Application of New Technologies in Power Circuit Breakers with Higher Interrupting

Capacity and Short Time Ratings

Charles J. Nochumson, P.E.
Cutler-Hammer, Inc.
601 Oakmont Lane, Suite 310
Westmont, IL, 60559

Abstract - A new Low Voltage Power Circuit Breaker
(LVPCB) has been introduced which has higher interrupting
capacity and higher short delay current ratings than previously
available in LVPCBs. The entire new power circuit breaker
including operating mechanism and contacts has been designed
and tested to meet or exceed the stringent requirements of ANSI
standard C37.16 “Low-Voltage Power Circuit Breakers and AC
Power Circuit Protectors – Preferred ratings, Related
Requirements, and Application Recommendations”, ANSI
C37.50 “Low-Voltage AC Power Circuit Breakers Used in
Enclosures – Test Procedures” and ANSI standard C37.17 “Trip
Devices for AC Low Voltage PCBs”. This paper will discuss the
evolution of technology in materials and electronics, which has
enabled improved performance, as well as provide examples of
specific applications in the industry where the new PCB higher
interrupting capacity and short time ratings are beneficial to the
user. A need to review both short delay time as well as short
delay current ratings of equipment will be discussed. Zone
selective interlocking functions to reduce damage to protected
equipment while still maintaining coordination will also be
reviewed.
I. A BRIEF DESCRIPTION OF AVAILABLE CLASSES OF LOW
VOLTAGE CIRCUIT BREAKERS
Low Voltage Power Circuit Breakers (LVPCBs) are rated
and tested to ANSI C37 standards. They are mainly used in
Low Voltage Metal Enclosed Drawout Switchgear built per
ANSI C37 standards. LVPCBs offer field maintainability of
main contacts, operating mechanism, and arc chute
replacement. LVPCBs are tested in the enclosure and are
rated for 100% applications. They offer 2 step stored energy-
closing mechanisms, which have typical opening or closing
times of 3 to 5 cycles. For electrical operation, they are
typically combined with an internal motor to change the
breaker closing springs and solenoids to release the spring
stored energy for closing and opening of the breaker. They
are typically applied in systems with selective coordination,
synchronizing schemes and automatic transfer scheme
applications.
Molded Case Circuit Breakers (MCCBs) are tested
according to UL489. They are typically applied in Low
Voltage Switchboards, Motor Control Centers and
Panelboards. MCCB current carrying parts, mechanism and
_________________________________________________
Originally presented at the 1999 TAPPI Conference in March 1999.
Copyright TAPPI 1999.
trip devices are completely contained within a molded case,
and are not designed to be field maintainable. MCCBs as
standard are tested in open air and are de-rated to 80% when
placed in an enclosure. Optional MCCBs are available which
have been UL tested for applications at 100% in the
enclosure. Molded case circuit breakers have over-center
toggle operating mechanisms. For electrical operation, they
are typically combined with external motor operating
mechanisms, which move the breaker handle. The external
motor operator is not fast enough for synchronizing or many
automatic transfer scheme applications. MCCBs are also
available in current-limiting type.
Insulated Case Circuit Breakers (ICCBs) are also rated
and tested in according to UL489. They are typically applied
as mains in Low Voltage Switchboards, Motor Control
Centers and some transfer switches. Similar to the MCCB,
the ICCB is generally contained in a sealed molded case, and
is not designed to be fully field maintainable. ICCBs are
found as either 80% rated devices or 100% rated devices
when mounted in the proper enclosure. ICCBs utilize 2 step
stored energy mechanisms, similar to LVPCBs. ICCBs are
normally not fast enough to qualify as current-limiting type.
II. THE HISTORIC EVOLUTION OF LOW VOLTAGE POWER CIRCUIT
BREAKER TECHNOLOGY
The first low voltage power circuit breaker designs go back
to the year 1929, when Dr. Slepian of Westinghouse invented
the DE-ion arc chute. During a fault, this arc chute device
enabled the LVPCB to effectively protect downstream
equipment by splitting the resulting arc into several
segments, which were then individually extinguished. Since
1930, power circuit breaker technology has advanced in
several areas as shown in the timeline, Fig 1.
A. Interrupting Ratings
Interrupting capacity is defined as the maximum short circuit
current the breaker can safely interrupt. Early designs of
power circuit breakers were designed with interrupting
capacity of 15/25kA. The latest designs of LVPCBs include
interrupting ratings of up to 100kA at 480 volts, without the
use of integral current-limiting fuses. Many users have
elected to move away from the use of LVPCBs with current
limiting fuses for some of the following reasons:

Presented at the 1999 IEEE IAS Pulp and Paper Industry Conference in Seattle, WA: © IEEE 1999 - Personal use of this material is permitted.
 ANSI/UL Low Voltage Power Circuit Breaker Timeline

Year Introduced 1930 1950 1967 1976 1998

Interrupting 15/25 kA 25 kA 30 kA 50/65 kA 100kA

Rating

Mechanism Solenoid Solenoid Stored Energy Stored Energy Stored Energy

Type Spring Spring Spring

Trip Sensor Electro- Electro- Solid State Microprocessor Microprocessor

Type mechanical mechanical Peak Sensing RMS Sensing RMS Sensing

Figure 1: Timeline of Low Voltage Power Circuit Breaker Technology Developments including interrupting capacity improvements,
available mechanisms and trip sensors from 1930 through 1998.

