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Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Brief # PTB#1 PTB#2 PTB#3 PTB#4 PTB#5 PTB#6 PTB#7 PTB#8 PTB#9 PTB#10 PTB#11 PTB#12 PTB#13 PTB#14 PTB#15 PTB#16 PTB#17 PTB#18 PTB#19 PTB#20 PTB#21 PTB#22 PTB#23 PTB#24 PTB#25 PTB#26 PTB#27 PTB#28 PTB#29 PTB#30 PTB#31 PTB#32 PTB#33 PTB#34 PTB#35 PTB#36
Issue Date (4/23/90) (5/18/90) (6/7/90) (7/28/90) (7/29/90) (7/30/90) (9/29/90) (10/22/90) (1/9/91) (1/10/91) (3/1/91) (3/4/91) (3/27/91) (4/1/91) (5/24/91) (6/12/91) (7/18/91) (7/19/91) (8/26/91) (8/27/91) (12/3/91) (12/4/91) (12/5/91) (2/7/92) (2/11/92) (4/13/92) (4/14/92) (8/25/92) (8/28/92) (10/16/92) (10/18/92) (10/19/92) (12/16/92) (12/17/92) (1/14/93) (3/4/93)
Contents of Brief Fast Bus Transfer Closing and Latching Capability of Medium Voltage Power Circuit Breakers Capacitance Current Switching Capability of PowlVac Circuit Breakers Umbilical Cord Used on PowlVac Circuit Breakers Comparison of Porcelain and Cycloaliphatic Epoxy Insulation Effect of Solar Radiation on Outdoor Metal-Enclosed Switchgear Seismic Testing of PowlVac Switchgear Preventing Voltage Feedback in Synchronizing Circuits Fuses for Use in DC Control Circuits Transient Recovery Voltage (TRV) Values for Testing of PowlVac Circuit Breakers Consequences of Vacuum Interrupter Failure Continuous Current Carrying Capability of Low Voltage Circuit Breakers Future Use of Space in Powell Equipments Autotransformer Starting of Motors Directional Overcurrent and Directional Power Relays Preventing Condensation in Medium Voltage Motors Ground Lead Disconnectors on Distribution-Class Surge Arresters Operating Times of PowlVac Circuit Breakers Use of PowlVac Circuit Breakers for Continuous Currents Above 3000 Amperes Application of Dummy Circuit Breakers in Metal-Clad Switchgear Switching Capability of Rollout or Tiltout Carriages Short Circuit Currents - Crest, rms Symmetrical and rms Asymmetrical Using Design Tests to Qualify Several Ratings of Equipment Sizing Bus Bars in Switchgear and Motor Control Application of Metal-Enclosed Switchgear at High Altitude Voltage Ratings of Surge Arresters Testing of Switchgear and Motor Control Equipment Short Circuit Current Levels Used to Test Various Types of Circuit Breakers Interchangeability of Drawout Circuit Breakers in Switchgear Assemblies Static Relays and Meters Effects of Harmonics on Switchgear Replacing Older Medium Voltage Circuit Breakers with Vacuum Circuit Breakers Partial Differential Relaying Polarity Markings on Instrument Transformers Settings of Targets on Electro-Mechanical Protective Relays Epoxy Bus Bar Insulation
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Brief # PTB#37 PTB#38 PTB#39 PTB#40 PTB#41 PTB#42 PTB#43 PTB#44 PTB#45 PTB#46 PTB#47 PTB#48 PTB#49 PTB#50 PTB#51 PTB#52 PTB#53 PTB#54 PTB#55 PTB#56 PTB#57 PTB#58 PTB#59 PTB#60 PTB#61 PTB#62 PTB#63 PTB#64 PTB#65 PTB#66 PTB#67 PTB#68 PTB#69 PTB#70
Issue Date (3/5/93) (4/21/93) (4/22/93) (4/23/93) (6/3/93) (6/4/93) (7/30/93) (8/2/93) (9/22/93) (9/23/93) (11/17/93) (12/2/93) (12/3/93) (12/10/93) (6/2/94) (6/14/94) (7/5/94) (11/16/94) (12/8/94) (12/19/94) (12/22/94) (1/17/95) (1/24/95) (1/30/95) (3/7/95) (3/28/95) (6/12/95) (6/22/95) (6/29/95) (11/3/95) (11/13/95) (11/28/95) (1/5/96) (1/10/96)
Contents of Brief Testing for Loss of Vacuum in Vacuum Interrupters Using Switchgear at Frequencies Other Than 60Hz Motor Branch Fault Short-Circuit Protection Temperature of Cable Terminations and Cable Compartments in Switchgear Plating of Contact Surfaces in Switchgear and Circuit Breakers Momentary Rating and Construction of Bus in Metal-Enclosed Switchgear Device Function Numbers Preparing Foundations for Indoor Installation of Switchgear MVA Interrupting Rating of Circuit Breakers Used in Metal-Clad Switchgear Significance of K Factor in Circuit Breaker Ratings X/R Ratio Temperature Rating of Conductors Connected to Molded Case Circuit Breakers Industry Standards Covering Powell Products NEC Article 384 - Switchboards and Panelboards Arc-Resistant Metal-Clad Switchgear Wire Fill in Seal Fittings Hardware for Bus Connections Arc-Resistant Switchgear Construction or Arc-Detection Devices? Useful Life of Metal-Enclosed Switchgear Control Wire and Wire Markers in Switchgear and Motor Control Ratings of Medium Voltage Circuit Breakers Rating of Ground Bus in Metal-Enclosed Switchgear Bus Spacings in Metal-Enclosed Switchgear Switching Small Currents with Vacuum Circuit Breakers Overcurrent Definitions Choosing Current Transformers for Relaying Use Capacitance Graded Bushings Load Switching Capability of NEMA General Purpose Contactors Starting Synchronous Motors Use of Auxiliary Current Transformers Using Latched Contactors in Medium Voltage Motor Control Centers Instantaneous Ground Fault Relays (50GS) and Zero-Sequence CTs Wound Rotor Induction Motors and Starters The Importance of Transient Recovery Voltage
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Brief # PTB#71 PTB#72 PTB#73 PTB#74 PTB#75 PTB#76 PTB#77 PTB#78 PTB#79 PTB#80 PTB#81 PTB#82 PTB#83 PTB#84 PTB#85 PTB#86 PTB#87 PTB#88 PTB#89
PTB#90
Issue Date (2/9/96) (4/10/96) (4/23/96) (7/12/96) (7/29/96) (2/19/97) (2/20/97) (10/1/97) (10/1/97) (10/27/97) (10/28/97) (4/16/98) (8/3/98) (11/17/98) (8/10/99) (8/11/99) (5/12/00) (5/8/01) (7/31/01)
(9/15/01)
Contents of Brief Starting Methods for Large Medium Voltage AC Motors Open Circuit Protectors for Current Transformers Metal-Clad Switchgear or Metal-Enclosed Switchgear: Which Is It? Enclosures for Metal-Enclosed Switchgear and Motor Control Overlap and Bolting of Bus Connections Bus Duct Enclosure Material Insulation of Bus Joints Circuit Breaker Trip Defeat Switch Ferroresonance of Voltage Transformer (VT) Circuits Switchgear in a Sulfur Rich Environment Direct Control of Motor Contactors via PLC's and Distributive Control Systems Physical Installations of Surge Arresters Additional Safety Features Capacitor Trip Unit The Application of 600 Volt Class Current Transformers in Medium Voltage Switchgear Altitude De-rating of Fuses, Surge Arresters and Potential Transformers Current Transformer Grounding Standard Voltage Ranges and Ratings
The New Medium Voltage Circuit Breaker Interrupting Ratings Based on a K Factor of 1 Asymmetrical Interrupting Current Rating of Medium Voltage Circuit Breakers
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #2 - Closing and Latching Capability of Medium Voltage Power Circuit Breakers
May 18, 1990 ANSI Standard C37.06-1987, American National Standard for Switchgear - AC High Voltage Circuit Breakers Rated on a Symmetrical Current Basis - Preferred Ratings and Related Required Capabilities, includes a column in Table 1 headed Closing and Latching Capability. In older editions of this standard, the current value in this column was given in rms kiloamperes, and was determined by multiplying the maximum symmetrical interrupting capability by 1.6. In the 1987 edition, this current is expressed in crest kiloamperes, and the value is determined by multiplying the maximum symmetrical interrupting capability by 2.7. Other standards had previously required the closing and latching current to have a crest value of 2.7 times the maximum symmetrical interrupting current, so the performance required of the circuit breaker has not really changed. Only the method of stating the requirement has changed. This change was made to bring the ANSI standard in line with the IEC standard, which also expresses closing and latching capability in crest amperes. Since many specification writers will be using older standards, or copying older specifications, we will probably see both methods of specifying closing and latching current used in specifications for many years. The following table gives both sets of values. Rated Maximum Voltage kV, rms 4.76 4.76 8.25 15.0 15.0 15.0 Rated Short Circuit Current kA, rms 29 41 33 18 28 37 Closing and Latching Capability per ANSI C37.06 1979 Edition kA, rms 250 350 500 500 750 1000 58 78 66 37 58 77 1987 Edition kA, Crest 97 132 111 62 97 130
Nominal MVA
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #2 - Closing and Latching Capability of Medium Voltage Power Circuit Breakers (Page 2)
If the specified value of closing and latching current matches a value from either edition of the standard, we can assume that a standard breaker is desired. If there is any possibility of confusion, the specifier should be contacted to determine which basis is being used to specify the close and latch rating.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
The circuit breaker cannot be inserted into the cell without plugging in the umbilical cord. Once the circuit breaker racking mechanism has been operated to start the circuit breaker insertion process, the plug cannot be removed. It is therefore not possible to disconnect the control circuits of a circuit breaker that is in service. Unplugging the umbilical cord trips the circuit breaker if it is closed and discharges the closing spring if it is charged. Since the plug must be removed in order to remove the circuit breaker from its cell, these interlocks insure that the circuit breaker is open and all energy storage springs are discharged when the circuit breaker is taken out of the cell.
Q. Why does Powell differ from all other manufacturers in the method of disconnecting the control connections to the circuit breaker? A. Powell does not differ from "all other manufacturers". While the umbilical cord design has not been used frequently in the United States, other American manufacturers have used it. It is also commonly used in Europe. We chose to use this design because we think it offers superior performance in total.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Cycloaliphatic epoxy ("cyclo") weighs less than 70% of porcelain's weight. The thermal coefficient of expansion of cyclo is 1/20th that of porcelain. The tensile strength of cyclo is about 11 times that of glazed porcelain. The compression strength of cyclo is 4 to 6 times that of glazed porcelain. The flexural strength of cyclo is 16 to 18 times that of glazed porcelain. The Izod impact strength, unnotched, is about the same as glazed porcelain. Dimensional and shape control is much easier in cyclos than in porcelain. While the repairability of cyclos is limited, porcelain is unrepairable.
The dielectric constant of cyclo is only about two-thirds that of porcelain. The temperature class of porcelain is much higher than that of cyclo, but cyclo mixtures with temperature classes of 105 C or 130 C are readily available. The track resistance of cyclo is slightly less than that of porcelain. The water absorption of cyclo is slightly greater than that of porcelain, but is still in the range of 2/10's of 1%.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
where
is the seismic zone coefficient, which varies from 0.125 for Zone 0 to 1 for Zone 4,
is the occupancy factor, which varies from 1 for Category I to 1.5 for Category III,
is the horizontal force factor, which is 0.3 for all machinery in a building,
and
From basic mechanics, Force = Mass x Acceleration. In the above formula, Fp is a force. W p is a weight, which is the product of a mass and the acceleration of gravity, or g. It follows that the product of Z, I and Cp is a dimensionless coefficient for g. For a worst case situation, where the switchgear is installed in a critical occupancy in Zone 4, the value of this coefficient is 1 x 1.5 x 0.3, or 0.45. Since seismic testing is performed in terms of acceleration rather than force applied, the test level for a worst case installation should be 0.45 g. The other aspect of suitability is the performance of the equipment under the specified conditions. Here, we have absolutely no guidance from ANSI standards. Based on past experience and input from various users, Powell has decided that the following are reasonable criteria for suitability:
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #10 - Transient Recovery Voltage (TRV) Values for Testing of PowlVac Circuit Breakers
January 10, 1991 The interrupting performance of any circuit interrupter is affected by the transient recovery voltage appearing across the first pole to interrupt. Both the absolute value of this voltage and its rate of rise are important in determining the interrupter's ability to meet its interrupting rating. The required values of transient recovery voltage are included in ANSI/IEEE C37.06-1987, along with the other ratings of circuit breakers.
