Index

Contents
Description Page Fuseology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Bussmann Power Distribution Fuses. . . . . . . . . . . . . . . . . . . . 12-14 Bussmann Fuseblocks, Holders, and Disconnect Switches. . . . . . 14 General Data Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . 15 General Data Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Conductor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18 Equipment Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-21 Transformer Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24 Cable Limiter Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 High Speed Fuse Applications . . . . . . . . . . . . . . . . . . . . . . . . 26-27 3 Short-Circuit Calculations . . . . . . . . . . . . . . . . . . . . . . . . . 28-30 1 Short-Circuit Calculations . . . . . . . . . . . . . . . . . . . . . . . . . 31-32 Short-Circuit, Impedance and Reactance Data. . . . . . . . . . . . . . . 33 C Values for Conductors and Busway . . . . . . . . . . . . . . . . . . . . 34 Voltage Drop Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-37 Selective Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Selective Coordination Reading Time-Current Curves . . . . . 39-41 Selective Coordination Current-Limiting Fuses . . . . . . . . . . 42-44 Selective Coordination Elevator Circuits . . . . . . . . . . . . . . . 45-46 Component Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-49 Component Protection Wire and Cable . . . . . . . . . . . . . . . 50-51 Component Protection Bus Short-Circuit Rating and Bracing Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-53 Component Protection Low Voltage Motor Controllers . . . . . . . 54 Component Component Component Component Protection Protection Protection Protection Ballasts. . . . . . . . . . . . . . . . . . . . . . . . 55 Circuit Breakers . . . . . . . . . . . . . . . 55-56 Transfer Switches . . . . . . . . . . . . . . . . 57 HVAC Equipment . . . . . . . . . . . . . . . . 57 Description Flash Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page . 63-64 . 65-74 . 75-77

Motor Protection Voltage Unbalance/Single-Phasing . . . . . . 78-83 Motor Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 115 Volt Single-Phase Motor Circuits. . . . . . . . . . . . . . . . . . . . . . 85 230 Volt Single-Phase Motor Circuits. . . . . . . . . . . . . . . . . . . . . . 86 200 Volt Three-Phase Motor Circuits . . . . . . . . . . . . . . . . . . . 87-88 208 Volt Three-Phase Motor Circuits . . . . . . . . . . . . . . . . . . . 89-90 230 Volt Three-Phase Motor Circuits . . . . . . . . . . . . . . . . . . . 91-92 460 Volt Three-Phase Motor Circuits . . . . . . . . . . . . . . . . . . . 93-94 575 Volt Three-Phase Motor Circuits . . . . . . . . . . . . . . . . . . . 95-96 90 Volt DC Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 180 Volt DC Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 120 Volt DC Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 240 Volt DC Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Main, Feeder, and Branch Circuit Protection. . . . . . . . . . . . . . . . 100 Protection of Motor Starters . . . . . . . . . . . . . . . . . . . . . . . . 101-103 Motor Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Group Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Group Switching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Overcurrent Devices for Motor Circuit Protection . . . . . . . . . 107-108 Motor Circuit Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109-110 Motor Control Circuit Protection . . . . . . . . . . . . . . . . . . . . . 111-113 Fuse Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114-116 Main, Feeder, and Branch Circuit Fuse Sizing. . . . . . . . . . . . . . . 117 Suggested Fuse Specification . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119-120 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Back Cover

Component Protection Let-Through Charts . . . . . . . . . . . . 58-62

This handbook is intended to clearly present product data and technical information that will help the end user with design applications. Bussmann reserves the right, without notice, to change design or construction of any products and to discontinue or limit their distribution. Bussmann also reserves the right to change or update, without notice, any technical information contained in this handbook. National Electrical Code is a trademark of the National Fire Protection Association, Inc., Batterymarch Park, Quincy, Massachusetts, for a triennial electrical publication. The term, National Electrical Code as used herein means the triennial publication constituting the National Electrical Code and is used with permission of the National Fire Protection Association, Inc. Copyright 1998 by Cooper Bussmann, Inc. http://www.bussmann.com Printed in U.S.A.

ELECTRICAL PROTECTION HANDBOOK

Bussmann

Selecting Protective Devices Based On the National Electrical Code

Contents

Index

Next

Fuseology
Circuit Protection Electrical distribution systems are often quite complicated. They cannot be absolutely fail-safe. Circuits are subject to destructive overcurrents. Harsh environments, general deterioration, accidental damage or damage from natural causes, excessive expansion or overloading of the electrical distribution system are factors which contribute to the occurrence of such overcurrents. Reliable protective devices prevent or minimize costly damage to transformers, conductors, motors, and the other many components and loads that make up the complete distribution system. Reliable circuit protection is essential to avoid the severe monetary losses which can result from power blackouts and prolonged downtime of facilities. It is the need for reliable protection, safety, and freedom from fire hazards that has made the fuse a widely used protective device. Short-Circuits Whereas overload currents occur at rather modest levels, the short-circuit or fault current can be many hundred times larger than the normal operating current. A high level fault may be 50,000 amperes (or larger). If not cut off within a matter of a few thousandths of a second, damage and destruction can become rampantthere can be severe insulation damage, melting of conductors, vaporization of metal, ionization of gases, arcing, and fires. Simultaneously, high level short-circuit currents can develop huge magnetic-field stresses. The magnetic forces between bus bars and other conductors can be many hundreds of pounds per linear foot; even heavy bracing may not be adequate to keep them from being warped or distorted beyond repair. Fuses The fuse is a reliable overcurrent protective device. A fusible link or links encapsulated in a tube and connected to contact terminals comprise the fundamental elements of the basic fuse. Electrical resistance of the link is so low that it simply acts as a conductor. However, when destructive currents occur, the link very quickly melts and opens the circuit to protect conductors and other circuit components and loads. Fuse characteristics are stable. Fuses do not require periodic maintenance or testing. Fuses have three unique performance characteristics: 1. They are safe. Modern fuses have an extremely high interrupting ratingcan withstand very high fault currents without rupturing. 2. Properly applied, fuses prevent blackouts. Only the fuse nearest a fault opens without upstream fuses (feeders or mains) being affectedfuses thus provide selective coordination. (These terms are precisely defined in subsequent pages.) 3. Fuses provide optimum component protection by keeping fault currents to a low value. . .They are said to be currentlimiting.

Fuses are constructed in an almost endless variety of configurations. These photos depict the internal construction of Bussmann DualElement and SEMI-TRON fuses.

Overcurrents An overcurrent is either an overload current or a short-circuit current. The overload current is an excessive current relative to normal operating current, but one which is confined to the normal conductive paths provided by the conductors and other components and loads of the distribution system. As the name implies, a short-circuit current is one which flows outside the normal conducting paths. Overloads Overloads are most often between one and six times the normal current level. Usually, they are caused by harmless temporary surge currents that occur when motors are started-up or transformers are energized. Such overload currents, or transients, are normal occurrences. Since they are of brief duration, any temperature rise is trivial and has no harmful effect on the circuit components. (It is important that protective devices do not react to them.) Continuous overloads can result from defective motors (such as worn motor bearings), overloaded equipment, or too many loads on one circuit. Such sustained overloads are destructive and must be cut off by protective devices before they damage the distribution system or system loads. However, since they are of relatively low magnitude compared to short-circuit currents, removal of the overload current within a few seconds will generally prevent equipment damage. A sustained overload current results in overheating of conductors and other components and will cause deterioration of insulation, which may eventually result in severe damage and short-circuits if not interrupted.

The Louisiana Superdome in New Orleans is the worlds largest fully enclosed stadium. The overall electrical load exceeds 30,000,000 VA. Distribution circuits are protected with BUSS LOW-PEAK fuses.

Contents

Index

Next

Previous

Fuseology
Interrupting Rating - Safe Operation A protective device must be able to withstand the destructive energy of short-circuit currents. If a fault current exceeds a level beyond the capability of the protective device, the device may actually rupture, causing additional damage. Thus, it is important when applying a fuse or circuit breaker to use one which can sustain the largest potential short-circuit currents. The rating which defines the capacity of a protective device to maintain its integrity when reacting to fault currents is termed its interrupting rating. The interrupting rating of most branch-circuit, molded case, circuit breakers typically used in residential service entrance panels is 10,000 amperes. (Please note that a molded case circuit breakers interrupting capacity will typically be lower than its interrupting rating.) Larger, more expensive circuit breakers may have interrupting ratings of 14,000 amperes or higher. In contrast, most modern, current-limiting fuses have an interrupting rating of 200,000 or 300,000 amperes and are commonly used to protect the lower rated circuit breakers. The National Electrical Code, Section 110-9, requires equipment intended to break current at fault levels to have an interrupting rating sufficient for the current that must be interrupted. The subjects of interrupting rating and interrupting capacity are treated later in more detail.

This photograph vividly illustrates the effects of overcurrents on electrical components when protective devices are not sized to the ampere rating of the component.

Considerable damage to electrical equipment can result if the interrupting rating of a protective device is inadequate and is exceeded by a short-circuit current.

Voltage Rating Most low voltage power distribution fuses have 250 volt or 600 volt ratings (other ratings are 125 volts and 300 volts). The voltage rating of a fuse must be at least equal to or greater than the circuit voltage. It can be higher but never lower. For instance, a 600 volt fuse can be used in a 208 volt circuit. The voltage rating of a fuse is a function of its capability to open a circuit under an overcurrent condition. Specifically, the voltage rating determines the ability of the fuse to suppress the internal arcing that occurs after a fuse link melts and an arc is produced. If a fuse is used with a voltage rating lower than the circuit voltage, arc suppression will be impaired and, under some fault current conditions, the fuse may not clear the overcurrent safely. Special consideration is necessary for semiconductor fuse application, where a fuse of a certain voltage rating is used on a lower voltage circuit. Ampere Rating Every fuse has a specific ampere rating. In selecting the ampere rating of a fuse, consideration must be given to the type of load and code requirements. The ampere rating of a fuse normally should not exceed the current carrying capacity of the circuit. For instance, if a conductor is rated to carry 20 amperes, a 20 ampere fuse is the largest that should be used. However, there are some specific circumstances in which the ampere rating is permitted to be greater than the current carrying capacity of the circuit. A typical example is the motor circuit; dual-element fuses generally are permitted to be sized up to 175% and non-time-delay fuses up to 300% of the motor full-load amperes. As a rule, the ampere rating of a fuse and switch combination should be selected at 125% of the continuous load current (this usually corresponds to the circuit capacity, which is also selected at 125% of the load current). There are exceptions, such as when the fuse-switch combination is approved for continuous operation at 100% of its rating.

Fuses are a universal protective device. They are used in power distribution systems, electronic apparatus, vehicles. . .and as illustrated, our space program. The Space Shuttle has over 600 fuses installed in it protecting vital equipment and circuits.

Contents

Index

Next

Previous

Fuseology
The table below depicts four different situations involving an overcurrent device with a normal current rating of 100 amperes and an interrupting rating of only 10,000 amperes.
Circuit with Overcurrent Protective Device Current Rating= 100A and Interrupting Rating= 10,000A Circuit Conditions Application And Action of Protective Device Proper Available fault current50,000 amps

Fuse must have short-circuit interrupting rating of at least 50,000 amperes.

Normal

Available fault current50,000 amps

80

100 Amperes AMMETER LOAD Overload Current Greater Than Devices Ampere Rating Proper-Safe Interruption of Current

Circuit breaker must have capability of interrupting at least 50,000 amperes.

200

10,000

Short-Circuit Proper-Safe Current Interruption Within Device of Current Interrupting Rating

As depicted in the diagram that follows, when using overcurrent protective devices with limited interrupting rating, it becomes necessary to determine the available short-circuit currents at each location of a protective device. The fault currents in an electrical system can be easily calculated if sufficient information about the electrical system is known. See the Point-to-Point Method for shortcircuit calculations. With modern fuses, these calculations normally are not necessary since the 200,000 ampere interrupting rating is sufficient for most applications.

50,000

Short-Circuit Current Exceeds Device Interrupting Rating

Improper Explosion or Rupture Could Result

75,000 Amperes

75,000 Amperes

In the first three instances, the circuit current condition is within the safe operating capabilities of the overcurrent protective device. However, the fourth case involves a misapplication of the overcurrent device. A short-circuit on the load side of the device has resulted in a fault current of 50,000 amperes flowing through the overcurrent device. Because the fault current is well above the interrupting rating of the device, a violent rupture of the protective device and resulting damage to equipment or injury to personnel is possible. The use of high interrupting rated fuses (typically rated at 200,000 amperes) would prevent this potentially dangerous situation. The first paragraph of Section 110-9 requires that the overcurrent protective device be capable of interrupting the available fault current at its line terminals.

25,000 Amperes

30,000 Amperes

15,000 Amperes

Available short-circuit current (indicated by X) at each panel location must be determined to assure short-circuit interrupting rating of overcurrent protective devices is not exceeded.

Contents

Index

Next

Previous

Fuseology
General Fuse Application Data For Compliance With NEC, Section 110-9.
Guideline New Installations 1. Use modern, high interrupting rated fuses throughout electrical system. Features 300,000 ampere interrupting rating, on LOW-PEAK YELLOW fuses. 200,000 ampere interrupting rating on other classes of modern current-limiting fuses. Correct type and size current-limiting fuse can protect low withstand rated equipment against high short-circuit currents. (See fuse protection of circuit breakers). 200,000 ampere interrupting rating. Benefits Assure proper interrupting rating compliance currently and future. Usually a short-circuit current calculation study is unnecessary. Compliance with NEC 110-9. Commonly Used Fuse Types All modern current-limiting fuses (most have 200,000 ampere interrupting rating). LOW-PEAK YELLOW fuses have a 300,000 ampere interrupting rating. LOW-PEAK YELLOW Dual-Element T-TRON Fast-Acting LIMITRON Fast-Acting

2. Use current-limiting fuses to protect low withstand rated components.

System UpGrading

3. Where available fault current has increased or is questionable, replace old style fuses such as One-Time and Renewable with modern high interrupting rated fuses. 4. Where existing equipment may have questionable withstand rating due to deterioration, or the available fault current has increased, install modern currentlimiting fuses.

Provide safer electrical system protection with simple direct retrofit. Easily achieved since older style fuses can physically be replaced with modern fuses with no system modification.

LOW-PEAK YELLOW Dual-Element FUSETRON Dual-Element LIMITRON Fast-Acting

Correct type and size current-limiting fuses can be put in switch, cut-in system or sometimes fuses can be cut in bus structure.

Provide sale electrical system protection. Small size of T-TRON fuse permits easy cut-in strategy.

T-TRON Fast-Acting LOW-PEAK YELLOW Dual-Element LIMITRON Fast-Acting LOW-PEAK YELLOW Time-Delay

Selective Coordination - Prevention of Blackouts The coordination of protective devices prevents system power outages or blackouts caused by overcurrent conditions. When only the protective device nearest a faulted circuit opens and larger upstream fuses remain closed, the protective devices are selectively coordinated (they discriminate). The word selective is used to denote total coordination. . .isolation of a faulted circuit by the opening of only the localized protective device.

Unlike electro-mechanical inertial devices (circuit breakers), it is a simple matter to selectively coordinate fuses of modern design. By maintaining a minimum ratio of fuse-ampere ratings between an upstream and downstream fuse, selective coordination is assured. Minimum selectivity ratios for BUSS fuses are presented in a composite table (see the Selectivity Ratio Guide, page 15). Adherence to the tabulated selectivity ratios normally proves adequate.

KRP-C 1200SP

LPS-RK 600SP

LPS-RK 200SP 2:1 (or more)

2:1 (or more)

This diagram shows the minimum ratios of ampere ratings of LOWPEAK YELLOW fuses that are required to provide selective coordination (discrimination) of upstream and downstream fuses.

Contents

Index

Next

Previous

Fuseology
Current-Limitation - Component Protection
Areas within waveform loops represent destructive energy impressed upon circuit components

Normal load current Circuit breaker trips and opens short-circuit in about 1 cycle

Initiation of short-circuit current

A non-current-limiting protective device, by permitting a short-circuit current to build up to its full value, can let an immense amount of destructive short-circuit heat energy through before opening the circuit.

Fuse opens and clears short-circuit in less than cycle

A current-limiting fuse has such a high speed of response that it cuts off a short-circuit long before it can build up to its full peak value. This burnt out switchboard represents the staggering monetary losses in equipment and facility downtime that can result from inadequate or deteriorated protective devices. It emphasizes the need for reliable protective devices that properly function without progressive deterioration over time.

If a protective device cuts off a short-circuit current in less than one-half cycle, before it reaches its total available (and highly destructive) value, the device is a current-limiting device. Most modern fuses are current-limiting. They restrict fault currents to such low values that a high degree of protection is given to circuit components against even very high short-circuit currents. They permit breakers with lower interrupting ratings to be used. They can reduce bracing of bus structures. They minimize the need of other components to have high short-circuit current withstand ratings. If not limited, short-circuit currents can reach levels of 30,000 or 40,000 amperes or higher in the first half cycle (.008 seconds, 60 hz) after the start of a short-circuit. The heat that can be produced in circuit components by the immense energy of short-circuit currents can cause severe insulation damage or even explosion. At the same time, huge magnetic forces developed between conductors can crack insulators and distort and destroy bracing structures. Thus, it is important that a protective device limit fault currents before they reach their full potential level.

Contents

Index

Next

Previous

Fuseology
Operating Principles of BUSS Fuses The principles of operation of the modern, current-limiting BUSS fuses are covered in the following paragraphs. Non-Time-Delay Fuses The basic component of a fuse is the link. Depending upon the ampere rating of the fuse, the single-element fuse may have one or more links. They are electrically connected to the end blades (or ferrules) (see Figure 1) and enclosed in a tube or cartridge surrounded by an arc quenching filler material. BUSS LIMITRON and T-TRON fuses are both single-element fuses. Under normal operation, when the fuse is operating at or near its ampere rating, it simply functions as a conductor. However, as illustrated in Figure 2, if an overload current occurs and persists for more than a short interval of time, the temperature of the link eventually reaches a level which causes a restricted segment of the link to melt. As a result, a gap is formed and an electric arc established. However, as the arc causes the link metal to burn back, the gap become progressively larger. Electrical resistance of the arc eventually reaches such a high level that the arc cannot be sustained and is extinguished. The fuse will have then completely cut off all current flow in the circuit. Suppression or quenching of the arc is accelerated by the filler material. Single-element fuses of present day design have a very high speed of response to overcurrents. They provide excellent shortcircuit component protection. However, temporary, harmless overloads or surge currents may cause nuisance openings unless these fuses are oversized. They are best used, therefore, in circuits not subject to heavy transient surge currents and the temporary overload of circuits with inductive loads such as motors, transformers, solenoids, etc. Because single-element, fast-acting fuses such as LIMITRON and T-TRON fuses have a high speed of response to short-circuit currents, they are particularly suited for the protection of circuit breakers with low interrupting ratings. Whereas an overload current normally falls between one and six times normal current, short-circuit currents are quite high. The fuse may be subjected to short-circuit currents of 30,000 or 40,000 amperes or higher. Response of current-limiting fuses to such currents is extremely fast. The restricted sections of the fuse link will simultaneously melt (within a matter of two or three-thousandths of a second in the event of a high-level fault current). The high total resistance of the multiple arcs, together with the quenching effects of the filler particles, results in rapid arc suppression and clearing of the circuit. (Refer to Figures 4 & 5) Shortcircuit current is cut off in less than a half-cycle, long before the short-circuit current can reach its full value (fuse operating in its current-limiting range).

Figure 1. Cutaway view of typical single-element fuse.

Figure 2. Under sustained overload, a section of the link melts and an arc is established.

Figure 3. The open single-element fuse after opening a circuit overload.

Figure 4. When subjected to a short-circuit current, several sections of the fuse link melt almost instantly.

Figure 5. The open single-element fuse after opening a shorted circuit.

With continued growth in electrical power generation, the higher levels of short-circuit currents made available at points of consumption by electrical utilities have greatly increased the need for protective devices with high short-circuit interrupting ratings. Devices that can interrupt only moderate levels of short-circuit currents are being replaced by the modern fuse having the ability to cut-off short-circuit currents at levels up to 300,000 amperes.

Contents

Index

Next

Previous

Fuseology
Dual-Element, Time-Delay Fuses as Manufactured by Bussmann Unlike single-element fuses, the dual-element, time-delay fuse can be applied in circuits subject to temporary motor overloads and surge currents to provide both high performance short-circuit and overload protection. Oversizing in order to prevent nuisance openings is not necessary. The dual-element, time-delay fuse contains two distinctly separate types of elements (Figure 6). Electrically, the two elements are series connected. The fuse links similar to those used in the non-time-delay fuse perform the short-circuit protection function; the overload element provides protection against low-level overcurrents or overloads and will hold an overload which is five times greater than the ampere rating of the fuse for a minimum time of 10 seconds. As shown in Figure 6, the overload section consists of a copper heat absorber and a spring operated trigger assembly. The heat absorber bar is permanently connected to the heat absorber extension (left end of illustration) and to the short-circuit link on the opposite end of the fuse by the S-shaped connector of the trigger assembly. The connector electrically joins the short-circuit link to the heat absorber in the overload section of the fuse. These elements are joined by a calibrated fusing alloy. As depicted in Figure 7, an overload current causes heating of the short-circuit link connected to the trigger assembly. Transfer of heat from the short-circuit link to the heat absorbing bar in the mid-section of the fuse begins to raise the temperature of the heat absorber. If the overload is sustained, the temperature of the heat absorber eventually reaches a level which permits the trigger spring to fracture the calibrated fusing alloy and pull the connector free of the shortcircuit link and the heat absorber. As a result, the short-circuit link is electrically disconnected from the heat absorber, the conducting path through the fuse is opened, and overload current is interrupted. A critical aspect of the fusing alloy is that it retains its original characteristic after repeated temporary overloads without degradation. BUSS dual-element fuses, typically LOW-PEAK YELLOW and FUSETRON fuses, utilize the spring-loaded design in the overload element.

Figure 6. The true dual-element fuse has distinct and separate overload and short-circuit elements.

Figure 7. Under sustained overload conditions, the trigger spring fractures the calibrated fusing alloy and releases the connector.

Figure 8. The open dual-element fuse after opening under an overload condition.

Figure 9. Like the single-element fuse, a short-circuit current causes the restricted portions of the short-circuit elements to melt and arcing to burn back the resulting gaps until the arcs are suppressed by the arc quenching material and increased arc resistance.

Figure 10. The open dual-element fuse after opening under a shortcircuit condition.

Bussmann high performance fuses are used in tens of thousands of industrial plants, commercial buildings, and homes throughout the world.

Contents

Index

Next

Previous

Fuseology
Advantages of Bussmann Dual-Element, Time-Delay Fuses The preceding table shows that a 40 ampere, dual-element fuse will protect the 32.2 ampere motor, compared to the much larger, 100 ampere, single-element fuse that would be necessary. It is apparent that if a sustained, harmful overload of 300% occurred in the motor circuit, the 100 ampere, single-element fuse would never open and the motor could be damaged. The nontime-delay fuse, thus, only provides ground fault and short-circuit protection, requiring separate overload protection per the NEC. In contrast, the 40 ampere dual-element fuse provides ground fault, short-circuit and overload protection. The motor would be protected against overloads due to stalling, overloading, worn bearings, improper voltage, single-phasing, etc. In normal installations, Bussmann dual-element fuses of motor-running, overload protection size, provide better short-circuit protection plus a high degree of back up protection against motor burnout from overload or single-phasing should other overload protective devices fail. If thermal overloads, relays, or contacts should fail to operate, the dual-element fuses will act independently and thus protect the motor. When secondary single-phasing occurs, the current in the remaining phases increases to a value of 170% to 200% of rated full-load current. When primary single-phasing occurs, unbalanced voltages that occur in the motor circuit cause excessive current. Dual-element fuses sized for motor overload protection can protect motors against the overload damage caused by single-phasing. Permit the Use of Smaller and Less Costly Switches
200V 3 Phase 200V 3 Phase

Bussmann Dual-Element, Time-Delay fuses have four distinct advantages over single-element, non-time-delay fuses:
1. Provide motor overload, ground fault and short-circuit protection. 2. Permit the use of smaller and less costly switches. 3. Give a higher degree of short-circuit protection (greater current limitation) in circuits in which surge currents or temporary overloads occur. 4. Simplify and improve blackout prevention (selective coordination).

Motor Overload and Short-Circuit Protection

200V 3 Phase Dual-Element LOW-PEAK YELLOW or FUSETRON Fuse

100A Switch

60A Switch

M
32.2 Full Load Amperes (10 HP)

100A Non-Time-Delay LIMITRON Fuse

40A Dual-Element FUSETRON or LOW-PEAK YELLOW Fuse

When used in circuits with surge currents such as those caused by motors, transformers, and other inductive components, the Bussmann LOW-PEAK YELLOW and FUSETRON dual-element, time-delay fuses can be sized close to full-load amperes to give maximum overcurrent protection. Sized properly, they will hold until surges and normal, temporary overloads subside. Take, for example, a 10 HP, 200 volt, three-phase motor with a full-load current rating of 32.2 amperes. Fuse and Switch Sizing for 10 HP Motor (200V, 3, 32.2 FLA) Maximum Fuse Required Switch *Fuse Type
Dual-Element, Time-Delay (LOW-PEAK YELLOW or FUSETRON) Single-Element, Non-TimeDelay (LIMITRON) *Per N.E.C. Section 430-32. Per N.E.C. Section 430-52. Size (Amperes) 40A* Size (Amperes) 60A

32.2 F.L.A. (10 HP)

32.2 F.L.A. (10 HP)

Aside from only providing short-circuit protection, the singleelement fuse also makes it necessary to use larger size switches since a switch rating must be equal to or larger than the ampere rating of the fuse. As a result, the larger switch may cost two or three times more than would be necessary were a dual-element LOW-PEAK YELLOW or FUSETRON fuse used. The larger, single-element fuse itself could generate an additional cost. Again, the smaller size switch that can be used with a dual-element fuse saves space and money. (Note: where larger switches already are installed, fuse reducers can be used so that fuses can be sized for motor overload protection.)

100A

100A

Contents

Index

Next

Previous

Fuseology
Better Short-Circuit Component Protection (Current-Limitation) The non-time-delay, fast-acting fuse must be oversized in circuits in which surge or temporary overload currents occur. Response of the oversized fuse to short-circuit currents is slower. Current builds up to a higher level before the fuse opens. . .the current-limiting action of the oversized fuse is thus less than a fuse whose ampere rating is closer to the normal full-load current of the circuit. Therefore, oversizing sacrifices some component protection. Oversizing should not exceed NEC requirements. Current-Limitation of Dual-Element Fuses Versus Non-Time-Delay Fuses Used to Protect 10 HP Motor (32.2 FLA).
Fuse Type Fuse Name Let-Through Current Versus Prospective Short-Circuit Currents (RMS Symmetrical) 25,000A 50,000A 100,000A 2000A 3300A 4400A 1800A 3100A 2200A 4100A 3000A 5000A

element fuses in the branch circuit for motor overload protection provides a large difference (ratio) in the ampere ratings between the feeder fuse and the branch fuse, compared to the singleelement, non-time-delay LIMITRON fuse. Better Motor Protection in Elevated Ambients The derating of dual-element fuses based on increased ambient temperatures closely parallels the derating curve of motors in elevated ambient. This unique feature allows for optimum protection of motors, even in high temperatures.

Dual-Element (40A)

FUSETRON LOW-PEAK YELLOW LIMITRON

Non-Time-Delay (100A)

In the table above, it can be seen that the 40 ampere LOWPEAK YELLOW dual-element fuse used to protect a 10 HP (32.2 FLA) motor keeps short-circuit currents to approximately half the value of the non-time-delay fuse. Better Selective Coordination (Blackout Prevention) The larger an upstream fuse is relative to a downstream fuse (for example, feeder to branch), the less possibility there is of an overcurrent in the downstream circuit causing both fuses to open (lack of selective coordination). Fast-acting, non-time-delay fuses require at least a 3:1 ratio between the ampere rating of a large upstream, line-side LOW-PEAK YELLOW time-delay fuse and that of the downstream, loadside LIMITRON fuse in order to be selectively coordinated. In contrast, the minimum selective coordination ratio necessary for LOW-PEAK YELLOW dual-element fuses is only 2:1 when used with LOW-PEAK YELLOW loadside fuses.
208V 3 Phase 208V 3 Phase

Affect of ambient temperature on operating characteristics of FUSETRON and LOW-PEAK YELLOW Dual-Element Fuses.

150A DualElement LOW-PEAK YELLOW or LIMITRON Fuse 90A NonTimeDelay LIMITRON Fuse

150/90 = 1.67:1 Inadequate (Minimum ratio must be at least 3:1 for Selective Coordination)

150A DualElement LOW-PEAK YELLOW Fuse 40A DualElement LOW-PEAK YELLOW Fuse

150/40 = 3.75:1 Adequate (Minimum ratio need only be 2:1 for Selective Coordination)

32.2 F.L.A. (10 HP)

32.2 F.L.A. (10 HP)

The use of time-delay, dual-element fuses affords easy selective coordinationcoordination hardly requires anything more than a routine check of a tabulation of required selectivity ratios. As shown in the preceding illustration, close sizing of BUSS dual-

Contents

Index

Next

Previous

Fuseology
Classes of Fuses Safety is the industry mandate. However, proper selection, overall functional performance and reliability of a product are factors which are not within the basic scope of listing agency activities. In order to develop its safety test procedures, listing agencies develop basic performance and physical specifications or standards for a product. In the case of fuses, these standards have culminated in the establishment of distinct classes of low-voltage (600 volts or less) fuses, Classes RK1, RK5, G, L, T, J, H and CC being the more important. The fact that a particular type of fuse has, for instance, a classification of RK1, does not signify that it has the identical function or performance characteristics as other RK1 fuses. In fact, the LIMITRON non-time-delay fuse and the LOW-PEAK YELLOW dual-element, time-delay fuse are both classified as RK1. Substantial difference in these two RK1 fuses usually require considerable difference in sizing. Dimensional specifications of each class of fuse does serve as a uniform standard. Class R Fuses Class R (R for rejection) fuses are high performance, to 600 ampere units, 250 volt and 600 volt, having a high degree of current-limitation and a short-circuit interrupting rating of up to 300,000 amperes (RMS symmetrical). BUSS Class Rs include Classes RK1 LOW-PEAK YELLOW and LIMITRON fuses, and RK5 FUSETRON fuses. They have replaced BUSS K1 LOWPEAK and LIMITRON fuses and K5 FUSETRON fuses. These fuses are identical, with the exception of a modification in the mounting configuration called a rejection feature. This feature permits Class R to be mounted in rejection type fuseclips. R type fuseclips prevent older type Class H, ONE-TIME and RENEWABLE fuses from being installed. Since Class H fuses are not current-limiting and are recognized by regulatory agencies as having only a 10,000 ampere interrupting rating, serious damage could results if a Class R fuse were replaced by a Class H fuse. The use of Class R fuseholders is thus an important safeguard. The application of Class R fuses in such equipment as disconnect switches permits the equipment to have a high interrupting rating. NEC Articles 1109 and 230-65 require that protective devices have adequate capacity to interrupt short-circuit currents. Article 240-60(b) requires fuseholders for current-limiting fuses to reject non-current-limiting type fuses.

In the above illustration, the fuse on the right has a grooved ring in one ferrule providing the rejection feature of the Class R fuse in contrast to the lower interrupting rating, non-rejection type.

The above illustration shows Class R type fuse rejection clips which accept only the Class R rejection type fuses. Branch-Circuit Listed Fuses Branch-circuit listed fuses are designed to prevent the installation of fuses that cannot provide a comparable level of protection to equipment. The characteristics of branch-circuit fuses are: 1. They must have a minimum interrupting rating of 10,000 amps. 2. They must have a minimum voltage rating of 125 volts. 3. They must be size rejecting such that a fuse of a lower voltage rating cannot be installed in the circuit. 4. They must be size rejecting such that a fuse with a current rating higher than the fuseholder rating cannot be installed.

10

Contents

Index

Next

Previous

Fuseology
Medium Voltage Fuseology General Fuses above 600 volts are classified under one of three classifications as defined in ANSI/IEEE C37.40. 1. GENERAL PURPOSE CURRENT-LIMITING FUSES A fuse capable of interrupting all currents from the rated interrupting current down to the current that causes melting of the fusible element in one hour. 2. BACK-UP CURRENT-LIMITING FUSE A fuse capable of interrupting all currents from the maximum rated interrupting current down to the rated minimum interrupting current. 3. EXPULSION FUSE A vented fuse in which the expulsion effect of gasses produced by the arc and lining of the fuseholder, either alone or aided by a spring, extinguishes the arc. One should note that in the definitions above, the fuses are defined as either expulsion or current-limiting. A current-limiting fuse is a sealed, non-venting fuse that, when melted by a current within its interrupting rating, produces arc voltages exceeding the system voltage, which in turn forces the current to zero. The arc voltages are produced by introducing a series of high resistance arcs within the fuse. The result is a fuse that typically interrupts high fault currents within the first 1/2 cycle of the fault. In contrast, an expulsion fuse depends on one arc to initiate the interruption process. The arc acts as a catalyst, causing the generation of de-ionizing gas from its housing. The arc is then elongated, either by the force of the gasses created or a spring. At some point, the arc elongates far enough to prevent a restrike after passing through a current zero. Therefore, an expulsion fuse may take many cycles to clear. Construction Current-limiting fuses have four parts common to all designs: tube, end ferrules, element, and arc quenching filler. The tube must have a high burst strength to withstand the pressures generated during interruption. The most common materials used are fiberglass reinforced epoxy and melamine tubing. End ferrule designs are usually dictated by the application. For example, a clip mounted fuse would have a silver-plated ferrule with a large surface area to insure good contact. In contrast, a stud mounted fuse may be cast bronze with very little surface area. In both designs it is very important that a good seal be provided between the tube and end ferrules. This is most commonly done with a gasket and magna-forming process, or with epoxy and screws. Fuse elements are currently made from silver. Silver is the most common material used for high voltage fuse elements because of its predictable melting properties. To achieve this low current operation, it is necessary to either add a series element of different material or reduce the melting temperature of the silver by adding an M spot. Finally, an arc quenching filler is added to aid in the interruption process. During interruption the arc quenching filler is changed into an insulating material called fulgurite. Application Many of the rules for applying expulsion fuses and current-limiting fuses are the same, but because the current-limiting fuse operates much faster on high fault currents, some additional rules must be applied. Three basic factors must be considered when applying any fuse. These are: VOLTAGE, CONTINUOUS CURRENT CARRYING CAPACITY, INTERRUPTING RATING. Voltage The fuse must have a voltage rating equal to or greater than the normal frequency recovery voltage which will be seen across the fuse under all conditions. On three-phase systems, it is a good rule of thumb that the voltage rating of the fuse be greater than or equal to the line-to-line voltage of the system. Continuous Current-Carrying Capacity Continuous current values that are shown on the fuse represent the level of current the fuse can carry continuously without exceeding the temperature rises as specified in ANSI C37.46. An application that exposes the fuse to a current slightly above its continuous rating but below its minimum interrupting rating, may damage the fuse due to excessive heat. This is the main reason overload relays are used in series with back-up current-limiting fuses for motor protection. Interrupting Rating All fuses are given a maximum interrupting rating. This rating is the maximum level of fault current that the fuse can safely interrupt. Back-up current-limiting fuses are also given a minimum interrupting rating. When using back-up current-limiting fuses, it is important that other protective devices are used to interrupt currents below this level. Additional Rules EXPULSION FUSES: When choosing a fuse, it is important that the fuse be properly coordinated with other protective devices located upstream and downstream. To accomplish this, one must consider the melting and clearing characteristics of the devices. Two curves, the minimum melting curve and the total clearing curve, provide this information. To insure proper coordination, the following rules should be used. 1. The total clearing curve of any downstream protective device must be below a curve representing 75% of the minimum melting curve of the fuse being applied. 2. The total clearing curve of the fuse being applied must lie below a curve representing 75% of the minimum melting curve for any upstream protective device. Current-Limiting Fuses To insure proper application of a current-limiting fuse it is important that the following additional rules be applied. 1. As stated earlier, current-limiting fuses produce arc voltages that exceed the system voltage. Care must be taken to make sure that the peak voltages do not exceed the insulation level of the system. If the fuse voltage rating is not permitted to exceed 140% of the system voltage, there should not be a problem. This does not mean that a higher rated fuse cannot be used, but points out that one must be assured that the system insulation level (BIL) will handle the peak arc voltage produced. 2. As with the expulsion fuse, current-limiting fuses must be properly coordinated with other protective devices on the system. For this to happen the rules for applying an expulsion fuse must be used at all currents that cause the fuse to interrupt in 0.01 seconds or greater. When other current-limiting protective devices are on the system it becomes necessary to use I2t values for coordination at currents causing the fuse to interrupt in less than 0.01 seconds. These values may be supplied as minimum and maximum values or minimum melting and total clearing I2t curves. In either case, the following rules should be followed. 1. The minimum melting I2t of the fuse should be greater than the total clearing I2t of the downstream current-limiting device. 2. The total clearing I2t of the fuse should be less than the minimum melting I2t of the upstream current-limiting device.