1. When current limiting fuses are utilized as part of feeder
circuit breakers, medium to high fault currents will cause
the limiter to open, thus losing coordination with
downstream protective devices.
2. Increased floor space of the low voltage metal-enclosed
switchgear is required when fuses are incorporated into
the assembly.
3. Increased downtime and cost associated with the
replacement of blown current-limiters.
Increases in ratings have come primarily from improved
materials in breaker frame construction. Earlier designs used
an open type, metal frame. Today’s designs use engineered
thermoset composite resins in a molded frame. The rigidity of
the frame is a critical design point during fault current
interruption, since much of the energy required to interrupt
the fault is absorbed in the frame. Increased interrupting
ratings mean higher spring energies in the operating
mechanism. Steel frame breakers deflect during fault
interruption and in some cases must absorb up to 40% of the
spring energy. Thus, open steel frame breakers require larger
springs and frames, which reduce overall mechanism life.
Newer epoxy resin design frames have superior
characteristics in overall frame deflection and include a
molded arc chamber that provides support to the current path
and protection from phase to phase arcing during
interruption. The improved structural rigidity of the frame
allows higher interrupting and short time ratings in a smaller
overall package. Typical 3200 amp breaker frames and power
contact designs in both steel and molded frame breakers are
shown in Fig. 2.