The conventional way of specifying the rate of rise of the transient recovery voltage is to specify the peak value (E2) and the time required to reach that peak (T2). The rate of rise is then determined by dividing E2 by T2. The nominal values are those for a full rated short circuit interruption. For lower currents, both higher peaks and faster times are specified. Table 6 of ANSI/IEEE C37.06-1987 lists the multiplying factors to be applied to E2 and T2 for interrupting currents below the full rating of a circuit breaker.
Table 1 of ANSI/IEEE C37.06-1987, which gives the preferred ratings of indoor oilless circuit breakers, such as PowlVac breakers, calls for E2 to be 1.88 times the breaker's rated maximum voltage for tests at 100% of the circuit breaker's interrupting rating. Unfortunately, values of T2 are not standardized, leaving the manufacturer with no guidance on this subject. In order to assign some reasonable value to T2, Powell decided to use the rate-of-rise values given in Table IIA of IEC Standard 56, interpolating between the listed values to match the ANSI voltage ratings, and multiplying the rate-of-rise values by E2 to obtain T2. The values obtained by this method were used in the testing of PowlVac circuit breakers, and are given in the table below.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #10 - Transient Recovery Voltage (TRV) Values for Testing of PowlVac Circuit Breakers (Page 2)
PowlVac Transient Recovery Voltage Test Values Transient Recovery Voltage Current % of Interrupter Rating Rated Maximum Voltage = 15 kV Rated Maximum Voltage = 4.76 kV
7 to 13 20 to 30 40 to 60 100
29 29 49 73.6
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Summing up, interrupter failures are rare, and when they do happen, most are not a major disaster.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #12 - Continuous Current Carrying Capability of Low Voltage Circuit Breakers
March 4, 1991 Various types of low voltage circuit breakers have differing continuous duty capabilities. Some are rated to carry 100 percent of their trip rating continuously, while others are rated to carry only 80 percent of their trip rating continuously. It is important that we understand the difference and apply these breakers properly. The general run of molded case circuit breakers in frame sizes of 400 A and below are rated to carry only 80 percent of their rated trip current on a continuous basis. Particularly when these breakers are mounted close to each other in a panelboard, the extra heat generated by carrying 100 percent of the trip rating will both lead to false tripping and cause long-term degradation of the insulating material of which these breakers are made. On the other hand, all low voltage power circuit breakers and the general run of insulated case circuit breakers are capable of carrying 100 percent of their trip rating on a continuous basis. Some confusion can arise when using large molded case circuit breakers, in frame sizes of 600 A and above. These breakers may be rated either 80 percent or 100 percent, depending on the model and the manufacturer. As you would expect, the 100% breaker costs considerably more than the 80% breaker. Some models have both 80% and 100% ratings available. The 100% rated breaker may require a larger enclosure and/or more ventilation than the 80% rated breaker of the same model. Please observe the following application rules: 1) Apply MCCB's in 400 A frame size and smaller based on continuous loads of not more than 80% of the circuit breaker's trip rating. If trip ratings are selected by our customer, assume that they are based on the 80% load requirement. 2) Apply insulated case breakers and low voltage power circuit breakers based on continuous loads of not more than 100% of the breaker's trip rating. If trip ratings are selected by our customer, assume that they are based on the 100% load requirement., Be sure that the insulated case breakers selected are 100% rated.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #12 - Continuous Current Carrying Capability of Low Voltage Circuit Breakers (Page 2)
3) Apply large molded case circuit breakers based on either the 80% or the 100% rating, making sure that the breaker selected fits the application, and that adequate space and ventilation is provided for the breaker chosen. If trip ratings are selected by our customer, be sure that you understand which basis was used for selection.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
An investigation of the failed autotransformers by their manufacturer showed that the failure had been a surface flashover from the line end of the winding either to another tap of the winding or to a ground point. There was no damage to the winding or the core, and the autotransformers could be easily repaired and put back into service. We consulted with both the autotransformer manufacturer and the manufacturer of the contactors used in the starter, and found that there had been previous experiences of this problem. The flashovers occurred because system transients generated during the starting sequence caused an excessive voltage to appear on the line end of the autotransformer winding. Upon analysis, we found several conditions that contributed to this problem:
The starter was located at the end of a rather weak supply line. During the starting sequence, the user switched in a rather large capacitor bank to minimize the line voltage drop. This bank was switched off automatically, during the starting sequence, when the voltage recovered to a fixed point. The autotransformer was set on the 80% tap. We are uncertain of the setting of the timer used to transfer from the starting connection to the running connection.
Although the contactors used in this particular installation were vacuum contactors, the manufacturer informs us that similar problems have been encountered with both air and vacuum contactors. The type of contactor used doesn't seem to be a factor in the occurrence of the problem.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Insulate the transformer connection points, both the taps that are used and the unused taps. This should be done on all future starters of this type. Use a lower voltage tap on the autotransformer, such as 65% or 50%, if the motor will accelerate successfully on these taps. For induction motors, be sure that the timer that transfers to the running connection is set at a long enough time so that the motor is fully accelerated before changing to the running connection. Add an instantaneous current relay to the circuit, set to pick up at about 5 A and drop out just below that current. This relay will pick up when the motor is started and drop out when it reaches full speed. Connect the coil of this relay in any phase CT. Use the contact of this relay to bypass the timing relay contact, insuring that the motor has fully accelerated before the starter is transferred to the running connection. See the control circuit below. In the future, please include this relay in all starters of this type.
In extreme cases, it may be necessary to connect intermediate class surge arresters to the line taps of the two autotransformer coils.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Connected to measure power flow into a generator, the relay will operate to trip the generator breaker if the generator begins to draw power from the system and act as a motor. This is usually due to loss of prime mover power. Connected to measure power flow into a transformer from the secondary side, a very sensitive directional power relay can measure core loss power input to the transformer, detecting loss of the primary source to the transformer. The transformer can then be disconnected from the system. A directional power relay can be used to limit power flow in a circuit. The relay may trip a breaker or initiate control action to change the system configuration. By using quadrature potential connections or a phase shifting transformer, these relays can be made to measure vars . A typical use would be to limit the real or reactive power drawn from a utility source to a contractual level.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
The heating contactor must be a full line voltage contactor, as the motor winding side of this contactor is energized at line voltage when the motor is running. The running contactor and the heating contactor must be mechanically and electrically interlocked so that only one of them can be closed at any time. There needs to be a time delay between the opening of the running contactor and the closing of the heating contactor, to allow the residual voltage on the motor to decay before the motor windings are connected to the low voltage source. Since it is not critical to apply the heating circuit immediately, it is recommended that this time delay be in the order of 2 to 5 minutes. Tests show that there is an open circuit time of approximately 75-80 milliseconds when the running contactor is picked up by a "b" contact of the heating contactor. The user should consider whether this is an adequate time period to prevent unwanted system problems. If not, a time delay of a few seconds can be inserted in the pickup circuit of the running contactor to be sure that the heating contactor has cleared before the motor is energized by the operating voltage. The voltage applied to the motor windings must be carefully selected to produce the proper heating. This value must be selected by the user, based on input from the motor manufacturer.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
All of these breakers are rated 5 cycles interrupting time in accordance with the preferred ratings found in Table 1 of ANSI C37.06-1987, even though they may be faster. The "Dash 2" breaker, in particular, is very nearly a 3 cycle breaker.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #19 - Use of PowlVac Circuit Breakers for Continuous Currents Above 3000 Amperes
August 26, 1991 In accordance with ANSI/IEEE Standard C37.06, the highest continuous current rating of our standard line of PowlVac circuit breakers is 3000 A. For systems that require continuous current ratings above 3000 A, we can offer two possible solutions. First, we can offer our standard 3000 A circuit breaker with cooling fans. We have a design that has been successfully tested at 3750 A, and the results of that test indicate that the fan-cooled breaker may be applied at 4000 A without overheating. This design requires a unit somewhat wider than the standard 36inch switchgear unit to include the necessary air ducts. The standard fan control equipment includes a current-actuated control to start the fans at about 2500 A and an alarm circuit which uses air flow switches to detect and alarm loss of cooling air at currents above this level. A completely redundant second set of fans can be furnished if desired. Fan cooling is our preferred method of obtaining higher continuous current ratings. A second method of providing for high continuous currents is to parallel two circuit breakers. Using this approach, we can provide for continuous currents of about 3500 A by paralleling two 2000 A breakers and about 5000 A by paralleling two 3000 A breakers. When breakers are paralleled, the interrupting rating is neither increased nor decreased. Precise timing in closing or opening the two paralleled breakers is not critical, as whichever breaker closes first can carry the continuous current for the few milliseconds until the second breaker closes, and the last breaker to open has the capability of interrupting the full fault current. Paralleling of breakers does require special circuitry to balance the currents between the two breakers and individual overcurrent protection for each breaker as well as combined overcurrent protection for the entire circuit. Main bus construction must also be very carefully balanced to insure equal impedance in both legs of the circuit. Parallel breakers should only be used for a user who refuses to use fan cooled circuit beakers. Regardless of which breaker uprating method is used, special attention must be given to the design of any portions of the switchgear bus which are rated over 3000 A. If the main bus exceeds 3000 A, standard PowlVac bus cannot be used, and the required special bus design limits the switchgear to one-high construction.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Voltage transformers: A set of three wye connected VT's or two open delta connected VT's can be switched with a rollout or tiltout without any interlocking of the secondary circuit. Control power transformers: A CPT up to 50 kVA single phase or 75 kVA three phase can be switched with a rollout or tiltout provided the carriage is interlocked so that the CPT must be unloaded before opening the primary device. The CPT may be mounted on the rollout or tiltout, or the rollout or tiltout may contain only the fuses for a stationary mounted CPT. Larger CPT's must be switched with some other mechanism, such as a load break disconnect switch. Capacitors: Rollouts or tiltouts must not be used to switch capacitors.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #22 - Short Circuit Currents - Crest, rms Symmetrical and rms Asymmetrical
December 4, 1991 The figure below shows a typical short circuit current wage form and defines the various component parts of this wave. At the moment of initiation of a short circuit the ac current wave, which is normally symmetrical about the zero axis BX is offset by some value, creating a waveform which is symmetrical about another axis, CC'. The degree of asymmetry is a function of several variables, including the parameters of the power system up to the point of the short circuit and the point on the ac wave at which the short circuit was initiated. In a 3-phase circuit, there is usually one phase which is offset significantly more than the other two phases.
It is convenient to analyze this asymmetrical waveform as consisting of a symmetrical ac wave superimposed on a dc current. CC' represents the dc current, and the value of that current at any instant is represented by the ordinate of CC'. The dc component of the current normally decays rapidly, and reaches an insignificant value within 0.1 s in most power systems. The rate of decay is a function of the system parameters. When the initial value of the dc current is equal to the initial peak value of the ac current, the resulting waveform is said to be fully offset, or to have a 100% dc component. It is possible, in some power systems, to have an offset in excess of 100%, which may result in a waveform that has no current zeros for one or more cycles of the ac power frequency. The ac component of the short circuit current will also decay, at a rate dependant on the system parameters. In general, the closer the fault is to generators or other large rotating machinery, the faster the decay will be.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #22 - Short Circuit Currents - Crest, rms Symmetrical and rms Asymmetrical (Page 2)
In the figure, IMC is the crest, or peak, value of the short circuit current. It is the maximum instantaneous current in the major loop of the first cycle of short circuit current. The rms symmetrical value of the short circuit current at any instant, such as EE', is the rms value of the ac portion of the current wave. Its value is equal to , and it is shown graphically by the distance from CC' to DD'. The rms asymmetrical value of the short circuit current is the rms value of the combined ac and dc waves, and it is calculated by the formula:
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Size and material (copper or aluminum) of the bus bar. Whether the bar is insulated. Surprisingly, a bus bar covered with insulation generally runs cooler than an equivalent bare bus bar, because the usually darker color of the insulating material is a better radiator of heat than the shiny surface of a bare bus bar. Size and material (magnetic or non-magnetic) of the enclosure around the bus. Flow of ventilating air past the bus bars or the bus enclosure. Proximity of other conductors and other heat-producing devices.