11

Contents

Index

Next

Previous

Bussmann Power Distribution Fuses

LOW-PEAK
(Time-Delay) KRP-C_SP (600V) 601 to 6000A 300,000AIR Current-Limiting STD 248-10 CLASS L UL Guide #JFHR UL File #E56412 CSA Class #1422-02 CSA File #53787 The all-purpose silver linked fuse for both overload and short-circuit protection of high capacity systems (mains and large feeders). Time-delay (minimum of four seconds at five times amp rating) for close sizing. Unlike fast-acting fuses, time-delay fuses pass harmless surge currents of motors, transformers, etc., without overfusing or any sacrifice of short-circuit current limitation (component protection). The combination use of to 600 ampere LOW-PEAK YELLOW dualelement time-delay fuses and 601 to 6000A KRP-C LOWPEAK YELLOW fuses is recommended as a total system specification. Easily selectively coordinated for blackout protection. Size of upstream fuse need only be twice that of downstream LOW-PEAK YELLOW fuses (2:1 ratio). LOW-PEAK YELLOW fuses can reduce bus bracing; protect circuit breakers with low interrupting rating as well as provide excellent overall protection of circuits and loads.

LOW-PEAK
(Dual-Element, Time-Delay) LPS-RK_SP (600VAC, 300VDC) LPN-RK_SP (250VAC, 125VDC) to 600A 300,000AIR Current-Limiting STD 248-12 CLASS RK1 UL Guide #JFHR UL File #E56412 CSA Class #1422-02 CSA File #53787 High performance, all-purpose fuses. Provide the very high degree of short-circuit limitation of LIMITRON fuses plus the overload protection of FUSETRON fuses in all types of circuits and loads. Can be closely sized to full-load motor currents for reliable motor overload protection, as well as backup protection. Close sizing permits the use of smaller and more economical switches (and fuses); better selective coordination against blackouts; and a greater degree of current-limitation (component protection), LOW-PEAK YELLOW fuses are rejection type but fit non-rejection type fuseholders. Thus, can be used to replace Class H, K1, K5, RK5 or other RK1 fuses.

LOW-PEAK
(Dual-Element, Time-Delay) LPJ_SP (600V) 1 to 600A 300,000AIR Current-Limiting STD 248-8 CLASS J UL Guide #JFHR UL File #E56412 CSA Class #1422-02 CSA File #53787 Space saving LPJ fuses have the advantage of timedelay, permitting them to pass temporary overloads, offering overload, back-up overload, and short-circuit protection. Ideal for IEC starter protection.

FUSETRON
(Dual-Element, Time-Delay) FRS-R (600VAC, 300VDC) FRN-R (250VAC, 125VDC) to 600A 200,000AIR Current-Limiting STD 248-12 CLASS RK5 UL Guide #JDDZ UL File #E4273 CSA Class #1422-02 CSA File #53787 Time-delay affords the same excellent overload protection of LOW-PEAK YELLOW fuses of motors and other type loads and circuits having temporary inrush currents such as those caused by transformers and solenoids. (In such circuits, LIMITRON fuses can only provide shortcircuit protection). FUSETRON fuses are not as fast-acting as LOW-PEAK YELLOW fuses and therefore cannot give as high a degree of component short-circuit protection. Like the LOWPEAK YELLOW fuse, FUSETRON fuses permit the use of smaller size and less costly switches. FUSETRON fuses fit rejection type fuseholders and can also be installed in holders for Class H fuses. They can physically and electrically replace Class H, K5, and other Class RK5 fuses.

DURALAG
(Dual-Element, Time-Delay) Construction Grade Fuses DLS-R (600VAC, 300VDC) DLN-R (250VAC, 125VDC) 1 to 600A 200,000 AIR Current-Limiting STD 248-12 CLASS RK5 UL Guide #JDDZ UL File # E4273 CSA Class #1422-02 CSA File #53787 Designed for contractor needs. Protects industrial equipment and large motors. Recommended for AC power distribution system mains, feeders and branch circuits. Industry standard time delay of 10 seconds at 5 times the fuse rating.

BIF No. 1006, 1007

BIF No. 1021, 1022

LOW-PEAK
(Dual-Element, Time-Delay) LP-CC to 30A Current-Limiting 200,000AIR STD 248-4 CLASS CC UL Guide #JDDZ UL File #E4273 CSA Class #1422-02 CSA File #53787 The Bussmann LOW-PEAK YELLOW Class CC fuse (LP-CC) was developed specifically for a growing need in the industry - a compact, space saving branch circuit fuse for motor circuits. Its superior performance characteristics of both timedelay and current-limitation make it the newest member of the LOW-PEAK YELLOW family of fuses.

BIF No. 1001, 1002,1003, 1004

BIF No. 1017, 1018, 1019, 1020

BIF No. 1008, 1009

BIF No. 1023

12

Contents

Index

Next

Previous

LIMITRON
(Fast-Acting) KTU (600V) 601 to 6000A 200,000AIR Current-Limiting STD 248-10 CLASS L UL Guide #JDDZ UL File #E4273 CSA Class #1422-02 CSA File #53787 Silver-linked fuse. Single-element units with no time-delay. Very fast-acting with a high degree of current limitation; provide excellent component protection. Can be used for short-circuit protection only in circuits with inrush currents. Must be oversized to prevent opening by the temporary harmless overloads with some sacrifice of current limitation. In motor circuits, must be sized at approximately 300% of motor full-load current and thus will not provide the overload protection of LOW-PEAK YELLOW KRP-C_SP fuses.

LIMITRON
(Fast-Acting) KTS-R (600V) KTN-R (250V) 1 to 600A 200,000AIR Current-Limiting STD 248-12 CLASS RK1 UL Guide #JDDZ UL File #E4273 CSA Class #1422-02 CSA File #53787 Single-element, fast-acting fuses with no time-delay. The same basic performance of the 601-6000A KTU fast-acting LIMITRON fuses. Provides a high degree of short-circuit current limitation (component protection). Particularly suited for circuits and loads with no heavy surge currents of motors, transformers, solenoids, and welders. LIMITRON fuses are commonly used to protect circuit-breakers with lower interrupting ratings. If used in circuits with surge currents (motors, etc.), must be oversized to prevent opening and, thus, only provide shortcircuit protection. Incorporate Class R rejection feature. Can be inserted in non-rejection type fuseholders. Thus, can physically and electrically replace fast-acting Class H, K1, K5, RK5, and other RK1 fuses.

LIMITRON
(Fast-Acting) JKS (600V) 1 to 600A 200,000AIR Current-Limiting STD 248-8 CLASS J UL Guide #JDDZ UL File #E4273 CSA Class #1422-02 CSA File #53787 JKS LIMITRON fuses are basically the same as RK1 LIMITRON fuses but somewhat smaller in physical size. JKS fuses are single-element units with no time-delay and are thus best applied in circuits free of the temporary overloads of motor and transformer surges. The smaller dimensions of Class J fuses prevent their replacement with conventional fuses.

ONE-TIME
(General Purpose) NOS (600V) NON (250V) to 600A Non-Current-Limiting (NON -60A) 50,000AIR (NOS 1-60A) 50,000AIR STD 248-9 CLASS K5 UL Guide #JDDZ UL File #E4273 CSA Class #1421-01 CSA File #53787 (NON 65-600A) 10,000AIR (NOS 70-600A) 10,000AIR STD 248-6 CLASS H UL Guide #JDDZ UL File #E4273 CSA Class #1421-01 CSA File #53787 With an interrupting rating of 10,000 amperes, and generally not considered current-limiting, Class H ONE-TIME fuses are used in circuits with low available short-circuit currents. Single-element ONE-TIME fuses do not incorporate time-delay.

T-TRON
(Fast-Acting) JJS (600V) 1-800A JJN (300V) 1-1200A 200,000AIR Current-Limiting STD 248-15 CLASS T UL Guide #JDDZ UL File #E4273 CSA Class #1422-02 CSA File #53787 The space-savers. Counterpart of the KTN-R/KTS-R LIMITRON fuses, but only one-third the size; thus, particularly suited for critically restricted space. A single-element fuse; extremely fast-acting. Provides a high degree of current limitation on shortcircuits for excellent component protection. Must be oversized in circuits with inrush currents common to motors, transformers, and other inductive components (will give only short-circuit protection). Commonly applied in electric heat circuits, load centers, disconnect switches, meters, stacks, etc. The small size of T-TRON fuses permits them to be installed in panelboards and control centers for system upgrading to protect static equipment with lower withstand ratings.

BIF No. 1026, 1027

BIF No. 1030

BIF No. 1010

LIMITRON
(Fast-Acting) KTK-R (600V) to 30A 200,000AIR Current-Limiting STD 248-4 CLASS CC UL Guide #JDDZ, UL File #E4273 CSA Class #1422-02 CSA File #53787 U.L. listed for branch circuit protection. A very small, high performance, fast-acting, single-element fuse for protection of branch circuits, motor control circuits, lighting ballasts, control transformers, street lighting fixtures. . .A diameter of only and a length of 1 give cost and space savings. A grooved ferrule permits mounting in rejection type fuseholders as well as standard non-rejection type holders.

LIMITRON
(Time-Delay) KLU (600V) 601 to 4000A 200,000AIR Current-Limiting STD 248-10 CLASS L UL Guide #JDDZ UL File #E4273 CSA Class #1422-02 CSA File #53787 5 second delay (minimum) at 500% of rated current. Not as current-limiting as KRP-C_SP or KTU fuses.

CC-TRON
(Time-Delay) FNQ-R (600V) to 30A 200,000AIR Current-Limiting STD 248-4 CLASS CC UL Guide #JDDZ UL File #E4273 CSA Class #1422-01 CSA File #53787 Ideal for control transformer protection. Meets requirements of NEC 430-72 (b) & (c) and UL 508. Its miniature design and branch circuit rating allow it to be used for motor branch circuit and short circuit protection required by NEC 430-52.

BIF No. 1044, 1043

BIF No. 1029, 1025

BIF No. 1013

BIF No. 1014

BIF No. 1015

13

Contents

Index

Next

Previous

Bussmann Fuseblocks, Holders, and Disconnect Switches

Plug Fuses
125V 10,000AIR

Optima Overcurrent Protection Modules

SAMI Fuse Covers with Option/Open Fuse Indication

SafetyJ Fuseholder for Class J Fuses

Type SC
(Fast-Acting) 1/2- 6A (Time-Delay) 8-60A SC (480V) 100,000AIR STD 248-5 CLASS G UL Guide #JDDZ UL File #E4273 CSA Class #1422-01 CSA File #53787 A high performance generalpurpose branch circuit fuse for lighting appliance, and motor branch circuits of 480 volts (or less). Fuse diameter is ; lengths vary with ampere rating from 1 to 2 (serves as rejection feature and, thus, prevents dangerous oversizing).

STD 248-11 Plug UL Guide #JFHR, #JEFV UL File #E56412, #E12112 (0-6A), (7-30A) CSA Class #1423-01 CSA File #53787 FUSTAT Type S fuses have a size limiting feature which prevents overfusing. Dual element construction provides the time-delay necessary for motor running protection. Sizes from thru 30 amps.

Compact, full-featured modules that deliver Type 2 coordinated protection, with properly sized fuses. Available in a broad range of combinations for process control panel applications. Mounts Class CC and midget style fuses.

Compact and touch-safe design that meets IP 20 Std. Fuse is removed/installed external to circuit. Open fuse indication available. Integral 35mm DIN Rail adapter.

BIF No. 1152

Dead front protection, optional open fuse indication. The SAMI fuse covers fit most fuses and fuseblocks. Covers snap on in seconds - no special wiring required.

Fuseblocks

BIF No. 1102, 1103

Modular Fuseholder CH Series

BIF No. 1204

Power Distribution Blocks

STD 248-11Plug UL Guide #JEFV UL File #E12112 FUSETRON Type T fuses are similar to Type S fuses except for the Edison (light bulb type) base.

BIF No. 1024

Excellent for switchboard panels, control consoles, small motors, transformers and similar applications. Touchsafe design with optional open fuse indication lights.

BIF No. 1151

STD 248-11 Plug UL Guide #JEFV UL File #E12112 Type W fuses are non-time delay, used with non-inductive loads.

Compact Disconnect Switches

For industrial controls, HVAC and other control automation panel applications. Available in 1, 2, or 3-pole versions and a wide range of input/output terminations.

BIF No. 1148

BIF No. 1032, 1034, 1036

Bussmann disconnect switches used in manual control of single-phase or three-phase AC motors.

Fusible and NonFusible Disconnect Switches

Buss fuseblocks are available in a wide range of sizes for power distribution, high speed semi-conductor protection and electronic applications. UL Listed, CSA certified. Classes H (K), R, T, J and CC fuses. Standard module and pyramid styles available.

BIF No. 1120

Panel-Mount Fuseholders
Feature packed line of fusible and non-fusible disconnect switches for virtually every industrial application.

BIF No. 1139

Shown above is a typical Buss panel-mount fuseholder. This HPS-RR holder is a rejection type which accepts rejection type branch circuit fuses such as the Buss LPCC, KTK-R and FNQ-R.

BIF No. 2113

14

Contents

Index

Next

Previous

General Data Selection Chart

Buss Fuse Selection Chart (600 Volts or Less)
Circuit Load Ampere Fuse Rating Type Symbol Voltage Rating (AC) Class Interrupting Rating (kA) 300 Remarks

Conventional DimensionsClass RK1, RK5 (0-600A), L (601-6000A) All type loads (optimum overcurrent protection). Motors, welder, transformers, capacitor banks (circuits with heavy inrush currents). 100,000A Interrupting Rating (RMS symmetrical) or Greater Current-Limiting 0 to 600A 601 to 6000A 0 to 600A 0 to 600A 601 to 4000A Non-motor loads (circuits with no heavy inrush currents). LIMITRON fuses particularly suited for circuit breaker protection. 0 to 600A LOW-PEAK (dual-element, time-delay) LOW-PEAK (time-delay) FUSETRON (dual-element, time-delay) DURA-LAGTM (dual-element, time-delay) LIMITRON (time-delay) LPN-RK_SP LPS-RK_SP KRP-C_SP FRN-R FRS-R DLN-R DLS-R KLU KTN-R KTS-R LIMITRON (fast-acting) KTU 600V L 200 250V 600V 600V 250V 600V 250V 600V 600V 250V 600V RK1 All-purpose fuses. Unequaled for combined short-circuit and overload protection. (Specification grade product) Moderate degree of current-limitation. Time-delay passes surge-currents.

L RK5

300 200

RK5

200

L RK1

200 200

Main, Feeder and Branch

All-purpose fuse. Timedelay passes surge-currents. Same short-circuit protection as LOW-PEAK fuses but must be sized larger for circuits with surge-currents; i.e., up to 300%. A fast-acting, high performance fuse.

_____
601 to 6000A

Reduced Dimensions For Installation in Restricted SpaceClass J(0-600A), T(0-1200A), CC(0-30A), G(0-60A) All type loads (optimum overcurrent protection). LOW-PEAK (dual-element, time-delay) LPJ_SP 600V J 300 All-purpose fuses. Unequaled for combined short-circuit and overload protection. (Specification grade product) Very similar to KTS-R LIMITRON, but smaller. The space saver ( the size of KTN-R/KTS-R). Very compact ( 1); rejection feature. Excellent for motor circuit protection. Very compact ( 1); rejection feature. Excellent for outdoor highway lighting. Very compact ( 1); rejection feature. Excellent for control transformer protection. Current limiting; dia. varying lengths per amp rating. Forerunners of the modern cartridge fuse. Base threads of Type S differ with amp ratings. T and W have Edison base. T & S fuses recommended for motor circuits. W not recommended for circuits with motor loads.

0 to 600A

__________
Non-motor loads (circuits with no heavy inrush currents). Motor loads (circuits with heavy inrush currents.) Non-motor loads (circuits with no heavy inrush currents.) Control transformer circuits and lighting ballasts; etc. General purpose; i.e., lighting panelboards. Miscellaneous

LIMITRON (quick-acting) 0 to 1200A 0 to 30A 0 to 30A 0 to 30A 0 to 60A 0 to 600A T-TRONTM (fast-acting) LOW-PEAK (time-delay)

JKS JJN JJS LP-CC

600V 300V 600V 600V

J T CC

200 200 200

LIMITRON (fast-acting)

KTK-R

600V

CC

200

Branch

TRON (time-delay) SC

FNQ-R

600V

CC

200

SC

480V

100

ONE-TIME

NON NOS S

250V 600V 125V

H or K5

10

10,00050,000 AIC

General Purpose (noncurrent limiting fuses)

Plug fuses can be used for branch circuits and small component protection.

0 to 30A

FUSTAT (dual-element, time-delay) FUSETRON (dual-element, time-delay) Buss Type W

10

125V

**

10

125V

**

10

** U.L. Listed as Edison Base Plug Fuse. Some ampere ratings are available as U.L. Class K5 with a 50,000A interrupting rating. RK1 and RK5 fuses fit standard switches, fuseblocks and holders; however, the rejection feature of Class R switches and fuseblocks designed specifically for rejection type fuses (RK1 and RK5) prevent the insertion of the non-rejection fuses (K1, K5, and H).

15

Contents

Index

Next

Previous

General Data Dimensions (Inches)

CLASS T
T-TRON Fuses JJN (300V) JJS (600V)
.88 .41 Dia. 1A to 30A .88 .56Dia. 35A to 60A 2.16 1.56 .84 601A to 800A .75 35A to 60A 3.98 2.95 1.78 1.25 .88 450A to 600A 110A to 200A 2.75 1.84 .86 1 225A to 400A 3.06 2.03 .88 .88 1.25 450A to 600A 3.38 2.22 .92 .75 1.75 70A to 100A 601A to 800A 4 2.53 1.08 .81 1.56 110A to 200A 2.95 2.36 1.64 225A to 400A 3.25 2.5 1.66 7.13 5.25 3.38 225A to 400A .58 8.0 6.0 3.75 450A to 600A .74 2.13 1 3.63 2.72 1.73 .43 1 .28 .13 70A to 100A 5.75 4.38 3.0 110A to 200A .43" 4.63 3.63 2.63 1.75 4.33 3.17 1.88

CLASS J
LOW-PEAK & LIMITRON Fuses LPJ & JKS (600V)
2.25 .5 .81

CLASS RK5 & RK1

FUSETRON, LOW-PEAK & LIMITRON Fuses (250V & 600V) FRN-R & FRS-R; LPN-RK & LPS-RK; KTN-R & KTS-R
Basic dimensions are same as Class H (formerly NEC) ONE-TIME (NON & NOS) and SUPERLAG Renewable RES & REN fuses. NOTE: These fuses can be used to replace existing Class H, RK1 and RK5 fuses relating to dimensional compatibility. A
1.13

1A to 30A 2.38 .63 1.06

70A to100A 2.44 1.69 .84

.75

250V
Ampere -30 35-60 A 2 3 A
1.63
B

600V
B .56 .81 A 5 5.5 B .81 1.06

1.13 .28

1.38"

.19"

FUSETRON & LIMITRON

250V
.41 1.63 1.88 .25 2

600V
A 7.88 9.63 11.63 13.38 B 1.34 1.84 2.59 3.13

Ampere 70-100 110-200 225-400 450-600

A 5.88 7.13 8.63 10.38

B 1.06 1.56 2.06 2.59

LOW-PEAK & FRS-R

250V
.53 2 2.5 .38

600V
A 7.88 9.63 11.63 13.38 B 1.16 1.66 2.38 2.88

Ampere 70-100 110-200 225-400 450-600

A 5.88 7.13 8.63 10.38

B 1.16 1.66 2.38 2.88

CLASS L
35A to 60A 2 .56 1.5 1A to 30A .88 1.75

LOW-PEAK & LIMITRON Fuses KRP-C, KTU, & KLU (601 - 4000A) (600V)
1.63 1.38 .81 1.75 .88 1.38

801A to 1200A

NOTE: KRP-CL (150A to 600A) fuses have same dimensions as 601A to 800A case size. KTU (400A to 600A) have same dimensions, except tube 3 lgth. 2 dia.; terminal 1/ width 1/ thick.

.63 All Slots and Holes

801A to 1200A

1350A to 1600A

1800A to 2000A

8.63 601A to 800A 10.75 6.75 5.75

2001A to 2500A

3000A

3500A to 4000A

4500A to 5000A

6000A

6.75 3.75

.38

.38

.44

.5 .75 .75

.75

2 2.5

2 2.5

2.38 3

2.75 3.5

3.5 5

4 5

4.75 5.75

5.25 6.25

5.75 7.13

16

Contents

Index

Next

Previous

Conductor Protection
General All conductors must be protected against overcurrents in accordance with their ampacities, as set forth in NEC Section 240-3. They must also be protected against short-circuit current damage, as required by Sections 240-1 (Note) and 110-10. The safest, most economical way to meet these requirements is through the use of current-limiting fuses. Fuse ampere ratings must not be greater than the ampacity of the conductor. Section 240-3(b) states that if such conductor rating does not correspond to a standard size fuse, the next larger size fuse may be used, provided its rating does not exceed 800 amperes and the conductor is not part of a multi-outlet branch circuit supplying receptacles for cord and plug connected portable loads. When the ampacity of busway or cable bus does not correspond to a standard fuse size, the next larger standard fuse rating may be used, even though this rating may be greater than 800 amperes (364-10 and 365-5). Standard fuse sizes per Section 240-6 are: 1, 3, 6, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 125, 150, 175, 200, 225, 250, 300, 350, 400, 450, 500, 600, 601, 700, 800, 1000, 1200, 1600, 2000, 2500, 3000, 4000, 5000, and 6000 amperes. Note: The small fuse ampere ratings of 1, 3, 6, and 10 were added to provide more effective short-circuit and ground-fault protection for motor circuits, in accordance with Sections 430-40 and 430-52 and U.L. requirements for protecting the overload relays in controllers for very small motors. Per Section 240-4 Flexible cords and extension cords shall have overcurrent protection rated at their ampacities. Supplementary fuse protection is an acceptable method of protection. For #18 fixture wire of 50 feet or more, a 6 amp fuse would provide the necessary protection. For #16 fixture wire of 100 feet or more, an 8 amp fuse would provide the necessary protection. For #18 extension cords, a 10 amp fuse would provide the necessary protection for a cord where only two conductors are carrying current, and a 7 amp fuse would provide the necessary protection for a cord where only three conductors are carrying current. Location of Fuses in Circuit (Section 240-21) Fuses must be installed at the point where the conductor receives its supply, i.e., at the beginning or lineside of a branch circuit or feeder (240-21). A) Fuses are not required at the conductor supply if a feeder tap conductor is not over ten feet long; is enclosed in raceway; does not extend beyond the switchboard, panelboard or control device which it supplies; and has an ampacity not less than the combined computed loads supplied, and not less than the rating of the device supplied, unless the tap conductors are terminated in a fuse not exceeding the tap conductor ampacity [240-21(b)]. For field installed taps, the ampacity of the tap conductor must be at least 10% of the overcurrent device rating. See Note following D. B) Fuses are not required at the conductor supply if a feeder tap conductor is not over 25 feet long; is suitably protected from physical damage; has an ampacity not less than 1/ 3 that of the feeder conductors or fuses from which the tap conductors receive their supply; and terminate in a single set of fuses sized not more that the tap conductor ampacity [240-21(c)]. See Note following D. C) Fuses are not required at the conductor supply if a transformer feeder tap has primary conductors at least 1/ 3 ampacity, and/or secondary conductors at least 1/ 3 ampacity, when multiplied by the approximate transformer turns ratio of the fuse or conductors from which they are tapped; the total length of one primary plus one secondary conductor (excluding any portion of the primary conductor that is protected at its ampacity) is not over 17 25 feet in length; the secondary conductors terminate in a set of fuses rated at the ampacity of the tap conductors; and if the primary and secondary conductors are suitably protected from physical damage [240-21(d)]. D) Fuses are not required at the conductor supply if a feeder tap is not over 25 feet long horizontally and not over 100 feet long total length in high bay manufacturing buildings where only qualified persons will service such a system. Also, the ampacity of the tap conductors is not less than 1/ 3 of the fuse rating from which they are supplied. The size of the tap conductors must be at least No. 6 AWG copper or No. 4 AWG aluminum. They may not penetrate walls, floors, or ceilings, and the taps are made no less than 30 feet from the floor [240-21(e)].
50 Amp Rated Conductor 150 Amp Feeder Fuse 480V. 150 Amp Rated Conductor TRANSFORMER 2:1 RATIO 100 Amp Fuse

100 Amp Rated Conductor 25 Feet or Less 100 Amp Rated Conductor

240V.

300 Amp Feeder Fuse 480V. 300 Amp Rated Conductor

100 Amp Fuse

TRANSFORMER 1:1 RATIO

100 Amp Rated Conductor

480V.

Note: Smaller conductors tapped to larger conductors can be a serious hazard. If not adequately protected against short-circuit conditions (as required in Sections 110-10 and 240-1), these unprotected conductors can vaporize or incur severe insulation damage. Molten metal and ionized gas created by a vaporized conductor can envelop other conductors (such as bare bus), causing equipment burndown. Adequate short-circuit protection is recommended for all conductors. When a tap is made to a switchboard bus for an adjacent panel, such as an emergency panel, the use of BUSS cable limiters is recommended for protection of the tapped conductor. These current-limiting cable limiters are available in sizes designed for short-circuit protection of conductors from #12 to 1000 kcmil. BUSS cable limiters are available in a variety of terminations to make adaption to bus structures or conductors relatively simple. E) Transformer secondary conductors of separately derived systems do not require fuses at the transformer terminals when all of the following conditions are met. [240-21(j)]: 1) Must be an industrial location. 2) Secondary conductors must be less than 25 feet long. 3) Secondary conductor ampacity must be at least equal to the secondary full-load current of transformer and sum of terminating, grouped, overcurrent devices. 4) Secondary conductors must be protected from physical damage. Note: Switchboard and panelboard protection (384-16) and transformer protection (450-3) must still be observed. F) Outside conductors that are tapped to a feeder or connected to the secondary terminals of a transformer do not require fuse protection when all of the following are met: 1) The conductors are protected from physical damage. 2) The conductors terminate in a single set of fuses, no larger than the ampacity of the conductors.

Contents

Index

Next

Previous

Conductor Protection
3) The conductors are outside, except for point of termination. 4) The overcurrent device is near or a part of the disconnecting means. 5) The disconnecting means is readily accessible outdoors or, if indoors, nearest the point of the entrance of the conductors. [240-21(m)]. Branch CircuitsLighting And/Or Appliance Load (No Motor Load) The branch circuit rating shall be classified in accordance with the rating of the overcurrent protective device. Classifications for those branch circuits other than individual loads shall be: 15, 20, 30, 40, and 50 amperes (210-3). Branch circuit conductors must have an ampacity of the rating of the branch circuit and not less than the load to be served (210-19). The minimum size branch circuit conductor that can be used is No. 14 (210-19). For exceptions to minimum conductor size, see 210-19. Branch circuit conductors and equipment must be protected by a fuse with an ampere rating which conforms to 210-20. Basically, the branch circuit conductor and fuse must be sized for non-continuous load (as calculated per Article 220) plus 125% of the continuous load (210-22 and 220-2). The fuse size must not be greater than the conductor ampacity (for exceptions, see 210-20). Branch circuits rated 15, 20, 30, 40, and 50 amperes with two or more outlets (other than receptacle circuits of 220-3b) must be fused at their rating and the branch circuit conductor sized according to Table 210-24 (see 210-24). Feeder Circuits (No Motor Load) The feeder fuse ampere rating and feeder conductor ampacity must be at least 100% of the non-continuous load plus 125% of the continuous load as calculated per Article 220 (220-10b). The feeder conductor must be protected by a fuse not greater than the conductor ampacity (for exceptions, see 240-3). Motor loads shall be computed in accordance with Article 430; see subsection on Motor Feeder Protection. For combination motor loads and other loads on feeders, see subsection on feeder combination motor, power, and lighting loads. Service Equipment Each ungrounded service entrance conductor shall have a fuse in series with a rating not higher than the ampacity of the conductor (for exceptions, see 230-90a-c). The service fuses shall be part of the service disconnecting means or be located immediately adjacent thereto (230-91). Service disconnecting means can consist of one to six switches for each service or for each set of service entrance conductors permitted in Section 230-2. When more than one switch is used, the switches must be grouped together (230-71). Service equipment must have adequate short-circuit ratings for the short-circuit currents available. (230-65) Transformer Secondary Conductors Secondary conductors need to be protected from damage by the proper overcurrent protective device. Although 240-3(i) provides an exception for conductors supplied by a single phase transformer with a 2-wire secondary, or a three-phase delta-delta transformer with a 3-wire, single voltage secondary, it is recommended that these conductors be protected. Primary overcurrent devices cannot adequately provide protection during internal transformer faults. Motor Circuit Conductor Protection Motors and motor circuits have unique operating characteristics and circuit components and therefore must be dealt with differently than other type loads. Generally, two levels of overcurrent protection are required for motor branch circuits: 1. Overload protection Motor running overload protection is intended to protect the system components and motor from damaging overload currents. 2. Short-circuit protection (includes ground fault protection)Shortcircuit protection is intended to protect the motor circuit components such as the conductors, switches, controllers, overload relays, motors, etc. against short-circuit currents or grounds. This level of protection is commonly referred to as motor branch circuit protection. Frequently, due to inherent limitations in various types of overcurrent devices for motor application, two or more separate protective devices are used to provide overload protection and shortcircuit protection. An exception is the dual-element fuse. For most motor applications, the beneficial features of dual-element fuse characteristics allow sizing of the FUSETRON and LOW-PEAK YELLOW fuses to provide both protection functions for motor circuits.