Figure 2: Shown at left is a comparison in size of a new epoxy resin frame LVPCB versus a traditional open steel frame construction.
Both breakers are rated for 3200A at 600 volts. Shown at right is a newer finger-type design power contact assembly versus
the traditional wedge-type design.
B. Operating Mechanism
Early designs of operating mechanisms included solenoid
operators. In 1967, higher closing speed requirements
resulted in development of a two-step stored energy
mechanism for Power circuit breakers. This mechanism
allowed for the capability of fast reclosure (Open, Close-
Open duty cycle) via the addition of a charging spring. This
also facilitated easy remote operation, fast reclosing (5 cycles
or less), and assured that energy was always on hand to
open/close the breaker. The latest designs continue to use the
two-step stored energy operating mechanism.
C. Trip Unit Sensing
Early design trip units in power circuit breakers were electro-
mechanical type. Solid state sensing trip units were
introduced in the late 1960’s, which replaced the initial
designs. Early versions of solid state trip units used analog
circuitry and were able to effectively sense and trip on peak
currents. In some cases, this resulted in nuisance tripping
conditions. In the 1980’s, digital solid state controls became
available that were able to effectively integrate the current
waveform to calculate a true rms current value. This
effectively eliminated early nuisance tripping problems.
Microprocessor based rms trip units were introduced in the
early 1990’s and advanced versions of these are used in the
latest design LVPCBs.
Today, Low Voltage Power Circuit Breakers (LVPCBs) and
metal-enclosed switchgear are designed and tested to ANSI,
NEMA, and UL standards [1].
II. APPLICATIONS OF POWER CIRCUIT BREAKERS
ANSI offers the following definition for Rated Short-Circuit
Current for LVPCBs:
Rated Short-Circuit Current for Unfused Circuit Breakers:
The rated short-circuit current of an unfused circuit breaker is
the designated limit of available (prospective) current at
which it shall be required to perform its short-circuit current
duty cycle (O-15s-CO) at rated maximum voltage under the
prescribed test conditions. This current is expressed as the
rms symmetrical value of current measured from the
available current wave envelope at a time ½ cycle after short
circuit initiation. Unfused circuit breakers shall be capable of
performing the short-circuit current duty cycle with all
degrees of current asymmetry produced by three-phase or
single-phase circuits having a short-circuit power factor of
15% or greater (X/R ratio of 6.6 or less). [2]
A. Definitions: Short Delay Current And Short Delay Time
Ratings
Short delay current ratings and short delay time settings are
critical factors in the overall function of a LVPCB when used
in a selectively coordinated system. For purposes of this
paper, in conjunction with trip unit settings, the following
definitions will be utilized:
• Short delay current rating of a LVPCB: The
maximum current for which the circuit breaker can
remain closed for a short delay time.
• The maximum short delay time of a LVPCB: The
time that a Power Circuit Breaker must keep its
contacts closed at a maximum short delay rated
current (typically ½ second or 30 cycles).
{The ANSI test standard for LVPCBs actually requires a
short delay fault test of 30 cycle duration, a 15 second zero
current interval and then another 30 cycle short delay fault
test.}
There are significant differences in short time delay ratings
for various circuit breaker types. Typically, the maximum
short delay time rating for Molded Case Circuit Breakers
(MCCB) equipped with electronic trips is 18 cycles and the
maximum short delay time rating for Insulated Case Circuit
Breakers (ICCB) is 30 cycles. It’s important to note that
although a ICCB may have a 30 cycle short delay time, the
current magnitude of that 30-cycle delay is at significantly
less current magnitude than it’s rated interrupting capacity.
Most MCCBs and ICCBs available on the market are
equipped with a fixed instantaneous override circuit (when
adjustable instantaneous is not furnished). These breakers
frequently have interrupting ratings, which are higher than
the breaker's short delay current rating. When the fault
current value exceeds the short delay current rating of the
breaker, the fixed instantaneous override circuit immediately
trips the breaker. This means that system coordination can
only be achieved up to the short delay current rating of the
breaker. For fault currents above the short delay rating, the
breaker opens and coordination is lost. However, the breaker
can still interrupt currents up to its published interrupting
capacity.
The industry test circuit standards used for testing low
voltage circuit breakers include power factor test ranges and
X/R test ranges shown in Table 1. When circuit breakers are
used in actual installations where the X (reactance) and R
(resistance) represent the total X and R from the faulted point
in the circuit back to the utility generating source, a de-rating
factor should be applied to the circuit breaker interrupting
rating if the calculated X/R ratio exceeds those listed in the
test standards. Typical recommended de-rating factors are
shown in Table 2. The LVPCB derating factors shown in
Table 2, are essentially the reciprocals of the multiplying
factor based on ANSI C37.13, Table 3. This ANSI
multiplying factor is applied to the calculated symmetrical
short circuit current, before comparing it to the LVPCB
interrupting rating.
The ratio of X to R determines the maximum degree of
asymmetry possible in the faulted circuit. In other words, the
Figure 3: Relation of X/R Ratio to Multiplication Factor
X to R ratio is the degree to which the first half cycle peak
current exceeds the steady state rms value of the fault. The
actual amount of asymmetry will depend on when the fault
occurs in the voltage wave.
The test circuit X/R ratio determines the first half cycle
Peak Multiplication Factor. The Peak Multiplication Factor
times the calculated or test rms symmetrical current equals
the first half cycle peak current. See Fig. 3 for the
relationship of X/R ratio to Peak Multiplication Factor.
B. The Need to Specify the X/R Ratio
The new low voltage power circuit breaker's RMS sensing
trip unit measures various points on the current wave within
each cycle and then calculates the rms value of the wave.
This calculation is used to support long delay and short delay
tripping decisions. However, the majority of trip units still
utilize peak sensing measurement for those circuits
associated with instantaneous trip adjustment or over-ride
circuits.
For example, if an insulated case circuit breaker has a
published short delay current rating of 50,000 amperes rms
symmetrical and an interrupting rating of 100,000 rms
symmetrical amperes, it must be determined from the
manufacturer whether the 50,000 ampere short delay current
rating and associated over-ride circuit is based on a
symmetrical wave (X/R = 0) or some other X/R ratio, such as
6.6, which is utilized with LVPCBs. In this example,
assuming the 50,000 ampere short delay current rating is
based on a perfect symmetrical wave, then the first half cycle
Peak Multiplying Factor would be 1.41, or the breaker would
begin to open instantaneously for peak current values over
1.41 x 50,000 A= 70,500 peak amperes. If this circuit
breaker were applied in an actual circuit location that had an
available fault current of 35,000 amperes rms symmetrical
and an X/R ratio of 6.6, the Peak Multiplying Factor would
be 2.3 (see Fig. 3). This 35,000 rms symmetrical available
fault current would have a first half cycle peak of 35,000 X
2.3 or 80,500 peak amperes. Since the available peak
amperes of 80,500 exceeds the breaker instantaneous
override peak setting of 70,500 amperes, the instantaneous
override circuit would cause the breaker to open. This would
not allow the short delay circuit to continue timing out. As a
result of the breaker opening, coordination with downstream
breakers would be lost. In this case of a hypothetical 50kA
short delay current rated breaker, the breaker would trip on a
35kA rms fault without any short time delay instead of
waiting for a load side breaker to trip (Since the X/R ratio it
was rated for was 0 and not the 6.6 required for the example
circuit). Thus, it is important to specify not only the breaker
short delay current rating required, but also that it must be
based on a test circuit with an X/R ratio of 6.6. In the
following discussion, all currents given are rms symmetrical
values, unless otherwise noted.
C. A Discussion of System Coordination
A number of variables can impact overall system
coordination. When a fault occurs at point "A" (refer to Fig.
4), the amount of fault current flowing from the source
(without motor contribution) through the main breaker M1,
feeder breaker F1, 200-Ampere breaker in DP-1 and the 50-
ampere breaker in LP-1 would be of the same magnitude.