The complex interaction of these and other factors makes it nearly impossible to calculate temperature rise, and leads to the requirement in all applicable standards for continuous current tests to determine the temperature rise of a bus design. Specifications will sometimes call for bus sized by current density, a favorite requirement being 1000 A per square inch for copper bus. This may be a good way to choose bus sizes for the mythical "single conductor in free air", but it isn't a satisfactory way to design buswork in practical equipments. Consider the following chart, based on bus sizes used in our PowlVac metal-clad switchgear: Switchgear Bus Rating Number of bus bars per phase Size of bus bar, inches Cross section area of bus, square inches Current density, amps per square inch 1200 A 2000 A 3000 A 1 1 1200 1 3 667 2 6 500 1/4 x 4 1/2 x 6 1/2 x 6
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PTB #24 - Sizing Bus Bars in Switchgear and Motor Control (Page 2)
The last line of the chart shows that the temperature rises of the three bus ratings are almost identical in spite of the 2.4:1 ratio of the current densities.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Medium Voltage Switchgear and Breakers Altitude (ft)* 3300 (1000 m) (and below) 5000 (1500 m) 10,000 (3000 m) Voltage Current 1.00 0.95 0.80 1.00 0.99 0.96
* Intermediate values may be obtained by interpolation. You will notice that there are different altitudes given for low voltage and medium voltage. I have never been able to get a reasonable answer as to why this is true, and I understand that the committee responsible for the standards is reviewing these values with the idea of reconciling them. In all cases, the current correction factor is applied to the continuous current rating of the switchgear and the circuit breakers. This does not usually present a problem, as we seldom design a system with load currents over 95% of the equipment rating. The current derating does not apply to interrupting current or any of the other high-current ratings of the breakers.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #28 - Short Circuit Current Levels Used to Test Various Types of Circuit Breakers
August 25, 1992 When applying interrupters of various types, it is important that we understand the meaning of the interrupting rating given to these devices. Consider, for instance, the methods of making interrupting tests on various types of circuit breakers. As the breakers get smaller and less costly, the test methods in the industry standards generally get less demanding. When testing the interrupting capability of a high-voltage (over 1000V) circuit breaker, the current measured is the actual fault current flowing through the circuit breaker at the moment of the interruption. To rate a breaker of this class as a 25kA interrupter, it must actually interrupt 25kA. Momentary and short-time current requirements of the switchgear are also based on actual current flowing during the test. The reference standards are ANSI/IEEE C37.04, C37.06 and C37.09 for the circuit breakers and C37.20.2 for the switchgear. For low voltage circuit breakers, this requirement changes to rating by prospective current. The test terminals of the laboratory source are short-circuited, as indicated by point A in Figure 1, and the required current flow is established. That short circuit is then removed and the equipment to be tested is connected to the test source. A short circuit is then applied to the equipment and the test made. The location of the short varies with the type of circuit breaker or equipment being tested:
Figure 1: Fault Locations for Testing Low Voltage Equipments (A) Low Voltage Power Circuit Breakers (B) Molded Case Circuit Breakers (C) Low Voltage Motor Control Centers
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PTB #28 - Short Circuit Current Levels Used to Test Various Types of Circuit Breakers (Page 2)
For a low voltage power circuit breaker, the fault is placed at the load terminals of the breaker, at point B in Figure 1. The reference standards are ANSI/IEEE C37.13 for the circuit breakers and C37.20.1 for the switchgear equipment. For a molded case circuit breaker, the fault is also placed at the load terminals of the circuit breaker, at point C in Figure 1. However, 4 feet of appropriately-sized conductor may be included between the test station terminals and the line terminals of the circuit breaker under test. The reference standard is UL 489. For a typical combination motor starter unit in a motor control center, the fault is placed at the end of 4 feet of appropriately-sized conductor connected to the load terminals of the starter unit, at point D in Figure 1. The reference standard is UL 845.
At each step of this chain, impedance is added to the test circuit, reducing the actual fault current the circuit breaker is required to interrupt. Several papers presented at recent IEEE conferences have raised questions about the adequacy of equipment certified to some of these test standards to interrupt all possible faults downstream of the circuit breaker. At least two IEEE subcommittees are discussing this matter.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
In general, static devices are more accurate and more repeatable than the equivalent electromechanical devices. A single static device can perform the functions of many electro-mechanical devices. Equivalent functions can often be obtained at lower cost, particularly if a multi-function device is used. Some functions or operating characteristics which are not possible with available electromechanical devices can be done with static devices. Static devices can be provided with communications capability which is not available in electromechanical devices. Static devices can be made highly resistant to corrosive or dirty atmospheres.
However, not every engineer is happy with the idea of relying on static devices for protection functions. Some of the reasons are:
Possibility of total failure of the protective system due to failure of one component on the critical path, such as a common power supply. Long-term familiarity and satisfactory experience with electro-mechanical devices. Lack of service capabilities for static devices. Existing company standards. Concerns about possible failure in adverse environments, both physical and electrical.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
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A highly distorted voltage wave can have a peak value much greater than the peak value of a sine wave of the same rms value. The repeated application of a higher peak value may result in premature failure of the insulating systems in the switchgear. Since the effective resistance of a conductor goes up as frequency rises, a current wave rich in harmonics may cause greater heating in the switchgear power conductors than a sine wave of the same rms value. However, since we seldom load switchgear to its maximum continuous current rating, this effect will probably not be a problem. Circuit breakers interrupt current flow at a current zero. A badly distorted current wave may contain current zeroes at locations other than the normal zero of the fundamental sine wave. If present, these spurious current zeroes could cause premature interruption and restrike during a circuit breaker opening operating. The effect of harmonics on the operation of protective and metering systems is not fully documented. Thermal devices, such as fuses or thermal elements in circuit breakers, are inherently rms sensing, as are many modern solid-state protective packages, but the heating effect of a harmonic-rich current on the protected load may require a different level of protection. Other relays may be designed to operate on certain selected frequencies and may thus operate incorrectly in the presence of a significant level of harmonics. Fortunately, high fault currents are generally not severely distorted, as the limiting impedance is that of the power system, and a level of harmonic current which may be quite significant when compared to load current is much less significant when compared to fault current.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #32 - Replacing Older Medium Voltage Circuit Breakers with Vacuum Circuit Breakers
October 19, 1992 Many older installations of metal-clad switchgear are candidates for modernizing or upgrading. The interrupting duty may have grown past the interrupting capacity of the existing circuit breakers, maintenance costs may be getting out of hand, or circuit breaker parts may no longer be available. Modernization may be accomplished by either of two methods, conversion of the existing equipment or replacement of the circuit breaker with a new, modern vacuum breaker. In some cases, modernization may involve conversion of the switchgear equipment and replacement of the circuit breaker. Modernization may also involve an increase in one or more ratings of the switchgear and/or circuit breaker. Powell offers a series of PowlVac circuit breakers, both conversions and replacement breakers, to aid in modernization. In any case, users should insist that modernization be done in accordance with applicable industry standards to insure that the modernized switchgear meets the required ratings. For replacement circuit breakers, this is fairly simple. The breakers should be tested in accordance with ANSI/IEEE C37.09-1979 and ANSI/IEEE C37.20.2-1987, just like any other new circuit breaker that is used in metal-clad switchgear. The only caution is that certain tests, including continuous current, momentary current, and BIL, should be performed in a switchgear cell of the basic design in which the breaker will be used. All of these tests involve interaction between the cell and the circuit breaker. For instance, we have performed full wave impulse (BIL) tests where both the breaker alone and the cell alone passed the test, but the combination would not pass, requiring additional work to the breaker to achieve the desired result. A new ANSI standard, ANSI/IEEE C37.59-1991, IEEE Standard Requirements for Conversion of Power Switchgear Assemblies, covers conversion of both switchgear equipments and power circuit breakers. This standard specifies the design and testing requirements for conversion, including uprating, of existing equipment. Requirements for new documentation, including nameplates and instructions, are included. Any user considering converting low-voltage or medium-voltage switchgear equipment should review this standard and insist that vendors conform to it. Powell, through our Powell Apparatus Service Division, offers both conversions and replacement breakers meeting these standards.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
True bus differential relaying compares all currents entering and leaving a switchgear bus. Within the limits of the accuracy of the CT's and the relays, true bus differential relaying will detect all faults on the protected bus. Since all currents are taken into account, the relays can be very fast. However, bus differential relaying provides no backup to the feeder overcurrent relaying, so additional overcurrent relays are required on main and tie breakers to provide this backup function. Also, high speed bus differential relaying can be quite expensive, and many switchgear users do not feel that it is economically justified. Partial differential relaying sums the currents entering or leaving a switchgear bus through main and tie breakers. If a fault exists on the protected bus, the currents will add in the relays, but if fault current is flowing through the bus to a fault on another bus, the currents will subtract and the relays will not respond. If the fault is on a feeder, the partial differential relays will act as backup to the feeder overcurrent relays.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Trip currents of modern medium voltage circuit breakers may be much lower than those of older breakers. For instance, at 125 V dc, typical trip currents are now in the 3A range, with some breakers drawing only a little over 1 A. Trip times are faster than in the past. Figure 1 is the trace of the trip current of a typical PowlVac circuit breaker. You will see that the duration of the trip current is about 41 or 42 ms, or 2 cycles on a 60 Hz basis. The target relay takes about 1 cycle to pick up.
Trip current rises slowly, barely reaching its nominal rating before being cut off, as seen in Figure 1. Some faults may cause the closure of two or more relay contacts at the same time, paralleling the target coils of these relays and reducing the current through each one. One manufacturer recommends expecting two relays to close simultaneously on time delay relays and three on instantaneous relays with target coils. (Note: The instantaneous elements on most 50/51 relays have mechanical targets, and are not a problem.) Thus, the selected tap on the target coil should operate properly on no more than half of the rated trip current of the breaker.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Trip Current Target Tap Trip Current Target Tap 24 V dc 48 V dc 125 V dc 250 V dc 120 V ac 240 V ac Capacitor Trip
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
The insulation is extremely rugged and has excellent dielectric properties. Conductors of any size and shape can be coated with equal ease. Using extruded rigid tubing limits the choice of conductor cross-sections to those for which the extruded tubing is available, which may not be the optimum size from a current-carrying or electric field standpoint. Already-bent bars can be coated, eliminating the need for tape or boots at bends. Unlike some heat-shrink tubings, the insulation conforms to the bar at all angles and bends. Heatshrink tubing may pull away from the bar at the inside of a bend. Since the coating conforms to the surface of the bus, there is no possibility of setting up a partialdischarge cell between the surface of the bus and the insulation. This is especially important at voltages above 15 kV.