18

Contents

Index

Next

Previous

Equipment Protection
Listed or Labeled Equipment Listed or labeled equipment must be installed in accordance with instructions included in the listing or labeling (110-3b). Be sure to observe maximum branch circuit fuse size labels. When the equipment label is marked with a Maximum Fuse Ampere Rating rather than marked with Maximum Overcurrent Device Ampere Rating, only fuses can be used for protection of this equipment. Panelboards A maximum of 42 fuses (excluding main fuses) are permitted to be installed in a lighting and appliance branch circuit panelboard (384-15). Each lighting and appliance branch circuit panelboard must be individually protected on the supply side by not more than two sets of fuses having a combined rating not greater than that of the panelboard (384-16). Exception No. 1: Individual protection is not required when the panelboard feeder has overcurrent protection not greater than that of the panelboard. Exception No. 2: Individual protection in existing installations is not required for individual residential occupancy service entrance panelboards (384-16a). Panels with snap switches rated at 30 amperes or less must be protected by fuses not larger than 200 amperes (384-16b). Fusible panelboards are available with heavy duty toggle switches rated more than 30 amperes; these panelboards are not restricted by this 200 ampere requirement. When the load continues for more than 3 hours under normal operation, the total load on any fuse in the panelboard should not exceed 80% of the fuse rating (384-16c). Exception No. 1: Where the assembly including the overcurrent device is approved for continuous duty at 100% of its rating. If the panelboard is supplied through a transformer, the fuses for the protection of the panelboard must be located on the transformer secondary (384-16d) except when the transformer is singlephase with a two-wire secondary and the fuse on the primary complies with Section 450-3(b)(1) and does not exceed the value determined by multiplying the panelboard rating by the secondary to primary voltage ratio (384-16d Exception). Appliances Appliance branch circuits shall be protected in accordance with Section 240-3. If a fuse rating is marked on an appliance, the branch circuit fuse rating cannot exceed that rating marked on the appliance (422-6) For branch circuits which supply a single non-motor operated appliance rated more than 13.3 amperes, the fuse rating shall not exceed 150% of the appliance rating (422-28e). Electric heating appliances using resistance heating elements rated more than 48 amperes shall have the heating elements subdivided such that each subdivision does not exceed 48 amps and each subdivision shall be protected by a branch circuit listed fuse not to exceed 60 amperes in rating. These fuses shall be factory installed by the heater manufacturer and they should be accessible (for Exceptions, refer to Section 422-28). Fixed appliances are considered protected when supplied from 15, 20, 25, or 30 ampere branch circuits. Fixed cooking appliances are permitted to be protected by 40 or 50 ampere branch circuits (210-23). Household appliances with surface heating elements that have a maximum rating greater than 60 amperes must be divided into two or more circuits, each of which is protected by a fuse of no greater than 50 amperes. Portable appliances are considered as protected when supplied from a 15, 20, or 30 ampere branch circuit (210-23). Supplementary Protection Supplementary overcurrent protection is recognized by the National Electrical Code for use in lighting fixtures, appliances, and other equipment or for internal control circuits and components of equipment. This type of protection should not be used as a substitute for branch circuit protection as described in Article 210. This type of protection is not required to be readily accessible as are branch circuit devices. There are a wide variety of supplementary fuses and fuseholders which have small physical dimensions and are easily installed in or on equipment, appliances, or fixtures. The advantages of supplementary protection are closer fuse sizing for better individual protection, isolation of equipment on overcurrents so that the branch circuit fuse is not disturbed, ease in locating troubled equipment, and generally direct access to the fuse at the location of the equipment. Air Conditioning and Refrigeration Air conditioning and refrigeration equipment requirements are covered in Article 440 of the National Electrical Code. Hermetic motorcompressors are not rated in full-load amperes as are standard motors. Instead, different terms are used, such as Rated Load Current, Branch Circuit Selection Current, Maximum Continuous Current, Minimum Circuit Ampacity, and Maximum Overcurrent Protection. This equipment has overcurrent protection requirements that differ from that for ordinary motors covered in Article 430. Some highlights are presented here. BRANCH CIRCUIT PROTECTION Individual Motor-Compressor(s) and HVAC Equipment Having MotorCompressor(s) and Other Loads (Such as Fan Motors, Electric Heaters, Coils, etc.). Fuses sized for branch circuit protection only must not exceed 175% of the hermetic motor-compressor rated-load current or branch circuit selection current (whichever is larger). If this size fuse cannot withstand the motor starting current, a higher ampere rating is permitted, but in no case can the fuse size exceed 225% [Section 440-22(a)]. LOW-PEAK YELLOW dual-element and FUSETRON dualelement fuses are recommended for branch circuit protection of air conditioning and refrigeration hermetic motor-compressors because these fuses have an adequate time-delay for motor starting surges. Refer to the nameplate on the equipment. The sizing (ampere rating) for the overcurrent protection has been determined by the manufacturer of the equipment. It is not necessary to apply any further multipliers to arrive at the proper size. This has already been done by the manufacturer. The nameplate will indicate MAXIMUM SIZE FUSE. . .or. . .MAXIMUM SIZE FUSE OR HACR TYPE CIRCUIT BREAKER. The marked protective device rating is the maximum protective device rating for which the equipment has been investigated and found acceptable by nationally recognized testing laboratories. Where the marking specifies fuses, or HACR type circuit breakers, the equipment is intended to be protected only by the type of protective device specified. See Listed or Labeled Equipment for requirement when nameplate states MAXIMUM SIZE FUSE. This is a critical requirement, and must be followed without exception to be in compliance with Section 110-3(b) of the Code. NEC Section 110-3(b) requires that listed or labeled equipment must be installed in accordance with any instructions included in the listing or labeling. Disconnecting Means (Individual hermetic motor compressor) The ampere rating of the disconnect shall be at least 115% of the compressors rated load current or branch-circuit selection current, whichever is greater [Section 440-12(a)(1)]. The horsepower rating can be obtained by referring to Table 430-151 of the NEC, which shows the conversions from locked rotor current to horsepower [Section 440-12(a)(2)].

19

Contents

Index

Next

Previous

Equipment Protection
Disconnecting Means (Equipment that has hermetic motor-compressor and other loads) The ampere rating of the disconnecting means must be at least 115% of the sum of all of the individual loads within the equipment. . .at rated load conditions [Section 440-12(b)(2)]. The horsepower rating of the disconnecting means must be at least equal to the sum of all of the individual loads within the equipment. . .at rated load conditions. . .and at locked rotor conditions [Section 440-12(b)(1)]. The equivalent horsepower rating of the compressor can be obtained by referring to Table 430-151 of the NEC. Controller The controller for a hermetic motor-compressor must have a continuous duty full-load current rating and locked-rotor current rating not less than the nameplate rated current or branch circuit selection current (whichever is larger), (Section 440-41). Where the controller serves a hermetic motor-compressor(s) plus other loads, the controller rating is determined according to Section 440-12(b), in much the same manner as determining the disconnecting means rating. It may be necessary to refer to Table 430-151 to convert locked rotor current values to horsepower. The branch circuit protective device rating shall not exceed the maximum protective device rating shown on a manufacturers heater table for use with a given motor controller [Section 440-22(c)]. Where the equipment is marked MAXIMUM SIZE FUSE ampere rating rather than stating MAXIMUM OVERCURRENT DEVICE ampere rating, only fuses can be used for the branch circuit protection. Available Short-Circuit Current As with most electrical equipment, HVAC equipment is tested and listed based upon circuits capable of delivering specific maximum values of short-circuit current. Because of this, it is important that the available fault current at the line side terminals of the equipment does not exceed these values. Where the available fault current does exceed the above levels, it will be necessary to limit the fault current to levels within the withstand rating of the equipment as tested. This is done by installing current-limiting overcurrent devices in the branch circuit that will limit the fault current to within the acceptable levels of the present standards. See information about Current Limitation. Short-Circuit Test Currents
110-120V 9.8 or less 9.9 - 16.0 16.1 - 34.0 34.1 - 80.0 Over 80.0 200-208V 2.12 or less 2.13 - 3.7 3.8 - 9.5 9.6 - 23.3 Over 23.3 SINGLE-PHASE 200-208V 5.4 or less 5.5 - 8.8 8.9 - 18.6 18.7 - 44.0 Over 44.0 THREE-PHASE 220-240V 2.0 or less 2.1- 3.5 3.6 - 9.0 9.1 - 22.0 Over 22.0 220-240V 4.9 or less 5.0 - 8.0 8.1 -17.0 17.1 - 40.0 Over 40.0 440-480V 1.8 or less Over 1.8 254-277V 6.65 or less Over 6.65 550-600V 1.4 or less Over 1.4 Circuit Capacity In Amperes 200 1000 2000 3500 5000

Room Air Conditioners Room air conditioners (hermetic refrigerant motor-compressor) installed in the conditioned room are considered as single-motor units when the conditions of Section 440-62 are met. This condition also applies to conditioners containing a heating unit. Branch circuit requirements are determined by nameplate rating (440-62).

Electric Heat Electric space heating equipment employing resistance type heating elements, rated more than 48 amperes, must have heating elements subdivided. Each subdivided load must not exceed 48 amperes, and the fuse for each load should not exceed 60 amperes (424-22b). If a subdivided load is less than 48 amperes, the fuse rating should be 125% of that load. Exception: Boilers employing resistance type immersion electric heating elements in an ASME rated and stamped vessel may be subdivided into circuits not exceeding 120 amperes, and protected by a fuse at not more than 150 amperes (424-22b and 42472a). If a subdivided load is less than 120 amperes, the fuse rating should be 125% of that load. FUSETRON dual-element fuses in the sizes required above provide protection for electric heat applications (their lower internal resistance offers cooler operation than ordinary fuses). T-TRON fast-acting fuses (JJN and JJS) in the sizes required above provide protection for electric heat applications and offer small physical size to reduce space and material cost. Capacitors A fuse must be provided in each ungrounded conductor (no protection is required for a capacitor connected on the load-side of a motor running overcurrent device). The fuse rating must be as low as practical (460-8b). Generally, size dual-element, current-limiting fuses at 150% to 175% of the capacitor rated current and size nontime-delay, fast-acting, current-limiting fuses at 250% to 300% of the capacitor rated current. Conductor ampacity must be at least 135% of the capacitor rated current (460-8a). The ampacity of conductors for a capacitor connected to motor circuit must be 1/3 the ampacity of the motor circuit conductors (460-8a). Welders AC Transformer, Motor-Generator, and DC Rectifier Arc Welders each welder must be protected by a fuse rated at not more than 200% of the rated primary current. The fuse protecting the supply conductor can serve as the welder protection, if the fuse is rated at not more than 200% of the welder rated primary current (630-12a) and (630-22a). Conductors supplying one or more welders must be protected by a fuse rated at not more than 200% of the conductor rating (630-12b) and (630-22b). Resistance welders must be protected by a fuse rated at not more than 300% of the rated primary current of the welder. The fuse protecting the supply conductor can serve as the welder protection if the fuse is rated at not more than 300% of the welder rated primary current (630-32a). Conductors supplying one or more welders must be protected by a fuse rated at not more than 300% of the conductor rating (630-32b). 20

200 1000 2000 3500 5000

Table showing values of available short-circuit current used in testing HVAC equipment.

Just as SERIES-RATED SYSTEMS must be installed per the listings of the various manufacturers equipment in order to meet the intent of Section 110-3(b) of the Code, so must HVAC equipment be properly installed to Meet Code. To connect HVAC equipment to available fault currents that exceed the listed test levels could present a real hazard to personnel working on the equipment.

Contents

Index

Next

Previous

Equipment Protection
For arc welder and resistance welder protection, FUSETRON and LOW-PEAK YELLOW dual-element fuses can be sized much closer than the above limits of 200% and 300%, respectively. Generally, the ampere rating of these dual-element fuses can be sized at 100% of the conductor ampacity as determined according to the respective duty cycle multipliers found in Sections 630-11a, 63021a and 630-31a2. As an example, for a resistance welder rated on a 50% duty cycle, FUSETRON or LOW-PEAK YELLOW dual-element fuses can be sized at 71% of the welder rated primary current. Hazardous (Classified) Locations The characteristics of various atmospheric mixtures of hazardous gases, vapors and dusts depend on the specific hazardous material involved. It is necessary therefore that equipment be approved not only for the class of location but also for the specific gas, vapor or dust that will be present (500-2). Class I, Divisions 1 and 2 (501-6a and 501-6b3)Fuses may be used provided they are within enclosures approved for the purpose and location. In Division 2 locations, fuses are permitted in general enclosures if they are non-indicating, silver-sand, and current-limiting. Approved cartridge fuses filled with a non-combustible material shall be permitted in lighting fixtures (501-6b5). Class II, Division 1 (502-6a1)Fuses must be provided with enclosures approved for Class II locations. Class II, Division 2 (502-6b or 502-10b3)Fuses must be provided with dust tight metal enclosures. Class III (503-4)Fuses must be provided with dust tight enclosures. Mobile Homes The branch circuit equipment may be combined with the disconnecting means as a single assembly. Such a combination may be designated as a distribution panel. Plug fuses must be Type S (550-6). Branch circuit overcurrent devices must be rated (550-6b): 1. Not more than the circuit conductors, 2. Not more than 150% of the rating of a single appliance rated 13.3 amperes or more supplied by an individual branch circuit. 3. Not more than the fuse size marked on the air conditioner or other motor-operated appliance. Ballasts Each light fixture ballast should be individually protected by fuses. Fusing each fixture provides protection and isolation of a faulted ballast. When a ballast does fail, only the fuse for that fixture opens, and the remaining fixtures continue in normal operation. Without this individual ballast protection, a faulted ballast could cause the branch circuit protective device to open, thereby blacking out all fixtures. Additionally, special integrally protected ballasts, known as Class P Ballasts, are U.L. Listed under a 200A short-circuit test condition. This test is conducted utilizing a fuse as the branch protection. The starting current and continuous current characteristics for lighting ballast can vary considerably for various manufacturers. For proper fuse ampere rating, observe ballast manufacturers recommendation. There is a wide variety of supplementary and branch circuit fuses available for protection of light fixture ballasts including fluorescent lighting, mercury vapor lighting, and sodium lighting, indoor and outdoor.

Transformer Protection
Transformers600 Volts or Less The requirements of Section 450-3 cover only transformer protection. In practice, other components must be considered in applying circuit overcurrent protection. For circuits with transformers, requirements for conductor protection per Articles 240 and 310 and for panelboards per Article 384, must be observed. Refer to Sections 240-3(i), 240-21(b) (d) and (j), and 384-16(d). Primary Fuse Protection Only (450-3b1) (See Figure below) If secondary fuse protection is not provided (as discussed in the next Section) then the primary fuses must not be sized larger than 125% of the transformer primary full-load amperes except if the transformer primary F.L.A. is that shown in Section 450-3(b)1. Individual transformer primary fuses are not necessary where the primary circuit fuse provides this protection. Primary Fuse Only
Primary Current 9 amps or more Primary Fuse Rating 125% or next higher standard rating if 125% does not correspond to a standard fuse size. 167% maximum 300% maximum TRANSFORMER No Secondary Protection Primary Secondary 600V 600V Or Less Or Less Fuse must not be larger than 125% of transformer primary F.L.A. When no transformer secondary protection is provided (exceptions as noted above). Note: Section 450-3 requirements pertain only to transformer protections. Additional circuit overcurrent protection for conductors or panelboards may be required per Articles 240, 310, 384, 430-72.

*Primary Fuse (600 Volts or less) and Secondary Fuse (600 Volts or less) (450-3b2). If secondary (600 Volts or less) fuses are sized not greater than 125% of transformer secondary current, individual transformer fuses are not required in the primary (600 Volt or less) provided the primary feeder fuses are not larger than 250% of the transformer rated primary current. [See 450-3b(2) for overcurrent protection requirements of thermally protected transformers]. Primary and Secondary Fuses
Primary Current 9 amps or more Primary Fuse Rating 250% max. Secondary Fuse Rating 125% or next higher standard rating if 125% does not correspond to a standard fuse size 167% max.

Less than 9 amps

250% max.

2 amps to 9 amps Less than 2 amps

21

Contents

Index

Next

Previous

Transformer Protection
Note: Transformer overload protection will be sacrificed by using overcurrent protective devices sized much greater than the transformer F.L.A. The limits of 150%, 167%, 250% and 300% may not adequately protect transformers. It is suggested that for the highest degree of transformer overload protection the fuse size should be within 125% of the transformer full-load amperes. There is a wide fuse ampere rating range available to properly protect transformers. FUSETRON and LOW-PEAK YELLOW dual-element fuses can be sized on the transformer primary and/or secondary rated at 125% of the transformer F.L.A. These dualelement fuses have sufficient time-delay to withstand the high magnetizing inrush currents of transformers. There is a wide ampere rating selection in the 0 to 15 ampere range for these dualelement fuses to provide protection for even small control transformers. The required secondary protection may be satisfied with multiple overcurrent devices that protect feeders fed from the transformer secondary. The total ampere rating of these multiple devices may not exceed the allowed value of a single secondary overcurrent device. If this method is chosen, dual-element, timedelay fuse protection offers much greater flexibility. Note the following examples. This Design 1 utilizes a single secondary overcurrent device. It provides the greatest degree of selective coordination, transformer protection, secondary cable protection, and switchboard/panelboard/load center protection. The transformer cannot be overloaded to a significant degree if future loads are added (improperly) in the future.
No Single Secondary Device

250% 480/277V 208/120V 150 KVA IFLA = 417A

200A Switch LPN-RK 110SP

200A Switch LPN-RK 110SP

200A Switch LPN-RK 110SP

200A Switch LPN-RK 110SP

200A Switch LPN-RK 110SP

M 83A

M 83A

M 83A

M 83A

M 83A

Design 2 If the single secondary main is eliminated and MCPs are utilized as branch circuit protection (Design 3), the transformer will be seriously under-utilized because only one motor can be connected. For one motor, 1 700% of 83 = 581 amps. For two motors, 2 700% of 83 = 1162 amps. Since the sum of the devices cannot exceed 600 amps, only one motor can be connected when the motor circuit is protected by an MCP.
No Single Secondary Device

250% 480/277V 208/120V 150 KVA IFLA = 417A 480/277V This fuse or circuit breaker may be sized at 1.25 x 417A = 522A. The exception allows the next standard size of 600A to be used. 208/120V 250% 150 KVA IFLA = 417A

581A MCP 200A Switch LPN-RK 110SP 200A Switch LPN-RK 110SP 200A Switch LPN-RK 110SP 200A Switch LPN-RK 110SP 200A Switch LPN-RK 110SP Only one motor can be connected when the MCP is utilized, and this assumes the motor will start when the MCP is sized at 700%. Higher settings will result in current rating higher than the maximum allowable 600 amps.

M 83A M 83A M 83A M 83A M 83A M 83A

Design 3 Using the same procedure, if the single secondary main is eliminated and thermal magnetic circuit breakers are utilized (Design 4) as branch circuit protection per Section 450-152, only three of the motors can be connected because the thermal magnetic breakers will have been sized at approximately 250% of the motor F.L.A. (83 250% = 207.5A.) Note: If sized less than permitted by Section 430-152, nuisance tripping may result since the new energy efficient motors have higher inrush currents.

Design 1 If the single secondary overcurrent device is eliminated, much of the protection described above will be reduced. Note: With this arrangement the transformers full capacity is utilized. If the single secondary main is eliminated (Design 2), and dual-element fuses are utilized as branch circuit protection, the transformer can continue to be loaded with the five 83 amp motors because 5 110 = 550 amps, (less than the maximum 600 amps). 22

Contents

Index

Next

Previous

Transformer Protection
No Single Secondary Device

In supervised locations, the maximum settings are as shown above except for secondary voltages of 600 volts or below, where the secondary fuses can be sized at a maximum of 250%.
PRIMARY Over 600V Max Fuse = 300% Over 600V 6% < Z 10% Max Fuse = 300% Over 600V SECONDARY Over 600V Max Fuse = 250% Over 600V Max Fuse = 225% 600V or Below Max Fuse = 250%

250% 480/277V 208/120V 200A ThermalMagnetic Circuit Breaker 150 KVA IFLA = 417A 200A ThermalMagnetic Circuit Breaker 200A ThermalMagnetic Circuit Breaker

6% %Z

M 83A

M 83A

M 83A

Max Fuse = 300%

Design 4 Using a 200 ampere circuit breaker would allow only three (600 200) motors to be connected. To add two additional motors of the same type as shown in Design 1 and Design 2 requires a larger transformer - one that would have a 1000 ampere or more secondary capability. A 300 KVA 208V transformer has a 830 ampere secondary rating which is not sufficient. Therefore, the next standard size 3 transformer is a 400 KVA with a 1110 ampere capacity to meet the new rule. Normal magnetizing inrush currents can range from 10 times to 12 times the transformer full load current, for up to 6 cycles, and as high as 25 times transformer full load current at .01 seconds. Some transformers may have inrush magnitudes substantially greater. Severe inrush should be compared with melting times to assure that unnecessary opening of the device does not occur. TransformersOver 600 Volts Primary and Secondary Protection In unsupervised locations, with primary over 600 volts, the primary fuse can be sized at a maximum of 300%. If the secondary is also over 600 volts, the secondary fuses can be sized at a maximum of 250% for transformers with impedances not greater than 6% or 225% for transformers with impedances greater than 6% and not more than 10%. If the secondary is 600 volts or below, the secondary fuses can be sized at a maximum of 125%. Where these settings do not correspond to a standard fuse size, the next higher standard size is permitted.
PRIMARY Over 600V Max Fuse = 300% Over 600V SECONDARY Over 600V Max Fuse = 250% Over 600V Max Fuse = 225% 600V or Below Max Fuse = 125%

Primary Protection Only In supervised locations, the primary fuses can be sized at a maximum of 250%, or the next larger standard size if 250% does not correspond to a standard fuse size. Note: The use of Primary Protection Only does not remove the requirements for compliance with Articles 240 & 384. See (FPN) in Section 450-3, which references Sections 240-3, 240-21, and 240100 for proper protection for secondary conductors. E-Rated Fuses for Medium Voltage Potential & Small Power Transformers Low amperage, E-Rated medium voltage fuses are general purpose current-limiting fuses. A general purpose current-limiting fuse is capable of interrupting all current from the rated interrupting current down to the current that causes melting of the fusible element in 1 hour (ANSI C37.40). The E rating defines the melting-time-current characteristic of the fuse and permits electrical inter-changeability of fuses with the same E Rating. For a general purpose fuse to have an E Rating the following condition must be met: The current responsive element shall melt in 300 seconds at an RMS current within the range of 200% to 240% of the continuous current rating of the fuse, fuse refill, or link (ANSI C37.46). Bussmann low amperage, E-Rated fuses are designed to provide primary protection for potential, small service, and control transformers. These fuses offer a high level of fault current interruption in a self-contained non-venting package which can be mounted indoors or in an enclosure. Application As for all current-limiting fuses, the basic application rules found in the fuseology section of this brochure should be adhered to. In addition, potential transformer fuses must have sufficient inrush capacity to successfully pass through the magnetizing inrush current of the transformer. If the fuse is not sized properly, it will open before the load is energized. The maximum magnetizing inrush currents to the transformer at system voltage, and the duration of this inrush current varies with the transformer design. Magnetizing inrush currents are usually denoted as a percentage of the transformer full-load current, i.e., 10, 12, 15, etc. The inrush current duration is usually given in seconds. Where this information is available, an easy check can be made on the appropriate Bussmann minimum melting curve to verify proper fuse selection. In lieu of transformer inrush data, the rule of thumb is to select a fuse size rated at 300% of the primary full-load current and round up to the next larger standard size. 23

6% %Z

10% 6% < Z

Max Fuse = 300% Over 600V Max Fuse = 300%

Contents

Index

Next

Previous

Transformer Protection
Example: The transformer manufacturer states that an 800VA 2400 Volt, single phase potential transformer has a magnetizing inrush current of 12 lasting for 0.1 second. A. IFL = 800VA/2400V = 0.333 ampere Inrush Current = 12 0.333 = 4 amperes Since the voltage is 2400 volts we can use either a JCW-1E or JCD-1 E. B. Using the rule of thumb300% of 0.333 amperes is 0.999 amperes. Therefore we would choose a JCW-1E or JCD-1E. Typical Potential Transformer Connections The typical potential transformer connections encountered in industry can be grouped into two categories:

Bussmann, Medium Voltage Fuse. E-Rated 2. Above 100E - the fuse element must melt in 600 seconds at 220% to 264% of its rating (ANSI C37.46). A fuse with an X rating does not meet the electrical interchangeability for an E rated fuse but offers the user other ratings that may provide better protection for his particular application. Application Transformer protection is the most popular application of E-Rated fuses. The fuse is applied to the primary of the transformer and is used solely to prevent rupture of the transformer due to shortcircuits. It is important, therefore, to size the fuse so that it does not clear on system inrush or permissible overload currents. See section on transformers over 600 volts for applicable sizing recommendations. Magnetizing inrush must also be considered when sizing a fuse. In general, power transformers have a magnetizing inrush current of 12 the full-load rating for a duration of second. Three-Phase Transformers (Or Transformer Bank)
Transformer System Voltage KVA Rating 2.4 kV Full-load Fuse Amperes 9 2.17 JCX-7E 15 3.6 JCX-10E 30 7.3 JCX-20E 45 10.8 JCX-25E 75 18.0 JCX-40E 112.5 27.0 JCX-65E 150 36.0 JCX-65E 225 54.0 JCX-100E 300 72.0 JCX-125E 500 120.0 JCX-200E 750 1000 Single-Phase Transformers 3 1.25 JCX-5E 5 2.08 JCX-7E 10 4.17 JCX-15E 15 6.25 JCX-15E 25 10.4 JCX-25E 37.5 15.6 JCX-40E 50 20.8 JCX-40E 75 31.3 JXC-65E 100 41.7 JCX-80E 167 70.0 JCX-100E 250 104.0 JCX-150E 333 139.0 JCX-200E 500 667 4.16 kV Full-load Fuse Amperes 1.25 2.08 4.2 6.2 10.4 15.6 20.8 31.2 41.6 69.4 104.0 139.0 0.72 1.20 2.40 3.61 6.01 9.01 12.0 18.0 24.0 40.0 60.0 80.0 120.0 JCY-5E JCY-7E JCY-15E JCY-15E JCY-25E JCY-40E JCY-40E JCY-65E JCY-80E JCY-125E JCY-150E JCY-200E JCY-3E JCY-5E JCY-7E JCY-10E JCY-15E JCY-20E JCY-25E JCY-40E JCY-80E JCY-100E JCY-125E JCY-125E JCY-200E 4.8 kV Full-load Fuse Amperes 1.08 1.8 3.6 5.4 9.0 13.5 18.0 27.0 36.0 60.0 90.0 120.0 0.63 1.04 2.08 3.13 5.21 7.81 10.4 15.6 20.8 35.0 52.0 69.5 104.0 139.0 JCY-5E JCY-7E JCY-10E JCY-15E JCY-20E JCY-30E JCY-40E JCY-65E JCY-65E JCY-100E JCY-125E JCY-200E JCY-3E JCY-5E JCY-7E JCY-10E JCY-15E JCY-20E JCY-25E JCY-30E JCY-40E JCY-65E JCY-100E JCY-100E JCY-150E JCY-200E

2. Those connections which must pass the magnetizing inrush of more than one potential transformer.

1. Those connections which require the fuse to pass only the magnetizing inrush of one potential transformer.

E-Rated Fuses for Medium Voltage Transformers & Feeders Bussmann E-Rated medium voltage fuses are general purpose current-limiting fuses. A general purpose current-limiting fuse is capable of interrupting all currents from the rated interrupted current down to the current that causes melting of the fusible element in 1 hour (ANSI C37.40). The fuses carry either an E or an X rating which defines the melting-time-current characteristic of the fuse. The ratings are used to allow electrical interchangeability among different manufacturers fuses. For a general purpose fuse to have an E rating, the following conditions must be met: 1. 100E and below - the fuse element must melt in 300 seconds at 200% to 240% of its rating (ANSI C37.46). 24

Contents

Index

Next

Previous

Cable Limiter Applications

RESIDENTIAL SERVICE ENTRANCE (Single cables per phase)
#1 #2 RESIDENCES #3 #4 Open Faulted cable isolated; the other services continue in operation without being disturbed

Cable Limiters Cable limiters are distinguished from fuses by their intended purpose of providing only short-circuit response: they are not designed to provide overload protection. Typically, cable limiters are selected based on conductor size. They are available in a wide range of types to accommodate the many conductor sizes, copper or aluminum conductors, and a variety of termination methods. There are two broad categories of cable limiters: 1. 600 Volt or less rated-for large commercial, institutional and industrial applications. 2. 250 Volt or less rated-for residential and light commercial applications . In institutional, commercial, and industrial systems, cable limiters are most often used at both ends of each cable on multiple cables per phase applications between the transformer and switchboard, as illustrated in the diagram and photographs below. COMMERCIAL/INDUSTRIAL SERVICE ENTRANCE (Multiple cables per phase)
CABLE LIMITERS

Cable limiters may be located on the supply side of the service disconnecting means. The advantages of using cable limiters on the supply side of the service disconnect are multi-fold: 1. Isolation of one or more faulted cables. Only the affected cable(s) are removed from service by the cable limiters at each end opening, (assuming 3 or more cables per phase, with cable limiters on each end). 2. The isolation of a faulted cable permits the convenient scheduling of repair service. 3. The hazard of equipment burndown due to a fault on the lineside of the main overcurrent protective device is greatly reduced. Typically, without cable limiters, a fault between the transformer and service switchboard is given little or no protection. 4. Their current-limiting feature can be used to provide protection against high short-circuit currents. Often, the available fault current exceeds the interrupting rating of service circuit breakers or the short-circuit current withstand of the metering. Cable limiters can provide the necessary degree of protection to meet the requirements of Sections 110-9, 110-10, and 230-65. There are many different cable limiters available for cables from #12 to 1,000 kcmil and many different type terminations. Below is the listing of those most commonly used. Copper Cable Limiter 600 Volts
Catalog Symbol Cable Size Catalog Symbol Cable Size

Service Disconnect (Open) (Open) Faulted cable isolated; only the cable limiters in faulted cable open; others remain in operation.

In residential systems, the cable limiters are normally installed on a single cable per phase basis at the source end of the lateral feeder to each residence.

KCY #4 KCF 4/0 KCZ #3 KCH 250 kcmil KCA #2 KCJ 350 kcmil KCB #1 KCM 500 kcmil KCC 1/0 KCV 600 kcmil KCD 2/0 KCR 750 kcmil KCE 3/0 KCS 1000 kcmil Tubular Terminal and Offset Bolt-Type Terminal KQV #12 KDD 2/0 KQT #10 KDE 3/0 KFZ #8 KDF 4/0 KIG #6 KDH 250 kcmil KDY #4 KDJ 350 kcmil KDA #2 KDM 500 kcmil KDB #1 KDU 600 kcmil KDC 1/0 KDR 750 kcmil Compression Connector Rod Terminal and Tubular Terminal KEX 4/0 KQO 350 kcmil KFH-A 250 kcmil KDT 500 kcmil *Center Bolt-Type Terminal and Off-Set Bolt-Type Terminal KPF 4/0 KDP 500 kcmil KFT 250 kcmil KFM 750 kcmil KEW 350 kcmil
*Copper or aluminum cable; sizes of all other limiters pertain to copper only.

25

Contents

Index

Next

Previous

High Speed Fuse Applications

The protection needs for solid-state power equipment often differ from conventional electrical equipment; hence, the high speed fuse evolved. The protection of power diodes and SCRs requires ultra current-limiting short-circuit fuses; semiconductor devices cannot withstand heavy short-circuit current. The circuits in which fuses are installed place certain requirements upon high speed fuses. These requirements are generally more stringent than the fuse requirements for typical 60 cycle AC power distribution systems in commercial buildings or industrial plants. The diodes or SCRs are at the heart of the solid-state power equipment. These semiconductor devices have relatively low short-circuit current withstand capabilities. The thin silicon chip imbedded in the semiconductor device package has a very low transient thermal capacity. The heating effect produced by low, moderate and high fault currents can quickly cause permanent damage to the device. Damage to a semiconductor device can occur in a very short time period; the current-limiting fuse protection is one of the fastest protection means available. Under fault conditions, restricting the short-circuit energy by a high speed fuse is essential to the protection of SCRs, diodes, and other semiconductor devices in the system. Section 430-52 recognizes the use of these types of fuses in motor applications: Suitable fuses shall be permitted in lieu of devices listed in Table 430-152 for an adjustable speed drive system provided that the marking for replacement fuses is provided adjacent to the fuses. There are several criteria that can be used to judge the performance of semiconductor fuses. Among these are the currentlimiting short-circuit capability and DC interrupting capability. From a design standpoint, I2t is most often used to evaluate the currentlimiting short-circuit performance. I2t (RMS amperes- squared seconds) is a parameter that indicates the heating effect associated with a current pulse. Typically the semiconductor data sheet specifies a maximum I2t withstand for a semiconductor device. To offer short-circuit protection to the semiconductor device, the fuse selected should have an I2t let-through less than the I2t withstand rating of the semiconductor device. Semiconductor fuses have excellent current-limiting ability, as indicated by their low I 2t letthrough and peak current let-through. High speed fuses are often applied where DC interrupting capabilities are required. Some semiconductor fuses have been designed and rigorously tested in developing their excellent DC characteristics. The type circuits often employed require specialized knowledge. Included in the following data are the current and voltage relationships for many of the common circuits. Ratios Of Circuit Currents
Circuit Diagram* No. 1 2 3 4 5 6 7 8 I1RMS I1average Relative Circuit Currents I1RMS I2RMS I1average I1average 1.57 1.11 0.79 1.11 0.79 1.02 0.59 1.00 0.58 1.00 0.41 I3RMS I1average 1.11 0.82 I2RMS I1RMS 0.71 0.71 0.58 0.58 0.41 0.71 0.71

*For example, in Diagram No. 1, = 1.57

The new square bodied high speed fuse is applied for short-circuit protection of power semiconductors. Voltage ratings through 20,000V, and current ratings through 6000A single body are available. Semitron fuses have interrupting ratings up to 300,000A RMS. Miniature switches are quite frequently used on square bodied high speed fuses for visual indication or for signaling purposes when the fuse has opened. Hockey puck versions are available with both U.S. and metric threads.

26

Contents

Index

Next

Previous

High Speed Fuse Applications

TYPICAL CIRCUITS

I1

L O A D

I2

I1

L O A D

1. Single-Phase, Half-Wave.

7. Single-Phase, Anti-Parallel, AC Control.

I2 I2 I1
L O A D

I1
L O A D

2. Single-Phase, Full-Wave, Center-Tap.

I1

8. Three-Phase, Anti-Parallel, AC Control. Not all systems are designed to have the fuse provide full protection for a diode or SCR. There are several degrees of protection for which to design: 1. Prevent Device RuptureFuse merely needs to interrupt current before SCR or diode ruptures. 2. Isolate Failed DeviceTypically, used only where three or more diodes or SCRs (devices) are used per conduction path. An individual fuse is not intended to protect an individual device. Rather, the purpose of the fuse is to remove the diode or SCR after it shorts out and permit the overall circuit to continue operating. At this level, the fuse must be able to protect the diodes or SCRs that are splitting the fault current in another leg, as illustrated in the following diagram. ISOLATION

I2 I3

L O A D

3. Single-Phase, Full-Wave, Bridge.

I2 I1
L O A D

A Normal Conducting Normal Blocking Shorted

4. Three-Phase, Half-Wave.

I1
B

+
Fuse opens when diode shorts out. Fuse should be able to clear before any damage is done to the diodes in leg A.

I2 I3

L O A D C

5. Three-Phase, Full-Wave.

I2

_
3. Protect The Device (Short-Circuits)In this case the fuse is selected to protect the diode or SCR against short-circuits external to the SCR or diode. Typically, the fuse has to be selected to give a much lower let-through current than that required in applications (1 ) or (2) above.

I1
L O A D

6.

Six-Phase, Single-Wave.