The fault current magnitude would be determined by the
system available fault current, the motor contribution, and the
total impedance between the faulted point and the utility and
motor sources, and the impedance of the arc itself.
 Figure 4: Typical Power Distribution System
To achieve perfect coordination, only the 50-Ampere, 3-
pole branch MCCB in Panel LP-1 would open, while the
200-ampere feeder MCCB in Panel DP-1, the feeder breaker
F1, and main breaker M1 in the main service equipment
would remain closed. This would remove only the faulted
circuit from service, while allowing the remainder of the
circuits in the facility to remain energized.
Typically, a molded case circuit breaker with a frame size
under 1200-amperes has a maximum short delay current
rating of approximately 10 to 13 times its frame size. This
being the case, the 200-ampere breaker in DP-1 would have a
short delay current rating of about 2000 to 2600 amperes. For
short circuit currents above 2000 to 2600 amperes, the
MCCBs adjustable instantaneous circuit would open, which
would open the breaker contacts, removing the circuit from
service. The same would be true on an electronic breaker
with an instantaneous override circuit, which would open the
breaker, or with a thermal magnetic breaker, where the
magnetic coil would open the breaker and take the circuit off-
line. In the case of extremely high faults, the fault current
itself is instrumental in opening the breaker contacts.
At a fault current level below approximately 2,000
amperes, the molded case feeder breaker in Panel DP-1
would coordinate with the 50-ampere molded case circuit
breaker in panel LP-1. For a fault current level above 2000
amperes, both the 200-ampere MCCB in panel DP-1 and the
50-ampere MCCB in panel LP-1 would open and all circuit
loads in Panel LP-1 would be de-energized.
Similarly, if the 800-ampere feeder breaker in the main
service equipment were an MCCB, it would have a short
delay current rating of approximately 8000 amperes. If the
fault current at point "A" was above approximately 8000
amperes, the MCCB feeder F1, the 200-ampere feeder
MCCB in DP-1 and the 50-ampere MCCB breaker in LP-1
would all probably open and de-energize the loads connected
to Panel DP-1. If the fault current at point "A" was above the
short delay current rating of the 2500-ampere main breaker
M1 in the main service equipment, and breaker M1 were of
the MCCB design, the entire facility would be without power
if the breaker opened.
D. The LVPCB Difference
Using LVPCBs in the system shown in Fig. 4 can make a
substantial difference in overall system performance. If the
main M1 and the feeder F1 in the main service equipment
were LVPCBs with a short delay current rating and
interrupting rating without instantaneous trips of 65,000
amperes, and the available fault current at their point of
application was less than 65,000 amperes, the LVPCBs
would continue to stay closed up to their short delay time
setting.
Feeder breakers such as those at F1, F2, F3, F4, and F5
typically would have a short delay time setting of 6 cycles to
allow downstream instantaneous devices to operate, or inrush
currents to flow. The main breaker M1 would have a short
delay time setting of 12 cycles to allow the main service
equipment feeder breakers -- F1 through F5 -- to open first if
a fault existed on their load side. This would create a
selectively coordinated system.
For example, if the fault current at point "A" were
approximately 55,000 amperes, the 50-ampere breaker in LP-
1 and the 200-ampere breaker in DP-1 would open.
However, the LVPCB type feeder breaker F1 and the
LVPCB type main breaker M1 would remain closed. As a
result, only the loads associated with LP-1 would be de-
energized.
If the feeder circuit breakers F1, F2, and F3, or the main
circuit breaker M1, were specified as LVPCBs and equipped
with instantaneous trips, they would still have the same
interrupting capacity. However, their short delay current
rating would be reduced to the maximum available setting of
the adjustable instantaneous pick-up -- typically 12 times the
rating plug. Thus, the 800-ampere feeder circuit breakers F1,
F2, and F3, would trip instantaneously at 9,600 amperes, and
the main circuit breaker M1 would trip instantaneously at
30,000 amperes. Their available short delay current rating
would essentially be reduced to these current values.
E. Guidelines for Specifying LVPCBs
To avoid unnecessary trips and unplanned instances of
system de-energizing, the following general guidelines
should be used when specifying LVPCBs:
• Specify main breakers and tie breakers with long
delay and short delay without adjustable
instantaneous;
• Select feeder breakers with long delay and short
delay without adjustable instantaneous where
coordination with down stream (load side) devices
is required.
• Select feeder breakers with long delay, short delay
and instantaneous for those feeder breakers feeding
an INDIVIDUAL transformer or an INDIVIDUAL
motor.
For example, where F4 is feeding an individual
transformer, the instantaneous current pick-up would be set
slightly above (approximately 10%) the calculated maximum
fault current on the secondary of the 225 kVA transformer
(without secondary motor contribution), multiplied by the
transformer voltage ratio.
For a 225 kVA transformer with 5% impedance, the
secondary maximum fault current with unlimited primary
available current would be {(624 secondary FLA) / 0.05}
equal to 12,480 amperes. The instantaneous pick-up setting
would then be {[12,480 x (208V / 480V)] x 1.10}, or
6000-ampere instantaneous setting passing through F4 would
have to be either a fault in the transformer primary winding
or a fault on the primary side of the transformer. As a result,
coordination with secondary devices would not be required.
Short delay would still be furnished for this breaker to
give good low-level short circuit protection. It would also
allow for transformer inrush current of approximately 12 x
primary FLA for 0.1 seconds. In the case of an individual
motor, such as feeder F5, the instantaneous current pick up
would be set slightly above (approximately 10%) motor
inrush 1/2 cycle current (typically 15 times full load
amperes).
New electronic trip units are available as standard with
Long Delay, Short Delay and field selectable Instantaneous
(instantaneous protection or no instantaneous protection).
This allows for more flexibility in applying the breakers for
various applications in the electrical distribution system, and
Figure 5: System Coordination Curves
approximately 6000 amperes. Values of current above this
more flexibility in utilizing spare breakers for different
applications.
F. The Time/Current Relationship
The relationship between time and current for the feeder
breaker F1 circuit of Fig. 4 is shown in Fig. 5. It uses PCBs
in the main service equipment, and MCCBs in DP-1 and LP-
1. At 2000 amperes, coordination is lost between the 200-
ampere MCCB and the 50-ampere MCCB. Coordination is
achieved between the 800-ampere PCB in the main service
equipment and the 200-ampere feeder breaker in DP-1.
Coordination is also achieved between the 2500-ampere main
PCB and the 800 ampere feeder PCBs. To achieve complete
coordination for all devices, the breakers in Panel DP-1
would have to be outfitted with ICCB or PCB units with
short delay current ratings equal to the available fault current
at their particular locations.
G. Achieving Coordination
When doing a coordination study on a given feeder
breaker, it's critical to select the largest overcurrent device on
the load side grouped equipment (panelboard, motor control
center, or busway bus plug) it supplies. Similarly, when
selecting settings of main breakers, it is important to select
the largest load side feeder overcurrent device or the load
side feeder overcurrent device with the highest settings to
achieve full coordination.
Many of today's Molded Case Circuit Breakers or
Insulated Case Circuit Breakers -- both of which are tested
per UL standard 489 for Molded Case Circuit Breakers --
may have interrupting capacities equal to those listed in
Table A, Columns 5 and 8. However, when their short delay
current ratings are compared to those shown in Column 7,
they are much lower. This significantly reduces selectivity or
continuity of service.
Table A indicates the three phase short circuit ratings in
symmetrical rms amperes for breakers with and without
instantaneous trips, and for breakers without current limiting
fuses. Column 9 gives the short delay current ratings for the
new LVPCBs.
The short delay current rating is the maximum current at
which the new LVPCBs can keep its contacts closed for up to
30 cycles. If the fault current exceeds the indicated current
values, the breaker will override the selected short time
setting and open the contacts through an instantaneous
override circuit. The breaker can interrupt fault current
maximums up to the ratings indicated by Column 8. The
instantaneous override circuit for the new LVPCB is based
on a system X/R ratio of 6.6.