We believe that this new insulating process is another step in our process of continuous improvement of Powell switchgear.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Use a thermal-magnetic circuit breaker rather than an MCP. NEC 430-52, Exception No. 2C, allows an inverse time circuit breaker rated up to 400% of the motor full load current to be used for motors with less than 100A full load current. Small circuit breakers, up to 150A rating, have fixed instantaneous settings, with minimum pickup varying from 7.5 to 12 times rated current, so the instantaneous pickup can be from 30 to 48 time the motor full load current, rather than the 13 times required for an MCP. You have degraded the protection of the circuit, but you have met the Code. A fine print note in NEC 430-52 allows an instantaneous trip circuit breaker to include a damping means to accommodate a transient motor inrush current without nuisance tripping of the circuit breaker. If you can find one of these, you can use it, but so far as we know, no such device is commercially available.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Use a fused switch instead of a circuit breaker to supply your motor circuit, and find a fuse that meets the requirements of 430-52 and still allows you to start the motor. Ignore the NEC. Not a recommended move, but I understand that it is being done.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #42 - Momentary Rating and Construction of Bus in Metal-Enclosed Switchgear (Page 2)
The standards require test to demonstrate the momentary rating of the bus, and most bus structures within switchgear are somewhat complex and not subject to easy analysis, so we seldom use calculations for the design of bus structures. However, for relatively simple bus configurations, such as bus duct, it may be easy to modify a design based on previous test data. For instance, if phases are spread apart further than they were in the tested sample, the allowable increase in spacing between supports can be easily calculated.
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In the 1979 edition, device 7 was an anode circuit breaker, a device frequently used in mercury arc rectifier equipments but no longer seen in this day of solid state rectifiers. In the 1987 edition, device 7 was "Reserved for future application." In the 1991 edition, device 7 is used for a rate-of-rise current relay. For many years, the description of device 50, which is commonly thought of as an instantaneous overcurrent relay, included the rate-of-rise feature. This feature is no longer part of device 50's description. In 1979, device 11 was reserved for future application. Beginning with the 1987 edition, device 11 became a multifunction device. This is defined as a device with three or more important functions. Typical use would be for a multifunction motor protective relay. When device 11 is used, the functions included in it should be defined in the drawing legend.
11
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24
In 1979, device 24 was reserved for future application. Beginning with the 1987 edition, device 24 became a volts per hertz relay. These relays are typically used to protect large generators from overvoltage during subsynchronous operation, and are seldom seen in Powell switchgear. I mention it because there are still those among us who remember the use of 24 for a bus tie circuit breaker. In the standard, the proper number for a bus tie breaker has been 52BT since some time in the 1950's, but we still see the designation 24 from time to time. Up through 1979, device 47 was a phasesequence voltage relay. Starting with the 1987 edition, this definition was expanded to read phase-sequence or phase-balance voltage relay, and the description specifically lists negative phase sequence overvoltage as one of its applications. See device 7. Up through 1987, device 82 is described as a dc reclosing relay. In the 1991 edition the description is expanded to read dc loadmeasuring reclosing relay.
47
50 82
Some other changes were made, but these are the ones most likely to affect switchgear for utility and industrial distribution systems.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Be sure to locate the channels where the manufacturer shows them. Normally, each lineup has a channel near the front of the gear and another near the rear of the gear. These are usually located under the bolt-down holes in the equipment, so their location is important. Frequently, in deep switchgear, such as PowlVac metal-clad switchgear, a third channel is shown somewhere between the first two. Often, this channel does not match any bolt-down holes, so its location may not seem to be as important as the location of the other two channels. However, the manufacturer may have located this channel under some feature of the design which need good support, so its location may be as important as the locations of the other two channels. The concrete needs to be no higher than the floor steel. If the circuit breakers roll out on the floor, the floor on the drawout side of the switchgear needs to be flush with the top of the floor steel so the breakers will roll in and out smoothly. Once a level surface is established by the floor channels, be sure that the equipment sits flush on the surface of the channels. This may seem elementary, but I have seen installations where one side of a 36" unit was flush with the channel and the other side was " above the channel. All the effort and expense put into the level floor channels was negated by a poor installation of the equipment on the channels.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #45 - MVA Interrupting Rating of Circuit Breakers Used in Metal-Clad Switchgear
September 22, 1993 Modern medium voltage circuit breakers used in metal-clad switchgear have no MVA interrupting rating. Undoubtedly, this statement will come as a surprise to some readers of this PTB. Although it is quite common for all of us to talk about 500 MVA circuit breakers or 1000 MVA circuit breakers, this rating does not appear anywhere in the ANSI standards applying to these breakers, nor does it appear anywhere on the nameplate of the breakers. A little history is in order. The first ANSI standards covering circuit breakers, including those for use in metal-clad switchgear, were developed about 50 years ago. Under these standards, interrupting ratings were based on the total current interrupted, including the dc component. These "total current" standards included ANSI C37.4 through C37.9 and C37.12. In the rating structure used in these standards, MVA was included, and those of us who date back to that era got used to referring to breakers by their MVA rating. In 1964, a new series of ANSI standards were first published. These standards used symmetrical, rather than total, current as the basis for interrupting rating. These new standards no longer referred to MVA in their rating structure. The interrupting rating in these standards is expressed kiloamperes. After a couple of decades of development, these standards now include six documents:
ANSI/IEEE C37.04-1979 Rating Structure ANSI C37.06-1987 Preferred Ratings ANSI/IEEE C37.09-1979 Test Procedure ANSI/IEEE C37.010-1979 Application Guide - General ANSI/IEEE C37.011-1979 Application Guide - Transient Recovery Voltage ANSI/IEEE C37.012-1979 Application Guide - Capacitance Current Switching
However, so that manufacturers would not have to retest all their breakers, certain equivalences were established, and for a few years the preferred rating tables carried "nominal" MVA ratings for "identification". This last appeared in the 1971 edition of ANSI C37.06, but was missing from the 1979 edition. Unfortunately, we have continued to use these identifications informally, and sometimes we get wrapped around the axle about just what they mean, particularly when applied to circuit breakers used at a voltage considerably less than their rated maximum voltage, such as 4760 V breakers used at 2400 V. The chart below compares the nominal MVA ratings to the actual MVA ratings calculated using the rated interrupting currents established in the current standards.
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PTB #45 - MVA Interrupting Rating of Circuit Breakers Used in Metal-Clad Switchgear (Page 2)
Rated Maximum Voltage kV, rms Rated Short Nominal Circuit Current MVA kA, rms System Operating Voltage kV, rms 4.76 4.76 29 250 4.16 2.4 4.76 4.76 41 350 4.16 2.4 8.25 8.25 33 500 7.2 6.6 15.0 15.0 18 500 13.8 11.5 15.0 15.0 28 750 13.8 11.5 15.0 15.0 37 1000 13.8 11.5 Interrupting Current @ Operating Voltage kA 29 33 36 41 47 49 33 38 41 18 20 23 28 30 36 37 40 48 Actual MVA @ Operating Voltage(1) MVA 239 238 150 338 338 204 472 472 469 468 478 458 727 717 717 961 956 956
(1) Slight variations in MVA may be due to rounding of interrupting current values.
If you are interested in the development of these standards, a good history of these standards appears in the forewords of the various documents.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
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PTB #48 - Temperature Rating of Conductors Connected to Molded Case Circuit Breakers
December 2, 1993 Books can be written, and probably have been written, on the subject of proper sizing of conductors to meet all the various requirements of the National Electrical Code. This PTB will address one small facet of that overall problem: the temperature rating of conductors connected to the terminals of molded case circuit breakers. The NEC, as a general principle, requires most material used in electrical systems to be listed by a thirdpart certifier, such as UL, and to be installed in accordance with the conditions attached to that listing. In UL's Electrical Construction Materials Directory ("Green Book") we find the following conditions attached to the listing of circuit breakers: 2. Circuit breakers with a current rating of 125 amperes or less are marked as being suitable for 60C, 75C only, or 60/75C rated conductors. It is acceptable to use conductors with a higher insulation rating, if the ampacity is based on the conductor temperature rating marked on the breaker. 3. Circuit breakers rated 125 amperes or less and marked suitable for use with 75C rated conductors are intended for field use with 75C rated conductors at full 75C ampacity only when the circuit breaker is installed in a circuit breaker enclosure or individually mounted in an industrial control panel with no other component next to it, unless the end use equipment (panelboard, switchboard, service equipment, power outlet, etc.) is also marked suitable for use with conductors rated 75C. 4. A circuit breaker with a current rating of more than 125 amperes is suitable for use with conductors rated 75C. In view of these rules, you might ask why anyone would want to use conductors with a higher temperature rating than the breaker rating, when these higher rated conductors are presumably more expensive than lower rated conductors. Outside of the possibility of convenience (the 90C wire was laying around doing nothing), you may find that other derating factors applying elsewhere in the conductor run will reduce the allowable ampacity so that the 60C or 75C rating at the terminal is met without difficulty. As an example, a #4/0 AWG copper conductor with 90C insulation has an ampacity of 260 A per Table 310-16 of the NEC. However, if you connect this conductor to a molded case circuit breaker terminal, its ampacity is limited to the ampacity of the same size conductor with 75C insulation, or 230 A. The MCCB terminal temperature rating is the limiting factor in this conductor application. Now, let's look at a circuit with two of these conductors per phase in parallel, with all size conductors run in the same conduit. Note 8 to Table 310-16 requires an adjustment of the ampacity to 80% of the ampacity listed in the table when there are 4 to 6 current carrying conductors in one raceway.
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PTB #48 - Temperature Rating of Conductors Connected to Molded Case Circuit Breakers (Page 2)
The two 90C cables now have an ampacity of 2 x 260 x 0.8 = 416 A. At the MCCB terminals, the allowable current is twice the 75C rating of the cable, or 460 A. Now the MCCB terminal temperature is no longer the limiting factor, and the use of the 90C insulation is advantageous. If 75C insulation were used, the wire size would have to be 250 kcmil to carry 408 A, and the conduit size would have to be increased from 2" to 3".
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Medium-Voltage Switch-and-Fuse Equipment ANSI/IEEE C37.20.31987 IEEE Standard for Metal-Enclosed Interrupter Switchgear
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Low-Voltage Power Circuit Breakers ANSI/IEEE C37.13-1990 ANSI C37.161988 ANSI C37.171979 ANSI C37.501979 IEEE Standard for Low-Voltage AC Power Circuit Breakers Used in Enclosures Low-Voltage Power Circuit Breakers and AC Power Circuit Protectors - Preferred Ratings, Related Requirements, and Application Recommendations American National Standard for Trip Devices for AC and GeneralPurpose DC Low-Voltage Power Circuit Breakers Low-Voltage AC Power Circuit Breakers Used in Enclosures - Test Procedures Low-Voltage Power Circuit Breaker Switchgear ANSI/IEEE C37.20.1-1987 ANSI C37.51-1989 UL 1558-1984 IEEE Standard for Metal-Enclosed Low-Voltage Power Circuit Breaker Switchgear Metal-Enclosed Low-Voltage Power Circuit-Breaker Switchgear Assemblies - Conformance Test Procedures Metal-Enclosed Low Voltage Power Circuit-Breaker Switchgear Bus Duct ANSI/IEEE C37.23- IEEE Standard for Metal-Enclosed Bus and Calculating 1987 Losses in Isolated-Phase Bus Medium-Voltage Motor Control Industrial Control Devices, Controllers and Assemblies, Part ICS 2-324, NEMA ICS AC General-Purpose Medium Voltage Contactors and Class E 2-1988 Controllers, 50 and 60 Hertz Low-Voltage Motor Control Centers NEMA ICS 2- Industrial Control Devices, Controllers and Assemblies, Part ICS 21988 322, AC Motor Control Centers UL 845-1988 Motor Control Centers
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Figure 1 - Panelboard/Transformer Arrangements (DS* is panelboard's Dedicated Space) Figure 1 shows three examples of a transformer located near a panelboard. View 1, with the transformer mounted below the panelboard, is not permitted, as the transformer intrudes into the work space required by 110-16 of the NEC. Views 2 and 3 are both installations permitted by the NEC. In View 2, the transformer is located above the work space, which only extends up to 6 feet from the floor. In View 3, the panelboard has been mounted away from the wall so that the transformer does not extend into the work space. Note that the "dedicated space" above and below the panelboard is the width and depth of the panelboard and extends from the floor to a point 25 feet above the floor, or to the structural ceiling, whichever is lower. A typical hung ceiling of drop-in panels is not considered to be a structural ceiling for this purpose.
