
opposite in the cubicle. Spring
loaded contacting- forces are kept
and neutralized within the IDS
solution itself.
Contacting-module VBS and cable-module together
form up an arc-fault-free-zone

13. Sample for a completed drawer-set
with all the necessary equipment.
The drawer is only a simple metal
sheet, combined with the contacting-
module it forms up a drawer unit at
highest level of safety and functionality
FUNCTIONAL UNITS

14. 3 contacting-modules but only two sizes up to
630A

15. FUNCTIONAL UNITS

16. Vertical Busbar

17. Cross Sectional View

18. Installment of the bus-bar-module into the EST-
Wall
Bus-bar-module:
existing of rear- and front-part
rear part is installed by push and drop, no tools are
required

19. Removable shutters close the vertical bus-section
Automatic-shutter for each drawer with connecting-windows.
Installment of the bottom-plate for drawer-
compartment

20. Inserted drawer with installed
contacting module
Contacting-module

21. Drawer-units might have fixed plate at the front or individual doors. This is in hand of IDS-partner.
Picture right shows cable compartment with profi-bus-line and vertical control-bus-bar up to 6-poles. This is in
hand of IDS partner how to realize control-wiring.
75mm Pitch
Video
Test Position
Service Position
Rack Out

22. Quarter-size and half-size drawers

23. Space Potential

24. FUNCTIONAL UNITS

25. FUNCTIONAL UNITS – 630A

26. FUNCTIONAL UNITS - Links

27. FUNCTIONAL UNITS - Link

28. Motor Starter Unit

29. iMCC - Motor Starter Unit

30. HIGH DENSITY PANELS

31. ½ AND ¼ WIDTH FEEDERS

32. CONFIGURATION
1.Set up density of quantity of drawers:
a.Using full-size drawers of a height of
75mm only.
b.Using fractional drawers:
i.4 drawers in one row minimum 150mm
height
ii.3 drawers in one row minimum 150 mm
height
iii.2 drawers in one row minimum 150 mm
height

33. INTERNAL CONSTRUCTION

35. © 2004 Xilinx, Inc. All Rights Reserved
NEW FIXED TYPE PANEL

36. INDEX
1. Standard Distribution Board Dimensions
2. Standard Distribution Board Construction Details
3. Standard MCC Panel Dimensions
4. Standard MCC Construction Details
5. Standard PCC Panel Dimensions
6. Standard Power Control Center (PCC) Construction Details
7. Constructional features – Cost effectiveness – Variation with existing
design
8. Costing pattern

37. Standard Distribution Board Construction Design.
(DATA FOR PDB)

38. Standard Distribution Board Construction Design.
(SINGLE FRONT PDB)

39. Standard Distribution Board Construction Design.
(SINGLE FRONT PDB)

40. Standard Motor Contol Center (MCC) Construction
Design DATA.

41. Standard Distribution Board Construction Design.
(DOUBLE FRONT PDB)

42. Standard Distribution Board Construction Design.
(SINGLE & DOUBLE FRONT PDB)

43. Standard Motor Control Center (MCC)
Construction Design.

44. Standard Power Control Center (PCC)
Construction Design DATA.

45. Standard Power Control Center (PCC)
Construction Design.

46. Power Control Center (PCC) Construction

47. Costing Pattern
CLIENT : M/S. Ahluwalia Contracts (India) Limited.
PROJECT : Jamia, Hamdard Nagar at New Delhi Project
SWITCHBOARD : Light Sub Panel-4-Second Floor-Block-1
S.No
.
Description Make Qty. Unit Rate Amnt Dis.
Mod
vat
Modvt
Amt.
S.T T.Amount
A INCOMER 1 5,464
1
100A,TP, 25KA, MCCB with Thermal Magnetic
release for adj. O/L & fixed S/C Protection
(Type DH) with Earth Fault module and ROH,
L&T 1 No 12806 12,806 58% 8% 430 0% 4,948
2 Phase Indicating Lights R,Y,B(LED Type),
L&T
(ESBEE)/C&S
1 set 385 385 35% 0% 0 2% 256
3 6A SP MCB 10KA C Curve HAGER 3 No 184 552 50% 8% 22 2% 260
5,464
B OUTGOING FEEDERS
1 OUTGOING MCB 1 12,900
1 63A 4P MCB 10KA C Curve HAGER 16 No 1710 27360 50% 8% 1,094 2% 12,900
12,900
C
Space Heater (50W, 240V AC) with
Thermostat(Dial type Temp Regulator,30-80
deg ) & 5A/15,3 pin,240V AC socket
REPUTED 1 SET 800 800 0% 0% 0 2% 816
Total Cost
of B/BAR
Equipment 19,180 0.5
Cost After CST + Freight :- 1 19,180 939
Fabrication 8,600 1878 1878
Bus Bar 1,900
Wiring 1,200
feeder Links 1,000
Packing (Polypack) 650 0.3
Total . 32,530 134
Cost After Overheads :- 1.25 40,700 268