AIC Rating - Symmetrical RMS Amperes AIC Rating - Symmetrical RMS Amperes Short Delay
With Instantaneous Trips Without Instantaneous Trips Current Rating
1 2 3 4 5 6 7 8 9

AC Breaker ANSI Typical New PCB ANSI Typical New PCB New PCB
Voltage Frame C37, 16-1980 PCB Maximum C37, 16-1980 PCB Maximum Maximum
Amperes Table 1 Maximum Table 1 Maximum
(3) (4)
240 800 42,000 65,000 100,000 22,000 65,000 100,000 85,000
240 1,600 65,000 65,000 100,000 42,000 65,000 100,000 85,000
240 2,000 65,000 65,000 100,000 50,000 65,000 100,000 85,000
240 3,200 85,000 85,000 100,000 85,000 65,000 100,000 85,000
240 4,000 130,000 130,000 130,000 85,000 85,000 100,000 100,000
240 5,000 (1) (2) 130,000 130,000 (2) 85,000 100,000 100,000
480 800 30,000 65,000 100,000 22,000 65,000 100,000 85,000
480 1,600 50,000 65,000 100,000 42,000 65,000 100,000 85,000
480 2,000 50,000 65,000 100,000 50,000 65,000 100,000 85,000
480 3,200 65,000 85,000 100,000 85,000 65,000 100,000 85,000
480 4,000 85,000 85,000 100,000 85,000 85,000 100,000 100,000
480 5,000 (1) (2) 85,000 100,000 (2) 85,000 100,000 100,000
600 800 22,000 50,000 100,000 22,000 50,000 100,000 85,000
600 1,600 42,000 50,000 100,000 42,000 50,000 100,000 85,000
600 2,000 42,000 50,000 100,000 42,000 50,000 100,000 85,000
600 3,200 65,000 65,000 100,000 65,000 65,000 100,000 85,000
600 4,000 85,000 85,000 100,000 85,000 85,000 100,000 100,000
600 5,000 (1) (2) 85,000 100,000 (2) 85,000 100,000 100,000

Notes ( ) :
1. Not an ANSI listed frame rating. Conventional PCB's may utilize fan cooling to achieve the indicated frame continuous
rating.
2. No ANSI short circuit rating available.
3. Breakers can interrupt currents up to the indicated values in Column 8 without adjustable instantaneous circuit, but will
only maintain contacts closed (short time rating) up to the values in Column 9 at which time a non-adjustable instantaneous
override will initiate interruption.
4. Short Delay Current Ratings for the new PCB - current value that the breaker will remain closed (withstand) for 30
cycles or 0.5 seconds.