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Properly secured doors, covers, etc., do not open. Parts which may cause a hazard do not fly off. Arcing does not cause a hole in the surfaces covered by the type under test. Black cotton cloth indicators are placed around the equipment under test, up to a height of 2 meters, wherever flame or hot gases might escape. These indicators must not ignite. The grounding connection must remain effective.
The arc-resistant rating is at a particular voltage and short-circuit current level. These ratings should match the ratings of the switchgear and circuit breakers, and the requirements of the system. The area of exposure should be considered. See descriptions in Table 1.
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Restricted to authorized personnel only. Test Front. Arc-resistant construction at the Test sides which are readily front only. accessible. Unrestricted accessibility, including general public. Test all accessible sides. -------------------------Arc-resistant construction at the front, back and sides. Arc-resistant construction at the front, back and sides, and between compartments within the same cell or between cells. 160 ms 1 second 10 cm from unit (all types)
Duration of Tests: Pressure 0.1 second (100 ms) Withstand Duration of Tests: 1 second Burnthrough Type A: 30 com from unit Indicator Location Type B: 10 cm from unit
Type A: 150 grams per Indicator Material square meter Weight Type B: 40 grams per square meter
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Baldwin Bridger, P.E. Technical Director Note: Thanks to Crouse-Hinds for the information calling industry attention to this situation.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Figure 1 -Proper Bolt Assembly Proper assembly of the hardware is vital to a low-resistance joint. The hardware should be assembled as shown in Figure 1, with the flat washers next to the bus bars on both sides of the joint and the lock washer under the nut. The bolt should be long enough that a minimum of two full threads extend out of the nut when the bolt is tightened. For the 1/2-13 size, use a bolt one inch longer than the combined thickness of the bus bars being bolted together. Other bolt sizes may take longer or shorter bolts to compensate for differences in the thickness of the nuts and washers used. The bolt should not be longer than necessary, either, as extra bolt length usually decreases the clearance from the bolt end to the nearest other phase or to ground. Proper bolt torque is vital to a good joint. Grade 5 hardware is used to allow high installation torque. Torques to be used for various size bolts are shown in the table. This information is given on a label installed in Powell switchgear near bolted field connections. Do not overtorque the bolts. Excessive torque can stretch the bolt past its elastic limit and cause failure. I've seen bolts which were barely half their original diameter in the middle removed from bus joints. Bolt Size 5/8 - 11 1/2 - 13 3/8 - 16 1/4 - 20 Torque, pounds-feet 55-70 35-50 20-30 5-7 How about other types of hardware? Some users specify aluminum hardware for aluminum bus, bronze (usually Everdur) hardware for copper bus, or stainless steel for either bus material. There are two reasons usually given for this requirement. The first is the inhibition of corrosion cells where dissimilar metals made contact. This may be a valid reason for joints that are exposed to the weather, such as
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Install it properly. Make sure the foundation is level, and that the equipment has been set level on the foundation and properly secured. Check alignment of all disconnects and interlocks on drawout circuit breakers to make sure that they fit properly into the cell. Be sure all bus splices are assembled properly, with the right size splice plates and the right size and number of bolts, properly torqued, and insulated if insulation is required. Connect cables carefully. Check out all control wire connections. Don't overheat it. Heat is one of the two great enemies of electrical insulation. Don't overload the equipment in service. Make sure that ventilation is adequate, and that any filters or other ventilating openings in the switchgear are clean and that air flow is not restricted. If artificial cooling is required to keep the ambient temperature within limits (usually a maximum of 40C), be sure it operates properly. Keep it dry. Moisture is the other great enemy of insulation. Make sure there are no leaks that will allow rain or other moisture to dampen the switchgear. For outdoor installations and indoor installations in damp climates, space heaters are recommended to deter condensation. Take care of it. The equipment should be inspected, cleaned, and lubricated on a regular schedule, and after any traumatic event, such as interrupting a major fault.
Treat your switchgear well, and it will last you a long time. Abuse it or neglect it, and it will die young.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #56 - Control Wire and Wire Markers in Switchgear and Motor Control
December 19, 1994 ANSI standards for metal-enclosed switchgear require the use of either Type TBS or Type SIS wire for control wire in this type of equipment. Further, the wire is required to have a minimum size of #14 AWG, and to be flexible (41 strand or more) where it is connected across a hinge. Powell's standard is to use Type SIS flexible wire for all switchgear wiring. The wire will be #14 AWG unless a larger wire is required by the circuit or is specified by the purchaser. Switchgear control wire has traditionally been colored gray, although this is not called for by any industry standard. Powell's standard is to use gray wire except for ground wires, which are green. Other colors may be used if specified by the purchaser, but elaborate color coding can be rather costly, as wire manufacturers require sizeable runs of special items such as unusual colors. Special wire types can also be used when required, but are also subject to special charges for nonstandard wire mill runs. Wire markers, or wire tags, are used in most equipments we produce, but are not required by standards. Therefore, they must be specified by the purchaser when desired. When wire markers are used, Powell's standard is a white tube marked with black characters. The wire marker is marked with the wire number shown on the schematic and wiring diagrams. Special wire markers can be furnished on request. Some special features requested from time to time include special sleeve materials, special colors, heat shrink installation, and special wire designations or numbering. All of these can be furnished, but at a cost.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Since interrupting ratings vary with voltage, it is absolutely imperative that purchaser and supplier communicate clearly about the voltage at which a specified interrupting rating applies.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Overcurrent: A current exceeding the rated current. Short circuit: The accidental or intentional connection, by a relatively low resistance or impedance, of two or more points in a circuit which are normal at different voltages. Short circuit current: An overcurrent resulting from a short circuit due to a fault or an incorrect connection in an electric circuit. Overload: Operating conditions in an electrically undamaged circuit which cause an overcurrent. Overload current: An overcurrent occurring in an electrically undamaged circuit. Fault current: A current resulting from an insulation failure or the bridging of insulation.
An overload current is always an overcurrent, but not all overcurrents are overload currents. An overload is not a fault. A short circuit current is both a fault current and an overcurrent. However, not all fault currents are short circuit currents. Also, not all overcurrents are short circuit currents. A fault current is not necessarily an overcurrent. Under some fault conditions, the fault current may be much less than the rated current. A typical example is a ground fault current on a highresistance grounded system. This current may be only an amp or two, compared to a rated current of up to several thousand amps.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Motor HP rms Amperes Full Voltage Peak Starting, CircuitNEMA Switching Rating NonClosing Size of Contactor plugging Amps and Non- (Inrush) Continuous Tungsten Resistance Current jogging Lamps Loads & duty (300V Discharge max.) Lamps 1 2 3 4 5 10 25 50 100 200 288 483 947 1581 3163 27 45 90 135 270 15 30 60 120 240 27 45 90 135 270
Inrush Inrush >20x <= 20x <=40X Full Full Load Load 8.5 14 28 47 94 4.3 7.2 14 23 47
These values are taken from tables in NEMA Standard ICS2-1988. Other tables in this standard give ratings for other sizes of contactors, other voltages and frequencies, single phase, other motor duties and starting methods, etc. In most cases, the rating limit is established by the contactor's ability to close a certain peak current. Loads with high inrush characteristics require oversized contactors to handle the inrush current without damage. For instance, consider a 15 kVA, 480 V, 3 phase transformer, which has a full load current of 18 A. This is well within the continuous current rating of a size 1 contactor, but switching the primary of this transformer required a size 3 contactor if the inrush current is <= 20 x full load, and a size 4 contactor if the inrush current is between 20 x and 40 x full load.
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A typical auxiliary CT circuit is shown in the figure above. The auxiliary CT secondary burden,
, is
reflected into the main CT secondary circuit by the square of the current ratios, per the following formula:
where
From this equation you can see that using an auxiliary CT to step the main CT secondary current up increases the burden on the main CT by the square of the step-up ratio, whereas using the auxiliary CT to step the main CT secondary current down decreases the burden by the square of the step-down ratio. From this, it would seem that, if you are matching two main CT ratios by using an auxiliary CT, it would always be preferable to step down the higher main CT secondary current, which is the current from the main CT with the lower ratio.
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The higher ratio CTs may have a higher burden capability than the lower ratio CTs, and thus be capable of handling a larger burden with the same accuracy. The lower current resulting from the step-down transformation may require a lower relay setting to achieve the desired sensitivity, and this lower setting may greatly increase the relay burden.
As always, the best solution is to do a complete burden calculation to see which way, step-up or stepdown, gives the best results. "Best results" means that all of the devices, including the main CTs, the auxiliary CTs, and the relays or meters connected in the circuit, are operating within their capabilities, and that the overall circuit will give the performance desired under all operating conditions.
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PTB #67 - Using Latched Contactors in Medium Voltage Motor Control Centers
November 13, 1995 The motor starting contactors used in medium voltage motor control are usually held closed by an operating coil, which is energized to close the contactor. When the coil is deenergized, the contactor opens. Since the contactor's coils is usually energized from a control power transformer connected to the primary circuit of the starter, this design provides automatic undervoltage protection for the motor. For loads other than motors, however, it is sometimes desirable to maintain the circuit during an undervoltage condition. This is commonly done for transformer feeders originating in the medium voltage MCC. To handle this type of circuit, latched contactors are available. When closed by its operating coil, a latched contactor will remain closed even if the closing coil is deenergized. The latched contactor is opened by energizing a trip coil, something like a circuit breaker is opened. Latched contactors may be equipped with manual closing and/or tripping operators if desired. These may be in addition to or in place of the operating coils, leading to quite a few possible combinations of operators. Several cautions are in order when latched contactors are used:
For non-motor loads, such as transformers or capacitors, the motor starting current-limiting fuses should be replaced with general purpose current-limiting fuses. These fuses may stand alone as the overcurrent protection, or they may be supplemented with overcurrent relays for better overload protection. Since automatic undervoltage protection disappears when a latched contactor is used, separate undervoltage relays must be provided if undervoltage protection is needed. There is a major difference between the control circuit for a latched contactor and the control circuit for a circuit breaker. The latched contactor has no anti-pump feature. If a latched contactor is presented with simultaneous, maintained close and trip signals, it will cycle closed and open until one of the signals is removed or until the contactor destroys itself. A circuit breaker, on the other hand, will close once and open once, then remain open until the closing signal is removed and reestablished. Control and interlocking circuits used with latched contactors should be investigated very carefully to make sure that there is not a circuit that could result in damage to the contactors.
Properly applied latched contactors are useful devices, but they don't work just like circuit breakers. Be sure you understand the differences and take them into account when using latched contactors.
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PTB #68 - Instantaneous Ground Fault Relays (50GS) and Zero-Sequence CTs
November 28, 1995 In PTB #62, I discussed the problem of low-ratio CTs used on systems with high fault current, and I mentioned the IEEE working group report on this subject. Because of the emphasis in this report on making sure that CTs do not saturate, a number of people have become concerned about the operation of instantaneous ground fault relays connected to zero-sequence, or core balance, CTs. Because of this concern, Powell recently ran a series of tests to check the operation of typical CT-relay combinations. Two different relays were tested with each of two CTs. The relays were the GE HFC and the ABB IT. Electro-mechanical relays were chosen for the test because their higher burden places a greater load on the CTs. The CTs used were both made by ITI. The first Model 141-500, 50/5, C10 accuracy. The second was Model 143-500, 50/5, C20 accuracy. The test results are given in the table below. Relay Under Test HFC IT Relay Pickup Setting 0.5 A 0.15 A Current Transformer 141-500 143-500 141-500 143-500 Primary Pickup Current 15.8 A 13.6 A 6.5 A 5.4 A Time to trip at indicated current (ms) Pickup 600 A 1200 A 1800 A 39.3 36.35 95.2 132.4 34.85 33.75 61.3 56.3 24.05 27.05 67.7 60.0 36.9 31.95 72.6 68.9
Both of these relays operated correctly and reliably with both CTs. However, we also tested a third relay, the ABB ITH, a high dropout version of the IT. We found that this relay was not reliable in this service. It picked up at quite low values, and operated well with primary currents up to about 150 A. At the higher currents, 600 A and up, it chattered quite badly and did not close its contacts for long enough to operate a circuit breaker. Asking around, I found that this relay had been recommended for 50 GS service some years ago, but its manufacturer (Westinghouse at that time) changed the recommendation when the chattering problem was discovered. Based on this information and the tests, Powell strongly recommends that the ITH relay not be used as a 50GS relay. Summarizing, both the HFC and the IT work quite well at primary ground fault currents up to 1800 A, even though the CTs are badly saturated at that current level. This circuit, with these CTs and relays, should not be used on solidly grounded systems with high ground fault current. For these systems, residually-connected relays should be used, or the zero-sequence CTs should have higher ratios.