27

Contents

Index

Next

Previous

3 Short-Circuit Calculations
Why Short-Circuit Calculations Several sections of the National Electrical Code relate to proper overcurrent protection. Safe and reliable application of overcurrent protective devices based on these sections mandate that a short-circuit study and a selective coordination study be conducted. These sections include, among others: 110-9 Interrupting Rating 110-10 Component Protection 230-65 Service Entrance Equipment 240-1 Conductor Protection 250-95 Equipment Grounding Conductor Protection 517-17 Health Care Facilities - Selective Coordination Compliance with these code sections can best be accomplished by conducting a short-circuit study and a selective coordination study. The protection for an electrical system should not only be safe under all service conditions but, to insure continuity of service, it should be selectively coordinated as well. A coordinated system is one where only the faulted circuit is isolated without disturbing any other part of the system. Overcurrent protection devices should also provide short-circuit as well as overload protection for system components, such as bus, wire, motor controllers, etc. To obtain reliable, coordinated operation and assure that system components are protected from damage, it is necessary to first calculate the available fault current at various critical points in the electrical system. Once the short-circuit levels are determined, the engineer can specify proper interrupting rating requirements, selectively coordinate the system and provide component protection. General Comments on Short-Circuit Calculations Short-circuit calculations should be done at all critical points in the system. These would include: - Service Entrance - Panel Boards - Motor Control Centers - Motor Starters - Transfer Switches - Load Centers Normally, short-circuit studies involve calculating a bolted 3phase fault condition. This can be characterized as all three phases bolted together to create a zero impedance connection. This establishes a worst case condition, that results in maximum thermal and mechanical stress in the system. From this calculation, other types of fault conditions can be obtained. Sources of short-circuit current that are normally taken under consideration include: - Utility Generation - Local Generation - Synchronous Motors - Induction Motors Capacitor discharge currents can normally be neglected due to their short time duration. Certain IEEE (Institute of Electrical and Electronic Engineers) publications detail how to calculate these currents if they are substantial. Interrupting Rating, Interrupting Capacity and Short-Circuit Currents Interrupting rating can be defined as the maximum shortcircuit current that a protective device can safely clear, under specified test conditions. Interrupting capacity can be defined as the actual shortcircuit current that a protective device has been tested to interrupt. The National Electrical Code requires adequate interrupting ratings in Sections 110-9 and 230-65. Section 110-9 Interrupting Rating. Equipment intended to break current at fault levels shall have an interrupting rating sufficient for the system voltage and the current which is available at the line terminals of the equipment. Section 230-65. Available Short-Circuit Current. Service equipment shall be suitable for the short-circuit current available at its supply terminals. Low voltage fuses have their interrupting rating expressed in terms of the symmetrical component of short-circuit current, I S. They are given an RMS symmetrical interrupting rating at a specific power factor. This means that the fuse can interrupt any asymmetrical current associated with this rating. Thus only the symmetrical component of short-circuit current need be considered to determine the necessary interrupting rating of a low voltage fuse. For listed low voltage fuses, interrupting rating equals its interrupting capacity. Low voltage molded case circuit breakers also have their interrupting rating expressed in terms of RMS symmetrical amperes at a specific power factor. However, it is necessary to determine a molded case circuit breakers interrupting capacity in order to safely apply it. The reader is directed to Buss bulletin PMCB II for an understanding of this concept. Procedures and Methods To determine the fault current at any point in the system, first draw a one-line diagram showing all of the sources of short-circuit current feeding into the fault, as well as the impedances of the circuit components. To begin the study, the system components, including those of the utility system, are represented as impedances in the diagram. The impedance tables include three-phase and single-phase transformers, cable, and busway. These tables can be used if information from the manufacturers is not readily available. It must be understood that short-circuit calculations are performed without current-limiting devices in the system. Calculations are done as though these devices are replaced with copper bars, to determine the maximum available short-circuit current. This is necessary to project how the system and the current-limiting devices will perform. Also, current-limiting devices do not operate in series to produce a compounding current-limiting effect. The downstream, or load side, fuse will operate alone under a short-circuit condition if properly coordinated.

28

Contents

Index

Next

Previous

3 Short-Circuit Calculations
The application of the point-to-point method permits the determination of available short-circuit currents with a reasonable degree of accuracy at various points for either 3 or 1 electrical distribution systems. This method can assume unlimited primary short-circuit current (infinite bus). Basic Point-to-Point Calculation Procedure Step 1. Determine the transformer full load amperes from either the nameplate or the following formulas: 3 Transformer x If.l. = KVA 1000 EL-L x 1.732 x If.l. = KVA 1000 EL-L At some distance from the terminals, depending upon wire size, the L-N fault current is lower than the L-L fault current. The 1.5 multiplier is an approximation and will theoretically vary from 1.33 to 1.67. These figures are based on change in turns ratio between primary and secondary, infinite source available, zero feet from terminals of transformer, and 1.2 x %X and 1.5 x %R for L-N vs. L-L resistance and reactance values. Begin L-N calculations at transformer secondary terminals, then proceed point-to-point. Step 5. Calculate "M" (multiplier). M= 1 1+f

1 Transformer

Step 2. Find the transformer multiplier. Multiplier = 100 *%Z trans

Step 6. Calculate the available short-circuit symmetrical RMS current at the point of fault. IS.C. sym RMS = IS.C. x M Calculation of Short-Circuit Currents at Second Transformer in System Use the following procedure to calculate the level of fault current at the secondary of a second, downstream transformer in a system when the level of fault current at the transformer primary is known.
MAIN TRANSFORMER

* Note. Transformer impedance (Z) helps to determine what the

short circuit current will be at the transformer secondary. Transformer impedance is determined as follows: The transformer secondary is short circuited. Voltage is applied to the primary which causes full load current to flow in the secondary. This applied voltage divided by the rated primary voltage is the impedance of the transformer. Example: For a 480 volt rated primary, if 9.6 volts causes secondary full load current to flow through the shorted secondary, the transformer impedance is 9.6/480 = .02 = 2%Z. In addition, U.L. listed transformer 25KVA and larger have a 10% impedance tolerance. Short circuit amperes can be affected by this tolerance. Step 3. Determine the transformer let-through short-circuit current**. IS.C. = If.l. x Multiplier
** Note. Motor short-circuit contribution, if significant, may be added

IS.C. primary H.V. UTILITY CONNECTION

IS.C. secondary

IS.C. primary

IS.C. secondary

to the transformer secondary short-circuit current value as determined in Step 3. Proceed with this adjusted figure through Steps 4, 5 and 6. A practical estimate of motor short-circuit contribution is to multiply the total motor current in amperes by 4. Step 4. Calculate the "f" factor. 3 Faults 1 Line-to-Line (L-L) Faults on 1 Center Tapped Transformer 1 Line-to-Neutral (L-N) Faults on 1 Center Tapped Transformer f = 1.732 x L x I3 C x EL-L f= 2 x L x IL-L C x EL-L

Procedure for Second Transformer in System Step 1. Calculate the "f" factor (IS.C. primary known) 3 Transformer (IS.C. primary and IS.C. secondary are 3 fault values) 1 Transformer (IS.C. primary and IS.C. secondary are 1 fault values: IS.C. secondary is L-L) Step 2. Calculate "M" (multiplier). M= 1 1+f IS.C. primary x Vprimary x 1.73 (%Z) 100,000 x KVA trans

f=

f=

IS.C. primary x Vprimary x (%Z) 100,000 x KVA trans

x x f = 2 L IL-N C x EL-N

Where: L = length (feet) of conductor to the fault. C = constant from Table of C values for conductors and busway. For parallel runs, multiply C values by the number of conductors per phase. I = available short-circuit current in amperes at beginning of circuit.
Note.

Step 3. Calculate the short-circuit current at the secondary of the transformer. (See Note under Step 3 of "Basic Point-to-Point Calculation Procedure".) IS.C. secondary = Vprimary Vsecondary x M x IS.C. primary

The L-N fault current is higher than the L-L fault current at the secondary terminals of a single-phase center-tapped transformer. The short-circuit current available (I) for this case in Step 4 should be adjusted at the transformer terminals as follows: At L-N center tapped transformer terminals, IL-N = 1.5 x IL-L at Transformer
Terminals.

29

Contents

Index

Next

Previous

3 Short-Circuit Calculations
System A
Available Utility Infinite Assumption 1500 KVA Transformer, 480V, 3, 3.5%Z, 3.45%X, 56%R If.l. =1804A 25' - 500kcmil 6 Per Phase Service Entrance Conductors in Steel Conduit 2000A Switch One-Line Diagram

Fault X1
Step 1. If.l. = 1500 x 1000 = 1804A 480 x 1.732

Fault X2
Step 4. Use IS.C.sym RMS @ Fault X1 to calculate f f= 1.732 x 50 x 49,803 = .4050 22,185 x 480 1 = .7117 1 + .4050

Step 2. Step 3. Step 4.

Multiplier = 100 = 28.57 3.5 IS.C.= 1804 x 28.57 = 51,540A

f

Step 5. Step 6.

M=

x x = 1.732 25 51,540 = 0.0349 6 x 22,185 x 480 1 = .9663 1 + .0349

IS.C.sym RMS = 49,803 x .7117 = 35,445A Isym motor contrib = 4 x 1,804 = 7,216A

Step 5.
KRP-C-2000SP Fuse Fault X1 400A Switch LPS-RK-400SP Fuse

M=

Itotal S.C. sym RMS = 35,445 + 7,216 = 42,661A

(fault X2)

Step 6.

IS.C.sym RMS = 51,540 x .9663 = 49,803A IS.C.motor contrib = 4 x 1,804 = 7,216A ItotalS.C. sym RMS = 49,803 + 7,216 = 57,019A
( fault X1)

50' - 500 kcmil Feeder Cable in Steel Conduit

Fault X2 Motor Contribution

M
One-Line Diagram

System B
Available Utility Infinite Assumption 1000 KVA Transformer, 480V, 3, 3.5%Z If.l.= 1203A

Fault X1
Step 1. If.l. = 1000 x 1000 = 1203A 480 x 1.732 Multiplier = 100 = 28.57 3.5

Fault X2
Step 4. f = 1.732 x 20 x 33,215 = .1049 2 x 11,423 x 480 M= 1 1 + .1049 = .905

Step 2. Step 3.

Step 5. Step 6.

IS.C. = 1203 x 28.57 = 34,370A f= 1.732 x 30 x 34,370 = .0348 4 x 26,706 x 480 1 = .9664 1 + .0348

IS.C.sym RMS = 33,215 x .905 = 30,059A

30 - 500 kcmil 4 Per Phase Copper in PVC Conduit

Step 4.

Fault X2
f= 30,059 x 480 x 1.732 x 1.2 = 1.333 100,000 x 225 1 = .4286 1 + 1.333 480 x .4286 x 30,059 = 29,731A 208

1600A Switch KRP-C-1500SP Fuse Fault X1 400A Switch LPS-RK-350SP Fuse 1

Step 5. Step 6.

M=

IS.C.sym RMS = 34,370 x .9664 = 33,215A

M=

IS.C. sym RMS =

20 - 2/0 2 Per Phase Copper in PVC Conduit

225 KVA transformer, 208V, 3 1.2%Z 2

30

Contents

Index

Next

Previous

1 Short-Circuit Calculations
Short-circuit calculations on a single-phase center tapped transformer system require a slightly different procedure than 3 faults on 3 systems. 1. It is necessary that the proper impedance be used to represent the primary system. For 3 fault calculations, a single primary conductor impedance is only considered from the source to the transformer connection. This is compensated for in the 3 short-circuit formula by multiplying the single conductor or single-phase impedance by 1.73. However, for single-phase faults, a primary conductor impedance is considered from the source to the transformer and back to the source. This is compensated in the calculations by multiplying the 3 primary source impedance by two. 2. The impedance of the center-tapped transformer must be adjusted for the half-winding (generally line-to-neutral) fault condition. The diagram at the right illustrates that during line-to-neutral faults, the full primary winding is involved but, only the half-winding on the secondary is involved. Therefore, the actual transformer reactance and resistance of the half-winding condition is different than the actual transformer reactance and resistance of the full winding condition. Thus, adjustment to the %X and %R must be made when considering line-to-neutral faults. The adjustment multipliers generally used for this condition are as follows: 1.5 times full winding %R on full winding basis. 1.2 times full winding %X on full winding basis. Note: %R and %X multipliers given in Impedance Data for Single Phase Transformers Table may be used, however, calculations must be adjusted to indicate transformer KVA/2. 3. The impedance of the cable and two-pole switches on the system must be considered both-ways since the current flows to the fault and then returns to the source. For instance, if a line-to-line fault occurs 50 feet from a transformer, then 100 feet of cable impedance must be included in the calculation. The calculations on the following pages illustrate 1 fault calculations on a single-phase transformer system. Both line-to-line and line-to-neutral faults are considered. Note in these examples: a. The multiplier of 2 for some electrical components to account for the single-phase fault current flow, b. The half-winding transformer %X and %R multipliers for the lineto-neutral fault situation, and c. The KVA and voltage bases used in the per-unit calculations
L1 PRIMARY SECONDARY A B C

SHORT CIRCUIT

PRIMARY SECONDARY SHORT CIRCUIT

L2

L1

SHORT CIRCUIT

L2 50 feet

31

Contents

Index

Next

Previous

1 Short-Circuit Calculations
Line-to-Line Fault @ 240V Fault X1
One-Line Diagram Available Utility Infinite Assumption

Fault X1 Step 1.
Step 2. Step 3. Step 4. If.l. = 75 x 1000 = 312.5A 240 100 = 71.43 1.40

Multiplier =

IS.C. = 312.5 x 71.43 = 22,322A x x f = 2 25 22,322 = .2096 22,185 x 240 M= 1 = .8267 1 + .2096

75KVA, 1 Transformer, 1.22%X, .68%R 1.40%Z 120/240V Negligible Distance

Step 5. Step 6.

IS.C. L-L (X1) = 22,322 x .8267 = 18,453A

400A Switch LPN-RK-400SP Fuse 25' - 500kcmil Magnetic Conduit

Line-to-Neutral Fault @ 120V Fault X1

One-Line Diagram

Fault X1
Step 1. If.l. = 75 x 1000 = 312.5A 240 Multiplier = 100 = 71.43 1.40

Available Utility Infinite Assumption

Step 2. Step 3.

IS.C. (L-L) = 312.5 x 71.43 = 22,322A IS.C. (L-N) = 22,322 x 1.5 = 33,483A

75KVA, 1 Transformer, 1.22% X, .68%R, 1.40%Z 120/240V Negligible Distance

Step 4.

f=

2* x 25 x 22,322 x 1.5 = .6288 22,185 x 120 1 = .6139 1 + .6288

Step 5. Step 6.

M=

IS.C. L-N (X1) = 33,483 x .6139 = 20,555A

400A Switch LPN-RK-400SP Fuse

* Assumes the neutral conductor and the line conductor are the

same size.

25' - 500kcmil Magnetic Conduit 1

32

Contents

Index

Next

Previous

Short-Circuit, Impedance and Reactance Data

TRANSFORMERS Short-Circuit Currents Available from Various Size Transformers
Full % ShortLoad Impedance Circuit Amps (Nameplate) Amps 25 104 1.58 11,574 37 156 1.56 17,351 120/240 50 209 1.54 23,122 1 ph.* 75 313 1.6 32,637 100 417 1.6 42,478 167 695 1.8 60,255 25 69 1.6 4,791 50 139 1.6 9,652 75 208 1.11 20,821 100 278 1.11 27,828 150 416 1.07 43,198 120/208 225 625 1.12 62,004 3 ph.** 300 833 1.11 83,383 500 1388 1.24 124,373 750 2082 3.5 66,095 1000 2776 3.5 88,167 1500 4164 3.5 132,190 2000 5552 5.0 123,377 2500 6950 5.0 154,444 112 135 1.0 15,000 150 181 1.2 16,759 225 271 1.2 25,082 300 361 1.2 33,426 277/480 500 601 1.3 51,362 3 ph. 750 902 3.5 28,410 1000 1203 3.5 38,180 1500 1804 3.5 57,261 2000 2406 5.0 53,461 2500 3007 5.0 66,822 * Single-phase values are L-N values at transformer terminals. These figures are based on change in turns ratio between primary and secondary, 100,000 KVA primary, zero feet from terminals of transformer, 1.2 (%X) and 1.5 (%R) multipliers for L-N vs. L-L reactance and resistance values and transformer X/R ratio = 3.
** Three-phase short-circuit currents based on infinite primary. U.L. listed transformers 25 KVA or greater have a 10% impedance toler-

Impedance Data for Single-Phase Transformers

Suggested Normal Range Impedance Multipliers** X/R Ratio of Percent For Line-to-Neutral kVA for Impedance (%Z)* Faults 1 Calculation for %X for %R 25.0 1.1 1.26.0 0.6 0.75 37.5 1.4 1.26.5 0.6 0.75 50.0 1.6 1.26.4 0.6 0.75 75.0 1.8 1.26.6 0.6 0.75 100.0 2.0 1.35.7 0.6 0.75 167.0 2.5 1.46.1 1.0 0.75 250.0 3.6 1.96.8 1.0 0.75 333.0 4.7 2.46.0 1.0 0.75 500.0 5.5 2.25.4 1.0 0.75 * National standards do not specify %Z for single-phase transformers. Consult manufacturer for values to use in calculation. ** Based on rated current of the winding (onehalf nameplate kVA divided by secondary line-to-neutral voltage).

Voltage And Phase

KVA

Note: U.L. Listed transformers 25 KVA and greater have a 10% tolerance on their impedance nameplate. This table has been reprinted from IEEEStd 242-1986 (R1991), IEEE Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems, Copyright 1986 by the Institute of Electrical and Electronics Engineers, Inc. with the permission of the IEEE Standards Department. . Impedance Data for Single-Phase and Three-Phase TransformersSupplement
kVA 1 10 15 3 75 150 225 300 333 500 500 These represent actual installations. Suggested %Z X/R Ratio for Calculation 1.2 1.1 1.3 1.1 1.11 1.5 1.07 1.5 1.12 1.5 1.11 1.5 1.9 4.7 1.24 1.5 2.1 5.5 transformer nameplate ratings taken from field

ance. Short-circuit amps reflect a worst case condition.

Fluctuations in system voltage will affect the available short-circuit current.

For example, a 10% increase in system voltage will result in a 10% increase in the available short-circuit currents shown in the table.

Note: U.L. Listed transformers 25KVA and greater have a 10% tolerance on their impedance nameplate.

33

Contents

Index

Next

Previous

C Values for Conductors and Busway

C Values for Conductors and Busway
Copper AWG Three Single Conductors Three-Conductor Cable or Conduit Conduit kcmil Steel Nonmagnetic Steel Nonmagnetic 600V 5KV 15KV 600V 5KV 15KV 600V 5KV 15KV 600V 5KV 15KV 14 389 389 389 389 389 389 389 389 389 389 389 389 12 617 617 617 617 617 617 617 617 617 617 617 617 10 981 981 981 981 981 981 981 981 981 981 981 981 8 1557 1551 1557 1558 1555 1558 1559 1557 1559 1559 1558 1559 6 2425 2406 2389 2430 2417 2406 2431 2424 2414 2433 2428 2420 4 3806 3750 3695 3825 3789 3752 3830 3811 3778 3837 3823 3798 3 4760 4760 4760 4802 4802 4802 4760 4790 4760 4802 4802 4802 2 5906 5736 5574 6044 5926 5809 5989 5929 5827 6087 6022 5957 1 7292 7029 6758 7493 7306 7108 7454 7364 7188 7579 7507 7364 1/0 8924 8543 7973 9317 9033 8590 9209 9086 8707 9472 9372 9052 2/0 10755 10061 9389 11423 10877 10318 11244 11045 10500 11703 11528 11052 3/0 12843 11804 11021 13923 13048 12360 13656 13333 12613 14410 14118 13461 4/0 15082 13605 12542 16673 15351 14347 16391 15890 14813 17482 17019 16012 250 16483 14924 13643 18593 17120 15865 18310 17850 16465 19779 19352 18001 300 18176 16292 14768 20867 18975 17408 20617 20051 18318 22524 21938 20163 350 19703 17385 15678 22736 20526 18672 22646 21914 19821 24904 24126 21982 400 20565 18235 16365 24296 21786 19731 24253 23371 21042 26915 26044 23517 500 22185 19172 17492 26706 23277 21329 26980 25449 23125 30028 28712 25916 600 22965 20567 17962 28033 25203 22097 28752 27974 24896 32236 31258 27766 750 24136 21386 18888 28303 25430 22690 31050 30024 26932 32404 31338 28303 1000 25278 22539 19923 31490 28083 24887 33864 32688 29320 37197 35748 31959 Aluminum 14 236 236 236 236 236 236 236 236 236 236 236 236 12 375 375 375 375 375 375 375 375 375 375 375 375 10 598 598 598 598 598 598 598 598 598 598 598 598 8 951 950 951 951 950 951 951 951 951 951 951 951 6 1480 1476 1472 1481 1478 1476 1481 1480 1478 1482 1481 1479 4 2345 2332 2319 2350 2341 2333 2351 2347 2339 2353 2349 2344 3 2948 2948 2948 2958 2958 2958 2948 2956 2948 2958 2958 2958 2 3713 3669 3626 3729 3701 3672 3733 3719 3693 3739 3724 3709 1 4645 4574 4497 4678 4631 4580 4686 4663 4617 4699 4681 4646 1/0 5777 5669 5493 5838 5766 5645 5852 5820 5717 5875 5851 5771 2/0 7186 6968 6733 7301 7152 6986 7327 7271 7109 7372 7328 7201 3/0 8826 8466 8163 9110 8851 8627 9077 8980 8750 9242 9164 8977 4/0 10740 10167 9700 11174 10749 10386 11184 11021 10642 11408 11277 10968 250 12122 11460 10848 12862 12343 11847 12796 12636 12115 13236 13105 12661 300 13909 13009 12192 14922 14182 13491 14916 14698 13973 15494 15299 14658 350 15484 14280 13288 16812 15857 14954 15413 16490 15540 17635 17351 16500 400 16670 15355 14188 18505 17321 16233 18461 18063 16921 19587 19243 18154 500 18755 16827 15657 21390 19503 18314 21394 20606 19314 22987 22381 20978 600 20093 18427 16484 23451 21718 19635 23633 23195 21348 25750 25243 23294 750 21766 19685 17686 25976 23701 20934 26431 25789 23750 29036 28262 25976 1000 23477 21235 19005 28778 26109 23482 29864 29049 26608 32938 31919 29135 Note: These values are equal to one over the impedance per foot for impedances found in IEEE std. 241-1990, IEEE Recommended Practice for Commercial Building Power Systems.

Ampacity

Busway Plug-In Feeder Copper Aluminum Copper 225 28700 23000 18700 400 38900 34700 23900 600 41000 38300 36500 800 46100 57500 49300 1000 69400 89300 62900 1200 94300 97100 76900 1350 119000 104200 90100 1600 129900 120500 101000 2000 142900 135100 134200 2500 143800 156300 180500 3000 144900 175400 204100 4000 277800 Note: These values are equal to one over the impedance in a survey of industry.

High Impedance Aluminum Copper 12000 21300 31300 44100 56200 15600 69900 16100 84000 17500 90900 19200 125000 20400 166700 21700 188700 23800 256400 impedance per foot for

34

Contents

Index

Next

Previous

Voltage Drop Calculations

Ratings of Conductors and Tables to Determine Volt Loss With higher rating on new installations, it is extremely important to bear volt loss in mind, otherwise some very unsatisfactory problems are likely to be encountered. The actual conductor used must also meet the other sizing requirements such as full-load current, ambient temperature, number in a raceway, etc. How to Figure Volt Loss Multiply distance (length in feet of one wire) by the current (expressed in amperes) by the figure shown in table for the kind of current and the size of wire to be used, by one over the number of conductors per phase. Then, put a decimal point in front of the last 6 digitsyou have the volt loss to be expected on that circuit. Example No. 6 copper wire in 180 feet of iron conduit3 phase, 40 amp load at 80% power factor. Multiply feet by amperes: 180 x 40 = 7200 Multiply this number by number from table for No. 6 wire threephase at 80% power factor: 7200 x 745 = 5364000 1 1 = 5364000 Multiply by 5364000 x #/phase 1 Place decimal point 6 places to left. This gives volt loss to be expected: 5.364 volts (For a 240 volt circuit the % voltage drop is 5.364 x 100 or 2.23%). 240 These Tables take into consideration reactance on AC circuits as well as resistance of the wire. Remember on short runs to check to see that the size and type of wire indicated has sufficient ampere capacity. How to Select Size of Wire Multiply distance (length in feet of one wire) by the current (expressed in amperes), by one over the number of conductors per phase. Divide that figure into the permissible volt loss multiplied by 1,000,000. Look under the column applying to the type of current and power factor for the figure nearest, but not above your resultyou have the size of wire needed. Example Copper in 180 feet of steel conduit3 phase, 40 amp Ioad at 80% power factorvolt loss from local code equals 5.5 volts. Multiply feet by amperes by 1 1 180 x 40 x = 7200. #/phase 1 Divide permissible volt loss multiplied by 1,000,000 by this number: 5.5 x 1,000,000 = 764. 7200 Select number from Table, three-phase at 80% power factor, that is nearest but not greater than 764. This number is 745 which indicates the size of wire needed: No. 6. Line-to-Neutral For line to neutral voltage drop on a 3 phase system, divide the three phase value by 1.73. For line to neutral voltage drop on a single phase system, divide single phase value by 2. Open Wiring The volt loss for open wiring installations depends on the separation between conductors. The volt loss is approximately equal to that for conductors in non-magnetic conduit. Section 310-15 offers a method to calculate conductor ampacity. 35 Installation in Conduit, Cable or Raceway NEC Tables 310-16 through 310-19 give allowable ampacities (current-carrying capacities) for not more than three conductors in a conduit, cable, or raceway. Where the number of conductors exceeds three the allowable ampacity of each conductor must be reduced as shown in the following tables: Installation in Conduit, Cable or Raceway
The Number of Conductors In One Conduit, Raceway Or Cable 4 to 6 7 to 9 10 to 20 21 to 30 31 to 40 41 and over Percentage of Values In Tables 310-16 And 310-18, Note 8 80% 70% 50% 45% 40% 35%

Conditions Causing Higher Volt Loss The voltage loss is increased when a conductor is operated at a higher temperature because the resistance increases. If type RH, RHW, THW, or THWN wire (75C wire) is loaded to near its full rating, or if room temperature is 15C higher than normal, add the following percentages to get the volt loss. Conditions Causing Higher Volt Loss
Direct Current 5.0% 5.0% 5.0% 5.0% Single Or Three PhasePower Factor 100% 90% 80% 70% 5.0% 4.8% 4.7% 4.7% 5.0% 4.2% 3.8% 3 5% 5.0% 3.1% 2.6% 2.4% 5.0% 2.5% 2.2% 1.6%

Wire Size #14 to #4 #2 to #000 #0000 to 500 kcmil 600 kcmil to 1000 kcmil

60% 4.6% 3.3% 2.0% 1.3%

Room Temperature Affects Ratings The ampacities (carrying capacities) of conductors are based on a room temperature of 86F or 30C. If room temperature is higher, the ampacities are reduced by using the following multipliers; (for 0-2000 volt, insulated conductors not more than 3 conductors in raceway or direct buried, Table 310-16). Room Temperature Affects Ratings
Room Ampacity Multiplier Temperature TW THW, THWN THHN, XHHW* C F (60C Wire) (75C Wire) (90C Wire) 31-40 88-104 .82 .88 .91 41-45 105-113 .71 .82 .87 46-50 114-122 .58 .75 .82 51-60 123-141 .58 .71 61-70 142-158 .35 .58 71-80 159-176 .41 If type RHH, THHN or XHHW wire (90C. wire) is loaded to near its full rating or if room temperature is 30C. higher than normal add twice the above percentages to get the volt loss.

Contents

Index

Next

Previous

Voltage Drop Calculations

Copper ConductorsRatings and Volt Loss
Conduit Wire Size Ampacity Type T, TW (60C Wire) Type RH, THWN, RHW, THW (75C Wire) 20* 25* 35* 50 65 85 100 115 130 150 175 200 230 255 285 310 335 380 420 475 545 20* 25* 35* 50 65 85 100 115 130 150 175 200 230 255 285 310 335 380 420 475 545 Type RHH, THHN, XHHW (90C Wire) 25* 30* 40* 55 75 95 110 130 150 170 195 225 260 290 320 350 380 430 475 535 615 25* 30* 40* 55 75 95 110 130 150 170 195 225 260 290 320 350 380 430 475 535 615 Direct Current Volt Loss (See Explanation p. 35) Three-Phase (60 Cycle, Lagging Power Factor.) 100% 90% 80% 70% 60% Single-Phase (60 Cycle, Lagging Power Factor.) 100% 90% 80% 70% 60%

Steel Conduit

NonMagnetic Conduit (Lead Covered Cables or Installation in Fibre or Other NonMagnetic Conduit, Etc.)

14 12 10 8 6 4 3 2 1 0 00 000 0000 250 300 350 400 500 600 750 1000 14 12 10 8 6 4 3 2 1 0 00 000 0000 250 300 350 400 500 600 750 1000

20* 25* 30 40 55 70 85 95 110 125 145 165 195 215 240 260 280 320 335 400 455 20* 25* 30 40 55 70 85 95 110 125 145 165 195 215 240 260 280 320 335 400 455

6140 3860 2420 1528 982 616 490 388 308 244 193 153 122 103 86 73 64 52 43 34 26 6140 3464 2420 1528 982 616 470 388 308 244 193 153 122 103 86 73 64 52 43 34 26

5369 3464 2078 1350 848 536 433 346 277 207 173 136 109 93 77 67 60 50 43 36 31 5369 3464 2078 1350 848 536 433 329 259 207 173 133 107 90 76 65 57 46 39 32 25

4887 3169 1918 1264 812 528 434 354 292 228 196 162 136 123 108 98 91 81 75 68 62 4876 3158 1908 1255 802 519 425 330 268 220 188 151 127 112 99 89 81 71 65 58 51

4371 2841 1728 1148 745 491 407 336 280 223 194 163 140 128 115 106 99 90 84 78 72 4355 2827 1714 1134 731 479 395 310 255 212 183 150 128 114 103 94 87 77 72 65 59

3848 2508 1532 1026 673 450 376 312 264 213 188 160 139 129 117 109 103 94 89 84 78 3830 2491 1516 1010 657 435 361 286 238 199 174 145 125 113 104 95 89 80 76 70 63

3322 2172 1334 900 597 405 341 286 245 200 178 154 136 128 117 109 104 96 92 88 82 3301 2153 1316 882 579 388 324 259 219 185 163 138 121 110 102 94 89 82 77 72 66

6200 4000 2400 1560 980 620 500 400 320 240 200 158 126 108 90 78 70 58 50 42 36 6200 4000 2400 1560 980 620 500 380 300 240 200 154 124 104 88 76 66 54 46 38 30

5643 3659 2214 1460 937 610 501 409 337 263 227 187 157 142 125 113 105 94 86 79 72 5630 3647 2203 1449 926 599 490 381 310 254 217 175 147 129 114 103 94 82 75 67 59

5047 3281 1995 1326 860 568 470 388 324 258 224 188 162 148 133 122 114 104 97 91 84 5029 3264 1980 1310 845 553 456 358 295 244 211 173 148 132 119 108 100 90 83 76 68

4444 2897 1769 1184 777 519 434 361 305 246 217 184 161 149 135 126 118 109 103 97 90 4422 2877 1751 1166 758 502 417 330 275 230 201 167 145 131 120 110 103 93 87 80 73

3836 2508 1540 1040 690 468 394 331 283 232 206 178 157 148 135 126 120 111 106 102 95 3812 2486 1520 1019 669 448 375 300 253 214 188 159 140 128 118 109 103 94 90 83 77

* The overcurrent protection for conductor types marked with an (*) shall not exceed 15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper; or 15 amperes for 12 AWG and 25 amperes for 10 AWG aluminum and copper-clad aluminum after any correction factors for ambient temperature and number of conductors have been applied. Figures are L-L for both single-phase and three-phase. Three-phase figures are average for the three-phase.

36

Contents

Index

Next

Previous

Voltage Drop Calculations

Aluminum ConductorsRatings and Volt Loss
Conduit Wire Size Ampacity Type T, TW (60C Wire) Type RH, THWN, RHW, THW (75C Wire) 20* 30* 40 50 65 75 90 100 120 135 155 180 205 230 250 270 310 340 385 445 20* 30* 40 50 65 75 90 100 120 135 155 180 205 230 250 270 310 340 385 445 Type RHH, THHN, XHHW (90C Wire) 25* 35* 45 60 75 85 100 115 135 150 175 205 230 255 280 305 350 385 435 500 25* 35* 45 60 75 85 100 115 135 150 175 205 230 255 280 305 350 385 435 500 Direct Current Volt Loss (See Explanation p.35) Three-Phase (60 Cycle, Lagging Power Factor.) 100% 90% 80% 70% 60% Single-Phase (60 Cycle, Lagging Power Factor.) 100% 90% 80% 70% 60%

Steel Conduit

NonMagnetic Conduit (Lead Covered Cables or Installation in Fibre or Other NonMagnetic Conduit, Etc.)

12 10 8 6 4 3 2 1 0 00 000 0000 250 300 350 400 500 600 750 1000 12 10 8 6 4 3 2 1 0 00 000 0000 250 300 350 400 500 600 750 1000

20* 25 30 40 55 65 75 85 100 115 130 150 170 190 210 225 260 285 320 375 20* 25 30 40 55 65 75 85 100 115 130 150 170 190 210 225 260 285 320 375

6360 4000 2520 1616 1016 796 638 506 402 318 259 200 169 141 121 106 85 71 56 42 6360 4000 2520 1616 1016 796 638 506 402 318 252 200 169 141 121 106 85 71 56 42

5542 3464 2251 1402 883 692 554 433 346 277 225 173 148 124 109 95 77 65 53 43 5542 3464 2251 1402 883 692 554 433 346 277 225 173 147 122 105 93 74 62 50 39

5039 3165 2075 1310 840 668 541 432 353 290 241 194 173 150 135 122 106 95 84 73 5029 3155 2065 1301 831 659 532 424 344 281 234 186 163 141 125 114 96 85 73 63

4504 2836 1868 1188 769 615 502 405 334 277 234 191 173 152 139 127 112 102 92 82 4490 2823 1855 1175 756 603 490 394 322 266 223 181 160 140 125 116 100 90 79 70

3963 2502 1656 1061 692 557 458 373 310 260 221 184 168 150 138 127 113 105 96 87 3946 2486 1640 1045 677 543 443 360 296 247 209 171 153 136 123 114 100 91 82 73

3419 2165 1441 930 613 497 411 338 284 241 207 174 161 145 134 125 113 106 98 89 3400 2147 1423 912 596 480 394 323 268 225 193 160 145 130 118 111 98 91 82 75

6400 4000 2600 1620 1020 800 640 500 400 320 260 200 172 144 126 110 90 76 62 50 6400 4000 2600 1620 1020 800 640 500 400 320 260 200 170 142 122 108 86 72 58 46

5819 3654 2396 1513 970 771 625 499 407 335 279 224 200 174 156 141 122 110 97 85 5807 3643 2385 1502 959 760 615 490 398 325 270 215 188 163 144 132 111 98 85 73

5201 3275 2158 1372 888 710 580 468 386 320 270 221 200 176 160 146 129 118 107 95 5184 3260 2142 1357 873 696 566 455 372 307 258 209 185 162 145 134 115 104 92 81

4577 2889 1912 1225 799 644 529 431 358 301 256 212 194 173 159 146 131 121 111 100 4557 2871 1894 1206 782 627 512 415 342 285 241 198 177 157 142 132 115 106 94 85

3948 2500 1663 1074 708 574 475 391 328 278 239 201 186 168 155 144 130 122 114 103 3926 2480 1643 1053 668 555 456 373 310 260 223 185 167 150 137 128 114 105 95 86

* The overcurrent protection for conductor types marked with an (*) shall not exceed 15 amperes for 14 AWG, 20 amperes for 12 AWG, and 30 amperes for 10 AWG copper; or 15 amperes for 12 AWG and 25 amperes for 10 AWG aluminum and copper-clad aluminum after any correction factors for ambient temperature and number of conductors have been applied. Figures are L-L for both single-phase and three-phase. Three-phase figures are average for the three-phase.