Table A: 3 Phase Short Circuit Ratings of ANSI Rated LVPCBs, Typical LVPCBs Available Today and the New LVPCB with Increased Ratings
 III. EXAMPLES REQUIRING HIGHER THAN NORMAL SHORT
DELAY CURRENT RATINGS
A. Example #1 –Double Ended Switchgear with 2 Mains
& Tie with Closed Transition Transfer or Tie Breaker
Normally Closed
Fig. 6 shows a typical Double-Ended switchgear line-up
with each incoming service fed by a 2000/2666 kVA
(AA/FA) Dry Type transformer.
Condition # 1 -- Tie Breaker Normally Open With Closed
Transition Re-Transfer
This system is normally operated with tie breaker "T"
open, and a closed transition retransfer is used. Both 480-volt
sources must be suitable for parallel operation, and properly
protected. The available fault current through each main
breaker "M1" and "M2" is 39,100 amperes symmetrical rms.
Using ANSI standards for lumping motor contribution at
the main bus for a 480 volt system, 4 x transformer
secondary full load amperes yields 4 x 2406 or approximately
9600 amperes. This additional motor contribution would be
Figure 6: Double Ended Switchgear with 2 Mains & Tie with Closed Transition Transfer or Tie Breaker Normally Closed
added at Bus 1 and Bus 2 for a total available fault current at
each bus of 48,700 amperes.
If voltage should be lost to Line 1, main breaker M1
automatically opens. Since the tie breaker T is open, the
loads on Bus 1 experience a complete voltage outage. When
the tie breaker closes, voltage is returned to Bus 1, and motor
circuits on the bus would typically have to be restarted in
sequential order.
When voltage is returned to Line 1, many industrial users
do not want to lose the loads to Bus 1 again during an open
transition retransfer, which first opens the tie breaker and
then closes the main M1 breaker. A closed transition
retransfer is achieved by first closing the main M1 breaker
and then, a few cycles to a few seconds later, opening the tie
breaker.
During the time of retransfer when both mains and the tie
breaker are closed, if a fault were to occur on the load side of
one of the feeder breakers -- such as location "A" near its
load side terminals -- then feeder breaker F2 would be
required to interrupt approximately {(2 x 39,100) + (2 x
9600)} amperes, or 97,400 amperes. NEC 110-9 requires,
"Equipment intended to break current at fault levels shall
have an interrupting rating sufficient for the nominal circuit
voltage and the current that is available at the line terminals
of the equipment.” In order to avoid an NEC violation, feeder
breakers would need an interrupting capacity of 97,400 or
nominally 100,000 A.I.C. If a full short circuit study was
performed, the motor contribution at point "A" would
typically be somewhat less than the 2 x 9600 amperes utilized
in the above calculation. This reduction would be due to the
cable impedance between the motors and point "A", and the
fact that the motor contribution from MCC-2 does not pass
through breaker F2. If a fault occurred at point "B" on the
load side of a combination starter in MCC-2 during the
closed transition transfer, breaker F2 would require a short
time rating equal to the available fault current at point "B" to
ensure a coordinated system. The fault current flowing
through breaker F2 during a fault at point "B" would be the
available fault current at point "A" reduced by the cable and
combination starter impedance from "A" to "B".
For increased coordination, a high short delay current
rating of 85,000 amperes rms symmetrical would be desired.
At a minimum, all feeder breakers and equipment
downstream from the main switchgear should have an
interrupting capacity rating for the higher available fault
current when the sources are paralleled with the tie closed.
Since the mains do not experience fault currents higher than
the current provided by one source, they could have
interrupting capacity and short time ratings equal only to the
one source feeding it. The tie breaker would experience only
the fault current from one source and motor contribution
from one side, and could have a rating equal to the highest
combination of one source, plus motor contribution on that
bus. It is also recommended that reverse current protection be
provided at the main breakers.
Condition # 2 -- Tie Breaker Normally Closed - Paralleling
Sources
The same situation as described in Condition 1 when a
closed transition retransfer occurs, is applicable to parallel
source operation.
Many industrial systems are operated with both sources
paralleled due to the critical nature of processes where even a
few cycles of lost power to the load could have significant
financial consequences. Many systems supplying welding
equipment are operated with two or more sources in parallel
in order to generate adequate voltage and current during the
welding process.
Referring to Fig. 6, reverse current and reverse power
relaying, as well as a synchronism check must be included
with the main LVPCBs M1 and M2. It would be
recommended under this continuous parallel operation to
consider replacing M1 and M2 with Network Protectors
equipped with forward phase and ground fault time
overcurrent protection in addition to network relaying.
B. Example #2 – Multiple Generators Paralleled on the
Same Bus
Parallel Operation with Utility
With the upcoming advent of electric utility de-regulation,
a growing number of industrial and commercial customers
have begun to consider local generation for either peak
shaving, selling power back to the utility or reducing overall
power consumption from the utility. Another advantage of
co-generation is a reliable back-up power source in the event
of a utility outage. The availability of an inexpensive source
of power for the generator, such as process gas or steam, is a
significant factor in justifying these systems. On-site
generation is common place in the pulp & paper,
petrochemical and other major industries.
The simple system shown in Fig. 7 consists of two 1000
kW generators paralleled on the same bus. They are then
paralleled with the utility. Each generator has an
approximate full load current of 1500 amperes, and can
supply approximately 15,000 amperes of fault current, based
on a Z equal to 10%. The utility or customer supply has a
2500 kVA transformer, which will let through approximately
50,000 amperes fault current.
If the Generator Switchgear and the Main Switchgear are
relatively close together and G1, G2, GT1, GT2, and M1
breakers are closed, approximately 80,000 amperes, plus
motor contribution of approximately 12,000 amperes -- or a
total of 92,000 amperes -- would be available at both the
generator bus and the main switchgear during parallel
operation. This would require all LVPCBs except LB1
(which would be operated only when GT1 was open) to have
an interrupting capacity of 100,000. The highest possible
short time rating would be needed for feeder breakers F1, F2,
and F3 for coordination purposes. This would provide a
greater degree of coordination, as well as selective tripping
with over-current devices in the motor control centers.
Non-Parallel Operation With Utility
Fig. 8 illustrates how multiple generation can be used to
serve the emergency and critical loads of a facility. The Tie
breaker GT is normally operated closed, and the generators
each are paralleled to common bus L/R. Although not
required, Tie breaker GT is provided to enhance reliability.