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Since the starting torque developed in an induction motor by a given starting current is proportional to the rotor resistance, adding resistance during the starting cycle can increase the starting torque, or lower the starting current for the same torque. By decreasing the rotor resistance as the motor accelerates, the torque can be controlled to provide a smooth acceleration of the load, sometimes called a "soft start". This can be very helpful for loads such as cranes, hoists, and loaded conveyors. Since the slip of an induction motor increases as the rotor resistance increases, some speed control is possible using a wound rotor motor and varying the rotor resistance while running.
Controllers for wound rotor motors include for the stator the same protection and switching functions that are used for squirrel cage motors. For the rotor, a multi-step resistor and switching means for that resistor are required. For a soft start application, the resistor is switched out of the circuit step by step as the motor accelerates. Once it reaches full speed, the resistor is completely shorted out, and the motor runs like a squirrel cage motor. The number of steps varies, depending on the motor size and the starting characteristics desired, but generally falls in the range of 3 to 7 steps. The switching may be done by a manual drum switch or by a series of contactors activated by timers. For speed control, some resistance remains in the rotor circuit for all speeds except maximum speed. The running resistor may be further steps of fixed resistance, like the starting resistors, or a continuously variable resistance, like a liquid rheostat.
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Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
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Autotransformer: An autotransformer is connected between the power source and the motor during the starting period. Motor starting autotransformers usually have taps that apply 80%, 65%, or 50% of the line voltage to the motor to start. Line current is reduced by the square of the tap; that is, using the 80% tap on the autotransformer requires only 64% of the across the line starting current. Starting torque is also 64% on the 80% tap. Unless otherwise requested, the autotransformer will be the medium duty type, allowing 3 starts, followed by an hour's rest before repeating the three starts. Modern starters use the closed transition switching sequence, in which the autotransformer winding is converted briefly to a series reactor near the end of the starting sequence, then shorted out. This sequence requires three switching devices (circuit breakers or contactors). Reactor: A reactor is connected in series with the motor. These reactors usually have taps that apply 80%, 65%, or 50% of the line voltage to the motor to start. Line current is reduced to the tap value; that is, using the 80% tap on the reactor requires 80% of the across the line starting current. Starting torque is reduced by the square of the tap, and is 64$ on the 80% tap. The reactor may be placed on the line side of the motor or in the neutral. Reactor start requires only two switching devices. Capacitor: A bank of capacitors is connected in parallel with the motor during starting, canceling out the large reactive current drawn by the motor on starting. The motor thinks it is seeing a full voltage start, while the power system thinks it is seeing a running motor. The capacitors are removed from the circuit as the motor reaches running speed. Two switching devices are required. Wound Rotor: For induction motors only. See PTB #69 for further information. Solid-state Drives: A wide variety of starting and speed control performance can be obtained through the use of modern solid-state drives.
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Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
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PTB #74 - Enclosures for Metal-Enclosed Switchgear and Motor Control (Page 2)
In addition to the standard indoor and outdoor enclosures, Powell offers arc resistant indoor enclosures for PowlVac metal-clad switchgear and weather-proof Power Control Room (PCR) enclosures for all types of equipment.
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Figure 1. Bolted Bus Connection In order to create the pressure necessary to deform the microprojections on the bus bars, the bolt torque must be rather high. Proper torques are given in PTB #53. To achieve high torques and large contact areas, it is preferable to use a few large bolts rather than many small ones. For most main buses in switchgear and motor control, we prefer to us 1/2" bolts. It is our experience, based on numerous temperature rise tests, that 1/2" bolts make a very satisfactory joint for bus rated up to 4000 A. Since most joints are made by bolting a bus bar to a splice plate or a riser bus, and then bolting the next section of bus to this same splice plate or riser bus, the complete bus-to-bus splice will normally have four bolts. Copper bus bars are normally plated with silver, tin, or nickel at all joints in order to prevent the formation of copper oxide in the joint. Copper oxide is a semiconductor, and its presence leads to increased resistance and high temperature in the joint.
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Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
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Figure 1
The coupling capacitance is primarily made up of the capacitance of the system dielectric between the phase conductor and ground. The value of the voltage transformers magnetizing reactance varies as a function of the amount of flux going through the iron. This results in an LC circuit and requires only a simple voltage transient to excite the resonant frequency. Once the ringing begins the voltage across the individual components of magnetizing reactance and coupling capacitance can reach high levels and the ringing can go undamped if the voltage transformer is lightly loaded. The loading of the VT has a very important part to play in limiting the magnitude of current in the oscilation circuit since the resistance of the load will act as a current divider and send a portion of the current to ground. This graph from the IEEE Red Book shows the impact of load on the magnitude of the current in the ringing circuit (see Figure 2).
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Figure 2 During the oscillation, the current can drive the magnetizing force to saturate the VT. When the VT is saturated, the reactance to ground will diminish and the current to ground through the primary of the VT will go high. At the end of the sinusoid the VT will drop out of saturation, but with a low loss system the stored charge remains relatively high across the system coupling capacitance. As the polarity of the sinusoid changes the process repeats itself. The current surges, through the VT primary during the periods of saturation, can be much greater than full load rating but not approaching fault current levels, making it very difficult for the fuses on the primary of the VT to interrupt. Thus current surging may result in a blown VT fuse but often results in a shorted VT. To keep the resonance magnitude down, the secondary side of the VT circuit can be artificially loaded. There are two common methods of loading used to minimize the effects of ferroresonance. One is to install the VTs with their secondary windings connected in a broken delta and with a resistor completing the broken delta circuit. The watts of the resistor should equal 50% of the VA of a single VT.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
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PTB #81 - Direct Control of Motor Contactors via PLC's and Distributive Control Systems
October 28, 1997 As we automate the process systems more and more we are looking for direct control of the motor starters with PLCs and Distributive Control Systems (DCS). A commonly asked question is whether the interposing relay situated between the two systems is really needed or not. I have gone through and looked at the more common systems and put together this technical brief to highlight some of the concerns involving the interposing relay. Digital Outputs Modules The electro-mechanical and the solid state (triac) output modules are commonly available for either PLCs or DCSs. Both of these digital output modules are listed in the vendor literature as having a 120 Vac rating of such and such current. Two amps seems to be the most popular for the electro-mechanical value and amp for the solid state output. The thing I had difficulty finding was the expected power factor of the load. A power factor of 0.5 seemed to be the most common although I did find one manufacturer who based his rating on a power factor of 1.0. The expected power factor obviously changes from one manufacturer to the next for both PLC and DCS. The normal contactor coil has a power factor of 0.1, at this level the output rating should be derated by 50%. This is without the consideration of the wire impedance connecting the two systems. In addition to confirming the make and break capability, the application engineer should realize that the turn off of the standard starter results in an inductive kick that sends a significant voltage spike though the system. The output relay ends up with contact pitting and the contactor coil receives a steep fronted voltage spike which shortens the life of the insulation. The spike can be limited by installing a snubber circuit across the output contacts. For solid state outputs the snubber is a 0.1 microfrad capacitor and a 100 ohm resister series together. The cap should have about a 400 Vdc rating for a 120 volt control system. For the electromechanical output internal protection is usually provided for loads up to 1 amp after that you need to provide it separately. In most cases the manufacturer has a kit available as an option. The triac outputs add an additional level of possible problem due to the triacs leakage current during turn off and forward bias requirements. The forward bias means that the triac must maintain some minimum current flow to keep the device in the on state. The leakage current is a small quantity of current that trickles through the device even after turn off. This few milli amps will be in parallel with the distributed wire capacitance of the wire between the control system and the MCC to make the turn off a significant problem. This appears to make the triac an undesirable combination with the standard contactor. Smart Motor Control When using many of the new smart motor control centers the control circuit is no longer interrupting the coil current directly, if it is wired properly! So the concerns relative to interrupting a large inductive load
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #81 - Direct Control of Motor Contactors via PLC's and Distributive Control Systems (Page 2)
are eliminated. The electro-mechanical relay output is less likely to have problems getting the two systems to match-up. The reliability of the triac output module will allow it to do more operations successfully than the electromechanical, but since the coil is not operated directly, you may have to add a swamping resistor in parallel with the MCC input to make sure the circuit draws sufficient current to keep the triac forward biased. In addition, the high relay input impedance of the smart MCC and the distributed wire capacitance may begin to play a part in the functionality of the stop circuit. The longer the length of the control circuit the higher the leakage current and the more likely resistance may need to be added to assure that the circuit will recognize a stop command. A separate concern about doing away with the interposing relay you may want to discuss with the end user is the safety aspects of bringing 120 volt control power from the MCC starter drawers into the PLC or DCS. The way most plant treat the insides of their PLC and DCS is as though there is no voltage level greater that 50 volts to ground. At 50 volts and below OSHA Standard 1910 and NFPA 70Es Electrical Safe Work Practices & Working Space Requirements need not apply. But by bringing the 110 Vac into the control system the rules identified in OSHA 1910 are applicable. In some cases this can have a tremendous impact on the cost of doing work. Based on the legwork I have done the interposing relay still makes good sense until the confidence in the twisted pair communication allows us direct communication between the smart MCC and the PLC or DCS, with a stop station in the field next to the load. If we can help with this or any other topic please do not hesitate to call.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
first skirt ring, and should form a continuous path from the conductor to the first ring of the arrester. To keep from "shorting out" the creepage distance, the boot may not make contact with more than the first skirt. These physical considerations play an important part in assuring that the arresters are able to function properly.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #85 - The Application of 600 Volt Class Current Transformers in Medium Voltage Switchgear
August 10, 1999 ANSI Medium Voltage Switchgear commonly uses 600-Volt Class window type current transformers in medium voltage circuits. For many years manufacturers have installed 600-volt class current transformers in medium voltage switchgear. The preferred location for the current transformers is the circuit breaker spouts. To certify the dielectric capability of the equipment the switchgear type tests are performed with the maximum number of current transformers mounted on the circuit breakers cells feed through bushings. A typical configuration of the switchgear with the smallest air gaps is then subjected to the series of Basic Impulse Levels Tests required by ANSI. The success of the BIL testing in the area around the circuit breaker feed through bushings relies on the following combination of insulation:
The solid dielectric of the circuit breakers feed through bushings The air gap between the conductor and spout The air gap between the spout and the case of the current transformer The 600 volt class insulation of the current transformer
This series combination of various insulating mediums provides an insulating system that goes through the dielectric testing along with the entire switchgear system. During the power frequency test (high potential) and the impulse test required in ANSI C37.20.2, it is proven that the system dielectric strength exceeds the nominal BIL rating for the voltage class. Bus Mounted Current Transformers Occasionally the clients current transformer requirements exceed the physical mounting capacity of the circuit breaker spouts. In these cases it becomes necessary to add additional window type current transformers. These additional current transformers are mounted in the cable compartment around the run-back bus. Since these are non-standard components, they do not get included in the switchgear BIL testing. To maintain the BIL of the equipment an industry rule of thumb for both factory and field installations requiring bus mounted window type current transformers is to allow a 1 inch air gap between the insulated bus and the current transformer housing. Powell went through the process of testing the 1-inch air gap rule of thumb with various bus insulation systems that we use in the manufacture of the switchgear. We have established an internal matrix that applies to the various insulating systems, the associated standard current transformer and a special "increased dielectric" current transformer. The table below indicates what configurations were acceptable when tested for 95kV BIL.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #85 - The Application of 600 Volt Class Current Transformers in Medium Voltage Switchgear (Page 2)
Table of BIL Tests on 6.5 Inch Bus Mounted Window Type Current Transformer Number of Bus Insulation Standard Current Increased Dielectric Bars per Phase Material Transformer Current Transformer and Size (inches) Hipoxy-2000 (1) 1/2 x 3 (1) 1/4 x 4 (1) 3/4 x 4 (2) 1/2 x 3 (2) 1/2 x 4 (2) 3/4 x 4 GE-Noryl (1) 1/4 x 4 (2) 3/4 x 4 Scotch BBI-4A Passed Failed @ 82kV Failed @ 78kV Failed @ 94kV Failed @ 74kV Failed @ 72kV No Test No Test Passed Passed Passed Passed Passed Passed Passed Failed @ 94kV
(3) 3/4 x 4 No Test Passed (sandwiched) Note: Standard current transformers would be suitable for all switchgear designs requiring 60kV.
