The Arçelik Manisa Plant is a large-scale industrial facility with a dense motor load and a production line that cannot be interrupted. Devpan supplied the Form 4b main distribution boards and the DevControl motor control centres in IP54 enclosures, within an architecture built around production continuity.
Electrical Profile of the Project
- LocationManisa, Türkiye
- Building typeManufacturing plant
- Installed power≈ 10,000 kVA
- Transformer configuration4 × 2,500 kVA
- Main busbar rated current2 × 4,000 A
- Short-time withstand current (Icw)80 kA / 1 s
- Devpan scopeLow voltage switchboards, engineering and site coordination
- Verification standardIEC 61439-1, IEC 61439-2
About the Project
In industrial facilities the character of the electrical distribution is set by motor loads. Starting currents, drive-generated harmonics, frequently switched loads and the cost of a stopped production line all separate switchboard design from that of building-type projects. When one line stops, the loss is not limited to that line but extends to every downstream process.
In line-based processes such as white goods manufacturing, the motor control centre is the nervous system of the plant. Hundreds of motor outgoing ways are collected into one enclosure family, each in its own compartment with dedicated protection and control. Because of dust and mechanical stress in the production environment, the degree of protection is raised, while the thermal design is strengthened to carry the high density of outgoing ways.
Devpan Scope and Switchboard Architecture
The Devpan scope reaches from main distribution at the transformer outgoing side to the motor control centres at the line side. Withdrawable motor outgoing ways and rapid module replacement are the key tools for production continuity.
- Main distribution boards (DevPanel): 4,000 A class, 80 kA / 1 s withstand, Form 4b internal separation.
- Motor control centres (DevControl): Withdrawable motor outgoing ways with direct-on-line, star-delta, soft starter and variable speed drive configurations, in IP54 enclosures.
- Power factor correction (DevComp): Detuned compensation matched to the drive density, with provision for harmonic filtering where required.
- Sub-distribution boards (DevBox): Line-side supply, maintenance workshop and warehouse panels.
- Lighting and power panels (DevPower): Production hall lighting, external area and emergency lighting circuits.
Technical Configuration
| Installed power | ≈ 10,000 kVA |
|---|---|
| Transformer configuration | 4 × 2,500 kVA |
| Medium voltage level | 34.5 kV |
| Low voltage / frequency | 400 / 230 V, 50 Hz |
| Main busbar rated current | 2 × 4,000 A |
| Short-time withstand current (Icw) | 80 kA / 1 s |
| Form of internal separation | Form 4b |
| Degree of protection (IP) | IP54 |
| Generator back-up | 2 × 1,500 kVA |
| Verification standard | IEC 61439-1, IEC 61439-2 |
Devpan Products Used in This Project
Project-Specific Engineering Topics
Withdrawable motor modules and rapid replacement
Every motor outgoing way sits in its own withdrawable module. In the event of a fault the module is replaced as a whole and the line is back in service within minutes, which directly reduces production loss.
Harmonic management and compensation
Variable speed drives feed 5th and 7th harmonics. Undetuned capacitor stages resonate in that environment, so detuned compensation is used and provision for an active filter is left where needed.
IP54 enclosure and thermal balance
Dust in the production environment calls for a higher degree of protection. Because heat dissipation is harder in a sealed enclosure, busbar cross-sections are increased and high-power outgoing ways are thermally distributed within the enclosure.
Discrimination and production continuity
A fault on one motor outgoing way must not trip the line incoming breaker. Protection curves are graded to achieve full discrimination in the sequence outgoing way, line, main distribution.
Frequently Asked Questions
What is a motor control centre (MCC) and why is it used in a plant?
An MCC is a distribution structure in which the motor outgoing ways of a facility are collected into one enclosure family, each motor sitting in its own compartment with dedicated protection and control devices. Plants prefer it because fault response can be carried out from a single location and production can be restarted quickly by exchanging a withdrawable module.
What is the installed power for the Arçelik Manisa plant?
For a production facility of this scale the installed power is approximately 10,000 kVA, with a typical transformer configuration of 4 x 2,500 kVA. The main busbar rating is planned at 2 x 4,000 A with a short-time withstand current of 80 kA / 1 s.
Which degree of protection is required in industrial switchboards?
IP54 is typically preferred inside a production hall, providing dust protection and resistance to water splashing from any direction. IP55 and above is used in wet process or wash-down areas, while IP31 to IP41 may be sufficient in clean spaces such as electrical rooms.
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Send us your single-line diagram, your transformer rating or simply your load list. Our engineering team runs the short-circuit and discrimination study and defines the form of separation and busbar cross-section with you.
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