37

Contents

Index

Next

Previous

Selective Coordination
What Is Selective Coordination? Today, more than ever, one of the most important parts of any installation - whether it is an office building, an industrial plant, a theater, a high-rise apartment or a hospital - is the electrical distribution system. Nothing will stop all activity, paralyze production, inconvenience and disconcert people and possibly cause a panic more effectively than a major power failure. ISOLATION of a faulted circuit from the remainder of the installation is MANDATORY in todays modern electrical systems. Power BLACKOUTS CANNOT be tolerated. It is not enough to select protective devices based solely on their ability to carry the system load current and interrupt the maximum fault current at their respective levels. A properly engineered system will allow ONLY the protective device nearest the fault to open, leaving the remainder of the system undisturbed and preserving continuity of service. We may then define selective coordination as THE ACT OF ISOLATING A FAULTED CIRCUIT FROM THE REMAINDER OF THE ELECTRICAL SYSTEM, THEREBY ELIMINATING UNNECESSARY POWER OUTAGES. THE FAULTED CIRCUIT IS ISOLATED BY THE SELECTIVE OPERATION OF ONLY THAT OVERCURRENT PROTECTIVE DEVICE CLOSEST TO THE OVERCURRENT CONDITION. Popular Methods of Performing a Selective Coordination Study Currently two methods are most often used to perform a coordination study: 1. Overlays of time-current curves, which utilize a light table and manufacturers published data, then hand plot on log-log paper. 2. Computer programs that utilize a PC and allow the designer to select time-current curves published by manufacturers and transfer to a plotter or printer, following proper selections. This text will apply to both methods. Overloads and Low Level Fault Currents This information is presented as an aid to understanding timecurrent characteristic curves of fuses and circuit breakers, and will discuss the major considerations in properly applying electrical protective devices. A thorough understanding of time-current characteristic curves of overcurrent protective devices is essential to provide a Selectively Coordinated System. It should be noted that the study of time-current curves indicates performance during overload and low level fault conditions. The performance of overcurrent devices that operate under medium to high level fault conditions are not reflected on standard curves. Other engineering methods must be utilized. Fuse Curves The figure to the right illustrates the time-current characteristic curves for two sizes of time-delay, dual-element fuses in series, as depicted in the one-line diagram. The horizontal axis of the graph represents the RMS symmetrical current in amperes. The vertical axis represents the time, in seconds, until the fault occurs. For example: Assume an available fault current level of 1000 amperes RMS symmetrical on the load side of the 100 ampere fuse. To determine the time it would take this fault current to open the two fuses, first find 1000 amperes on the horizontal axis (Point A), follow the dotted line vertically to the intersection of the total clear curve of the 100 ampere time-delay dual-element fuse (Point B) and the minimum melt curve of the 400 ampere time-delay dualelement fuse (Point C). Then, horizontally from both intersection points, follow the dotted lines to Points D and E. At 1.75 seconds, Point D represents the maximum time the 100 ampere time-delay dual-element fuse will take to open the 1000 ampere fault. At 88 seconds, Point E represents the minimum time at which the 400 ampere time-delay dual-element fuse could open this available fault current. Thus, selective operation is assured. The two fuse curves can be examined by the same procedure at various current levels along the horizontal axis (for example, see Points F and G at the 2000 ampere fault level). It can be determined that the two fuses are selectively coordinated, since the 100 ampere time-delay dual-element fuse will open before the 400 ampere time-delay dual-element fuse can melt.
100A 400A

600 400 300 200

400A
100 80 60 40 30 20

Point E

Point C

100A
Available Fault Current Level 1000A

TIME IN SECONDS

10 8 6 4 3 2

Point G

Figure 3a.

Point D
1 .8 .6 .4 .3 .2

Point B

Point F
.1 .08 .06 .04 .03 .02

Minimum Melt Total Clearing

8000 10,000

Point A 1000A

CURRENT IN AMPERES

38

20,000

.01 100 200 300 400 600 800 1000 2000 3000 4000 6000

Contents

Index

Next

Previous

Selective Coordination Reading Time-Current Curves

Circuit Breaker Curves The following curve illustrates a typical thermal magnetic molded case circuit breaker curve with an overload region and an instantaneous trip region (two instantaneous trip settings are shown). Circuit breaker time-current characteristic curves are read similar to fuse curves. The horizontal axis represents the current, and the vertical axis represents the time at which the breaker interrupts the circuit. When using molded case circuit breakers of this type, there are four basic curve considerations that must be understood. These are: 1. Overload Region 2. Instantaneous Region 3. Unlatching Time 4. Interrupting Rating 1. Overload Region - The opening of a molded case circuit breaker in the overload region is generally accomplished by a thermal element, while a magnetic coil is generally used on power breakers. Electronic sensing breakers will utilize CTs. As can be seen, the overload region has a wide tolerance band, which means the breaker should open within that area for a particular overload current. 2. Instantaneous Region - The instantaneous trip setting indicates the multiple of the full load rating at which the circuit breaker will open as quickly as possible. The instantaneous region is represented in the following curve and is shown to be adjustable from 5 to 10 the breaker rating. When the breaker coil senses an overcurrent in the instantaneous region, it releases the latch which holds the contacts closed. The unlatching time is represented by the curve labeled average unlatching time for instantaneous tripping. After unlatching, the overcurrent is not halted until the breaker contacts are mechanically separated and the arc is extinguished. Consequently, the final overcurrent termination can vary over a wide range of time, as is indicated by the wide band between the unlatching time curve and the maximum interrupting time curve. The instantaneous trip setting for larger molded case and power breakers can usually be adjusted by an external dial. Two instantaneous trip settings for a 400 amp breaker are shown. The instantaneous trip region, drawn with the solid line, represents an I.T. = 5, or five times 400 amperes = 2000 amperes. At this setting, the circuit breaker will trip instantaneously on currents of approximately 2000 amperes or more. The 25% band represents the area in which it is uncertain whether the overload trip or the instantaneous trip will operate to clear the overcurrent. The dashed portion represents the same 400 ampere breaker with an I.T. = 10, or 10 times 400 amperes = 4000 amperes. At this setting the overload trip will operate up to approximately 4000 amperes (10%). Overcurrents greater than 4000 amperes (10%) would be cleared by the instantaneous trip. 3. Unlatching Times - As explained above, the unlatching time indicates the point at which the breaker senses an overcurrent in the instantaneous region and releases the latch holding the contacts. However, the fault current continues to flow through the breaker and the circuit to the point of fault until the contacts can physically separate and extinguish the arc. Once the unlatching mechanism has sensed an overcurrent and unlatched, the circuit breaker will open. The final interruption of the current represented on the breaker curve in the instantaneous region occurs after unlatching, but within the maximum interruption time. The relatively long delay between unlatching and the actual interruption of the overcurrent in the instantaneous region is the primary reason that molded case breakers are very difficult to coordinate. This is an inherent problem since the breaking of current is accomplished by mechanical means. 4. Interrupting Rating - The interrupting rating of a circuit breaker is a critical factor concerning protection and safety. The interrupting rating of a circuit breaker is the maximum fault current the breaker has been tested to interrupt in accordance with testing laboratory standards. Fault currents in excess of the interrupting rating can result in destruction of the breaker and equipment and possible injury to personnel. In other words, when the fault level exceeds the circuit breaker interrupting rating, the circuit breaker is no longer a protective device. The interrupting rating at 480 volts is 30,000 amperes. The interrupting ratings on circuit breakers vary according to breaker type and voltage level. When drawing circuit breaker time-current curves, determine the proper interrupting rating from the manufacturers literature and represent this interrupting rating on the drawing by a vertical line at the right end of the curve. Typical Circuit Breaker Time-Current Characteristic Curve
1000 800 600 400

400 Ampere Circuit Breaker

Average Unlatching Times Breaker Tripping Magnetically Current in RMS Amps 5,000 10,000 15,000 20,000 25,000 Time in Seconds .0045 .0029 .0024 .0020 .0017

gion d Re rloa Ove

300 200

Minimum Unlatching Time

100 80 60 40 30 20

Maximum Interrrupting Time

Interrupting Rating RMS Sym. 240V 480V 600V Amps 42,000 30,000 22,000

10 8 6 4 3

Adjustable Magnetic Instantaneous Trip Set at 10 Times I.T. = 10X ( 10% Band)

TIME IN SECONDS

1 .8 .6 .4 .3 .2

Adjustable Instantaneous Trip Set at 5 Times I.T. = 5X ( 25% Band)

.1 .08 .06 .04 .03 .02

Maximum Interrupting Time

Instantanous Region

.01 .008 .006 .004 .003 .002

Interrupting Rating at 480 Volt Average Unlatching Times for Instantaneous Tripping

10,000

20,000

30,000

40,000

60,000

80,000

CURRENT IN AMPERES

39

100,000

100

200

300

400

600

800

1000

2000

3000

4000

6000

8000

.001

Contents

Index

Next

Previous

Selective Coordination Reading Time-Current Curves

Short-Time-Delay And Instantaneous Override - Circuit breaker short-time-delay (STD) mechanisms allow an intentional delay to be installed on low voltage power circuit breakers. Short-timedelays allow the fault current to flow for several cycles, which subjects the electrical equipment to unnecessarily high mechanical and thermal stress. Most equipment ratings, such as short-circuit ratings for bus duct and switchboard bus, do not apply when short-time-delay settings are employed. The use of short-timedelay settings on circuit breakers requires the system equipment to be reinforced to withstand the available fault current for the duration of the short-time-delay. Ignoring equipment ratings in relation to the protective device opening time and let-through characteristics can be disastrous. An insulated case circuit breaker (ICCB) may also be equipped with short-time-delay. However, ICCBs will have a builtin override mechanism. This is called the instantaneous override function, and will override the STD for medium to high level faults. This override may kick in for faults as low as 12 the breakers ampere rating. This can result in non-selective tripping of the breaker and load side breakers where overlaps occur. This can be seen in the example. As the overlap suggests, for any fault condition greater than 21,000 amperes, both devices will open, causing a blackout. Note: Choosing overcurrent protective devices strictly on the basis of voltage, current, and interrupting rating will not assure component protection from short-circuit currents. The interrupting rating of a protective device pertains only to that device and has absolutely no bearing on its ability to protect connected downstream components. High interrupting rated electro-mechanical overcurrent protective devices, such as circuit breakers, especially those that are not current-limiting, may not be capable of protecting wire, cable or other components within the higher short-circuit ranges. Quite often, the component is completely destroyed under shortcircuit conditions while the protective device is opening the faulted circuit. Low Voltage Power Circuit Breaker
1000 800 600 400 300 200

LVPCB
100 80 60 40 30

TIME IN SECONDS

20

10 8 6 4 3 2

1 .8 .6 .4 .3 .2

STD = 21 Cycles

1,000

2,000

3,000

4,000

6,000

8,000

CURRENT IN AMPERES

40

100,000

10,000

20,000

30,000

40,000

60,000

80,000

.1

Contents

Index

Next

Previous

Selective Coordination Reading Time-Current Curves

Insulated Case Circuit Breaker
1000 800 600 400 300 200

Instantaneous Override Opens at 21,000 Amps

1000 800 600 400 300 200 2000A

100A

100 80 60 40 30 20

100 80

ICCB

60

2000A ICCB 100A CB

40 30 20

8 6 4 3

TIME IN SECONDS Instantaneous Override = 12X

10

10 8 6 4 3 2

TIME IN SECONDS

1 .8 .6 .4 .3 .2

1 .8 .6 .4 .3 .2

.1 .08 .06 .04 .03 .02

.1 .08 .06 .04 .03 .02

BLACKOUT!

100,000

10,000

20,000

30,000

40,000

60,000

80,000

.01 1000 2000 3000 4000 6000 8000 100 200 300 400 600 800

10,000

20,000

30,000

40,000

60,000

80,000

CURRENT IN AMPERES

CURRENT IN AMPERES

41

100,000

1000

2000

3000

4000

6000

8000

100

200

300

400

600

800

.01

Contents

Index

Next

Previous

Selective Coordination Current-Limiting Fuses

Medium to High Level Fault Currents The available short-circuit current will reach a peak value of Ip during the first half cycle unless a protective device limits the peak fault current to a value less than Ip. A current-limiting fuse will reduce the available peak current to less than Ip, namely Ip, and will clear the fault in approximately one-half cycle or less. Note that tc is the total clearing time of the fuse, tm the melting time and ta the arcing time of the fuse. Where high values of fault current are available, the sub-cycle region becomes the most critical region for selective operation of current-limiting fuses. The area under the current curves indicates the energy letthrough. If no protective device were present, or if mechanical type overcurrent devices with opening times of one-half cycle or longer were present, the full available short-circuit energy would be delivered to the system. The amount of energy delivered is directly proportionate to the square of the current. So we can see how important it is to have fuses which can limit the current being delivered to the system to a value less than the available current. The amount of energy being produced in the circuit while the fuse is clearing is called the total clearing energy and is equal to the melting energy plus the arcing energy. Selectivity between two fuses operating under short-circuit conditions exists when the total clearing energy of the load side fuse is less than the melting energy of the line side fuse. An engineering tool has been developed to aid in the proper selection of fuses for selective coordination. This Selectivity Ratio Guide (SRG) is shown below.

* Selectivity Ratio Guide (Line-Side to Load-Side) for Blackout Prevention

Circuit Load-Side Fuse Current Rating Type Trade Name 601-6000A TimeDelay LOW-PEAK YELLOW (L) KRP-CSP 601-4000A TimeDelay LIMITRON 0-600A Dual-Element Time-Delay LOW-PEAK YELLOW (RK1) (J)** LPN-RKSP LPJ-SP LPS-RKSP 2:1 2:1 601-6000A 0-600A 0-1200A Fast-Acting Fast-Acting 0-600A 0-60A TimeDelay SC (G) SC N/A

FUSETRON LIMITRON LIMITRON T-TRON LIMITRON (J) JKS 2:1

Class (L) (RK5) (L) (RK1) (T) Buss KLU FRN-R KTU KTN-R JJN Symbol FRS-R KTS-R JJS 601 to Time- LOW-PEAK KRP-CSP 2:1 2.5:1 4:1 2:1 2:1 2:1 6000A Delay YELLOW (L) 601 to Time- LIMITRON KLU 2:1 2:1 2:1 2:1 4:1 2:1 2:1 2:1 4000A Delay (L) LOW-PEAK LPN-RKSP 2:1 2:1 8:1 3:1 3:1 YELLOW 0 Dual- (RK1) LPS-RKSP to Ele- (J) LPJ-SP** 2:1 2:1 8:1 3:1 3:1 600A ment FUSETRON FRN-R 1.5:1 1.5:1 2:1 1.5:1 1.5:1 (RK5) FRS-R 601 to LIMITRON KTU 2:1 2.5:1 2:1 2:1 6:1 2:1 2:1 2:1 6000A (L) 0 to Fast- LIMITRON KTN-R 3:1 3:1 8:1 3:1 3:1 600A Acting (RK1) KTS-R 0 to T-TRON JJN 3:1 3:1 8:1 3:1 3:1 1200A (T) JJS 0 to LIMITRON JKS 2:1 2:1 8:1 3:1 3:1 600A (J) 0 to Time- SC SC 3:1 3:1 4:1 2:1 2:1 60A Delay (G) * Note: At some values of fault current, specified ratios may be lowered to permit closer fuse sizing. Plot fuse curves or consult with Bussmann. General Notes: Ratios given in this Table apply only to Buss fuses. When fuses are within the same case size, consult Bussmann. ** Consult Bussmann for latest LPJ-SP ratios. Line-Side Fuse

2:1 3:1

N/A 4:1

3:1 1.5:1 2:1 3:1 3:1 3:1 2:1

4:1 1.5:1 N/A 4:1 4:1 4:1 2:1

For the next example, the Selectivity Ratio Guide suggests that the minimum ratio between line side and load side fuse should be at least 2:1. The one-line shows LOW-PEAK fuses KRPC1000SP feeding a LPS-RK200SP. The ratio of ampere ratings is

5:1 (1000:200) which indicates coordination between these fuses. Continuing further into the system the LPS-RK-200SP feeds a LPJ60SP. This ratio of ampere ratings is 3.33:1 (200:60), which also indicates a selectively coordinated system.

42

Contents

Index

Next

Previous

Selective Coordination Current-Limiting Fuses

Ip Available Short-Circuit Current

I'p 480/277 Volts

KRP-C-1000SP Amp Fuse Let-Through Energy*

Line Side Load Side

LOW-PEAK Time-Delay Fuse KRP-C-1000SP

tm tc

ta

LOW-PEAK LPS-RK-200SP Dual-Element Fuse

LPS-RK-200SP Amp Fuse Let-Through Energy* tm Line Side Load Side tc

LOW-PEAK LPJ-60SP Dual-Element Fuse

Fault tc

LPJ-60SP Amp Fuse Let-Through Energy*

Requirements for selectivityTotal clearing energy of load side fuse is less than melting energy of line side fuse.

*Area under the curves indicates let-through energy.

43

Contents

Index

Next

Previous

Selective Coordination Current-Limiting Fuses

Medium to High Level Fault Currents The following curve illustrates a 400 ampere circuit breaker ahead of a 90 ampere breaker. Any fault above 1500 amperes on the load side of the 90 ampere breaker will open both breakers. The 90 ampere breaker will generally unlatch before the 400 ampere breaker. However, before the 90 ampere breaker can separate its contacts and clear the fault current, the 400 ampere breaker has unlatched and also will open. Assume a 4000 ampere short-circuit exists on the load side of the 90 ampere circuit breaker. The sequence of events would be as follows: 1. The 90 ampere breaker will unlatch (Point A) and free the breaker mechanism to start the actual opening process. 2. The 400 ampere breaker will unlatch (Point B) and it, too, would begin the opening process. Once a breaker unlatches, it will open. At the unlatching point, the process is irreversible. 3. At Point C, the 90 ampere breaker will have completely interrupted the fault current. 4. At Point D, the 400 ampere breaker also will have completely opened the circuit. Consequently, this is a non-selective system, causing a complete blackout to the load protected by the 400 ampere breaker. As printed by one circuit breaker manufacturer, One should not overlook the fact that when a high fault current occurs on a circuit having several circuit breakers in series, the instantaneous trip on all breakers may operate. Therefore, in cases where several breakers are in series, the larger upstream breaker may start to unlatch before the smaller downstream breaker has cleared the fault. This means that for faults in this range, a main breaker may open when it would be desirable for only the feeder breaker to open.
1000 800 600 400 300 200 90A 100 80 60 40 30 20 90Amp Circuit Breaker 10 8 6 4 3 TIME IN SECONDS 2 400Amp Circuit Breaker I.T. = 5X 4000A 400A

1 .8 .6 .4 .3 .2

.1 .08 .06 .04 .03 .02 .01 .008 .006 .004 .003 .002 A B D C

.001 8000 10,000 40,000 800 1000 2000 3000 6000 10 20 30 40 60 80 100 200 300 400 600 1,500A CURRENT IN AMPERES 80,000 100,000 20,000 30,000 60,000

4,000A

14,000A 30,000A I.R. I.R.

44

Contents

Index

Next

Previous

Selective Coordination Elevator Circuits

The 1996 NEC, Section 620-62 states: Where more than one driving machine disconnecting means is supplied by a single feeder, the overcurrent protective devices in each disconnecting means shall be selectively coordinated with any other supply side overcurrent protective devices. This wording is unprecedented in the NEC in that absolute selective coordination is indeed required. A design engineer must specify main, feeder, sub-feeder, and branch circuit protective devices that are selectively coordinated for all values of overloads and shortcircuits.
200A Sub-Feeder

100A Branch

EL-1

EL-2

EL-3

400A Feeder

Utility Transformer

1600A Main

The following design consists of an insulated case circuit breaker (ICCB) and molded case circuit breakers (MCCBs). It shows a lack of coordination for any value of current in excess of 750 amperes. Faults in excess of 16,000 amperes cause a total system blackout, violating Section 620-62.
200A Sub-Feeder

1,000 800 600 400 300 200

100 80 60 40

1600A ICCB 400A MCCB 200A MCCB 100A MCCB

100A MCCB

30 20

10 8 6

TIME IN SECONDS

EL-1

EL-2

EL-3

4 3 2

400A MCCB

Utility Transformer

1600A ICCB

1 .8 .6 .4 .3 .2

.1 .08 .06 .04 .03 .02

800 1,000

2,000

3,000

4,000

6,000

8,000 10,000

BLACKOUT (PARTIAL) CURRENT IN AMPERES

BLACKOUT (TOTAL)

45

60,000 80,000 100,000

20,000

30,000

40,000

.01 100 200 300 400 600

Contents

Index

Next

Previous

Selective Coordination Elevator Circuits

This design consists of Class RK1 LOW-PEAK fuses. It complies with Section 620-62 because the fuses selectively coordinate.
LPS-RK200SP
1,000 800 600 400 300 200

LPS-RK400SP LPS-RK100SP
100 80 60 40 30 20

LPS-RK200SP KRP-C1600SP LPS-RK100SP

EL-1

EL-2

EL-3

TIME IN SECONDS

LPS-RK-400SP

10 8 6 4 3 2 1 .8 .6 .4 .3 .2

Utility Transformer

KRP-C-1600SP

.1 .08 .06 .04 .03 .02

6,000 8,000 10,000

20,000

30,000

40,000

CURRENT IN AMPERES

Conclusions
Unnecessary power OUTAGES, such as the BLACKOUTS we so often experience, can be reduced by isolating a faulted circuit from the remainder of the system through the proper selection of MODERN CURRENT-LIMITING FUSES. The SELECTIVITY RATIO GUIDE may be used for an easy check on fuse selectivity regardless of the shortcircuit current levels involved. Where medium and high voltage primary fuses are involved, the time-current characteristic curves of the fuses in question should be plotted on standard NEMA log-log graph paper for proper study.

46

60,000 80,000 100,000

600 800 1,000

2,000

3,000 4,000

100

200

300

400

.01

Contents

Index

Next

Previous

Component Protection
Introduction This issue analyzes the protection of electrical system components from fault currents. It gives the specifier the necessary information regarding the withstand rating of electrical circuit components, such as wire, bus, motor starters, etc. Proper protection of circuits will improve reliability and reduce the possibility of injury. Electrical systems can be destroyed if the overcurrent devices do not limit the short-circuit current to within the withstand rating of the systems components. Merely matching the ampere rating of a component with the ampere rating of a protective device will not assure component protection under short-circuit conditions. In the past several years, there have been numerous reports in newspapers, magazines and insurance company files about destroyed electrical systems. Recognizing this as a serious problem to safety of life and property, much more emphasis has been placed on COMPLIANCE with THE NATIONAL ELECTRICAL CODE. The National Electrical Code covers COMPONENT PROTECTION in several sections. The first section to note is Section 11010. Component Protection and the National Electrical Code Section 110-10. Circuit Impedance and Other Characteristics. The overcurrent protective devices, the total impedance, the component short-circuit withstand ratings, and other characteristics of the circuit to be protected shall be so selected and coordinated as to permit the circuit protective devices used to clear a fault without the occurrence of extensive damage to the electrical components of the circuit. This fault shall be assumed to be either between two or more of the circuit conductors, or between any circuit conductor and the grounding conductor or enclosing metal raceway. This requires that overcurrent protective devices, such as fuses and circuit breakers be selected in such a manner that the short-circuit withstand ratings of the system components will not be exceeded should a short-circuit occur. The short-circuit withstand rating is the maximum shortcircuit current that a component can safely withstand. Failure to provide adequate protection may result in component destruction under short-circuit conditions. After calculating the fault levels throughout the electrical system, the next step is to check the withstand rating of wire and cable, but circuit breakers, transfer switches, starters, etc. not only under overload conditions but also under short-circuit conditions. Note: The let-through energy of the protective device must be equal to or less than the short-circuit withstand rating of the component being protected. CAUTION: Choosing overcurrent protective devices strictly on the basis of voltage, current, and interrupting rating alone will not assure component protection from short-circuit currents. High interrupting capacity electro-mechanical overcurrent protective devices, especially those that are not current-limiting, may not be capable of protecting wire, cable or other components within high short-circuit ranges. The interrupting rating of a protective device pertains only to that device and has absolutely no bearing on its ability to protect connected downstream components. Quite often, an improperly protected component is completely destroyed under short-circuit conditions while the protective device is opening the faulted circuit. Before proceeding with the study of component withstandability, the technology concerning current-limitation will be reviewed. CURRENT-LIMITATION A Definition of Current-Limitation Today, most electrical distribution systems are capable of delivering very high short-circuit currents, some in excess of 200,000 amperes. If the components are not capable of handling these short-circuit currents, they could easily be damaged or destroyed. The current-limiting ability of todays modern fuses allows components with low short-circuit withstand ratings to be specified in spite of high available fault currents. Section 240-11 of the NEC offers the following definition of a current-limiting device: A current-limiting overcurrent protective device is a device which, when interrupting currents in its current-limiting range, will reduce the current flowing in the faulted circuit to a magnitude substantially less than that obtainable in the same circuit if the device were replaced with a solid conductor having comparable impedance. The concept of current-limitation is pointed out in the following graph, where the prospective available fault current is shown in conjunction with the limited current resulting when a current-limiting fuse clears. The area under the current curve indicates the amount of short-circuit energy being dissipated in the circuit. Since both magnetic forces and thermal energy are directly proportional to the square of the current, it is important to limit the short-circuit current to as small a value as possible. Magnetic forces vary as the square of the PEAK current and thermal energy varies as the square of the RMS current. Current-Limiting Effect of Fuses
100,000

Prospective available short-circuit current that would flow when a fuse is not used.

Current

10,000 0

Peak Let-Through Current of Fuse

tc Total Clearing Time of Fuse

Time

Thus, the current-limiting fuse in this example would limit the let-through energy to a fraction of the value which is available from the system. In the first major loop of fault current, standard noncurrent-limiting, electro-mechanical protective devices would letthrough approximately 100 times* as much destructive energy as the fuse would let-through. * 100,000 2 10,000

47

Contents

Index

Next

Previous

Component Protection
Analysis of Current-Limiting Fuse Let-Through Charts The degree of current-limitation of a given size and type of fuse depends, in general, upon the available short-circuit current which can be delivered by the electrical system. Current-limitation of fuses is best described in the form of a let-through chart which, when applied from a practical point of view, is useful to determine the let-through currents when a fuse opens. Fuse let-through charts are plotted from actual test data. The test circuit that establishes line A-B corresponds to a short-circuit power factor of 15%, which is associated with an X/R ratio of 6.6. The fuse curves represent the cutoff value of the prospective available short-circuit current under the given circuit conditions. Each type or class of fuse has its own family of let-through curves. The let-through data has been generated by actual shortcircuit tests of current-limiting fuses. It is important to understand how the curves are generated, and what circuit parameters affect the let-through curve data. Typically, there are three circuit parameters that can affect fuse let-through performance for a given available short-circuit current. These are: 1. Short-circuit power factor 2. Short-circuit closing angle 3. Applied voltage Current-limiting fuse let-through curves are generated under worst case conditions, based on these three variable parameters. The benefit to the user is a conservative resultant let-through current (both Ip and IRMS). Under actual field conditions, changing any one or a combination of these will result in lower let-through currents. This provides for an additional degree of reliability when applying fuses for equipment protection.

Analysis of a Current-Limiting Fuse

B I

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

400,000 300,000 200,000

Available Peak ShortCircuit Current = 198,000A Available RMS ShortCircuit Current = 86,000A

100,000 80,000 60,000

800A

Peak Let-Through Current of Fuse= 49,000A RMS Let-Through Current of Fuse = 21,000A tm ta tc tm = Fuse Melt Time ta = Fuse Arc Time tc = Fuse Clearing Time TIME

30,000 20,000 10,000 8000 6000

A
2000 1000 1000 2000 3000 4000 6000

8000 10,000

20,000

30,000 40,000

60,000 80,000

100,000

PROSPECTIVE SHORT-CIRCUIT CURRENT SYMMETRICAL RMS AMPS

200,000

AMPERE RATING

4000 3000

48

Contents

Index

Next

Previous

Component Protection
INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

Prior to using the Fuse Let-Through Charts, it must be determined what let-through data is pertinent to equipment withstand ratings. Equipment withstand ratings can be described as: How Much Fault Current can the equipment handle, and for How Long? Based on standards presently available, the most important data which can be obtained from the Fuse Let-Through Charts and their physical effects are the following: A. Peak let-through current - mechanical forces B. Apparent prospective RMS symmetrical let-through current - heating effect This is a typical example showing the short-circuit current available to an 800 ampere circuit, an 800 ampere LOW-PEAK current-limiting time-delay fuse, and the let-through data of interest. 800 Ampere LOW-PEAK Current-Limiting Time-Delay Fuse and Associated Let-Through Data
86,000 Amps RMS Sym. Available KRP-C800SP Ampere Fuse Short-Circuit

Current-Limitation Curves Bussmann LOW-PEAK Time-Delay Fuse KRP-C800SP

400,000 300,000 200,000

C
100,000 80,000 60,000

800A

D
30,000 20,000 10,000 8000 6000

A
2000 1000 1000 2000 3000 4000 6000

80,000 100,000

PROSPECTIVE SHORT-CIRCUIT CURRENT SYMMETRICAL RMS AMPS

How to Use the Let-Through Charts Using the example given, one can determine the pertinent letthrough data for the KRP-C800SP ampere LOW-PEAK fuse. The Let-Through Chart pertaining to the 800 ampere LOW-PEAK fuse is illustrated. A. Determine the PEAK LET-THROUGH CURRENT. Step 1. Enter the chart on the Prospective Short-Circuit current scale at 86,000 amperes and proceed vertically until the 800 ampere fuse curve is intersected. Step 2. Follow horizontally until the Instantaneous Peak LetThrough Current scale is intersected. Step 3. Read the PEAK LET-THROUGH CURRENT as 49,000 amperes. (If a fuse had not been used, the peak current would have been 198,000 amperes.) B. Determine the APPARENT PROSPECTIVE RMS SYMMETRICAL LET-THROUGH CURRENT. Step 1. Enter the chart on the Prospective Short-Circuit current scale at 86,000 amperes and proceed vertically until the 800 ampere fuse curve is intersected. Step 2. Follow horizontally until line A-B is intersected. Step 3. Proceed vertically down to the Prospective Short-Circuit Current. Step 4. Read the APPARENT PROSPECTIVE RMS SYMMETRICAL LET-THROUGH CURRENT as 21,000 amperes. (The RMS SYMMETRICAL LET-THROUGH CURRENT would be 86,000 amperes if there were no fuse in the circuit.)

A I RMS Available = 86,000 Amps B I RMS Let-Through = 21,000 Amps C I p Available = 198,000 Amps D I p Let-Through = 49,000 Amps

Most electrical equipment has a withstand rating that is defined in terms of an RMS symmetrical-short-circuit current, and in some cases, peak let-through current. These values have been established through short-circuit testing of that equipment according to an accepted industry standard. Or, as is the case with conductors, the withstand rating is based on a mathematical calculation and is also expressed in an RMS short-circuit current. If both the let-through currents (IRMS and Ip) of the current-limiting fuse and the time it takes to clear the fault are less than the withstand rating of the electrical component, then that component will be protected from short-circuit damage. The following components will be analyzed by establishing the short-circuit withstand data of each component and then selecting the proper current-limiting fuses for protection: Wire and Cable Bus (Busway, Switchboards, Motor Control Centers and Panelboards) Low-Voltage Motor Controllers Ballasts Circuit Breakers Transfer Switches HVAC Equipment

49

200,000

20,000

A. Peak Let-Through Current B. Apparent Prospective RMS Sym. Let-Through Current

B
8000 10,000 30,000 40,000 60,000

AMPERE RATING

4000 3000

Contents

Index

Next

Previous

Component Protection Wire and Cable

The circuit shown originates at a distribution panel where 40,000 amperes RMS symmetrical is available. To determine the proper fuse, first establish the short-circuit withstand data for the #10 THW copper cable shown in the diagram. Short-Circuit Protection of Wire and Cable
Short-Circuit To Load #10 THW Copper
SHORT CIRCUIT CURRENT - THOUSANDS OF AMPERES

Short-Circuit Current Withstand Chart for Copper Cables with Thermoplastic Insulation Allowable Short-Circuit Currents for Insulated Copper Conductors*
100 80 60 40 30 20
1 C YC C 4 YC LE 8 CY LE C 0. 16 Y CL S 0 30 C CLE ES 0 16 Y 60 CY CL S 0 .03 7 S EC 10 C C E .0 3 O 0 YC LE S 0.1 66 3 S N C L S E 7 3 D YC E 0 3 S C S LE S 0 .26 3 S EC ON D E . O 6 50 7 S C N S 1 .0 00 SE O D 1. 00 S C ND S 66 0 EC O S 67 SE O ND SE CO ND S C ND S O S N D S 2

40,000 Amps RMS Sym. Available Distribution Panel

LOW-PEAK Dual-Element Fuse LPS-RK30SP

The following table shows the short-circuit withstand of copper cable with 75C thermoplastic insulation based on Insulated Cable Engineers Association (ICEA) formulae. The short-circuit withstand of the #10 THW copper conductor is 4,300 amperes for one cycle (.0167 seconds). Short-circuit protection of this conductor requires the selection of an overcurrent device which will limit the 40,000 amperes RMS symmetrical available to a value less than 4,300 amperes, and clear the fault in one cycle or less. The LOW-PEAK dual-element fuse let-through chart shows that the LPS-RK30SP LOW-PEAK dual-element fuse will letthrough an apparent prospective RMS current of less than 1,800 amperes, when 40,000 amperes is available (and would clear the fault in less than 1/2 cycle). Short-Circuit Currents for Insulated Cables The recent increase in KVA capacity of power distribution systems has resulted in possible short-circuit currents of extremely high magnitude. Conductor insulation may be seriously damaged by fault induced, high conductor temperatures. As a guide in preventing such serious damage, maximum allowable short-circuit temperatures, which damage the insulation to a slight extent only, have been established for various insulation as follows: Paper, rubber and varnished cloth 200C. Thermoplastic 150C. The chart shows the currents which, after flowing for the times indicated, will produce these maximum temperatures for each conductor size. The system short-circuit capacity, the conductor cross-sectional area and the overcurrent protective device opening time should be such that these maximum allowable shortcircuit currents are not exceeded. Thus, if the protective device requires one cycle to open (such as a circuit breaker) then 1/0 THW copper cables must be specified for the 30 ampere circuit in order to prevent damaging temperature rise to the insulation. Using the formula shown on the ICEA protection table will allow the engineer to calculate withstand ratings of cable not shown on these pages. It may be advantageous to calculate withstand ratings below one cycle, when the opening time of the current-limiting device is known. An example of additional withstand ratings for 75C copper wire is shown below. Copper, 75 Thermoplastic Insulated Cable Damage Table (Based on 60 HZ)
Copper Maximum Short-Circuit Withstand Current in Amperes Wire Size 75C 1/8 1/4 1/2 1 2 Thermoplastic Cycles* Cycles* Cycles* Cycle Cycles 3 Cycles

10 8 6 4 3 2

1 .8 .6 .4 .3 .2

CONDUCTOR: COPPER INSULATION: THERMOPLASTIC CURVES BASED ON FORMULA: I 2 T2 + 234 t = .0297 log A T1 + 234

[ ]

WHERE: I = SHORT-CIRCUIT CURRENT - AMPERES A = CONDUCTOR AREA - CIRCULAR MILS t = TIME OF SHORT-CIRCUIT - SECONDS T1 = MAXIMUM OPERATING TEMPERATURE 75C T2 = MAXIMUM SHORT-CIRCUIT TEMPERATURE 150C

.1 4/0 AWG 500 MCM 1,000 2/0 3/0 10 8 6 4 2 1

CONDUCTOR SIZE

*Copyright 1969 (reaffirmed March, 1992) by the Insulated Cable Engineers Association (ICEA). Permission has been given by ICEA to reprint this chart.