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PTB #86 - Altitude De-rating of Fuses, Surge Arresters and Potential Transformers
August 11, 1999 As a dielectric dry air works satisfactorily. However as the altitude at which we apply our electrical equipment increases, the effectiveness of the dielectric property decreases. An increased altitude also decreases the continuous current carrying capability of electrical equipment due to the reduced thermal conductivity of the lower density air. In the past we have discussed the altitude de-rating factors for switchgear (see Powell Technical Brief #25). The IEEE Standard for Metal Clad Switchgear (C37.20.2) explains that switchgear assemblies, which depend on air as an insulating medium, will have a lower dielectric withstand capability when operating in altitudes above 3300 feet. This Powell Technical Brief will explain how altitude de-rating effects the installation of medium voltage fuses, surge arresters, and voltage transformers. Fuse De-rating The IEEE Standard for Conditions and Definitions for High Voltage Fuses, Distribution Enclosed Single Pole Switches, Fuse Disconnecting Switches, and Accessories (C37.40 section 2.3) offers de-rating factors for high voltage fuses. The de-rating is a function of the ability of the fuse to clear a fault and achieve a dielectric across the fuse element gap faster than the system voltage across the fuse can be established. This de-rating would be applicable for non-sealed fuses like expulsion fuses and current limiting fuses, where the outside air is the insulating means used to isolate the line and faulted load. Since the dielectric strength of air is reduced as the altitude is increased, the fuse has to be de-rated in accordance with the published chart. (see Table) The thinner air also results in lower thermal conductivity, which requires a de-rating of the continuous current. To compensate for the reduced thermal conductivity the standard allows for a reduction in either the maximum ambient temperature or the continuous current rating, but not both. Rated Dielectric Ambient Altitude in Feet Continuous Strength Temperature Current 0 to 3,330 3,301 to 5,000 5,001 to 10,000 1.00 0.95 0.80 1.00 0.99 0.96 1.00 0.98 0.92
10,001 to 16,000 0.65 0.92 0.848 When the dielectric strength of the fuse is de-rated, the application engineer is often required to choose a fuse of higher voltage class. This approach may result in higher current chopping and associated voltage transients. An alternate solution is the hermetically sealed fuse, which does not require de-rating of the internal operating mechanism. Note that hermetically sealed fuses are both expensive and may have a long delivery time. Care must also be taken to confirm that the outer creepage distance is acceptable within the de-rated values.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #86 - Altitude De-rating of Fuses, Surge Arresters and Potential Transformers (Page 2)
Surge Arrester De-rating There are two types of surge arresters in common use today -- the expulsion-type arrester and the metal oxide arrester. The expulsion-type arresters have an internal system that depends on ambient air as a dielectric and, as such, must be de-rated as a function of altitude just as fuses. The metal oxide surge arresters are sealed and outside air does not play a part in the isolating process, so the surge arrester does not require de-rating for the internals to operate properly. However, air also plays a part in the external surface creepage distance of the housing. The outer surface has a certain creepage distance that prevents the surge arrester housing from tracking across the surface of the arrester. Powell Technical Brief # 59 describes the acceptable surface creepage distance for various impulse levels given insulated conductors. The insulated conductor distances can only be used if an insulating boot properly covers the ferrule at the top of the arrester. Care must be exercised when applying the altitude de-rating factor. To maintain the desired discharge level of the arrester and the required creep distance, it may be necessary to have special arresters manufactured with a standard duty cycle arrester in a housing with higher creep levels. A special caution when applying de-rated higher voltage current limiting fuses. Each fuse has a characteristic current chop that results in a maximum allowable voltage transient of three times the rated fuse voltage. The transients that result from applying a higher voltage class fuse due to altitude de-rating can often result in the surge arrester conducting during a fuse interruption. This should be avoided for line side station class and intermediate class arresters as the conducting impedance of this arrester is low enough that conducting during a fault will cause serious damage. Distribution class arresters have a high enough conducting impedance that this is not a problem.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #86 - Altitude De-rating of Fuses, Surge Arresters and Potential Transformers (Page 3)
Voltage Transformer De-rating When voltage transformers are applied at higher altitudes, ANSI C57.13, section 4.3, identifies the derating factors. This de-rating requires use of a higher voltage class transformer with the appropriate primary voltage and the ratio to maintain the desired secondary voltage. For example: Given a line-up of switchgear operating at 4.16kV at an altitude of 10,000 feet, the appropriate choice is a voltage transformer with a primary voltage of 4200 Volts and a secondary of 120 Volts. The transformer would have an insulation class of 8.7kV with a BIL at sea level of 75kV. When the 80% de-rating factor is applied due to the altitude, this VT has a BIL of 60kV. This Powell Technical Brief should clarify some of the concerns expressed by customers on recently shipped substations installed at higher altitudes. If I can be of further assistance please do not hesitate to call.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Figure 1 To demonstrate what happens with a second ground on the current transformer circuit, Figure 1 shows a typical differential relay with two current transformers. The recommended method of grounding is to install a single ground point at the first point of application (switchboard or relay panel) of the current transformer secondary circuit.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Figure 2 A substation circuit breaker should have the wye or delta connections made-up at the CT terminal blocks in the equipment. If the protective relay is mounted in the breaker the wye connection is grounded at the circuit breaker. If the protective relays are mounted in a separate building, then the wye connection is in the breaker but is grounded at the relay house. The same applies for current transformers in the transformer tank. The CTs are grounded at the place where the metering or relaying is located (see Figure 2).
Figure 3 Note: For a fault, external to the protective zone, insufficient voltage develops across the operating relay to pick up the coil. For an external fault (see Figure 3), this allows the current flowing through the current transformer on the line side of the protected zone and the current flowing through the load side current transformers to develop a voltage of opposite polarities. The result is a voltage of very small magnitude across the
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Figure 4 Note: With a fault in the protective zone, sufficient voltage develops across the operating relay coil to pick up the coil. In the final example (Figure 5) there is a second ground is on a current transformer mounted near where a ground fault occurs. If the fault creates a ground potential rise of 100 volts, then the protective relay will experience sufficient voltage across the operating coil to cause the relay to nuisance trip even though the fault was outside the fault zone. Just as with any other event there is an exception to this standard. Many of the new multifunction relays (ABB, Schweitzer, GE/Multilin, and Basler) are designed to connect all current transformers coming into the relay in a wye connection. Each wye has to be grounded. The most desirable way to do this is to bus the wye points together at the relay panel and have a single conductor to ground, to make certain the relay has but one ground potential. As you can see, there are significant considerations in the proper grounding of current transformer circuits.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Figure 5 Note: With a second ground at a remote location, the voltage across the operating coil is sufficient to result in a miss-operation for an external fault and cause a nuisance trip situation.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
An example of how the chart works: For a 480V system the maximum voltage will be proportional to the new systems nominal system voltage by the ratio of the maximum per unit voltage (127 per unit) to the nominal voltage (120 per unit). X 127 per unit Maximum Voltage Rating = = 480 120 per unit Maximum Voltage Rating for 480V is 508V. Therefore, the 508V will appear on the nameplate of the low voltage power circuit breaker as the maximum voltage. The motor control center will list the system voltage of 480V. The motors connected to the motor control center will list the utilization voltage of 460V.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #89 - The New Medium Voltage Circuit Breaker Interrupting Ratings Based on K Factors of 1
July 31, 2001 The ANSI Standard for Medium Voltage Circuit Breaker Test Procedures, IEEE C37.09 was revised in 1999. This standard defines the short circuit tests required to certify a medium voltage circuit breakers interrupting rating. In the past the interrupting rating changed as a function of the voltage at which the breaker was applied. The new standards are an effort to recognize that modern vacuum and SF6 interrupting technologies more closely represent a constant current interrupting device, independent of the nominal system voltage. The standards evolved from the 1945 revision when breakers were rated based on interrupting MVA (see figure below). In 1968 the standards established varying k factors to adjust interrupting rating as a function of the voltage. The k factor reflects the performance of the oil and air interrupting technologies available at that time. This practice ended with the 1999 change, where circuit breaker k factors were all set at to a value of one. The k factor of 1 results in all medium voltage breakers, tested to the 1999 version of C37.09, having a constant interrupting rating irrespective of nominal system voltage. The changes in interrupting rating at the system voltage can be seen in the graphs below.
Using the 1968 standards, the 250MVA breaker had a 29kA interrupting rating if applied at 4.76kV while the same breaker applied at 4.16kV had a 33kA interrupting rating and when applied at 3.85kV it had a 35.5kA rating. Using the 1999 standards, a newly certified 36kA breaker with a k factor of 1 will retain the 36kA interrupting rating independent of the applied voltage.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #89 - The New Medium Voltage Circuit Breaker Interrupting Ratings Based on K Factors of 1 (Page 2)
Important Note: Circuit breaker short circuit interrupting rating is the symmetrical RMS current at the time power contacts part. These new rating structures do not change the rating of circuit breakers certified prior to the 1999 revision. They only impact breakers that are certified to the new testing standards. The new 1.0 k factor ratings will simplify breaker application and align with the long-standing IEC nomenclature. It is important that we do not make the mistake of trying to apply a short circuit rating that varies as a function of the voltage to circuit breakers certified to have a k factor of 1.
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PTB #89 - The New Medium Voltage Circuit Breaker Interrupting Ratings Based on K Factors of 1 (Page 3)
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
PTB #90 - Asymmetrical Interrupting Current Rating of Medium Voltage Circuit Breakers
September 15, 2001 As discussed in the last Powell Technical Brief, the 1999 revision of ANSI Standard C37.04 and C37.09 changed several definitions relating to the rating structure of medium voltage circuit breakers. The earlier revision of the circuit breaker standards utilized the S factor as a multiplying factor that defined the total current a breaker was rated to interrupt at contact part. The newest revision of C37.04 replaced the S factor with the %dc as the method of evaluating the asymmetrical current offset. The %dc is utilized to calculate the total interrupting current. The asymmetrical current is an important component of the total fault current. It is critical that not only the symmetrical interrupting current, but also the circuit breaker total interrupting rating be greater than the system worst-case available fault condition. In the past, we have been able to pay very little attention to the possibility of a system x/r ratio higher than the nominal value of 17 and the resulting total current. Today, with more generation being installed, the momentary rating and the total current capability play a greater role in the sizing of equipment because local generation increases system x/r ratio.
The maximum fault current occurs during the first loop of sinusoidal current after the instant of fault initiation. An asymmetrical offset containing a dc component of as much as 160% of the symmetrical
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PTB #90 - Asymmetrical Interrupting Current Rating of Medium Voltage Circuit Breakers (Page 2)
current can be impressed on top of the symmetrical ac current in one or two of the three phase currents. This dc component quickly decays and the fault current is greatly reduced in magnitude by the time the contacts part on the circuit breaker (see figure on structure of an asymmetrical current wave). The speed at which this dc component decays is a function of the system x/r ratio. A high x/r ratio means a greater system inductance will dominate the fault current and slow the attenuation of the dc offset.
