01SWITCHBOARD

Switchboards
Components
Introduction
Selection
Considerations
Switchboards
• Objectives:
• At the end of this session you should understand the

basic components of switchboards; and how
transformers are used to reduce current/voltage to
manageable levels
Safety Interlock
Status lights Disconnect
PT
Start button
Hand/Off/Auto Isolation handle
Ammeter Main Fuses

Instrument Transformer
CT’s
Fuses
Backspin Relay
Fuse Block
Vacuum/Air break contactor

Basic Operation
The basic circuit can be divided into two parts:
1. The control circuit which operates at 120 Volts, and

up to 5 Amps.
2. The power circuit which operates at the voltage and

current of the ESP (allowing for cable loss).
Power Circuit
Incoming power to the controller is
applied to the manually operated
disconnect switch.
A TVSS can be attached below here
which gives protection against
lightning strikes.
The power cables pass through current
transformers (CT’s), which step the
current down to manageable levels.
A potential transformer (PT) brings the
voltage down to about 120 volts for
use by the control circuit.
Control Circuit
Each CT in the power circuit transmits current to one of the
three overload relay coils.
The recording ammeter; and underload relay; are in series
with two of these coils – and allow recording of running
current; and underload sensing.
Each overload relay has a normally closed contact, which
are in series with one side of the 120V control circuit.
An overload causes the contact to open, turning off the
control circuit; and shutting down the motor.
Potential Transformers
9 Used to step-down the high voltage (from between 330 to

4900 volts) to a control voltage of 120 volts.
9 The 120 volt control voltage is used to run all the control
circuitry in the Switchboard.
9 Motor controllers will monitor the control voltage and using

the P.T. ratio calculate the line voltage in the switchboard.
Potential Transformers
Accuracy is tested to a tolerance of +/- 2%.
The rated secondary voltage is 126 volts at no-load condition.
Note: It is not 120 volts. Fully loaded there is a 5 – 7%

secondary voltage loss through the transformer.
Therefore the voltage ratio should be obtained using

126 instead of 120 volts.
Potential Transformers - Example
High voltage is 1430 volts low voltage is 120 volts
The 120 is for loaded condition – for no load it is 126 volts
Therefore the correct voltage ratio would be 1430/126 = 11.35
Using 120 volts we get 1430/120 = 11.92
which is almost a 5% error!

Transformer Rating is 1430/126

Measured Secondary voltage is 119 volts
What is the voltage on the primary side?
Calculate the Ratio 1430 / 126 = 11.35
Primary Voltage 119 x 11.35

= 1350 Volts
Using 120 volts instead of 126 we get
Transformer Rating is 1430/120
Measured Secondary voltage is 119 volts
What is the voltage on the primary side?
Calculate the Ratio 1430 / 120 = 11.92
Primary Voltage 119 x 11.92 = 1418 Volts compared

with 1350 Volts for no load condition
Current Transformers
Another type of transformer which is used in the

motor controller is the "current transformer". This
type of transformer changes one current to a
different current.
To monitor the motor current it has to be reduced to a level

which is easier to measure.
If this was not reduced then measuring devices would be large

and cumbersome in order to cope with the high currents.
To reduce the level to a more manageable one current

transformers are used
A conductor passes through the
winding of the CT and energizes it.
Typically the CT ranges used in the

SPS controllers have a TR of 200:5,
300:5, 150:5, etc. although in VSD
applications, the CT ratio can be
much higher.
As an example, if 180A is flowing through the conductor and the
TR is 200:5, what will the current on the secondary side of the
CT be?
A 200:5 ratio is 40 (200 / 5)
180 180A
Sec. Amps = 200:5
180
Sec. Amps = 40 = 4.5 A
4.5 A
Since most control circuits operate in a 0 – 5 amp
range, the CT is used to convert actual amperage to a
value useful to the controller.
180A
4.5 A
If one pass of the wire results in a control circuit current greater
than 5 amps, the C.T. ratio must be increased by going to one with
a higher turns ratio.
Control Circuit amperage can also be doubled by looping the wire
for two passes or increased by three with three passes.
Current Transformers - Example
Take a motor load of 90 amps – and the only current transformers
available are 300 : 5
What current would the ammeter see in each of the situations

below?
Motor load 90 amps – current transformer ratio 300 : 5 (= 60)
90/(300/1 : 5) 90/(300/2 : 5) 90/(300/3 : 5)
1.5 Amps 3 Amps 4.5 Amps

Sizing Current Transformers (CT’s)
Example 59 amps goes through the switchboard

which is the best CT ratio to use?
Motor Controllers work best between 2.5 -3.5 Amps. This has the
amp chart pen tracking the centre of the chart.
200 : 5 ratio 59 / (200 / 5) = 1.48 Amps

150 : 5 ratio 59 / (150 / 5) = 1.97 Amps
100 : 5 ratio 59 / (100 / 5) = 2.95 Amps
Sizing Current Transformers (CT’s)
Example 59 amps goes through the switchboard

which is the best CT ratio to use?
A short cut is to simply multiply the current by 1.6 to get the

nearest ratio
Eg. 59 x 1.6 is 94.4

the nearest ratio is 100 : 5
In a previous example we examined 90 amps – what would the

ratio be using this quick method?
Motor load 90 amps – current transformer ratio 300 : 5 (= 60)
90/(300/1 : 5) 90/(300/2 : 5) 90/(300/3 : 5)

300 : 1 150 : 1 100 : 1
1.5 Amps 3 Amps 4.5 Amps
Backspin Shunts
This is an optional device – which is now widely used.
Reports from the field of incorrect wiring procedures

having caused downhole units not to operate
Always check the wiring diagrams when connecting

backspin shunts.
Switchboards
• Ratings
• DFH2 600 Volt
• MFH 1000 Volt
• MDFH 1500 Volt
• AB 1512 3900 Volt*
* Available to 5000V by changing P.T.