48. Feeder Dimension – MCCB feeder
STANDARD FEEDER DIMENSION
MCCB UPTO 36 KA C&S / L&T ABB MG Siemens
Accessories considered - 3CT+3 i/l + 1
sp mcb + nlk DH-3P DH-4P Dsine-3P Dsine-4PTMAX-3PTMAX-4P CVS-3P CVS-4P NS-3P NS-4P VL-3P VL-4P VT-3P VT-4P
Upto 100A 200 250 200 200 200 250 200 250 200 250 200 250 200 250
125A - 160A 200 250 200 250 200 250 200 250 200 250 200 250 200 250
200A-250A 200 250 250 300 250 300 250 300 250 300 250 300 250 300
300A-400A NA NA 300 350 300 350 300 350 300 350 300 350 300 350
500A-630A NA NA 400 400 400 400 400 400 400 400 400 400 400 400
800A NA NA 600 600 600 600 600 600 600 600 600 600 600 600
1000A-1600A NA NA 800 800 800 800 800 800 800 800 800 800 800 800
MCCB 50 KA C&S / L&T ABB MG Siemens
DL-3P DL-4P Dsine-3P Dsine-4PTMAX-3PTMAX-4P CVS-3P CVS-4P NS-3P NS-4P VL-3P VL-4P VT-3P VT-4P
Upto 100A 200 250 200 200 200 250 200 250 200 250 200 250 200 250
125A - 160A 200 250 200 250 200 250 200 250 200 250 200 250 200 250
200A-250A 200 250 250 300 250 300 250 300 250 300 250 300 250 300
400A NA NA 300 350 300 350 300 350 300 350 300 350 300 350
500A-630A NA NA 350 400 400 400 400 400 400 400 400 400 400 400
800A NA NA 500 500 600 600 600 600 600 600 600 600 600 600
1000A-1600A NA NA 600 600 800 800 800 800 800 800 800 800 800 800

49. Feeder Dimension – SFU/MCB
SDFU C&S / L&T ABB MG Siemens
32A 200 200 200 200
63A 200 200 200 200
100A 300 300 300 300
125A 300 300 300 300
160A 350 350 350 350
200A 350 350 350 350
250A 400 400 400 400
400A 500 500 500 500
630A 500 500 500 500
800A 600 600 600 600
MCB
Quanti
ty
Feeder
Size
#63A TPN & FP** 2 200
40A TPN & FP 3 200
**32A TPN & FP &
below 3 200

50. Feeder Dimension – Fixed Starter
STANDARD FEEDER DIMENSION
STARTERS - DOL with MPCB/
MCCB / SDFU
Rating Contactor Switch Feeder Size
Upto 5.5KW 26A 32A 200
7.5- 11KW 30A 63A 250
15-22KW with Ammeter and 3 CT 50A 100A 350
30-45KW with Ammeter and 3 CT 95A 125A 400
55-80 kW with Ammeter and 3 CT 140A 200A 600
90-110kW 225A 250A 800
STARTERS - Star Delta with MPCB/
MCCB / SDFU
Rating Contactor Switch Feeder Size
Upto 5.5KW 25A 32A 300
7.5- 11KW 25A 32A 300
15-22KW with Ammeter and 3 CT 25A 63A 350
30-45KW with Ammeter and 3 CT 70A 100A 450
55-80 kW with Ammeter and 3 CT 95A 160A 500
90-110kW 110A 200A 700
125-150KW 185A 250A 900
160-225KW 265A 400A 900
250-300KW 550A 630A 1200

51. Feeder Dimension – Capacitor
CAPACITOR FEEDER
Rating CAP
Upto 25KVAR 250
> 25KVAR < 50KVAR 350
50KVAR < 75KVAR 500
>75KVAR < 100KVAR 600
Max Cap Banks per Vertical
Normal With Reactor
300 200
ABOVE 100KVAR IN EVERTY VERTICAL PROVIDE MINIMUM 9" EX FAN
AND BELOW 6" EX FAN