The %dc that circuit breakers are certified to interrupt, is based on the contact part time and a standard x/r decrement curve. (Refer to Figure 1 above). The combination of the contact part time and the nominal x/r value, results in the maximum value for % dc that the circuit breaker must interrupt. The nominal x/r of 17 coincides well with the typical 60 Hz industrial substation and utilities distribution systems. The %dc is then used to compute the total interrupting current of the circuit breaker at the moment of contact part. The following equation shows how this total current is computed.
Utilizing the chart and this formula we can compute the total current. An illustration will help clarify the calculation. To find the asymmetrical interrupting capability of a 36kA, 3-cycle rated breaker with a published opening time of 25msec, a contact part time of 33msec is used. The contact part time includes
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PTB #90 - Asymmetrical Interrupting Current Rating of Medium Voltage Circuit Breakers (Page 3)
cycle of minimum relaying time added to the opening time of the breaker. Using the 33msec contact part time of our sample, we find the breaker is capable of interrupting the 36kA symmetrical current with a 50% dc component riding on top of the symmetrical current when these values are plugged into the formula above, the total rms current is 44kA. Since, this breaker is certified as a 3-cycle breaker it is certified to interrupt a total current of 44kA at time from 3 cycles to 2 seconds. Note that if a 5-cycle breaker was certified, the contact part time is 50 msec. The total interrupting current rating would be 40kA, whether it clears in 5-cycles or 2 seconds. Where does this all become significant? With more and more generation being installed we find that the system x/r ratio plays a much more significant part in applying equipment properly. In many generator bus cases the equipment may have to be oversized to handle the higher level of total current or the tripping of the breaker may have to be delayed a few cycles to allow the dc to decay to an acceptable level.
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Current Transformers, Application of 600 Volt Class in Medium Voltage Switchgear #85 Auxiliary #66 Burden #66 Grounding #87 Relaying #62 Saturation #62, #68 Secondary Circuits #72 Zero-Sequence #68 Cycloaliphatic Epoxy Insulation See Insulation, Epoxy **D** Design Tests #23 Device Function Numbers #43 Differential Relays, Partial #33 Direct Control of Motor Contactors #81 Directional Overcurrent Relays #15 Directional Power Relays #15 Distributive Control Systems (DCS) #81 Dummy Circuit Breakers in Metal-Clad Switchgear #20 **E** Effects of Harmonics on Switchgear #31 Enclosures #74, #76 Epoxy Insulation See Insulation, Epoxy Equipment Design Tests #23 **F** Failure, Vacuum Interrupter #11 Fast Bus Transfer #1 Fault #61 Ferroresonance in Voltage Transformer Circuits #79 Field Application, Synchronous Motors #65 Floor Preparation #44 Floor Steel #44 Frequency other than 60 Hz #38 Fuses for dc Control Circuits #9 Fuses, Altitude De-rating #86 Function Numbers, Device #43 Future Use of Space #13
**G** Ground Bus, Rating #58 Ground Lead Disconnectors in Distribution-Class Surge Arresters #17 Ground Sensor Relaying #68 Grounding, Current Transformers #87 **H** Hardware #53 Harmonics #31 Harsh Environment Application #80 High Altitude Application of Switchgear #25 **I** IEEE Standards See Industry Standards Induction Motors #69 Industry Standards #49, #89 Installation of Switchgear #44 Instrument Transformers Altitude De-rating #86 Polarity Markings #34 Insulation, Bus Joints #77 Insulation, Epoxy #5 , #36 Insulation, Porcelain #5 Interchangeability of Drawout Circuit Breakers #29 Interrupter Failure #11 Interrupter Switchgear #73 Interrupting Rating #45 IP Enclosures See Enclosures **J** **K** K Factor #46, #89 **L** Labels, Shutter #83 Latched Contactors #67 Life of Switchgear #55 Lightning Arresters See Surge Arresters Locks, Cell and Shutter #83
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Loss of Vacuum Testing #37 Low Voltage Circuit Breakers See Circuit Breakers, Low Voltage Low Voltage Switchgear See Switchgear, Low Voltage **M** Medium Voltage Contactors See Contactors, Medium Voltage Medium Voltage Motor Control See Motor Control, Medium Voltage Medium Voltage Power Circuit Breakers See Circuit Breakers, Medium Voltage Power Medium Voltage Switchgear See Switchgear, Medium Voltage Metal Enclosed Switchgear See Switchgear, Metal Enclosed Metal-Clad Switchgear See Switchgear, Metal-Clad Meters, Static #30 Modernization of Switchgear #32 Molded Case Circuit Breakers See Circuit Breakers, Molded Case Momentary Rating, Bus #42 Motor Branch Fault Short-Circuit Protection #39 Motor Control, Enclosures #74 Medium Voltage #67 Sizing Bus Bars #24 Testing #27 Wiring of #56 Motors, Autotransformer Starting #14 Induction #69 Large #71 Medium Voltage #71 Preventing Condensation #16 Starting #65, #71 Synchronous #75 MVA Rating #45, #89
**N** National Electrical Code #50, #52 NEMA Contactors, Switching Capability #64 NEMA Enclosures See Enclosures NEMA Standards See Industry Standards **O** Open Circuit Protectors #72 Operating Times of PowlVac Circuit Breakers #18 Overcurrent #61 Overload #61 **P** Panelboards, Cable Termination Temperature #48 Installation #50 Partial Differential Relaying #33 Plating #41 Polarity Markings on Instrument Transformers #34 Porcelain Insulation See Insulation, Porcelain PowlVac Circuit Breakers See Circuit Breakers, PowlVac PowlVac Switchgear See Switchgear, PowlVac Preventing Condensation in Medium Voltage Motors #16 Programmable Logic Controllers (PLC) #81 **Q** Qualifying Equipment by Design Tests #23 **R** Ranges and Ratings, Standard Voltage #88 Ratings of Circuit Breakers #57 Relaying Accuracy of CTs #62 Relays, Directional Overcurrent #15 Ground Sensor #68 Partial Differential #33 Power Directional #15 Setting Targets #35 Static #30
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Replacement Circuit Breakers #32 Rollout Carriages, Switching Capability of #21 **S** Safety Features #83 Seal Fittings, Wire Fill #52 Seismic Testing #7 Setting Targets on Relays #35 Short Circuit #61 Short Circuit Current Levels Used to Test Various Types of Circuit Breakers #28 Short Circuit Currents - Crest, rms Symmetrical and rms Asymmetrical #22 Short-Circuit Protection, Motor Branch Fault #39 Shutter Locks and Labels #83 Silver Plating #41 Sizing Bus Bars in Switchgear and Motor Control #24 Small Currents, Switching #60 Solar Radiation #6 Space, Future Use #13 Spacings, Bus #59 Standards See Industry Standards Standard Voltage Ranges and Ratings #88 Starters, Motor #69 Starting Methods for Motors #71 Starting of Motors, Autotransformer #14 Static Relays and Meters #30 Sulfur Rich Environments #80 Surge Arresters, Altitude De-rating #86 Ground Lead Disconnectors #17 Voltage Rating #25 Physical Installation #82 Switch, Circuit Breaker Trip Defeat #78 Switchboards, Installation #50 Switchgear, Arc-Resistant #51, #54 Cable Termination Temperature #40 Conversion #32 Frequency other than 60 Hz #38
Harmonics Effects #31 High Altitude Applications #25 Installation #44 Life of #55 Low Voltage #73 Medium Voltage #73 Metal-Enclosed #73 Metal-Enclosed, Bus Spacings #59 Metal-Enclosed, Enclosures #74 Metal-Enclosed, Ground Bus, Rating #58 Metal Enclosed, Solar Radiation #6 Metal-Enclosed, Useful Life #55 Metal-Clad #73 Metal-Clad, Dummy Circuit Breakers in #20 Metal-Clad, Arc-Resistant #51, #54 Modernization #32 Momentary Rating #42 Plating #41 PowlVac, Seismic Testing #7 PowlVac, Umbilical Cord #4 Sizing Bus Bars #24 Testing #27 Wiring of #56 Switching Capability of Rollouts and Tiltouts #21 Switching with NEMA Contactors #64 Symmetrical Short Circuit Currents #22 Synchronizing Circuits #8 Synchronous Motors, Starting #65 **T** Targets, Relay #35 Testing for Loss of Vacuum #37 Testing of Switchgear and Motor Control Equipment #27 Tiltout Carriages, Switching Capability of #21 Tin Plating #41 Transformers, Instrument See Instrument Transformers Transient Recovery Voltage #10, #70
Powell Electrical Manufacturing Company PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Umbilical Cord #4 **V** Vacuum Interrupter Failure #11, #37 Voltage Feedback in Synchronizing Circuits #8 Voltage Rating of Surge Arresters #26 Voltage, Standard Ranges and Ratings #88 Voltage Transformers, Circuit Ferroresonance #79 **W** Wire, Control #56 Wire Fill #52 Wire Markers #56 Wound Rotor Induction Motors #69 **X** X/R Ratio #47 , #90 **Y** **Z**
PO Box 12818 Houston Texas 77217-2818 713-944-6900 713-947-4453 fax www.powellelectric.com info@powellelectric.com
Powell Electrical Manufacturing Company PO Box 12818 Houston, TX 77217-2818 Phone: (713) 944-6900 Fax: (713) 947-4453 info@powellelectric.com www.powellelectric.com
Products & Services PowlVac Metal-Clad Switchgear 5-15kV PV System 27 Metal-Clad Switchgear 27kV PV System 38 Metal-Clad Switchgear 38kV Vacuum Circuit Breakers 5-38kV PowlVac-AR Arc Resistant Metal-Clad Switchgear Low Voltage Metal Enclosed Switchgear Power Control Rooms (PCR) Secondary Unit Substations Load Interrupter Switchgear LV and MV Motor Control Centers High Resistance Grounding DC Switchgear Systems Vacuum Circuit Breaker Modules Station Circuit Breakers Transit Power Systems Traction Power Substations
Traction Power Systems, Inc. 8967 Pleasantwood Avenue NW North Canton, OH 44720-4761 Phone: (330) 966-1750 Fax: (330) 966-1787 info@tractionpower.com www.tractionpower.com
Products & Services Transit Power Substations Project Management Field Engineering and Testing Turn-Key Installation
Powell Electrical Manufacturing CompanyNorth Canton Division 8967 Pleasantwood Avenue NW North Canton, OH 44720-4761 Phone: (330) 966-1750 Fax: (330) 966-1787 info@powellncd.com www.powellncd.com
Products & Services Metal Enclosed Capacitor Banks Metal Enclosed Harmonic Filter Systems Mobile Capacitor Banks DC Switchgear
Powell Apparatus Service Division Texas Office 8550 Mosley Houston, TX 77075-1180 Phone: (713) 944-6900 Fax: (713) 948-4569 info@powellservice.com www.powellservice.com Arizona Office Scottsdale, AZ Phone: (480) 998-7718 Fax: (480) 998-0238 Pennsylvania Office Bromall, PA Phone: (610) 544-8600 Fax: (610) 544-8609 California Office Los Angeles, CA Phone: (818) 363-5666 Fax: (818) 368-9228
Products & Services Service for All Products Field Startup Services Turn-Key Projects Retrofill Products Replacement Breakers Field Testing Spare Parts, Components Field Modifications Match and Line Equipment Engineering Support Emergency Assistance Factory Refurbishment
Powell Industries Offshore 16535 Jacintoport Boulevard Houston, TX 77015-6540 Phone: (281) 452-4885 Fax: (281) 452-9956 info@powelloffshore.com www.powelloffshore.com
Products & Services Custom Packaged Modules Custom Designed Modules Single Lift Modules Power Control Modules Generator Packages Living Quarters
Powell Power Electronics Company, Inc. 5669 Gibraltar Drive Pleasanton, CA 94588-8547 Phone: (925) 225-0505 Fax: (925) 225-0606 info@ppeco.com www.ppeco.com
Products & Services Solid State Power Electronics Rectifiers Rectifier Transformers DC Protective Relays
2001
PTB-4