Switchboard
• Ratings:
– Maximum Voltage
– Maximum Amp Load
– Maximum KVA
Selecting a Switchboard
• Select a Switchboard with the appropriate Volt, Amp

and KVA rating
• Select a motor controller
• Select a wiring harness for the motor controller.

Motor Controller Options
• Optional Features
– A095 Backspin Shunt
• 400 - 1000V
• 800 - 2000V
• 1800 - 4000V
– D095 Ground Fault Converter
• Ground Fault Current Transformer
– Bulkhead Connector Cable (used to interface with
WellviewTM Software)
K095 Motor Controller
• IMPAC Data Management System
– Wellsite
• EPROM Upgrade for the L095 Display?
• Data Receptacle
• Bristol Chart Recorder Mounting Bracket
• Data Card (20,40,80,160 Site)
– Office
• Data Receptacle
• PC/AT Parallel Port Adapter
• WellviewTM Software
Switchboards - Surveyor/Pumpwatcher
• SIGMA Sensor Information Gathering and Modulation
– WB-2, p/n 2000089
– Optional Smart Display SD1, p/n 2000090
• Surface Wiring Kit, p/n 1237585
• 3 Phase Choke
– stand-alone, p/n 1071182
– Enclosure in a NEMA box for DFH2/SB, p/n 330621
• Bulkhead Cable (used when SIGMA is portable or externally mounted),
p/n 315622
• Power Output Cable (connects SIGMA to Bulkhead Cable) p/n 315721
• Power Cable if SIGMA is to be mounted internally in SB
Switchboards - Surveyor/Pumpwatcher
• Printer Option
– Thermal Printer DPU-414, p/n 1133891
– Power Supply, p/n 7019532
– Battery Pack, p/n 7019524
– Printer Cable 9 feet, p/n 2003139
– Roll of Thermal Paper, p/n 1133909
Switchboards
• TVSS (Transient Voltage Surge Suppresser)

– Hybrid Network of Surge Arresting Devices
– Encapsulated in a Electrochemical Compound
– Ability to Withstand Numerous Surges with Degradation or
Breakdown
– Response and Recovery Time less than a Nanosecond
– Low Let Through Voltages
Switchboards
• TVSS Available Models
REDA Max. Total Peak Total

Part Continuous Surge Energy
Number Operating Current Dissipation
Voltage (amps) (joules)
(rms)
1164086 680 360,000 9,900
1164094 680 720,000 17,280
1181189 1300 240,000 12,960
1181197 1950 240,000 16,200
1183284 3350 240,000 25,800
1181205 4000 240,000 28,200
Summary
Two sections of switchboard Control Circuit
Power Circuit
Two types of Transformers Current

Potential
Potential Transformers No load is 126 Volts NOT 120

Motor Controllers ideal range is between 2.5 & 3.5 Amps

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Switchboards

• At the end of this session you should understand the

Hand/Off/Auto Isolation handle

Ammeter Main Fuses

Vacuum/Air break contactor

1. The control circuit which operates at 120 Volts, and

2. The power circuit which operates at the voltage and

9 Used to step-down the high voltage (from between 330 to

9 Motor controllers will monitor the control voltage and using

Accuracy is tested to a tolerance of +/- 2%.

The rated secondary voltage is 126 volts at no-load condition.

Note: It is not 120 volts. Fully loaded there is a 5 – 7%

Therefore the voltage ratio should be obtained using

High voltage is 1430 volts low voltage is 120 volts

The 120 is for loaded condition – for no load it is 126 volts

Therefore the correct voltage ratio would be 1430/126 = 11.35

Using 120 volts we get 1430/120 = 11.92

which is almost a 5% error!

Transformer Rating is 1430/126

Calculate the Ratio 1430 / 126 = 11.35

Primary Voltage 119 x 11.35

Calculate the Ratio 1430 / 120 = 11.92

Primary Voltage 119 x 11.92 = 1418 Volts compared

Another type of transformer which is used in the

To monitor the motor current it has to be reduced to a level

If this was not reduced then measuring devices would be large

To reduce the level to a more manageable one current

Typically the CT ranges used in the

What current would the ammeter see in each of the situations

90/(300/1 : 5) 90/(300/2 : 5) 90/(300/3 : 5)

1.5 Amps 3 Amps 4.5 Amps

Example 59 amps goes through the switchboard

200 : 5 ratio 59 / (200 / 5) = 1.48 Amps

Example 59 amps goes through the switchboard

A short cut is to simply multiply the current by 1.6 to get the

Eg. 59 x 1.6 is 94.4

In a previous example we examined 90 amps – what would the

90/(300/1 : 5) 90/(300/2 : 5) 90/(300/3 : 5)

Reports from the field of incorrect wiring procedures

Always check the wiring diagrams when connecting

* Available to 5000V by changing P.T.

• Select a Switchboard with the appropriate Volt, Amp

• Select a motor controller

• Select a wiring harness for the motor controller.

• TVSS (Transient Voltage Surge Suppresser)

REDA Max. Total Peak Total

Two types of Transformers Current

Potential Transformers No load is 126 Volts NOT 120

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