If a bus fault occurred on bus L or R, the generation
system would not go completely off-line, as would happen if
a solid bus without a Tie breaker were used instead. The Tie
breaker allows for maintenance on either bus L or bus R,
while still keeping two generators available for supplying the
emergency and critical loads.
 Figure 7: Multiple Generators paralleled on the Same Bus
From the generator bus, the emergency and critical loads
are supplied through a feeder breaker (GF1, GF2, GF3, or
GF4) to a distribution panel, such as EDP2. Current is then
routed through a transfer switch -- in this case, ATS1. Since
the emergency loads are typically lighting, and the critical
loads are usually far from the emergency switchgear fed by
smaller conductors, the motor contribution for this example is
assumed to be insignificant.
Each generator is capable of supplying 24,000 amperes of
fault current. A total of 96,000 amperes of fault current for
the four generators would be available at the Bus L/R.
Generator LVPCBs G1, G2, G3, and G4 would only be
required to have interrupting capacities of 3 x 24,000
amperes, or 72,000 amperes. For example, for a fault at point
"A" in the conductors between Generator G2 and Generator
Breaker G2, generator breaker G2 would only have to
interrupt the fault current from Generators G1, G3, and G4.
Generator G2 fault current would not pass through generator
breaker G2. For a load side main Bus L fault at point "B",
generator breaker G2 would only have to interrupt the fault
current from G2.
The tie breaker GT would have to be capable of
interrupting 2 x 24,000 amperes. Feeder breakers GF1, GF2,
GF3, and GF4 would need to be capable of interrupting 4 x
24,000 amperes, or 96,000 amperes. For example, if a fault
occurred at point "C", all four generators would contribute to
the fault current. The highest possible short delay current
rating for the LVPCB feeder breakers would also be needed
to allow the MCCB breakers in downstream EDP panels to
open first if a fault occurred on the load side of an ATS (for
example at point "D"). This would keep the entire EDP panel
from losing service.
A better design to support coordination and continuity of
service to the critical loads would involve eliminating the
EDP panels equipped with MCCB breakers. Instead, each
transfer switch would be fed directly from additional
LVPCBs. However, this improved design would be more
costly, and would require automatic transfer switches able to
withstand (momentary) time ratings equal to the short delay
time setting on the power circuit breakers [Refer to the
discussion for example 3].
Cautions to Keep in Mind
In many cases, the X/R ratio of generators is very high,
and the system X/R ratio can exceed the tested X/R ratio
equal to 6.6 for LVPCBs. This would require de-rating of
the breaker interrupting and short delay current capability.
For smaller generators, or systems where the symmetrical
rms interrupting capacity of the breaker appears to be
adequate for the calculated symmetrical rms current, de-
rating may also be required. A breaker with higher
interrupting capacity and a higher short delay current rating
may be needed so the
 Figure 8: Power Distribution System with Multiple Generators
breaker's interrupting capacity will still exceed the system's
available symmetrical rms current when the de-rating
appropriate X/R factor is applied.
In large generating systems, it is critical that the X/R ratio
is checked when using load side molded case circuit
breakers. Also, spot network transformers may have a higher
X/R ratio than conventional transformers, and may require
de-rating of conventional equipment and selection of higher
than normal device interrupting and short delay current
ratings.
C. Example #3 – Large KVA Transformers or Transformers
with Low Impedance
Since the installed cost for low voltage substations is
significantly lower in terms of $’s/KVA for larger KVA rated
substations, there is a trend toward higher ratings including
3000KVA, 3750KVA and beyond. The example shown in
Fig. 9 utilizes an outdoor 3750 kVA liquid filled transformer
with a double secondary throat connection. The two
secondary bus runs feed a 3000 ampere main breaker, which
in turn feeds 800 ampere feeder breakers.
With this configuration, several users have elected to rely
on Insulated Case Circuit Breakers (ICCBs) to obtain an
interrupting capacity that was high enough to support this
application. Since this system has 78,466 amperes available
from the transformer [3750 kVA / (0.480 x 1.732 x 0.0575
Z)], plus approximately 15,000 amperes of motor
contribution, it required devices with 100,000 ampere
interrupting capacity. The use of fused LVPCBs would
result in likely loss of selectivity for high fault conditions and
significantly higher costs along with additional floor space.
Thus, ICCBs with higher 100KA interrupting ratings, has
been the historic best solution. However, this technology
only supports short delay current rating of 25,000 amperes
for the feeder breakers and 35,000 amperes for the main
breakers.
If a fault greater than 25,000 amperes occurred on the load
side of any of the combination starters within a motor control
center, total coordination for that MCC would be lost. In the
event of a 50,000-ampere fault at point "A" on a branch
circuit of MCC1, the entire MCC1 would be out of service
because of breaker F1 opening. In addition, all MCCs
connected to switchgear bus 1 would be lost due to the
Figure 9: Power Distribution System with 3750KVA Power Transformer
a current magnitude greater than 35,000 amperes would be
more than likely based on the high available fault current of
the source. With the advent of new LVPCB technology with
short delay current ratings of 85,000 amperes and
interrupting ratings of 100,000 amperes, significantly better
coordination can be achieved without sacrificing the floor
space required by fused LVPCBs.
IV. CONSIDERATION OF SHORT DELAY TIME SETTINGS AS
THEY AFFECT LOAD SIDE EQUIPMENT PROTECTION
Fig. 10 shows a facility fed by a basic single line, with
normal loads served by LVPCB Feeders F1, F2, and F3. The
facility has its critical computer or process loads served by
LVPCB feeder F4, through ATS 1, LVPCB feeder CUPS,
through the Uninterruptable Power Supply "UPS", and
critical feeders CF-1, CF-2, and CF-3. In addition, there is a
maintenance bypass LVPCB that's designated CBP. Critical
panels CP-1, CP-2 and CP-3 serve the critical loads and
utilize molded case circuit breakers. Circuit Breakers CF-1,
CF-2, and CF-3 were selected as LVPCBs to provide
coordination with the molded case breakers in the critical
panels. Typically with modern microprocessor trip units and
breaker operating mechanisms, a 6-cycle short time delay
difference is sufficient to achieve coordination between these
types of devices.
Since coordination between breakers is desired at all levels,
bypass breaker CBP and CUPS would have their short delay
time set at 12 cycles. Feeder F4 would require an 18-cycle
short delay time setting and the main M1 would require a 24-
opening of main breaker M1. If a fault were to occur,
cycle short delay time setting. If the scheme incorporated
two incoming lines with normal mains M1, M2 and a tie
breaker, the tie breaker short delay time would be set at 24
cycles and the main breakers short delay time set at either 24