#14* #12* #10 #8 #6 #4

4,800 7,600 12,000 19,200 30,400 48,400

3,400 2,400 5,400 3,800 8,500 6,020 13,500 9,600 21,500 16,200 34,200 24,200

1,700 2,700 4,300 6,800 10,800 17,100

1,200 1,900 3,000 4,800 7,600 12,100

1,000 1,550 2,450 3,900 6,200 9,900 50

* Extrapolated data.

Protecting Equipment Grounding Conductors Safety issues arise when the analysis of equipment grounding conductors is discussed. Table 250-95 of the NEC offers minimum sizing for equipment grounding conductors. The problem of protecting equipment grounding conductors was recognized more than 30 years ago when Eustace Soares, wrote his famous grounding book Grounding Electrical Distribution Systems for Safety. In his book he states that the validity rating corresponds to the amount of energy required to cause the copper to become loose under a lug after the conductor has had a chance to cool back down. This validity rating is based upon raising the copper temperature from 75C to 250C. In addition to this and the ICEA charts, a third method promoted by Onderdonk allows the calculation of the energy necessary to cause the conductor to melt (75C to 1,083C). The following table offers a summary of these values associated with various size copper conductors. It becomes obvious that the word Minimum in the heading of table 250-95 means just that - the values in the table are a minimum - they may have to be increased due to the available shortcircuit current and the current-limiting, or non-current-limiting ability of the overcurrent protective device. Good engineering practice requires the calculation of the available short-circuit currents (3-phase and phase-to-ground values) wherever equipment grounding conductors are used. Overcurrent protective device (fuse or circuit breaker) manufacturers literature must be consulted. Let-through energies for these devices should be compared with the short-circuit ratings of the equipment grounding conductors. Wherever let-through energies exceed the minimum equipment grounding conductor withstand ratings, the equipment grounding conductor size must be increased until the withstand ratings are not exceeded.

Contents

Index

Next

Previous

Component Protection Wire and Cable

Comparison of Equipment Grounding Conductor Short-Circuit Withstand Ratings
5 Sec. Rating (Amps) ICEA P32-382 Insulation Damage 150C Soares 1 Amp/30 cm Validity 250C Onderdonk Melting Point 1,083C I2t Rating x106 (Ampere Squared Seconds) ICEA Soares P32-382 1 Amp/30 cm Insulation Validity Damage 150C 250C Onderdonk Melting Point 1,083C

Conductor Size

14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1,000

97 155 246 391 621 988 1,246 1,571 1,981 2,500 3,150 3,972 5,009 5,918 7,101 8,285 9,468 11,835 14,202 16,569 17,753 18,936 21,303 23,670

137 218 346 550 875 1,391 1,754 2,212 2,790 3,520 4,437 5,593 7,053 8,333 10,000 11,667 13,333 16,667 20,000 23,333 25,000 26,667 30,000 33,333

253 401 638 1,015 1,613 2,565 3,234 4,078 5,144 6,490 8,180 10,313 13,005 15,365 18,438 21,511 24,584 30,730 36,876 43,022 46,095 49,168 55,314 61,460

.047 .120 .303 .764 1.93 4.88 7.76 12.3 19.6 31.2 49.6 78.9 125.0 175.0 252.0 343.0 448.0 700.0 1,008.0 1,372.0 1,576.0 1,793.0 2,269.0 2,801.0

.094 .238 .599 1.51 3.83 9.67 15.4 24.5 38.9 61.9 98.4 156.0 248.0 347.0 500.0 680.0 889.0 1,389.0 2,000.0 2,722.0 3,125.0 3,556.0 4,500.0 5,555.0

.320 .804 2.03 5.15 13.0 32.9 52.3 83.1 132.0 210.0 331.0 532.0 845.0 1,180.0 1,700.0 2,314.0 3,022.0 4,721.0 6,799.0 9,254.0 10,623.0 12,087.0 15,298.0 18,867.0

Take the example below. The EGC must be protected from damage. It can withstand 4,300 amperes of current for 1 cycle. The 1 cycle opening time of the circuit breaker will cause damage to the #10 EGC. However, a current-limiting fuse will limit the curVIOLATION Grounded Service Neutral Grounding Electrode 50,000A RMS Service Equipment Metal enclosure 60A Non-Current-Limiting Circuit Breaker with 1 cycle opening time under short-circuit conditions Non-Metallic Raceway

rent to within the withstand rating of the EGC. An LPS-RK60SP will limit the line to ground current to approximately 3300 amperes, providing protection.

COMPLIANCE Grounded Service Neutral Grounding Electrode 50,000A RMS Service Equipment Metal enclosure 60A Current-Limiting Fuse with 1/4 cycle opening time under short-circuit conditions Non-Metallic Raceway

#10 Equipment Grounding Conductor (Copper) 3 Load

#10 Equipment Grounding Conductor (Copper) 3 Load

Metal Enclosure

Metal Enclosure

Would need to increase Equipment Grounding Conductor to 2/0, per ICEA Std. P-32-382.

Conforms to Section 110-10 and 250-95.

51

Contents

Index

Next

Previous

Component Protection
Bus Short-Circuit Rating and Bracing Requirements
Bus Short-Circuit Rating Requirements When Protected by CurrentLimiting Fuses NEMA Standards require that busways have a symmetrical short-circuit withstand rating at least as great as the average available symmetrical short-circuit current.* Since the short-circuit ratings of busways are established on the basis of minimum three-cycle duration tests, these ratings will not apply unless the protective device used will remove the fault within three cycles or less.* BUSWAYS MAY BE USED ON CIRCUITS HAVING AVAILABLE SHORT-CIRCUIT CURRENTS GREATER THAN THE BUSWAY RATING WHEN PROPERLY COORDINATED, AND RATED WITH CURRENT-LIMITING DEVICES.* If a busway has been listed or labeled for a maximum shortcircuit current with a specific overcurrent device, it cannot be used where greater fault currents are available without violating the listing or labeling. If a busway has been listed or labeled for a maximum short-circuit current without a specific overcurrent device (i.e., for three cycles), current-limiting fuses can be used to reduce the available short-circuit current to within the withstand rating of the busway. Refer to Figure below for an analysis of the short-circuit rating requirements for the 800 ampere plug-in bus. Determining the Short-Circuit Ratings of Busway
KRP-C800SP Amp LOW-PEAK Time-Delay Fuses Short-Circuit

65,000 Amps RMS Sym. Available

800 Amp Switch Bracing Required?

The following examples compare busway short-circuit overcurrent protection by low voltage circuit breakers and currentlimiting fuses. This study looks at the development of the busway mechanical withstand curves and the time-current curves of the breakers and fuses. In this example, the 800 ampere plug-in busway has a 65 kA short-circuit rating. A plot of the busway mechanical limit characteristic on log-log paper passes through the short-circuit rating at (65 kA, 0.05 seconds) and is a constant I2t down to 32.5 kA (one-half the shortcircuit rating of 65 kA). Assume the available short-circuit current at the busways is equal to the 65 kA rating. The overcurrent devices are assumed to have the proper interrupting capacity. In order to coordinate selectively with circuit breakers that are instantaneously tripped, the power circuit breaker protecting the busway does not have an instantaneous trip. There is a problem with the protection of this busway. The short-time-delay needed to achieve coordination results in a lack of protection of the 800 ampere busway. A short-circuit on this busway can result in damage. As noted on the curve, a 65,000 ampere fault will intersect the mechanical damage curve before the breaker trips. This busway would have to be braced to withstand 65,000 amperes of short-circuit current for a minimum of 12 cycles. A plot of the same system utilizing LOW-PEAK Class L and Class RK1 fuses is also shown. Current-limitation by the KRPC800SP will offer short-circuit protection for the busway, as it lets through 19,000 amperes. Note: The busway is protected by the fast speed of response in the high short-circuit region. Protection is achieved, as is selective coordination, with the downstream LPS-RK400SP fuse. NEMA (Standard Short-Circuit Ratings of Busway*)
Continuous Current Rating of Busway (Amperes) Short-Circuit Current Ratings (Symmetrical Amperes) Plug-In Duct

800 Amp Plug-in Bus

The 800 ampere plug-in bus could be subjected to 65,000 amperes at its line side; however, the KRP-C800SP ampere LOWPEAK time-delay fuse would limit this available current. When protected by KRP-C800SP ampere LOW-PEAK time-delay fuses, the 800 ampere bus need only be braced for 19,000 amperes RMS symmetrical. This would allow a standard 22,000 ampere RMS symmetrical (3-cycle) rated bus to be specified, whereas, if a noncurrent-limiting type protective device were specified, the bracing requirements would have been 65,000 amperes for three cycles. CURRENT-LIMITING FUSES GENERALLY REDUCE BUS BRACING REQUIREMENTS TO ALLOW A STANDARD SHORTCIRCUIT RATED BUSWAY TO BE SPECIFIED. When applying air frame circuit breakers with short-time-delay (STD), the engineer must specify additional short-circuit bracing based on the STD time setting. For example, an 800 ampere air frame circuit breaker may have an intentional 18 cycle STD to selectively coordinate with downstream breakers. It is imperative that the 800 ampere busway also be braced for this 18 cycles to avoid damage or destruction.
*NEMA Pub. No. BU1-1988.

Feeder Duct

100 225 400 600 800 1000 1200 1350 1600 2000 2500 3000 4000 5000

10,000 14,000 22,000 22,000 22,000 42,000 42,000 42,000 65,000 65,000 65,000 85,000 85,000

42,000 42,000 75,000 75,000 75,000 100,000 100,000 150,000 150,000 200,000 200,000

The busway short-circuit short-time rating has a mechanical limit. Exceeding this limit invites mechanical damage due to the high magnetic forces associated with the peak current of the fault. The mechanical limit typically applies for high faults near and below the busway short-circuit rating. Allowable durations of shortcircuit current, longer than the 3-cycles at 60 Hz (0.05 seconds) required at the maximum short-circuit rating, are obtained from a constant I2t mechanical damage limit curve. Typically, for currents below one-half of the short-circuit current rating, where mechanical stresses are reduced to one-quarter of those at the maximum rating, the mechanical capabilities become less important than the thermal capability. The lower limit duration at one-half the busway rating is determined by the busway thermal (I2t) capabilities. 52

This table pertains to feeder and plug-in busway. For switchboard and panelboard standard ratings refer to manufacturer. U.L. Standard 891 details short-circuit durations for busway within switchboards for a minimum of three cycles, unless the main overcurrent device clears the short in less than three cycles.
*Reprinted with permission of NEMA, Pub. No. BU1-1988.

Contents

Index

Next

Previous

Component Protection
Bus Short-Circuit Rating and Bracing Requirements
1,000 800 600 400 300 200
1,000 800 600 400 300 200

800A AFCB 400A MCCB

100 80 60 40 30 20
100 80 60 40 30 20

LPS-RK400SP KRP-C800SP

10 8 6

10

800A AFCB
TIME IN SECONDS

8 6

TIME IN SECONDS

4 3 2

KRP-C800SP
4 3 2

400A CB

LPS-RK400SP

1 .8 .6 .4 .3 .2

1 .8

800A Plug-in Busway

.6 .4 .3 .2

.1 .08 .06 .04 .03 .02

.1

Short Time Delay - 6 Cycles

.08

Busway Mechanical Capability

.06 .04 .03 .02

Busway Mechanical Capability

60,000

80,000 100,000

1,000

2,000

3,000

4,000

6,000

8,000

10,000

20,000

30,000

40,000

.01 100 200 300 400 600 800

10,000

20,000

30,000

40,000

60,000

CURRENT IN AMPERES

65,000A Short-Circuit

CURRENT IN AMPERES

65,000A Short-Circuit

53

80,000 100,000

1,000

2,000

3,000

4,000

6,000

8,000

.01 100 200 300 400 600 800

Contents

Index

Next

Previous

Component Protection Low Voltage Motor Controllers

The diagram below shows a Size 2, combination motor controller supplying a 460 volt, 3, 20HP motor. The short-circuit withstand of this and other motor controllers are established so that they may be properly protected from short-circuit damage. Short-Circuit Protection of Motor Controller
40,000 RMS Symmetrical Available 3, 460V LOW-PEAK Dual-Element, Time-Delay Fuse

20HP

M 3, 460V
27 F.L.A. Typical Size 2 Controller

There are several independent organizations engaged in regular testing of motor controllers under short-circuit conditions. One of these, Underwriters Laboratories, tests controllers rated one horsepower or less and 300 volts or less with 1000 amperes shortcircuit current available to the controller test circuit. Controllers rated 50HP or less are tested with 5000 amperes available and controllers rated above 50HP to 200HP are tested with 10,000 amperes available. See the table below for these values.*
Motor Controller HP Rating Test Short-Circuit Current Available

1HP or less and 300V or less 50HP or less Greater than 50HP to 200HP 201HP to 400HP 401HP to 600HP 601HP to 900HP 901HP to 1600HP

1,000A 5,000A 10,000A 18,000A 30,000A 42,000A 85,000A

It should be noted that these are basic short-circuit requirements. Higher, combination ratings are attainable if tested to an applicable standard. However, damage is usually allowed. Type 1 vs. Type 2 Protection U.L. has developed a short-circuit test procedure designed to verify that motor controllers will not be a safety hazard and will not cause a fire. Compliance to the standard allows deformation of the enclosure, but the door must not be blown open and it must be possible to open the door after the test. In the standard short-circuit tests, the contacts must not disintegrate, but welding of the contacts is considered acceptable. When testing with fuses, damage to the overload relay is not allowed, and it must perform in accordance with the calibration requirements. Tests with circuit breakers allow the overload relay to be damaged with burnout of the current element completely acceptable. For short-circuit ratings in excess of the standard levels listed in U.L. 508, the damage allowed is even more severe. Welding or complete disintegration of contacts is acceptable and complete burnout of the overload relay is allowed. Therefore, a user cannot be certain that the motor starter will not be damaged just because it has been U.L. Listed for use with a specific branch circuit protective device. U.L. tests are for safety, but do allow a significant amount of damage as long as it is contained within the enclosure.
*From Industrial Control Equipment, U.L. 508.

In order to properly select a branch circuit protective device that not only provides motor branch circuit protection, but also protects the circuit components from damage, the designer must look beyond mere safety standards. Coordination of the branch circuit protective device and the motor starter is necessary to insure that there will be no damage or danger to either the starter or the surrounding equipment. There is an IEC (International Electrotechnical Commission) Standard that offers guidance in evaluating the level of damage likely to occur during a short-circuit with various branch circuit protective devices. IEC Publication 947, Low Voltage Switchgear and Control, Part 4-1: Contractors and Motor Starters, addresses the coordination between the branch circuit protective device and the motor starter. It also provides a method to measure the performance of these devices should a short-circuit occur. IEC defines two levels of protection (coordination) for the motor starter: Type 1. Considerable damage to the contactor and overload relay is acceptable. Replacement of components or a completely new starter may be needed. There must be no discharge of parts beyond the enclosure. Type 2. No damage is allowed to either the contactor or overload relay. Light contact welding is allowed, but must be easily separable. Where Type 2 protection is desired, the controller manufacturer must verify that Type 2 protection can be achieved by using a specified protective device. U.S. manufacturers have recently begun having both their NEMA and IEC motor controllers verified to meet the Type 2 requirements outlined in IEC 947-4. As of this writing only current-limiting fuses have been able to provide the current-limitation necessary to provide verified Type 2 protection. In many cases, Class J, Class RK1, or Class CC fuses are required, because Class RK5 fuses and circuit breakers arent fast enough under short-circuit conditions to provide Type 2 protection. Section 430-52 of the National Electrical Code allows dualelement, time-delay fuses and other overcurrent protective devices to be sized for branch circuit protection (short-circuit protection only). Controller manufacturers often affix labels to the inside of the motor starter cover which recommend the maximum size fuse for each overload relay size. A paragraph in Section 430-52 states: Where maximum branch circuit protective device ratings are shown in the manufacturers overload relay table for use with a motor controller or are otherwise marked on the equipment, they shall not be exceeded even if higher values are allowed as shown above.** This paragraph means that the branch circuit overcurrent protection for overload relays in motor controllers must be no greater than the maximum size as shown in the manufacturers overload relay table. These maximum branch circuit sizes must be observed even though other portions of Section 430-52 allow larger sizing of branch circuit overcurrent protection. The reason for this maximum overcurrent device size is to provide short-circuit protection for the overload relays and motor controller.
**Above refers to other portions of Section 430-52 not shown here.

54

Contents

Index

Next

Previous

Component Protection Ballasts

The National Electrical Code requires integral thermal protection for ballasts in Section 410-73(e). Testing agencies list ballasts for general use in lighting fixtures which pass specific thermal and short-circuit tests. The ballast must incorporate a thermal protector to sense certain overtemperature conditions and must also be able to withstand 200 amperes of short-circuit current when tested with a 20 ampere fuse. See the figure at right for a typical test for ballasts. Most systems today will deliver more than 200 amperes of short-circuit current to a row of fixtures. The fixtures should, therefore, be specified to incorporate individual ballast fusing within the fixture and external to the ballast. Fusing each fixture will also provide isolation of the faulted ballast and reduce costly and dangerous blackouts. When a ballast does fail, only the fuse protecting that individual fixture opens the remaining fixtures continue in normal operation. Without this individual ballast protection, a faulted ballast could cause the branch circuit protective device to open, thereby shutting off all the lights. With individual fusing, the maintenance electrician can trouble shoot the problem much more quickly because only one fixture is out. And this trouble shooting can be performed as part of a scheduled maintenance procedure. It doesnt have to become an emergency because employees are left in the dark. Note: Refer to fixture manufacturer for recommended fuse size. Underwriters Laboratories Short-Circuit Test for Ballast Protectors
Thermal Protector 200A 0.9-1.0 P .F. Ballast Winding Short Ballast

20 Amp Fuse

Fusing Fixture Ballasts to Provide Short-Circuit Protection and Isolation of Faulted Ballast. Good Ballasts Remain on the Line
20' #10 THW Wire 277 Volt Lighting Panel 2,000 Amperes Available Row of Lighting Fixtures

Fuse Opens

Fixture Faulted Ballast

Ballasts

Component Protection Circuit Breakers

As has been discussed previously, the two parameters IRMS and Ip, must be compared to the equipment withstand rating. The rule is simple: if the RMS and peak let-through value of the fuse are less than the equipment withstand rating, the equipment will be protected. This philosophy holds true for various static components, such as wire and cable, busway, and motor starters. This basic protection requirement is mandated in NEC Section 110-10. It will also be true for non-current-limiting circuit breakers when their opening time is greater than one-half cycle. In the past, as long as the fuse let-through values were less than the breakers interrupting rating, the system was considered sound. THIS METHOD HAS A SOLID HISTORY OF SUCCESSFUL APPLICATIONS. However, due to changes in circuit breaker design, the method may not always work with todays circuit breakers. Selecting a current-limiting fuse to protect a downstream molded case circuit breaker has now become an increasingly more complex problem. Quicker Operating Circuit Breakers Simply put, if the total clearing energy of a quicker acting molded case circuit breaker is less than the melting energy of a larger upstream fuse, the molded case circuit breaker will interrupt the full value of the system fault without the benefit of the fuses current-limiting effect. This situation can have catastrophic effects on the circuit breaker as it tries to interrupt faults beyond its interrupting capacity. Currently, there is no available engineering method to predict protection of these faster breakers. Molded Case Circuit Breakers - Agency Test Procedures Some agency standards allow a unique test set-up for testing circuit breaker interrupting ratings. The Graph at the right illustrates a typical calibrated test circuit waveform for a 20A, 240-volt, two-pole molded case circuit breaker, with a marked interrupting rating of 22,000 amperes RMS symmetrical. The Figure also illustrates the calibration required by the standard, and the maximum peak current available at a 20% power factor. However, agency standards allow for a random close during the short-circuit test, so the peak available current may be as low as 1.414 times the RMS current for one- and two-pole circuit breakers. For threepole circuit breakers, one pole may see a peak of only 1.414 RMS. The conservative approach would therefore assume a 1.414 multiplier also for three-pole breakers.

Ip = 48,026A

IRMS = 22,000A Amps P.F. = 20% IRMS = 22,000 Amp

Time

S.C.P.F. = 20% S.C. Avail. = 22,000A

RLINE RS XS XLINE

20A
RCB XCB RLOAD XLOAD

SOURCE:

4' Rated Wire (#12 Cu)

10" Rated Wire (#12 Cu)

Note: For calculations, R CB and X CB are assumed negligible.

55

Contents

Index

Next

Previous

Component Protection Circuit Breakers

Standard interrupting rating tests will allow for a maximum 4foot rated wire on the line side, and a 10-inch rated wire on the load side of the circuit breaker. Performing a short-circuit analysis of this test circuit results in the following short-circuit parameters, as seen by the circuit breaker. Actual short-circuit RMS current = 9,900 amperes RMS symmetrical Actual short-circuit power factor = 88% Actual short-circuit peak current = 14,001 amperes A graphic analysis of this actual short-circuit follows.
Ip = 14,001A P.F. = 88% IRMS = 9,900 Amp Amps IRMS = 9,900A

Following is a partial table showing the actual Ip and IRMS values to which a circuit breaker may be tested. 240V - 2-Pole CB Interrupting Capacities (KA)
CB Rating 10kA Ip IRMS 14kA Ip IRMS 18kA Ip IRMS

15 20 25 30 40 50 60 70 80 90 100

7.2 8.9 10.7 10.7 11.7 11.7 12.5 13.0 13.0 13.2 13.2

5.1 6.3 7.5 7.5 8.3 8.3 8.8 9.2 9.2 9.3 9.3

8.7 11.4 14.2 14.2 16.0 16.0 17.3 18.1 18.1 18.3 18.3

6.1 8.1 10.1 10.1 11.3 11.3 12.2 12.8 12.8 12.9 12.9

9.3 12.6 16.5 16.5 19.2 19.2 21.3 22.6 22.6 23.0 23.0

6.6 8.9 11.7 11.7 13.6 13.6 15.1 16.0 16.0 16.3 16.3

Time

After reviewing the values to which the circuit breaker can be tested (its interrupting capacity) it becomes obvious that a circuit breakers interrupting rating cannot be considered its short-circuit withstand rating (especially for breakers with higher interrupting ratings). Agency standards allow for a random close during the short-circuit test, so the peak available current may be as low as 1.414 times the RMS symmetrical current. Thus, the circuit breaker is actually tested to interrupt 9,900 amperes at 88% power factor, not 22,000 amperes at 20% power factor. The following graph shows the waveforms superimposed for comparison. Henceforth, this RMS test value will be identified as the circuit breaker interrupting capacity. (Dont confuse this with the circuit breaker marked interrupting rating.)
Ip = 48,026A

Fully Rated System: A fully rated system is a combination of overcurrent devices that have an interrupting rating equal to or greater than the available short-circuit current. Series Rated System: Although there is no official definition, a series rated system can be described as a combination of circuit breakers or fuses and breakers that can be applied at available fault levels above the interrupting rating of the load side circuit breakers, but not above that of the main or line side device (formerly known as a Cascaded System). Bussmanns recommendation is to use fully rated overcurrent devices. But, when a series rated system is desired, the recommended alternative is to use listed switchboards, panelboards, and load centers which have been tested listed and marked for use with recognized combinations of line side fuses and load side circuit breakers.

IRMS = 22,000A Ip = 14,001A P.F. = 88% IRMS = 9,900 Amp Amps IRMS = 9,900A

Time

The following definitions should be noted: Interrupting Rating (CB): The marked rating shown on the Circuit Breaker. It has been established by testing.* Interrupting Capacity (CB): Actual test Ip and IRMS the circuit breaker sees during the tests for standard circuit breaker applications.* Equally important, the short-circuit power factor is greatly affected due to the high R values of the small, rated wire. This results in a lower peak value that the circuit breaker must tolerate during the first one-half cycle. * These definitions paraphrase those given in the IEEE Standard Dictionary of
Electrical and Electronic Terms, page 462, 1984 edition.

56

Contents

Index

Next

Previous

Component Protection Transfer Switches

Transfer switches are designed to transfer power sources under load in order to feed a system, typically an emergency system, on critical loads. These devices are tested to meet basic short-circuit testing requirements. Transfer switches are often tested per U.L. Standard 1008. Transfer switches should always be evaluated on the basis of the maximum available short-circuit currents. The automatic transfer switch must withstand: a) the magnetic stresses imposed by the instantaneous peak current available at the point of application, and b) the thermal stresses imposed by the available RMS short-circuit current. The short-circuit current withstand rating of the transfer switch must be equal to or greater than the available short-circuit current at the point of application. When properly coordinated with current-limiting devices, automatic transfer switches can be used on circuits having available short-circuit currents greater than their unprotected withstand short-circuit current rating. Modern current-limiting fuses, when properly sized, limit the short-circuit current to within the withstand rating of a transfer switch. Transfer switches must withstand minimum short-circuit currents at specified power factors, as listed in U.L. Standard 1008, until the overcurrent protective devices open. U.L. 1008 Minimum Withstand Test Requirement
Automatic Transfer Switch Rating U.L. Minimum Current Amps U.L. Test Current Power Factor

100 Amps or less 101-400 Amps 401 Amps and greater

5,000 10,000 20 times rating but not less than 10,000 Amps

40% to 50% 40% to 50% 40% to 50% for current of 10,000 Amps. OR 25% to 30% for currents of 20,000 Amps or less. OR 20% or less for current greater than 20,000 Amps.

Transfer switch manufacturers generally publish the withstand rating data for their products. When the available short-circuit current exceeds the withstand rating of the transfer switch, currentlimitation is required. Properly sized modern current-limiting fuses ahead of the transfer switch limit the available short-circuit current to within the withstand rating of a transfer switch, thereby protecting the transfer switch. The transfer switch manufacturer will mark the equipment with the fuse class and rating required to achieve these higher short-circuit ratings.

Component Protection HVAC Equipment

Heating and cooling equipment must meet short-circuit test requirements in U.L. Standard 1995 and CSA-C22.2 No. 236-M90. Short-circuit tests are conducted at various levels, up to a maximum of only 5000 amperes, depending on the rated current and voltage of the equipment. Where available fault currents exceed the values given in Table 55.1 of U.L. 1995 it is necessary to specify a current-limiting device to reduce the available current down to within the withstand capabilities of the equipment. Class J and Class RK1 dual-element current-limiting fuses will offer the best component short-circuit protection and currentlimiting characteristics for this type of equipment. Short-Circuit Test Currents*
Product Ratings, A 110-120V Single-Phase 200-208V 220-240V 254-277V Circuit Capacity, A

9.8 or less 9.9-16.0 16.1-34.0 34.1-80.0 Over 80.0

200-208V

5.4 or less 5.5-8.8 8.9-18.6 18.7-44.0 Over 44.0

3-Phase 220-240V

4.9 or less 5.0-8.0 8.1-17.0 17.1-40.0 Over 40.0

440-480V

6.65 or less Over 6.65

550-600V

200 1000 2000 3500 5000

Circuit Capacity, A

2.12 or less 2.13-3.7 3.8-9.5 9.6-23.3 Over 23.3

2.0 or less 2.1-3.5 3.6-9.0 9.1-22.0 Over 22.0

1.8 or less Over 1.8

1.4 or less Over 1.4

200 1000 2000 3500 5000

*Table 55.1 of U.L. Standard 1995.

57

Contents

Index

Next

Previous

Component Protection Let-Through Charts

LOW-PEAK YELLOW Class L Time-Delay Fuses KRP-C_SP
400,000

KRP-C_SP Fuse RMS Let-Through Currents (kA)

Prosp. Short C.C. Fuse Size 601 IRMS 800 IRMS 1200 1600 IRMS IRMS 2000 2500 3000 4000 IRMS IRMS IRMS IRMS 5000 IRMS 6000 IRMS

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

300,000 200,000

100,000 80,000 60,000 50,000 40,000 30,000 20,000

6,000 5,000 4,000 3,000 2,500 2,000 1,600 1,200 800 601 AMPERE RATING

5,000

5 10 11 12 13 14 15 16 17 18 19 20 21 22 25 28

5 10 14 15 17 18 18 19 22 24 25 27 28 29 34 37

5 10 15 20 22 24 25 26 28 30 31 32 34 35 39 43

5 10 15 20 25 26 28 29 31 33 35 37 38 39 46 50

5 10 15 20 25 29 30 32 35 38 41 43 46 48 57 65

5 10 15 20 25 30 35 38 43 46 48 52 54 57 70 78

5 10 15 20 25 30 35 40 48 52 56 59 63 65 83 96

5 10 15 20 25 30 35 40 50 60 65 70 74 78 96 109

5 10 15 20 25 30 35 40 50 60 70 80 85 89 113 130

10,000 7 15,000 9 20,000 10 25,000 11 30,000 11 35,000 12 40,000 13 50,000 14 60,000 15 70,000 16 80,000 16 90,000 17 100,000 18 150,000 21 200,000 23

10,000 8,000 6,000 5,000 4,000 3,000

A
2,000

1,000

2,000

3,000

4,000 5,000 6,000

8,000 10,000

80,000 100,000

200,000

20,000

30,000

40,000 50,000 60,000

1,000

Note: For IRMS value at 300,000 amperes, consult Factory.

PROSPECTIVE SHORT-CIRCUIT CURRENTSYMMETRICAL RMS AMPS

LOW-PEAK YELLOW Class J, Dual-Element Time-Delay Fuses LPJ_SP

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS B 600A 400A 200A 100A 60A 50A 40A 30A 20A 15A 8A 3A 1A AMPERE RATING

LPJ_SP Fuse RMS Let-Through Currents (kA)

Prosp. Short C.C. Fuse Size 15 IRMS 30 IRMS 60 IRMS 100 IRMS 200 IRMS 400 IRMS 600 IRMS

100,000

1,000 3,000 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 50,000 60,000 80,000 100,000

0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 2

0 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3

1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4

1 2 2 2 3 3 3 4 4 4 4 5 5 5 6 7

1 2 3 4 4 4 5 5 5 6 6 6 7 8 9 10

1 3 4 6 6 7 8 8 8 9 9 10 11 12 14 16

1 3 5 8 9 10 11 12 13 13 14 15 16 17 19 21

10,000

1,000

A 100 100 1,000 10,000 100,000 200,000

150,000 200,000

PROSPECTIVE SHORT-CIRCUIT CURRENT SYMMETRICAL RMS AMPS

Note: For IRMS value at 300,000 amperes, consult Factory.

58

Contents

Index

Next

Previous

Component Protection Let-Through Charts

LOW-PEAK YELLOW Class RK1 Dual-Element Time-Delay Fuses LPN-RK_SP
400,000

LPN-RK_SP RMS Let-Through Currents (kA)

Prosp. Short C.C. Fuse Size 30 IRMS 60 IRMS 100 IRMS 200 IRMS 400 IRMS 600 IRMS

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

300,000

1,000
200,000

1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3

1 1 1 2 2 2 2 3 3 3 3 3 3 3 4 4 4 4 5

1 2 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 5 6

1 2 3 3 4 4 5 5 5 6 6 6 7 7 7 7 8 8 9

1 2 3 5 7 7 8 9 9 10 10 10 11 12 12 13 13 16 18

1 2 3 5 9 10 11 12 13 13 13 14 15 16 17 17 17 20 22

2,000
AMPERE RATING

3,000 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 50,000 60,000 70,000 80,000 90,000

100,000 80,000 60,000 50,000 40,000 30,000 20,000

600 400 200 100 60 30

10,000 8,000 6,000 5,000 4,000 3,000

A
2,000

1,000

2,000

3,000

4,000 5,000 6,000

8,000 10,000

80,000 100,000

200,000

20,000

30,000

40,000 50,000 60,000

1,000

100,000 150,000 200,000

PROSPECTIVE SHORT-CIRCUIT CURRENTSYMMETRICAL RMS AMPS

Note: For IRMS value at 300,000 amperes, consult Factory.

LOW-PEAK YELLOW Class RK1 Dual-Element Time-Delay Fuses LPS-RK_SP

400,000

LPS-RK_SP RMS Let-Through Currents (kA)

Prosp. Short C.C. Fuse Size 30 IRMS 60 IRMS 100 IRMS 200 IRMS 400 IRMS 600 IRMS

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

300,000

1,000
200,000

1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3

1 1 1 2 2 2 3 3 3 3 3 3 3 4 4 4 4 5 5

1 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 5 6 7

1 2 3 3 4 5 5 5 6 6 6 7 7 7 8 8 8 9 10

1 2 3 5 7 8 8 9 10 10 10 11 12 13 13 13 14 16 17

1 2 3 5 9 10 11 12 13 13 14 15 16 17 17 18 19 22 23

2,000
AMPERE RATING

3,000 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 50,000 60,000 70,000 80,000 90,000

100,000 80,000 60,000 50,000 40,000 30,000 20,000

600 400 200 100 60

10,000 8,000 6,000 5,000 4,000 3,000 2,000

30

8,000 10,000

20,000

30,000

40,000 50,000 60,000

80,000 100,000

1,000

2,000

3,000

4,000 5,000 6,000

200,000

1,000

100,000 150,000 200,000

PROSPECTIVE SHORT-CIRCUIT CURRENTSYMMETRICAL RMS AMPS

Note: For IRMS value at 300,000 amperes, consult Factory.

