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  • 7 July 2023
  • Electrical Switchboard Manufacturer | Technical Articles

How Are Electrical Switchboards Sized?

The single most significant factor in determining switchboard size is the total amount of electrical load the installation should handle. Technically speaking, this is considered the maximum demand. A licensed electrician will calculate this based on the configuration of your home, appliances, and projected usage patterns. For instance, if you’ve got air conditioning, an electric oven, a pool pump, and perhaps even an EV charger, your home will require a much larger switchboard than a small apartment with only basic lighting and power outlets. The electrician uses demand factors and diversity allowances based on AS/NZS 3000 to estimate a realistic load rather than simply adding up the maximum ratings of every appliance.

Standard Switchboard Ratings

The standard house usually needs between 100 and 160 amps of service capacity, but the bigger or more demanding houses might need 200 amps or more. For instance, if you have a house with an area greater than 300 square metres, three-phase air conditioning, an induction cooktop, multiple bathrooms, and a solar battery system, a standard switchboard might no longer suffice. It’s now very normal to see houses constructed with increased capacity boards from the beginning to future-proof for new technologies like solar storage and electric vehicles.

Number of Circuits and Physical Space

While the current capacity is paramount, it’s not the sole consideration. Another significant consideration when sizing switchboards is how many individual circuits will be installed.\. Every circuit requires its own protection device, and the devices occupy physical space along the DIN rail within the enclosure. For an average family home, you may have distinct circuits for lighting, power, kitchen, air conditioning, and hot water. Throw in outdoor lighting, garden power, garage sub-boards, and any solar or battery systems, and the number of modules you need can quickly mount. If the switchboard is too small to accommodate these, you’ll run out of space—and options.

Planning Ahead for Future Loads

It’s also worthwhile to make provision for future additions. Even if you don’t presently have a solar inverter or EV charger, it is wise to provide room for them. Future planning is especially valuable if your board is hard to get to or your distributor has stringent rules regarding upgrades. It may be cheaper to oversize now rather than to retrofit or replace a congested switchboard further down the line.

Indications That You Could Use an Upgrade

Most houses are still using older boards with ceramic fuses that are outdated, which cannot give the protection level that the existing wiring rules demand. The boards usually do not have RCD protection at all, which is now required on all final subcircuits in new installation. If your board fails to meet these minimum safety requirements, or if it’s loaded or worn out, it’s time to look at an upgrade. Some of the common symptoms include flickering lights, breakers that keep tripping, warm power points, or buzzing and humming noises from the board. These are usually the signs of an undersized or worn-out switchboard and should never be neglected.

What Happens During a Switchboard Upgrade?

A switchboard upgrade typically begins with a licensed electrician carrying out a site inspection and load assessment. This helps determine not only the appropriate amp rating of the new board but also how many modules are required for circuit protection. In some cases, the electrician may recommend upgrading the service mains, especially if your current connection is only rated for 63 amps and you’re planning to install high-demand equipment. To upgrade your primary switch to 100 or 160 amps can give the additional headroom that is required for contemporary living.

The process of installation typically involves uninstalling the old board, fitting a new enclosure with sufficient space, rewiring existing circuits where required, and replacing old fuses with modern circuit breakers or RCBOs. The switchboard will also be earthed suitably by the electrician and neutral and earth bars labelled properly and separated. In a few installations, other equipment such as surge protection devices or main isolators for meter compliance may also be fitted.

Environmental and Practical Factors

Location and environmental protection are factors in switchboard sizing and selection too. If your board is installed outdoors, it needs to be IP-rated appropriately to stop the entry of water or dust. Some electricians favor boards with metal housings or weather covers for added toughness. Ventilation and ease of access are essential considerations for an indoor installation. The switchboard should be installed at a convenient height and free from obstructions so that it can be serviced or reached in case of an emergency.

Modular Switchboards and Smart Features

It’s also important to mention that the majority of switchboards nowadays are planned in a modular way. That is to say that they can be extended with additional modules or rows if necessary. There are even some newer switchboards that come with built-in load monitoring, Wi-Fi-based smart capabilities, and energy management system integration points. These are being seen more frequently, especially in new houses with solar, batteries, and smart metering systems. Opting for a board that has room for these technologies today can prevent you from incurring higher changes in the future.

We design and manufacture high-quality switchboards. Contact us today to discuss your requirements and get started!

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