or 30 cycles.
For a fault at point "A" of current magnitude at least ten
times the MCCB frame, the MCCB breaker in CP-1 would
open, while all upstream LVPCBs would stay closed. For a
fault at point "B" in the main bus of panel CP-1, or in the
conductors at Point "C", feeder breaker CF-1 would time for
6 cycles and then open to clear the fault. For a fault at point
"D" in the bypass feeder, breaker CBP would time for 12
cycles and then clear the fault.
If a fault occurred at point "E", Main Switchgear LVPCB
short delay would time for 18 cycles and then clear the fault.
This would mean the fault current would be passing through
the main switchgear bus and ATS1 for the 18-cycle period of
time. In this application, an Automatic Transfer Switch
"ATS1" would have to "withstand" the fault current passing
through it for a minimum of 18 cycles.
Most conventional contactor type automatic transfer
switches have a "Momentary" or "Withstand" time rating of
only 3-cycles. Transfer switches outfitted with Insulated
Case Breakers or PCBs are available with up to 30-cycle
withstand time ratings. The transfer switch momentary
current rating must be greater than the available fault current
at its point of application.
Per ANSI standards, low voltage switchgear bus is
designed and braced to carry rated short circuit current for 30
cycles. On the other hand, the switchboard bus, the motor
 Figure 10: Ratings of Load Equipment for Short Time Delay Service
control center bus, and the panelboard bus have only 3 cycle
momentary ratings. While busway is only required to be rated
for a 3-cycle momentary rating, some types are available with
a 6-cycle rating.
If a fault were to occur at point "A" at the critical panel, at
point "F" at MCC 1, or at point "G" on the bus plug feeder,
the appropriate molded case circuit breaker would open
within one cycle. As a result, the critical panel or MCC or
busway 3-cycle momentary rating would be sufficient.
V. ZONE SELECTIVE INTERLOCKING
Today's modern microprocessor trip units are usually
available with zone selective interlocking. If zone selective
interlocking is specified to be wired between trip units within
a switchgear assembly -- or from one switchgear assembly to
another switchgear assembly -- this feature can be used.
Zone selective interlocking allows the short delay time
settings to be set in 6-cycle steps for coordination purposes.
However, it will override these settings when the fault
condition is located directly on the load side of each
protective device.
Zone selective interlocking makes the full short delay
capability of the selected breaker available for coordination
with load side protective devices, while it provides fast
opening of a breaker when a fault is located directly on its
load side to minimize damage. If zone selective interlocking
were specified for the power circuit breakers located in the
main switchgear in Figure 10, the time settings previously
discussed would still be used. A fault occurring on the main
switchgear bus at point "H", is on the load side of main
breaker M1, and the line side feeders, F1, F2, F3 and F4. Due
to the location of the fault, only the trip unit in main breaker
M1 would sense high fault current. Since breakers F1, F2,
F3, and F4 did not sense a high fault current they would not
send a restraining signal to main breaker M1. This would
indicate that the fault was not on the load side of any of the
feeder breakers. Instead of timing out to the M1 breaker
preset value of 24 cycles, main breaker M1 would open in
approximately 3 to 5 cycles, minimizing damage.
If the fault were located at point "E", then breaker F4
would send a restraining signal to main breaker M1
indicating the fault was on the load side of the F4 feeder
breaker. Main breaker M1 would then continue to time out
to its preset 24-cycle value. When the F4 feeder breaker
opened in 18 cycles to clear the fault, the fault current would
no longer be present at M1 main breaker and M1 breaker trip
unit would stop timing.
Similarly, consider the results if zone selective
interlocking were wired between the Main Switchgear and
the UPS Switchgear breaker trip units. If a fault occurred at
point “E”, breakers CUPS and CBP would not send a
restraining signal to breaker F4. Without a restraint signal,
breaker F4 would open in 3 to 5 cycles in lieu of its preset
timing value of 18 cycles, and would minimize damage. On
the other hand, if a fault was at point “D”, breaker CBP
would send a signal back to breaker F4 allowing it to proceed
and time out to its 18 cycle short delay setting. Meanwhile
breaker CBP would open after 12 cycles and cleared the
fault. Obviously, if zone selective interlocking were wired
between the UPS switchgear breakers and the critical
switchgear breakers, for the same fault at point “D”, breaker
CBP would open in 3 to 5 cycles.
Problems can arise when Insulated Case Breakers or
LVPCBs are used as both mains and feeder breakers in
switchboards (in lieu of ANSI metal-enclosed switchgear),
and can subject the switchboard bus to momentary time
requirements past its 3-cycle rating. This being the case, the
momentary current rating of load side equipment and
conductors, along with the momentary time rating must be
considered.
VI. SUMMARY
Adequate short delay current and short delay time ratings
are needed to facilitate coordinated distribution systems
during fault conditions. This ensures that only the circuit
breaker closest to the fault opens. An MCCB and a LVPCB
with identical published short delay current ratings will
respond to the same fault current in a different manner, based
on their individual X/R ratio design test capabilities. The
specifier should understand the circuit X/R ratio for his
system, and it’s effect on the published short time rating of
the circuit breaker protective devices. When the X/R ratio of
the application exceeds breaker test standards, a de-rating
factor must be used to calculate the effective short delay
current and interrupting rating of the breaker. There is a need
to review both current and time ratings of load equipment
during design. The availability of a new LVPCB with higher
than previously available short delay current and interrupting
capacity can in many applications enable the systems
designer to engineer a fully coordinated system, resulting in
better protection while improving system performance.
VII. REFERENCES
[1] ANSI C37.13 IEEE Standard for Low-Voltage AC
Power Circuit Breakers Used in Enclosures
ANSI C37.16 Low Voltage Power Circuit Breakers
and AC Power Circuit Protectors – Preferred
Ratings, Related Requirements, and Application
Recommendations
ANSI C37.17 Trip Devices for AC and General
Purpose DC Low-Voltage Power Circuit Breakers
ANSI C37.20.1 IEEE Standard for Metal-Enclosed
Low-Voltage Power Circuit-Breaker Switchgear
ANSI C37.50 Low-Voltage AC Power Circuit
Breakers Used in Enclosures – Test Procedures
ANSI C37.51 Metal-Enclosed Low-Voltage AC
Power-Circuit-Breaker Switchgear Assemblies –
Conformance Test Procedures
NEMA SG3 Low-Voltage Power Circuit Breakers
NEMA SG5 Power Switchgear Assemblies
UL1066 Low-Voltage AC and DC Power Circuit
Breakers Used in Enclosures
UL1558 Metal-Enclosed Low-Voltage Power
Circuit Breaker Switchgear
[2] ANSI C37.13-1981, Paragraph 5.6.1
[3] UL489 and UL1066 Test Standards for low voltage
power circuit breakers