59

Contents

Index

Next

Previous

Component Protection Let-Through Charts

FUSETRON Class RK5 Dual-Element Time-Delay Fuses FRN-R
B
400,000

FRN-R RMS Let-Through Currents (kA)

Prosp. Short C.C. Fuse Size 30 IRMS 60 IRMS 100 IRMS 200 IRMS 400 IRMS 600 IRMS

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

300,000

5,000
AMPERE RATING

1 1 1 2 2 2 2 2 2 2 3 3 3 3 3 4

2 3 3 4 4 4 5 5 5 6 6 6 7 7 8 8

3 5 6 7 7 7 8 8 9 9 10 10 10 10 11 12

5 7 8 8 9 10 11 11 12 12 13 13 14 14 16 17

5 9 11 12 13 14 15 15 16 17 18 19 19 20 23 24

5 10 14 16 17 19 20 20 22 23 24 25 26 27 30 32

200,000

10,000 15,000 20,000 25,000 30,000 35,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 150,000 200,000

100,000 80,000 60,000 50,000 40,000 30,000 20,000

600 400 200 100 60

10,000 8,000 6,000 5,000 4,000 3,000

30

A
2,000

1,000

2,000

3,000

4,000 5,000 6,000

8,000 10,000

80,000 100,000

PROSPECTIVE SHORT-CIRCUIT CURRENTSYMMETRICAL RMS AMPS

200,000

20,000

30,000

40,000 50,000 60,000

1,000

FUSETRON Class RK5 Dual-Element Time-Delay Fuses FRS-R

B 400,000

FRS-R RMS Let-Through Currents (kA)

Prosp. Short C.C. Fuse Size 30 IRMS 60 IRMS 100 IRMS 200 IRMS 400 IRMS 600 IRMS

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

5,000 10,000
100,000 AMPERE RATING 600A 400A 200A 100A 60A 10,000 30A

1 2 2 2 3 3 3 3 3 4 4 4 4 4 5 6

2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 8

3 5 5 6 6 7 7 8 8 9 9 9 10 10 11 11

5 7 8 10 10 11 12 12 13 14 15 15 16 16 18 19

5 10 13 14 16 17 18 19 20 21 22 23 23 24 26 27

5 10 15 17 19 20 22 23 24 26 27 28 29 30 33 35

15,000 20,000 25,000 30,000 35,000 40,000 50,000 60,000 70,000 80,000 90,000

100,000 150,000 200,000

10,000 100,000 200,000 1,000

1,000

PROSPECTIVE SHORT-CIRCUIT CURRENT SYMMETRICAL RMS AMPERES

60

Contents

Index

Next

Previous

Component Protection Let-Through Charts

TRON Class T Fast-Acting Fuses JJN
INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS
400,000 300,000 200,000 100,000 80,000 60,000 40,000 30,000 20,000 10,000 8,000 6,000 4,000 3,000 2,000 1,000 800 600 400 300 200

JJN RMS Let-Through Current (kA)

Prosp. Short C.C. Fuse Size 15 IRMS 30 IRMS 60 IRMS 100 IRMS 200 IRMS 400 IRMS 600 IRMS 800 IRMS 1200 IRMS

500
AMPERE RATING

0 0 0 1 1 1 1 1 1 1 1 1 1 1 1

0 0 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2

0 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3

1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 4 4 4

1 1 2 2 3 3 3 3 4 4 4 4 5 5 6 6 6 7

1 1 3 4 4 5 5 5 6 6 7 7 7 8 8 8 9 9

1 1 5 6 6 7 7 8 8 9 9 10 10 11 11 12 13 15

1 1 5 7 9 10 10 11 11 11 12 13 14 15 15 16 17 19

1 1 5 9 10 11 12 13 13 13 15 16 17 17 18 19 22 23

1,000 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 50,000 60,000 70,000 80,000 90,000

1200 800 600 400 200 100 60 30 15

A
6,000 8,000 10,000 20,000 30,000 40,000 60,000 80,000 100,000 100 200 300 400 600 800 1,000 2,000 3,000 4,000 200,000

100,000 1 150,000 1 200,000 2

PROSPECTIVE SHORT-CIRCUIT CURRENTSYMMETRICAL RMS AMPS

TRON Class T Fast-Acting Fuses JJS

400,000 300,000 200,000 100,000 80,000 60,000 40,000 30,000 20,000 10,000 8,000 6,000 4,000 3,000 2,000 1,000 800 600 400 300 200

JJS RMS Let-Through Current (kA)

Prosp. Short C.C. AMPERE RATING Fuse Size 15 IRMS 30 IRMS 60 IRMS 100 IRMS 200 IRMS 400 IRMS 600 IRMS 800 IRMS

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

500 1,000 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 50,000 60,000 70,000 80,000 90,000

0 0 1 1 1 1 1 1 1 1 1 1 1 1 1

0 0 1 1 1 1 1 1 1 2 2 2 2 2 2 2 3 3

0 1 1 1 2 2 2 2 2 2 2 3 3 3 3 3 4 4

1 1 2 2 3 3 3 3 3 4 4 4 4 4 4 5 6 6

1 1 3 3 4 4 5 5 5 5 6 6 7 7 7 7 8 9

1 1 4 6 7 7 7 8 9 9 10 10 11 11 12 12 14 16

1 1 5 8 10 10 11 12 13 13 14 16 17 17 18 19 22 24

1 1 5 9 11 12 13 14 15 15 17 18 19 20 21 22 25 28

800 600 400 200 100 60 30 15

A
6,000 8,000 10,000 20,000 30,000 40,000 60,000 80,000 100,000 100 200 300 400 600 800 1,000 2,000 3,000 4,000 200,000

100,000 2 150,000 2 200,000 2

PROSPECTIVE SHORT-CIRCUIT CURRENTSYMMETRICAL RMS AMPS

61

Contents

Index

Next

Previous

Component Protection Let-Through Charts

LOW-PEAK YELLOW Class CC Time-Delay Fuses LP-CC
AMPERE RATING
4,000

LP-CC RMS Let-Through Currents (kA)

Prosp. Short C.C. Fuse Size 11/4 IRMS 2 8/10 IRMS 15 IRMS 20 IRMS 25 IRMS 30 IRMS

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

3,000 2,000

1,000 3,000 5,000 10,000 20,000 30,000 40,000 50,000 60,000 80,000 100,000 200,000

100 140 165 210 260 290 315 340 350 390 420 525

135 210 255 340 435 525 610 650 735 785 830 1100

240 350 420 540 680 800 870 915 1050 1130 1210 1600

305 440 570 700 870 1030 1150 1215 1300 1500 1600 2000

380 575 690 870 1090 1300 1390 1520 1650 1780 2000 2520

435 580 710 1000 1305 1520 1700 1820 1980 2180 2400 3050

1,000 800 600 500 400 300 200

30 25 20 15 2-8/10 1-1/4

100 80 60 50 40 30 20

800 1,000

PROSPECTIVE SHORT-CIRCUIT CURRENTSYMMETRICAL RMS AMPS

LIMITRON Class J Fast-Acting Fuses JKS

400,000

2,000

10

20

30

40 50 60

80 100

200

300

400 500 600

10

JKS RMS Let-Through Currents (kA)

Prosp. Short C.C. Fuse Size 30 IRMS 60 IRMS 100 IRMS 200 IRMS 400 IRMS 600 IRMS

INSTANTANEOUS PEAK LET-THROUGH CURRENT IN AMPS

300,000

5,000
200,000

1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 3

1 2 2 2 3 3 3 3 3 3 3 3 4 4 5 5

2 3 3 3 3 3 4 4 4 5 5 5 6 6 6 7

3 4 4 5 6 6 6 7 7 7 8 8 9 9 9 10

4 6 7 8 9 9 9 10 10 11 11 12 13 13 14 16

5 9 10 11 12 13 13 14 15 16 17 17 18 18 22 24

AMPERE RATING

10,000 15,000 20,000 25,000 30,000 35,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 150,000 200,000

100,000 80,000 60,000 50,000 40,000 30,000 20,000

600 400 200 100 60 30

10,000 8,000 6,000 5,000 4,000 3,000 2,000

1,000

2,000

3,000

4,000 5,000 6,000

8,000 10,000

80,000 100,000

PROSPECTIVE SHORT-CIRCUIT CURRENTSYMMETRICAL RMS AMPS

200,000

20,000

30,000

40,000 50,000 60,000

1,000

62

Contents

Index

Next

Previous

Flash Protection
MEETING NFPA 70E REQUIREMENTS FOR FLASH PROTECTION Introduction On January 7, 1976 a new electrical standards development committee was formed to assist the Occupational Safety and Health Administration (OSHA) in preparing electrical safety standards. This committee was needed for a number of reasons. First, when adopted by Congress, OSHA incorporated the 1971 National Electrical Code. OSHA refrained from adopting later editions due to the danger that the NEC requirements would be significantly changed due to the required public comment. Second, the NEC is an installation manual, while OSHA addresses employee safety in the workplace. Third, not all sections in the NEC are safety related. Fourth, many safety related work and maintenance practices are not covered, or not adequately covered, in the NEC. As a result, the idea of a new standard was conceived. It consisted of four parts; Part I Installation Safety Requirements Part II Safety-Related Work Practices Part III Safety-Related Maintenance Requirements Part IV Safety Requirements for Special Equipment Since each part was independent of the others, it was decided that they would be published as they were completed. The new standard (NFPA 70E, Standard for Electrical Safety Requirements for Employee Workplaces) was first published in 1979 and consisted of only Part I. The second edition, published in 1981, consisted of the original Part I and a new Part II. The third edition was published in 1988. It included a revision of the original Parts I and II and a new Part III. The fourth edition (1995) is a major rewrite of existing text. Part IV will be developed at a later date. The following will explore some of the new requirements in Part II as they pertain to the protection of workers against burns caused by electric arcs. I. ARC BASICS When a maintenance worker, that is working a panel hot, goes to ground or phase to phase with a screwdriver, an arc is often formed. The temperature at the ends of an arc can reach approximate 35,000F, or about four times as hot as the surface of the sun. These temperatures can easily cause serious or fatal burns to exposed skin and/or ignite clothing. II. SAFE WORKING DISTANCE FORMULA Because employees were being seriously burned by electric arcs, NFPA 70E adopted formulas to define the safe working distance from a potential arc. The formulas for this calculation are based upon the work and a technical paper by Ralph Lee, The Other Electrical Hazard: Electrical Arc Blast Burns, IEEE Transactions on Industrial Applications, Volume IA-18. No.3, May/June 1982. Lees work showed, for example, that skin temperature above 96C for .1 sec. resulted in total destruction of the tissue (incurable burn) and that skin temperature below 80C for .1 sec. allowed for skin which could be cured (just curable burn). At a distance of 3 feet, the arc energy required to produce these temperatures was determined to be 23MW and l7MW respectively. He also found that the maximum arc energy occurred when it represented 50% of the available three phase bolted fault. Therefore, the arc from a 46MVA available source for .1 second could cause an incurable burn at a distance of 3 feet. And, the arc from a 34 MVA available fault for .1 seconds at 3 feet would result in a just curable burn. Following are the formulas developed by Mr. Lee and incorporated into NFPA 70E. Dc = (2.65 MVAbf x t)1/2 Df = (1.96 MVAbf x t)1/2* where Dc = distance in feet for a just curable burn Df = distance in feet for an incurable burn* MVAbf = bolted three phase MVA at point of short-circuit = 1.73 VOLTAGEL-L AVAILABLE SHORT-CIRCUIT CURRENT l0-6 t = time of exposure in seconds
*Not included in NFPA 70E.

Example 1: Assume an available 40896 ampere bolted 3 phase fault on a 480 volt system with a clearing time of 6 cycles (.1 second). Find the distance in feet for a just curable burn. Dc = (2.65 MVAbf t)1/2 ft Dc = (2.65 1.732 480 40896 10-6 .1)1/2 ft Dc = (9.00)1/2 ft Dc = 3 ft This means that any exposed skin, closer than 3 feet to this available fault, for .1 seconds or longer, may not be curable, should an arcing fault occur. If the employee must work on this equipment where parts of his/her body would be closer than 3 feet from the possible arc, suitable protective equipment must be utilized so that the employee injury is minimized.

Overcurrent protective device with clearing time of 6 cycles

40,896 Amperes available 480V 3 480V 3 Main lug only panel Main lug only panel

Example 2: Assume that the same criteria exists as for Example 1 except that the equipment is being protected by a LPJ-200SP LOW-PEAK YELLOW upstream fuse. The opening time is assumed at cycle (.004 seconds) and the equivalent RMS let-through current is read off a chart as 6,000 amperes. Dc = (2.65 MVAbf t)1/2 ft Dc = (2.65 1.732 480 6000 10-6 .004)1/2 Dc = (.0528)1/2 ft Dc = .229 ft (or 2.75 inches) Thus, the flash protection boundary was significantly decreased, from 3 feet (Example 1) to 2.75 inches (Example 2), by limiting the short-circuit current from 40,896 to 6000 amperes and by reducing the exposure time from 6 cycles to cycle.

63

Contents

Index

Next

Previous

Flash Protection
The user also needs to examine the flash protection boundary for low levels of arcing faults. Low level faults, below the currentlimiting threshold of a fuse or the instantaneous trip of a circuit breaker will often produce a greater flash protection boundary than higher level faults. TYPE OF DEVICE Standard molded case circuit breakers (600 volt & below) without short-time-delay (STD) with short-time-delay (STD) Insulated case circuit breakers (600 volt & below) without short-time-delay with short-time-delay Low voltage power (air frame) circuit breakers (600 volt & below) without short-time-delay with short-time-delay Current-limiting molded case circuit breaker (600V & below)
480V 480V3 3 Main lug only panel Main lug only panel 480V 3 MCC Instantaneous trip breaker with cycle clearing time 40,896 Amperes available 6000 Equivalent RMS LetThrough

TIME (Seconds)

.0083-.0167 STD Setting

Class J, 200A fuse with a clearing time of cycle under short-circuit conditions.

.033 STD Setting

.05 STD Setting .004

Where equivalent RMS let-through data is available, it can be used in the flash distance formula. Where data is unavailable, the full available short-circuit must be used.
400A STD = 12 cycles

III. PROTECTIVE EQUIPMENT Employees must wear, and be trained in the use of, appropriate protective equipment for the possible electrical hazards with which they are faced. Examples of equipment could include head, face, neck, chin, eye, ear, body, and extremity protection as required. All protective equipment must meet the requirements as shown in Table 3-3.6 of NFPA 70E-1995. Protective equipment, sufficient for protection against an electrical flash, would be required for any part of the body which could be within 3 feet of the fault in Example 1. Such equipment would likely include a hard hat, face shield, flame retardant neck protection, ear protectors, Nomex suit, insulated rubber gloves with leather protectors, and insulated footwear. IV. EXPOSURE TIME & FAULT CURRENT Much equipment is manufactured with an integral main overcurrent device/disconnecting means. If it is possible to create a fault on the line side of the main, the opening time and let-through characteristics of the overcurrent device which feeds the main device should be considered. Example 3 A 10HP motor starter utilizes an instantaneous trip breaker for the main overcurrent device/disconnecting means. Even though it has an opening time of approximately cycle (.0083 sec), the cycle time cannot be used for the flash distance calculation if it is possible for a fault to be created on the line side of the instantaneous trip breaker (and its almost always possible to create a fault on the line side). Assuming that this starter is fed from a 400 ampere air frame circuit breaker with short-time-delay set at 12 cycles (.2 sec.), the time which must be used in the flash distance calculation would be .2 seconds. Thats the time it would take for the 400 ampere device on the line side to clear a fault if the fault occurred on the line side of the instantaneous trip breaker. The full available fault current, at the line side of the instantaneous trip breaker, would be used in the formula, because the 400 amp breaker would not be current-limiting. The Standard suggests clearing times for current-limiting fuses of cycle and for 5KV and 15KV circuit breakers of 6 cycles. Industry accepted values for other devices are as follows: 64

Arcing fault could occur here

V. OTHER ARC HAZARDS In addition to the extreme heat generated by the arc, molten metal is often expelled. This metal can easily burn skin, eyes, and clothing. Although natural fibers, such as cotton, have been found to provide excellent resistance to ignition, the modern Aramid fibers will not ignite, and may therefore provide the best protection. Safety glasses with side shields and gloves are an absolute necessity to protect the eyes and hands against molten metal. There are also tremendous pressures developed during an arcing fault. In Ralph Lees paper Pressures Developed by Arcs IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL.IA-23, No. 4, JULY/AUGUST 1987, he calculates that the pressure developed at two feet from a 25,000 amp arc is 160 pounds per square foot. That is equivalent to a total pressure on a typical workers body of about 480 pounds, more than enough to blow the worker off a ladder or scaffolding. On a somewhat positive note, because the arc pressure blows the worker away, it tends to reduce the time that the person is exposed to the extreme heat of the arc. Finally, a short-circuit created within an open enclosure may create such enormous explosive forces that shrapnel is expelled toward the workman. The greater the available short-circuit current the greater the explosive forces. Equipment listed to a nationally recognized safety standard does not assure shrapnel protection because the equipment was tested with the doors closed. Once the doors are opened, equipment listings are void. Current-limitation is an important factor in the protection of the worker from the potentially dangerous shrapnel.

Contents

Index

Next

Previous

Ground Fault Protection

Ground fault protection is equipment protection from the effects of ground faults. The National Electrical Code (N.E.C.) has specific ground fault equipment protection requirements in Sections 215-10, 230-95, 240-13 and 517-17. Ground fault relays (or sensors) are used to sense low magnitude ground faults. When the ground fault current magnitude and time reach the G.F. relay pick up setting, the control scheme signals the circuit disconnect to open. Ground fault relays can only offer protection for equipment from the effects of low magnitude ground faults. Equipment protection against the effects of higher magnitude ground faults is dependent on the speed of response of the conventional overcurrent protective devices (fuses or circuit breakers.) What It Is Not Ground Fault Protection IS NOT: - People protection. It will not prevent shock - Ground fault prevention - Protection from 3-phase, phase-phase, or phase-neutral faults - Protection from high level ground faults - A guarantee of a selectively coordinated system. In fact, coordination may be compromised. Reliability Ground fault relays are not simple and the ultimate reliability depends on the reliability of each element such as solid state sensor, monitor, control wiring, control power source, shunt trip, and circuit disconnecting means. If one element is incorrectly wired, inoperative, miscalibrated, or damaged, the low level ground fault protection may be negated. If the system neutral is incorrectly or accidentally grounded on the load side of the sensor, a ground fault can have a return path over the neutral and never trip the relay. Unfortunately, a nuisance outage often encourages the building owner or maintenance crew to disconnect the ground fault relay so that the power stays on. Ground fault relays are not maintenance free devices. Ground fault relay equipment relies on sensing equipment, shunt trips, switching devices, control circuits, etc. Complete periodic maintenance and electrical testing of the equipment by qualified personnel is necessary since it has components and mechanisms which can fail, malfunction, and/or lose calibration. NATIONAL ELECTRICAL CODE - SECTION 230-95 230-95. Ground Fault Protection of Material This Section means that 480Y/277 volt, solidly grounded wye only connected service disconnects, 1000 amperes and larger, must have ground fault protection in addition to conventional overcurrent protection. Ground fault protection, however, is not required on a service disconnect for a continuous process where its opening will increase hazards. All delta connected services are not required to have ground fault protection. The maximum setting for the ground fault relay (or sensor) can be set to pick up ground faults at a maximum of 1200 amperes and actuate the main switch or circuit breaker to disconnect all phase conductors. A ground fault relay with a deliberate time-delay characteristic of up to 1 second, may be specified, for currents greater than or equal to 3000 amperes. (The use of such a relay greatly enhances system coordination and minimizes power outages). Ground fault protection in itself will not limit the line-to-ground or phase-to-phase short-circuit current. When mechanical protective devices such as conventional circuit breakers are used with GFP, all of the available short-circuit current will flow to the point of fault, limited only by circuit impedance. Therefore, it is recommended that current-limiting overcurrent protective devices be used in conjunction with GFP relays. 65
Service Disconnect less than 1000 Amperes Any Size Service Disconnect 480Y/277V. 3/4W 1000 Ampere or Larger Switch CurrentLimiting Fuses G.F. Relay

SWBD

This system offers: 1. Some degree of arcing and low magnitude ground fault protection by the ground fault relay operating the switch. 2. Current-limitation for high magnitude ground faults and short-circuits by current-limiting fuses, which provides component protection for the switchgear. This system offers:

480Y/277V. 1. Some degree of arcing and 3/4W 1000 Ampere Circuit Breaker or Larger

G.F. Relay SWBD

low magnitude ground fault protection by the ground fault relay operating the circuit breaker. Note: This system DOES NOT provide current-limitation for high magnitude ground faults and short-circuits.

Services where Ground Fault Relays are NOT Required There are many services and feeders where Section 230-95 does not require ground fault protection including: 1. Continuous industrial process where a non-orderly shut down would increase hazards. 2. All services or feeders where the disconnect is less than 1000 amperes. 3. All 208Y/120 volt, 3, 4W (wye) services or feeders. 4. All single-phase services or feeders including 240/120 volt. 5. High or medium voltage services or feeders. (See NEC Sections 240-13 and 215-10 for feeder requirements.) 6. All services or feeders on delta systems (grounded or ungrounded) such as 240 volt, 3, 3W delta, or 240 volt, 3, 4W delta with midpoint tap. 7. Service with six disconnects or less (Section 230-71) where each disconnect is less than 1000 amperes. A 4000 ampere service could be split into 5-800 ampere switches. 8. Resistance or impedance grounded systems. For instance, ground fault relays are not required on these systems.
480Y/277V. 208Y/120V.

480V 3 3W Delta

480V/ 277V

Any Size Service Disconnect

Six Service Disconnects 800 amperes or Less

Contents

Index

Next

Previous

Ground Fault Protection

215-10. Ground Fault Protection of Equipment Equipment classified as a feeder disconnect must have ground fault protection as specified in Section 230-95.
High Voltage Service 4160V VIOLATION 480Y/277V 1000A or Greater Feeder Provided w/G.F.P . Feeder w/o G.F.P .

relays. In health care facilities where no ground fault relay is placed on the main, no ground fault relays are necessary on the feeders. Therefore, if the requirements of Section 230-95 do not require a ground fault relay and no ground fault relay is placed on the main service disconnect, then no ground fault relays are required on the feeders either (unless required by Sections 215-10 and 240-13). A ground fault relay time band includes the disconnect operating time and any tolerances in the G.F. relay control signal. Health Care Facility 1. When a ground fault relay is placed on the main service of a health care facility then, 2. Ground fault relays must also be placed on the feeders, and the feeder ground fault relay time band must have a 6 cycle separation from the main ground fault relay.
1,000 800 600 400 300 200

High Voltage Service 4160V COMPLIANCE 480Y/277V

1000A or Greater

GFP will not be required on feeder equipment when it is provided on the supply side of the feeder (except for certain Health Care facilities requirements, Article 517).

480Y/277V. 3/4W

G.F.P . COMPLIANCE 480Y/277V Feeder of any rating no G.F.P . Required (Except Per Article 517)

1000A or Greater

100 80 60 40

MAIN GFR FDR GFR SWBD

G.F. Relay

TIME IN SECONDS

This requirement for GFP on feeders may subject the system to blackouts due to downstream ground faults as discussed previously. A selective coordination analysis is required to assure that needless blackouts do not occur. 240-13. Ground Fault Protection of Equipment Equipment ground fault protection of the type required in Section 230-95 is now required for each disconnect rated 1000A or more, 480Y/277V systems, that will serve as a main disconnect for a separate building or structure. Refer to sections 215-10 and 230-95.
High Voltage Service G.F.P . Not Required Building A Service G.F.P . Not Required

30 20

10 8 6 4 3 2

G.F. Relay

1 .8 .6 .4 .3 .2

MAIN GFR 1200 Ampere 12 Cycles

800A 480Y/277V Building B Service

1000A or Greater 480Y/277V

G.F.P . Required

.1 .08 .06 .04 .03 .02

Minimum 6 Cycle Separation

Note: GFP without current-limitation may not protect system components. See Section 110-10 and 250-1(FPN).

FEEDER GFR 800 Ampere 2 Cycles

CURRENT IN AMPERES

FOR HEALTH CARE FACILITIES 517-17. Ground Fault Protection If ground fault protection is placed on the main service of a health care facility, ground fault relays must also be placed on the feeders. The separation between ground fault relay time bands for any feeder and main ground fault relay must be at least 6 cycles in order to achieve coordination between these two ground fault Note: Merely providing coordinated ground fault relays does not prevent a main service blackout caused by feeder ground faults. The overcurrent protective devices must also be selectively coordinated. The intent of Section 517-17 is to achieve 100 percent selectivity for all magnitudes of ground fault current and overcurrents. 100% selectivity requires that the overcurrent protective devices also be selectively coordinated for medium and high magnitude ground fault currents because the conventional overcurrent devices may operate at these levels. 66

60,000 80,000 100,000

This requirement for GFP on equipment may subject the system to blackouts due to downstream ground faults, as discussed previously. A selective coordination analysis is required to assure that needless blackouts do not occur.

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

.01 100 200 300 400 600

Contents

Index

Next

Previous

Ground Fault Protection

Analysis of Ground Fault Relay Curves and Overcurrent Device Curves To a fuse or circuit breaker, ground fault current is sensed just as any other current. If the ground fault current is high enough, the fuse or circuit breaker responds before the ground fault relay (this depends on the ground fault relay setting, overcurrent device characteristics, speed of response of the overcurrent device, and ground fault current magnitude). Therefore, when analyzing ground fault protection it is necessary to study the characteristics of the ground fault relay and overcurrent protective device as a combination. The combination of the ground fault relay and overcurrent device have a ground fault effective curve. This is a composite of the ground fault relay and overcurrent protective device curves. When analyzing line-to-ground faults, the effective curve of the ground fault relay and conventional overcurrent protective device must be examined.
1,000 800 600 TIME IN SECONDS 400 300 200

The graph below is the effective ground fault curve for a 1600 ampere circuit breaker in combination with a ground fault relay scheme set at 1200 amperes and 12 cycle delay. Notice that for ground faults above approximately 14,000 amperes the fused bolted pressure switch combination has the advantage of faster response and above 22,000 amperes the fused switch has the advantage of current-limitation.
1,000 800 600 400 300 200

MAIN GFR

1600A CB
100 80 60 40 30

MAIN GFR

20

KRP-C 1600SP
100 80 60 40 30 TIME IN SECONDS 20

10 8 6 4 3 2

1 .8 .6 .4 .3 .2

10 8 6 4 3 2

1 .8 .6 .4 .3 .2

.1 .08 .06 .04 .03 .02

1600A CB

Main G.F.R. SWBD

800 1,000 2,000 3,000 4,000 6,000 8,000 10,000 20,000 30,000 40,000 60,000 80,000 100,000

.01 100 200 300 400 600

.1 .08 .06 .04 .03 .02

CURRENT IN AMPERES

KRP-C1600SP

Main G.F.R.

Effective time current curve for line to ground fault with 1600 ampere circuit breaker and ground fault sensor setting at 1200 amperes.

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

CURRENT IN AMPERES

Effective time current curve for line to ground fault with 1600 ampere fuse and ground fault protection scheme set at 1200 amperes (switch clearing time of 4 cycles). The graph above is the effective ground fault curve for a 1600 ampere fuse in combination with a ground fault relay scheme set at 1200 amperes pick-up and 12 cycle delay.

60,000 80,000 100,000

.01 100 200 300 400 600

67

Contents

Index

Next

Previous

Ground Fault Protection

Coordination is the act of isolating a faulted circuit from the remainder of the electrical system, thereby eliminating unnecessary power outages. However, the term coordination is sometimes interpreted to mean a degree of coordination where more than one protective device is allowed to open under a given shortcircuit condition. Therefore, the term selective coordination or selectivity is used to mean positive coordination over the entire range of possible fault currents, assuring that the faulted circuit is cleared and that other parts of the system are not affected.
Blackout! Selective Coordination G.F. Relay Not Open Main Overcurrent Device Main Overcurrent Device Feeder Feeder Feeder Overcurrent Device Opens Not Open Feeder Overcurrent Device Feeder Ground Fault Branch Circuit G.F. Relay

A. One Step Ground Fault Relaying When a ground fault occurs on a feeder or branch circuit it is highly desirable for the feeder or branch circuit overcurrent device to clear that fault before the main device opens, thus preventing an unnecessary system blackout. However, this is not always the case when a ground fault relay is located on the main or when the overcurrent protective devices are not selectively coordinated.

Opens

OR

Branch Circuit

Branch Circuit Overcurrent Device Short-Circuit Opens Opens

Branch Circuit Overcurrent Device Short-Circuit

Branch Circuit Ground Fault

This system does not have selective coordination. A short-circuit on a branch circuit causes the main overcurrent device to open thereby causing a BLACKOUT.

This system has selective coordination. Only the nearest overcurrent device opens on any short-circuit.

To avoid unnecessary service disruptions (or BLACKOUTS): 1. the characteristics of the feeder and/or branch circuit overcurrent devices must be analyzed with relation to the main ground fault relay characteristics and; 2. the characteristics of the main overcurrent device must be analyzed with relation to the feeder and branch circuit overcurrent protective devices. Selective coordination should be investigated for low and high magnitude ground faults. Generally on low magnitude ground faults the feeder overcurrent device must be selective with the main ground fault relay. For high magnitude ground faults it is necessary also to consider selective coordination between the main overcurrent device and feeder overcurrent device.

Modern current-limiting fuses can be selectively coordinated simply by maintaining at least a minimum ampere rating ratio between two fuses in series. This ratio is dependent on the fuse types used. When ground fault relays are used in a system, selective coordination considerations are more difficult. The relay curve must be studied in reference to the overcurrent protective devices in the system. The topic of selective coordination that follows has been separated into two parts: A. One step ground fault relaying. B. Two step ground fault relaying.

68

Contents

Index

Next

Previous

Ground Fault Protection

Low Magnitude Ground Faults on Feeders - One Step Ground Fault Relaying. For low magnitude feeder ground faults, the feeder overcurrent protective device can clear the circuit without disrupting the main service if the feeder overcurrent device lies to the left of the ground fault relay and does not cross at any point. In the following two graphs, the ground fault relay located on the main has an operating time-delay of 18 cycles and 1200 ampere pickup. Its inverse-time characteristic with the maximum 1 second opening time at 3000 amperes improves selective coordination with downstream devices. Fuse System
TIME IN SECONDS 1,000 800 600 400 300 200

Circuit Breaker System

1,000 800 600 400 300 200

MAIN GFR

100 80 60 40 30 20

200A CB
10 8 6 4 3 2

MAIN GFR
100 80 60 40 30 TIME IN SECONDS 20

LPS-RK200SP

1 .8 .6 .4 .3

10 8 6 4 3 2

.2

Main G.F.R.

LPS-RK200SP

.1 .08 .06 .04 .03

200A CB

1 .8 .6 .4 .3 .2

.02

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

CURRENT IN AMPERES

.1 .08 .06 .04 .03 .02

Coordination considerations for low magnitude feeder ground faults. Consider main ground fault relay and feeder overcurrent device. A lack of coordination exists for ground faults between 1200 amperes and 1800 amperes. The graph above illustrates that for some low magnitude ground faults a 200 ampere circuit breaker will not coordinate with the ground fault relay. This and circuit breakers of larger sizes will not be selective with the ground fault relay and total service disruption can be caused by a feeder or branch circuit ground fault.

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

CURRENT IN AMPERES

Selective coordination considerations for low magnitude feeder ground faults. Longer G.F. relay delay permits larger feeder fuse to coordinate with main relay. The graph above illustrates that an inverse-time main ground fault relay may permit a larger size feeder fuse to selectively coordinate with the ground fault relay. In this case the inverse time ground fault relay is set at 1200 amperes, 18 cycle delay. A LPSRK200SP ampere feeder fuse coordinates with this main ground fault relay.

60,000 80,000 100,000

.01 100 200 300 400 600

69

60,000 80,000 100,000

.01 100 200 300 400 600

Contents

Index

Next

Previous

Ground Fault Protection

High Magnitude Ground Faults on Feeders - One Step Ground Fault Relaying For higher magnitude ground faults, it is generally necessary to consider the characteristics of the main overcurrent protective device as well as the ground fault relay. Conventional overcurrent protective devices, fuses or circuit breakers, cannot differentiate between a high magnitude ground fault or a high magnitude phase-to-phase short-circuit. Therefore, when a high magnitude feeder ground fault occurs the main overcurrent device must be considered in relation to the feeder overcurrent device. To achieve selective coordination and prevent a blackout for high magnitude ground faults, the feeder overcurrent device must be selective with the main overcurrent device. Fuse System
1,000 800 600 400 300 200

Circuit Breaker System

1,000 800 600 400 300 200

100 80 60 40 30

MAIN GFR

200A CB

1200A CB

TIME IN SECONDS

20

MAIN GFR

10 8 6 4 3 2

BLACKOUT AREA

100 80 60 40 30 TIME IN SECONDS 20

1 .8 .6 .4 .3 .2

1200A CB

LPS-RK200SP
10 8 6 4 3 2

KRP-C1200SP
.1 .08 .06 .04 .03 .02

Main G.F.R.

BLACKOUT AREA

200A CB

1 .8 .6 .4 KRP-C1200SP .3 .2

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

CURRENT IN AMPERES

.1 .08 .06 .04 .03 .02

Selective coordination considerations for high magnitude feeder ground faults requires analysis of main and feeder overcurrent devices. In this case feeder ground faults greater than 11,000 amperes will cause the main circuit breaker to open unnecessarily creating a BLACKOUT! Thus the entire service is blacked-out because of a lack of coordination. The ground fault relay is not of concern because it has an 18 cycle delay. The graph above illustrates that for feeder ground faults above 11,000 amperes the main service 1200 ampere circuit breaker as well as the 200 ampere circuit breaker will open. This is because an 11,000 ampere or greater fault current unlatches both the 200 ampere and 1200 ampere circuit breakers. This condition will create a service blackout when a feeder ground fault occurs.

LPS-RK200SP

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

CURRENT IN AMPERES

Selective coordination considerations for high magnitude feeder ground faults requires analysis of main and feeder overcurrent devices. In this case the fuses are selectively coordinated so that an unnecessary blackout does not occur. The graph above illustrates that for high magnitude feeder ground faults the LPS-RK200SP ampere fuse opens before the main service KRP-C1200SP ampere fuse. This is referred to as selective coordination for ground faults. This assures that any high magnitude ground faults on the branch circuits or feeders will be isolated without disrupting the main service. 70

60,000 80,000 100,000

.01 100 200 300 400 600

60,000 80,000 100,000

.01

800 100

200

300

400

600

Contents

Index

Next

Previous

Ground Fault Protection

This fact is commonly overlooked when applying ground fault relays. Generally, the short-time-delay on the ground fault relay is thought to provide coordination for higher magnitude feeder ground faults. However, as shown by this example the main circuit breaker operates to cause an unnecessary blackout. Note: Circuit breakers with short-time-delay trip units were not considered in this section. The reason is that a short-time-delay on a circuit breaker defeats the original purpose of protection. Shortcircuit currents and high magnitude ground fault currents, when intentionally permitted to flow for several cycles, dramatically increase the burn time and damage to the system. Electrical systems are not designed to withstand, for long periods, the torturous forces that fault currents produce. Circuit breaker short-time-delay trip units with typical delays of 6, 18, 24, or 30 cycles greatly exceed the short-circuit withstandability of system components. According to NEMA standards, the duration for equipment short-circuit current testing is four cycles for switchboard bus (PB-2,1989) and three cycles for busway (BU1-1988). The short-circuit current withstandability for insulated conductors decreases as the overcurrent device operating time increases (reference Insulated Cable Engineers Association Publication P-32382, Short-Circuit Characteristics of Cable). Short-circuit currents and high magnitude ground fault currents must be interrupted as rapidly as possible (preferably with current-limiting devices) to minimize equipment damage. Whenever insulated case and molded case circuit breakers have a short-time-delay feature they also have an instantaneous override This requires the sensing mechanism (typically solid state) to override the short-time-delay feature for high ground fault or line-line faults. The result is a lack of coordination with the feeder breakers for any fault current above the instantaneous override setting. Selective coordination is therefore very difficult to achieve. B. Two Step Ground Fault Relaying Two step ground fault relaying includes ground fault relays on the main service and feeders. In many instances, this procedure can provide a higher degree of ground fault coordination to prevent unnecessary service blackouts. Yet it is mistakenly believed by many that two step ground fault relays assure ground fault coordination. For complete selective coordination of all ground faults, the conventional overcurrent protective devices must be selectively coordinated as well as the ground fault relays. The fact is that even with this two step relay provision, ground fault coordination is not assured on many systems designed with mechanical overcurrent protective devices which incorporate instantaneous unlatching mechanisms.
RESULT: BLACKOUT

amperes, 6 cycle delay. These ground fault relay settings could mistakenly be interpreted to mean that feeder ground faults would be cleared by only the feeder ground fault relay opening the feeder disconnect. But the analysis must also include the overcurrent device characteristics since these devices also respond to current.
1,000 800 600 400 300 200

100 80 60 40 30

MAIN GFR FDR GFR 1200A CB 200A CB

TIME IN SECONDS

20

10 8 6 4 3 2

1 .8 .6 .4 .3 .2

.1 .08 .06 .04 .03 .02

BLACKOUT AREA

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

CURRENT IN AMPERES

1200A CB Circuit Breaker Opens

Main G.F. Relay 1200 Amp 18 Cycle Delay Circuit Breaker Opens 200A CB Feeder G.F. Relay 100 Amps 6 Cycle Delay Ground Fault 11,000 Amperes or Greater

The two step ground fault relays give a false sense of security. The graph above illustrates that the ground fault relays are coordinated, but overcurrent devices are not coordinated for feeder or branch circuit ground faults above 11,000 amperes. This is indicated as the BLACKOUT AREA on the curve. In this case the main overcurrent device and the feeder overcurrent device both open on a feeder circuit fault. Thus the entire system is blacked out; even though two step ground fault relays are provided. WARNING! For Health Care Facilities - Section 517-17 requires the main and feeders to be 100% selectively coordinated for all magnitudes of ground fault current - including low, medium, and high ground fault currents.

The system above illustrates the typical problem concerning this point. The main ground fault relay is set at 1200 amperes, 18 cycle delay and the feeder ground fault relay is set at 100 71

60,000 80,000 100,000

.01

800 100

200

300

400

600

Contents

Index

Next

Previous

Ground Fault Protection

In many cases two step relays do provide a higher degree of ground fault coordination. When properly selected, the main fuse can be selectively coordinated with the feeder fuses. Thus on all feeder ground faults or short-circuits the feeder fuse will always open before the main fuse. When selectively coordinated main and feeder fuses are combined with selectively coordinated main and feeder ground fault relays, ground fault coordination between the main and feeder is predictable.
1,000 800 600 400 300 200

LPS-RK 200SP
100 80 60 40 30

MAIN GFR FDR GFR KRP-C1200SP

KRP-C1200SP Does Not Open

Main G.F. Relay 1200 Amps 18 Cycle Delay

TIME IN SECONDS

20

10 8 6 4 3 2

LPS-RK200SP Only Feeder Disrupted

Feeder G.F. Relay 100 Amps 6 Cycle Delay

1 .8 .6 .4 .3

Any Level Ground Fault Current

.2

The above figure illustrates a selectively coordinated main and feeder for all levels of ground faults, overloads and shortcircuits. Any fault on the feeder will not disrupt the main service.

.1 .08 .06 .04 .03 .02

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

CURRENT IN AMPERES

This system offers full selective coordination for all levels of ground faults or short-circuits. 1. The feeder ground fault relay is set at a lower time band than the main ground fault relay, therefore the relays are coordinated. 2. The feeder fuses are selectively coordinated with the main fuses for all ground faults, short-circuits, or overloads on the load side of the feeder. The feeder fuses would clear the fault before the main fuses open. Conclusion: This system is completely selective for all levels of ground faults and short-circuits. This system meets the intent of NEC Section 517-17 for 100% selectivity. Complete Ground Fault Selective Coordination Is Necessary To Prevent Blackouts! To assure complete selective coordination for all ground faults, it is essential that the conventional overcurrent protective devices be selectively coordinated as well as the ground fault relays requirement. The intent of Section 517-17 is to achieve 100 percent selectivity for all magnitudes of ground fault current.

72

60,000 80,000 100,000

.01

800 100

200

300

400

600

Contents

Index

Next

Previous

Ground Fault Protection

The Need for Current-Limitation If ground fault protection is required, then the best protection is a switch equipped with a ground fault relay scheme, a shunt trip mechanism, and current-limiting fuses. The reason is that this system will offer protection for high magnitude ground faults as well as low magnitude ground faults. Ground fault relay schemes and shunt trip mechanisms on switches or circuit breakers can protect equipment against extensive damage from low magnitude ground faults - this is their intended purpose. However, burn downs still occur in switchboards, large motor control centers, and large distribution panels generally located in equipment rooms where high available ground fault currents are present.
1,000 800 600 400 300 200

The National Electrical Code requires ground fault protection for intermediate and high ground faults as well as low grade ground faults. For high magnitude ground faults, ground fault relay schemes operate too slowly to prevent extensive equipment damage. The main or feeder overcurrent devices, such as fuses or circuit breakers must clear the circuit. Current-limiting fuses substantially limit the energy let-through for higher magnitude ground faults and thereby offer a higher degree of protection. Conventional circuit breakers are not current-limiting protective devices and during higher magnitude ground faults can let-through large amounts of damaging energy.

1,000 800 600 400 300 200

100 80 60 40 30 TIME IN SECONDS 20

100 80 60

1600A CB

KRP-C1600SP
TIME IN SECONDS

40 30 20

10 8 6 4 3 2

10 8 6 4 3 2

1 .8 .6 .4 .3 .2

1 .8 .6 .4 .3 .2

.1 .08 .06 .04 .03 .02

.1 .08 .06 .04 .03 .02

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

60,000 80,000 100,000

CURRENT IN AMPERES

CURRENT IN AMPERES

Clearing characteristic for a 1600 ampere fuse. A 20,000 ampere fault is cleared by the KRP-C 1600SP fuse in .015 to .030 seconds (between one and two cycles). For currents greater than 25,000 amperes the fuse enters its current-limiting range. Then the clearing time is less than one half cycle.

Clearing characteristic for 1600 ampere circuit breaker. A 20,000 ampere fault is cleared by the 1600 ampere circuit breaker in .05 seconds. The circuit breaker has a fixed operating time for high values of current. This time is approximately .05 seconds (3 cycles). Therefore, high magnitude ground faults and short-circuits are permitted to flow for at least 3 cycles.

73

60,000 80,000 100,000

100

200

300

400

800 1,000

2,000

3,000

4,000

6,000 8,000 10,000

20,000

30,000 40,000

80 100

200

300

400

600

600

.01

.01

Contents

Index

Next

Previous

Ground Fault Protection

The previous two figures illustrate the time-current characteristics for a 1600 ampere current-limiting fuse and a 1600 ampere circuit breaker. The higher the fault current the faster the fuse operates. Notice, the mechanical overcurrent protective device reaches an irreducible operating time. For large conventional service entrance circuit breakers this fixed operating time varies from 1 cycles to 5 cycles depending on the type and size. (If shorttime-delay tripping units are used the operating time can be as long as 30 cycles.) Of importance is the fact that modern, rejection type fuses are current-limiting protective devices. For faults above approximately 25,000 amperes, the 1600 ampere fuse operates in its currentlimiting range; clearing the circuit in less than cycle and limiting the peak current and energy let-through to the circuit components. Current-Limitation The effect of a fuse protecting the circuit is to limit the instantaneous peak current and thermal or heating effect current to a value less than that which would flow in the first half cycle had the fuse not been in the circuit. Current-limitation for high level ground faults can substantially reduce the damaging effect. Current-Limitation
Available current that would flow without a fuse.

The large conventional mechanical overcurrent protective device reaches an irreducible minimum clearing time and therefore permits the full fault current flow for several cycles. The damaging peak current and thermal or heating effect current flow unrestricted without limitation for several cycles. At higher magnitude fault currents, large amounts of heating energy and magnetic forces are permitted to flow and the equipment must absorb the full available fault current energy. No Current-Limitation
Available current flows for operating time of circuit breaker.

3 Cycle Clearing Time

Fuse CurrentLimiting Effect

74

Contents

Index

Next

Previous

Motor Protection
OVERLOAD PROTECTION Overcurrents An overcurrent exists when the normal load current for a circuit is exceeded. It can be in the form of an overload or short-circuit. When applied to motor circuits an overload is any current, flowing within the normal circuit path, that is higher than the motors normal full load amperes (F.L.A.). A short-circuit is an overcurrent which greatly exceeds the normal full load current of the circuit. Also, as its name infers, a short-circuit leaves the normal current carrying path of the circuit and takes a short cut around the load and back to the power source. Motors can be damaged by both types of currents. Single-phasing, overworking and locked rotor conditions are just a few of the situations that can be protected against with the careful choice of protective devices. If left unprotected, motors will continue to operate even under abnormal conditions. The excessive current causes the motor to overheat, which in turn causes the motor winding insulation to deteriorate and ultimately fail. Good motor overload protection can greatly extend the useful life of a motor. Because of a motors characteristics, many common overcurrent devices actually offer limited or no protection. Motor Starting Currents When an AC motor is energized, a high inrush current occurs. Typically, during the initial half cycle, the inrush current is often higher than 20 times the normal full load current. After the first halfcycle the motor begins to rotate and the starting current subsides to 4 to 8 times the normal current for several seconds. As a motor reaches running speed, the current subsides to its normal running level. Typical motor starting characteristics are shown in Curve 1.
1,000 Motor Starting Current (Inrush)

Fast Acting Fuses To offer overload protection, a protective device, depending on its application and the motors service factor, should be sized at 115% to 125% of the motors F.L.A. However, as shown in Curve 2, when fast-acting, non-time-delay fuses are sized to the recommended level the motors inrush will cause nuisance openings.
1,000 Motor Starting Current (inrush) Non-Time-Delay Fuse Sized to Protect Motor

100

TIME IN SECONDS

10

1 Fuse Opens .1

.01 1 100 10 CURRENT IN AMPERES Curve 2 1,000

100

A fast-acting, non-time-delay fuse sized at 300% will allow the motor to start but sacrifices the overload protection of the motor. As shown by Curve 3 below, a sustained overload will damage the motor before the fuse can open.
1,000 300% Overload Non-Time-Delay Fuse Sized to Allow Motor to Start Motor Starting Current (Inrush) TIME IN SECONDS 10 Motor Damage Curve

TIME IN SECONDS

10 100 1

.1

.01 1 100 CURRENT IN AMPERES Curve 1 1,000 10

.1

Because of this inrush, motors require special overload protective devices that can withstand the temporary overloads associated with starting currents and yet protect the motor from sustained overloads. There are four major types. Each offers varying degrees of protection.

.01 1 10 100 CURRENT IN AMPERES Curve 3 1,000

75

Contents

Index

Next

Previous

Motor Protection
MCPS and Thermal Magnetic Breakers Magnetic only breakers (MCPs) and thermal magnetic breakers are also unsatisfactory for the protection of motors. Once again to properly safeguard motors from overloads, these devices should be sized at 115% to l25% of the motors F.L.A. When sized this close to the F.L.A. the inrush causes these breakers to open needlessly. Curve 4 shows an MCP opening from motor inrush and an unaffected 15 amp thermal magnetic circuit breaker (the minimum standard size).
1,000 Motor Starting Current (inrush) MCP Level Set at the Minimum TIME IN SECONDS 100 Thermal-Magnetic Circuit Breaker (15 Amp) TIME IN SECONDS 10 10

Overload Relays Overload relays, or heaters, installed in motor starters are usually the melting alloy or bi-metallic type. When properly sized and maintained, the relay can offer good overload protection. When operating properly, overload relays allow the motor to start, but when a sustained overload occurs the overload relays cause the contacts to open (Curve 6).
1,000 300% Overload Overload Relay 100 Motor Damage Curve

1 .1

.1 100 1,000 MCP Opens .01 1 10 CURRENT IN AMPERES Curve 4 1,000 100 Curve 6 .01 1 CURRENT IN AMPERES 10

To allow the motor to start, the MCP must be sized at about 700-800% of the F.L.A. and the thermal magnetic breaker must be sized at about 250% of F.L.A. Curve 5 clearly shows that breakers sized to these levels are unable to protect motors against overloads.
1,000 230% Overload Thermal Magnetic Circuit Breaker (15 Amp)

However, if the overload relays are oversized or if the contacts fail to open for any reason (i.e., welded contacts), the motor is left unprotected. Also, overload relays cannot offer any protection for short-circuits, and in fact must be protected by fuses or circuit breakers under short-circuit conditions Curve 7 .
1,000 300% Overload Overload Relay 100 Motor Damage Curve

TIME IN SECONDS

100 Motor Starting Current (Inrush) TIME IN SECONDS 10 Motor Damage Curve MCP Level Set to Allow Motor to Start 1

10

.1

.1 .01 1 10 100 CURRENT IN AMPERES .01 1 100 10 CURRENT IN AMPERES Curve 5 1,000 Curve 7 1,000

76

Contents

Index

Next

Previous

Motor Protection
The dual-element fuse is unaffected by the motor inrush current (Curve 8), but opens before a sustained overload can reach the motor damage curve (Curve 9).
1,000 Fusetron Dual-Element Time-Delay Fuse (FRN-R-1) Motor Starting Current (Inrush)

100

TIME IN SECONDS

10

Given a motor with 1.15 service factor or greater, size the LPNRK_SP, LPS-RK_SP, FRN-R, or FRS-R fuse at 125% of the motor full load current or the next smaller available fuse size. With a motor having a service factor of less than 1.15, size these same fuses at 115% of the motors F.L.A. or the next smaller standard size. By using the following backup method of fusing, it is possible to have two levels of overload protection. Begin by sizing the overload relays according to the manufacturers directions. Then, size the fuse at 125%-130% or the next larger size. With this combination you have the convenience of being able to quickly reset the overload relay after solving a minor problem, while the fuses remain unopened. However, if the overload relays are sized too large or if the contacts fail to open for any reason, the fuses will open before the motor damage curve is reached. Curve 10 graph below shows the backup protection available with this method.
1,000 300% Overload Overload Relay 100 Fails to Open Motor Damage Curve Fusetron Dual-Element Time-Delay Fuse Sized for Back Up Protection (FRN-R-1)

.1

.01 1 10 1,000 100 CURRENT IN AMPERES Curve 8

TIME IN SECONDS

10

The NEC allows dual-element fuses to be used by themselves for both overload and short-circuit protection, (see NEC sections 430-36, 430-37, 430-55, 430-57, & 430-90). All other types of overcurrent protective devices must be used in combination. Curve 9 shows that the dual-element fuse offers excellent overload protection of motors.
1,000 300% Overload Fusetron Dual-Element Time-Delay Fuse (FRN-R-1) 100 Motor Damage Curve TIME IN SECONDS

.1

.01 1 10 100 CURRENT IN AMPERES Curve 10 1,000

10

.1

.01 1 10 100 CURRENT IN AMPERES Curve 9 1,000

77

Contents

Index

Next

Previous

Motor Protection Voltage Unbalance/Single-Phasing

Historically, the causes of motor failure can be attributed to: Overloads 30% Contaminants 19% Single-phasing 14% Bearing failure 13% Old age 10% Rotor failure 5% Miscellaneous 9% 100% From the above data, it can be seen that 44% of motor failure problems are related to HEAT. Allowing a motor to reach and operate at a temperature 10C above its maximum temperature rating will reduce the motors expected life by 50%. Operating at 10C above this, the motors life will be reduced again by 50%. This reduction of the expected life of the motor repeats itself for every 10C. This is sometimes referred to as the half life rule. Although there is no industry standard that defines the life of an electric motor, it is generally considered to be 20 years. The term, temperature rise, means that the heat produced in the motor windings (copper losses), friction of the bearings, rotor and stator losses (core losses), will continue to increase until the heat dissipation equals the heat being generated. For example, a continuous duty, 40C rise motor will stabilize its temperature at 40C above ambient (surrounding) temperature. Standard motors are designed so the temperature rise produced within the motor, when delivering its rated horsepower, and added to the industry standard 40C ambient temperature rating, will not exceed the safe winding insulation temperature limit. The term, Service Factor for an electric motor, is defined as: a multiplier which, when applied to the rated horsepower, indicates a permissible horsepower loading which may be carried under the conditions specified for the Service Factor of the motor. Conditions include such things as operating the motor at rated voltage and rated frequency. Example: A 10 H.P. motor with a 1.0 S.F. can produce 10 H.P. of work without exceeding its temperature rise requirements. A 10 H.P. motor with a 1.15 S.F. can produce 11.5 H.P. of work without exceeding its temperature rise requirements. Overloads, with the resulting overcurrents, if allowed to continue, will cause heat build-up within the motor. The outcome will be the eventual early failure of the motors insulation. As stated previously for all practical purposes, insulation life is cut in half for every 10C increase over the motors rated temperature. Voltage Unbalance When the voltage between all three phases is equal (balanced), current values will be the same in each phase winding. The NEMA standard for electric motors and generators recommends that the maximum voltage unbalance be limited to 1%. When the voltages between the three phases (AB, BC, CA) are not equal (unbalanced), the current increases dramatically in the motor windings, and if allowed to continue, the motor will be damaged. It is possible, to a limited extent, to operate a motor when the voltage between phases is unbalanced. To do this, the load must be reduced.
Voltage Unbalance in Percent Derate Motor to These Percentages of the Motors Rating*

1% 2% 3% 4% 5%

98% 95% 88% 82% 75%

*This is a general rule of thumb, for specific motors consult the motor manufacturer.

Some Causes of Unbalanced Voltage Conditions Unequal single-phase loads. This is why many consulting engineers specify that loading of panelboards be balanced to 10% between all three phases. Open delta connections. Transformer connections open - causing a single-phase condition. Tap settings on transformer(s) not proper. Transformer impedances (Z) of single-phase transformers connected into a bank not the same. Power factor correction capacitors not the same. . .or off the line. Insulation Life The effect of voltage unbalance on the insulation life of a typical T-frame motor having Class B insulation, running in a 40C ambient, loaded to 100%, is as follows:
Insulation Life Service Factor 1.15

Voltage Unbalance

Service Factor 1.0

0% 1% 2% 3% 4%

1.00 0.90 0.64

2.27 2.10 1.58 0.98 0.51

Note that motors with a service factor of 1.0 do not have as much heat withstand capability as does a motor that has a service factor of 1.15. Older, larger U-frame motors, because of their ability to dissipate heat, could withstand overload conditions for longer periods of time than the newer, smaller T-frame motors.

78

Contents

Index

Next

Previous

Motor Protection Voltage Unbalance/Single-Phasing

Insulation Classes The following shows the maximum different classes of insulation. Class A Insulation Class B Insulation Class F Insulation Class H Insulation operating temperatures for 105C 130C 155C 180C Two motor overload protective devices provide adequate protection against balanced voltage overload conditions where the voltage between phases is equal. When a balanced voltage overload persists, the protective devices usually open simultaneously. In some cases, one device opens, and shortly thereafter, the second device opens. In either case, three-phase motors are protected against balanced voltage overload conditions. Three-phase motors protected by two overload protective devices are not assured protection against the effect of single-phasing. For example, when the electrical system is WYE/DELTA or DELTA/WYE connected, all three phases on the secondary side of the transformer bank will continue to carry current when a singlephasing caused by an open phase on the primary side of the transformer bank occurs. As will be seen later, single-phasing can be considered to be the worst case of unbalanced voltage possible.
Open 115% of Normal Current

How to Calculate Voltage Unbalance and the Expected Rise in Heat

Phase A 248 Volts Phase B 230 Volts Phase C 236 Volts

Step 1: Add together the three voltage readings: 248 + 236 + 230 = 714 volts Step 2: Find the average voltage. 714 = 238 volts 3 Step 3: Subtract the average voltage from one of the voltages that will indicate the greatest voltage difference. In this example: 248 238 = 10 volts Step 4: greatest voltage difference 100 average voltage 10 = 100 = 4.2 percent voltage unbalance 238 Step 5: Find the expected temperature rise in the phase winding with the highest current by taking. . . 2 (percent voltage unbalance)2 In the above example: 2 (4.2)2 = 35.28 percent temperature rise. Therefore, for a motor rated with a 60C rise, the unbalanced voltage condition in the above example will result in a temperature rise in the phase winding with the highest current of: 60C 135.28% = 81.17C The National Electrical Code The National Electrical Code, in Table 430-37, requires three overload protective devices, one in each phase, for the protection of all three-phase motors. Prior to the 1971 National Electrical Code, three-phase motors were considered to be protected from overload (overcurrent) by two overload protective devices. These devices could be in the form of properly sized time-delay, dual-element fuses, or overload heaters and relays (melting alloy type, bimetallic type, magnetic type, and solid-state type.)
Motor Overload Devices

230% of Normal Current

3 MOTOR

115% of Normal Current

Two motor overload protective devices cannot assure protection against the effects of PRIMARY single-phasing. The middle line current increase to 230% is not sensed.

Diagram of a WYE/DELTA transformation with one primary phase open. The motor is protected by two overload devices. Note that one phase to the motor is carrying two times that of the other two phases. Without an overload device in the phase that is carrying two times the current in the other two phases, the motor will burn out. The 1996 National Electrical Code, Section 430-36 requires that when fuses are used for motor overload protection, a fuse shall be inserted in each phase. Where thermal overload devices, heaters, etc. are used for motor overload protection, Table 430-37 requires one be inserted in each phase. With these requirements, the number of single-phasing motor burnouts are greatly reduced, and are no longer a serious hazard to motor installations. The following figure shows three overload protective devices protecting the three-phase motor.

ThreePhase Source

3 MOTOR

N.E.C. REQUIREMENT Three-phase motors require three motor overload protective devices

Since 1971, The National Electrical Code has required three overload protective devices for the protection of three-phase motors, one in each phase.
ThreePhase Source 3 MOTOR

Diagram showing two overload devices protecting a three-phase motor. This was acceptable by the National Electrical Code prior to 1971. 79

Contents

Index

Next

Previous

Motor Protection Voltage Unbalance/Single-Phasing

Motor Branch Circuit, Short-Circuit and Ground Fault Protection When sized according to NEC Section 430-52, a 3-pole common trip circuit breaker or MCP can not protect against singlephasing damage. It should be emphasized, the causes of single-phasing cannot be eliminated. However, motors can be protected from the damaging effects of single-phasing through the use of proper overcurrent protection. Dual-element, time-delay fuses can be sized at or close to the motors nameplate full-load ampere rating without opening on normal motor start-up. This would require sizing the fuses at 100125% of the motors full-load current rating. Since all motors are not necessarily fully loaded, it is recommended that the actual current draw of the motor be used instead of the nameplate rating. This is possible for motors that have a fixed load, but not recommended where the motor load varies.* Thus, when single-phasing occurs, FUSETRON and LOWPEAK dual-element, time-delay fuses will sense the overcurrent situation and respond accordingly to take the motor off the line. For motor branch-circuit protection only, the following sizing guidelines per section 430-52 of the National Electrical Code are allowed. Normal Maximum Dual-element, timedelay fuses 175% 225% Non-time-delay fuses 300% 400% and all Class CC fuses Inverse-time circuit breaker 250% 400% for motors 100 amperes or less. 300% for motors more than 100 amperes. Instantaneous only trip** 800% 1300% circuit breakers (sometimes referred to as MCPs. These are motor circuit protectors, not motor protectors.)
See NEC 430-52 for specifics and exceptions. 1100% for design E motors 1700% for design E motors

For lightly loaded three-phase motors, say 70% of normal fullload amperes, the phase current will increase by the square root of three (3) under secondary single-phase conditions. This will result in a current draw of approximately 20% more than the nameplate full load current. If the overloads are sized at 125% of the motor nameplate, circulating currents can still damage the motor. That is why it is recommended that motor overload protection be based upon the actual running current of the motor under its given loading, rather than the nameplate current rating. Single-Phasing Causes Are Numerous One fact is sure: Nothing can prevent or eliminate all types of single-phasing. There are numerous causes of both primary and secondary single-phasing. A device must sense and respond to the resulting increase in current when the single-phasing condition occursand do this in the proper length of time to save the motor from damage. The term single-phasing is the term used when one phase of a three-phase system opens. This can occur on either the primary side or secondary side of a distribution transformer. Threephase motors, when not individually protected by three time-delay, dual-element fuses, or three overload devices, are subject to damaging overcurrents caused by primary single-phasing or secondary single-phasing. Single-Phasing on Transformer Secondary Typical Causes 1. Damaged motor starter contactone pole open. The number of contact kits sold each year confirms the fact that worn motor starter contacts are the most common cause of single-phasing. Wear and tear of the starter contacts can cause contacts to burn open, or develop very high contact resistance, resulting in single-phasing. This is most likely to occur on automatically started equipment such as air conditioners, compressors, fans, etc. 2. Burned open overload relay (heater) from a line-to-ground fault on a 3 or 4 wire grounded system. This is more likely to occur on smaller size motor starters that are protected by noncurrent-limiting overcurrent protective devices. 3. Damaged switch or circuit breaker on the main, feeder, or motor branch circuit. 4. Open fuse or open pole in circuit breaker on main, feeder, or motor branch circuit. 5. Open cable or bus on secondary of transformer terminals. 6. Open cable caused by overheated lug on secondary side connection to service. 7. Open connection in wiring such as in motor junction box (caused by vibration) or any pull box. Poor connections, particularly when aluminum conductors are not properly spliced to copper conductors, or when aluminum conductors are inserted into terminals and lugs suitable for use with copper conductors or copper-clad conductors only. 8. Open winding in motor. 9. Open winding in one phase of transformer. 10. ANY open circuit in ANY phase ANYWHERE between the secondary of the transformer and the motor.

Note: When sized according to table 430-152, none of these overcurrent devices can provide single-phasing protection.
*When sizing to the actual running current of the motor is not practical, an economic analysis can determine if the addition of one of the electronic black boxes is financially justified. These electronic black boxes can sense voltage and current unbalance, phase reversal, single-phasing, etc. **Instantaneous only trip breakers are now permitted to have time-delay. This could result in more damaging let-through current during short-circuits.

Single-Phasing The term single-phasing, means one of the phases is open. A single-phasing condition subjects an electric motor to the worst possible case of voltage unbalance. If a three-phase motor is running when the single-phase condition occurs, it will attempt to deliver its full horsepower enough to drive the load. The motor will continue to try to drive the loaduntil the motor burns out. . . or until the properly sized overload elements and/or properly sized dual-element, time-delay fuses take the motor off the line.

80

Contents

Index

Next

Previous

Motor Protection Voltage Unbalance/Single-Phasing

Hazards of Secondary Single-Phasing for a Three-Phase Motor When one phase of a secondary opens, the current to a motor in the two remaining phases theoretically increase to 1.73 (173%) times the normal current draw of the motor. The increase can be as much as 2 times (200%) because of power factor changes. Where the motor has a high inertia load, the current can approach locked rotor values under single-phased conditions. Three properly sized time-delay, dual-element fuses, and/or three properly sized overload devices will sense and respond to this overcurrent. SINGLE-PHASING ON SECONDARY NORMAL CONDITION SINGLE-PHASING CONDITION
10A 10A 10A 17.3A (173%) 17.3A (173%) 0A Assume the contacts on one phase are worn out resulting in an open circuit.

SINGLE-PHASING ON SECONDARY NORMAL CONDITION SINGLE-PHASING CONDITION

17 .3 A

10 A

17.3A

10A

10 A

0A

10A

10A

10A

17.3A (173%)

17.3A (173%)

0A

Assume the contacts on one phase are worn out resulting in an open circuit.

WYE-Connected Motor FLA = 10 Amperes (WYE-Connected Motor) Diagram showing the increase in current in the two remaining phases after a single-phasing occurs on the secondary of a transformer.

11 .6 A

5.

5.

8A

8A

8A

5.

5.8A

5.8A

Delta-Connected Motor FLA = 10 Amperes (Delta-Connected Motor) Diagram showing the increase in current in the two remaining phases after a single-phasing occurs on the secondary of a transformer.

81

Contents

Index

Next

Previous

Motor Protection Voltage Unbalance/Single-Phasing

SINGLE-PHASING ON SECONDARY NORMAL CONDITION SINGLE-PHASING CONDITION Single-Phasing on Transformer Primary Typical Causes 1. Primary wire broken by: a. Storm wind b. Ice sleet hail c. Lightning d. Vehicle or airplane striking pole or high-line e. Falling trees or tree limbs f. Construction mishaps 2. Primary wire burned off from short-circuit created by birds or animals. 3. Defective contacts on primary breaker or switch failure to make up on all poles. 4. Failure of 3-shot automatic recloser to make up on all 3 poles. 5. Open pole on 3-phase automatic voltage tap changer. 6. Open winding in one phase of transformer. 7. Primary fuse open. Hazards of Primary Single-Phasing for a Three-Phase Motor Probably the most damaging single-phase condition is when one phase of the primary side of WYE/DELTA or DELTA/WYE transformer is open. Usually these causes are not within the control of the user who purchases electrical power. When primary singlephasing occurs, unbalanced voltages appear on the motor circuit, causing excessive unbalanced currents. This was covered earlier in this bulletin. When primary single-phasing occurs, the motor current in one secondary phase increases to 230% of normal current. Normally, the overload relays will protect the motor. However, if for some reason the overload relays or controller fail to function, the LOWPEAK or FUSETRON dual-element fuses properly sized to provide overload protection will clear the motor from the power supply. Effect of Single-Phasing on Three-Phase Motors The effects of single-phasing on three-phase motors varies with service conditions and motor thermal capacities. When singlephased, the motor temperature rise may not vary directly with the motor current. When single-phased, the motor temperature rise may increase at a rate greater than the increase in current. In some cases, protective devices which sense only current may not provide complete single-phasing protection. However, PRACTICAL experience has demonstrated that motor running overload devices properly sized and maintained can greatly reduce the problems of single-phasing for the majority of motor installations. In some instances, additional protective means may be necessary when a higher degree of single-phasing protection is required. Generally, smaller horsepower rated motors have more thermal capacity than larger horsepower rated motors and are more likely to be protected by conventional motor running overload devices.

Contact Open 6.5A 6.5A 6.5A 11.2A 11.2A 0A

3. 8A

7. 4A

3. 8A
3.8A

3. 8A
3.8A

Delta-connected three-phase motor loaded to only 65% of its rated horsepower. Normal FLA = 10 amperes. Overload (overcurrent) protection should be based upon the motors actual current draw for the underloaded situation for optimum protection. If load varies, overload protection is difficult to achieve. Temperature sensors, phase failure relays and current differential relays should be installed. When a motor is single-phased, the current in the remaining two phases increases to 173% of normal current. Normally the overload relays will safely clear the motor from the power supply. However, should the overload relays or controller fail to do so, LOW-PEAK or FUSETRON time-delay, dual-element fuses properly sized to provide back-up overload protection will clear the motor from its power supply.

82

Contents

Index

Next

Previous

Motor Protection Voltage Unbalance/Single-Phasing

SINGLE-PHASING ON PRIMARY Delta-Connected Motor; FLA = 10 Amperes NORMAL CONDITION
10A 5.8A 5.8A 10A 5.8A 10A WYE PRIMARY DELTA SECONDARY 5.8A 5.8A 5.8A

SINGLE-PHASING CONDITION
Open by Wind Storm 11.5A (115%)

23A (230%)

11.5A (115%) WYE PRIMARY DELTA SECONDARY

(Delta-Connected Motor) Diagram showing how the phase currents to a three-phase motor increase when a single-phasing occurs on the primary. For older installations where the motor is protected by two overload devices, the phase winding having the 230% current will burn up. However, properly sized overload relays or LOW-PEAK or FUSETRON dual-element, time-delay fuses will clear the motor from the power supply. SINGLE-PHASING ON PRIMARY Wye-Connected Motor; FLA = 10 Amperes NORMAL CONDITION
10A 5.8A 5.8A 10A 5.8A 10A WYE PRIMARY DELTA SECONDARY 10A 10A 10A

SINGLE-PHASING CONDITION
Open by Wind Storm 11.5A (115%)

23A (230%)

23A

11.5A 11.5A

11.5A (115%)

(Wye-Connected Motor) Diagram showing how the phase currents to a three-phase motor increase when a single-phasing occurs on the primary. For older installations where the motor is protected by two overload devices, the phase winding having the 230% current will burn up. However, properly sized overload relays or LOW-PEAK or FUSETRON dual-element, time-delay fuses, will clear the motor from the power supply.

83

Contents

Index

Next

Previous

Motor Circuit Protection

MOTOR CIRCUIT PROTECTION TABLES FOR MOTORS COVERED IN NEC ARTICLE 430 Columns 1 & 2 Motor horsepower ratings are listed in Column 1. Full load amps from Tables 430-147 through 430-150 are provided in Column 2. Column 3 Various fuse types are listed in Column 3. The LPJ_SP is a 600 volt AC, 0-600 ampere, time-delay, Class J, LOW-PEAK YELLOW fuse, with a 300,000 ampere interrupting rating. The LP-CC is a 600 volt AC, 0-30 ampere, time-delay, Class CC, LOWPEAK YELLOW fuse with a 200,000 ampere interrupting rating. The LPS-RK_SP and LPN-RK_SP are 600 and 250 volt AC, 0-600 ampere, time-delay, Class RK1, LOW-PEAK YELLOW fuses with interrupting ratings of 300,000 amperes. FRS-R and FRN-R are 600 and 250 volt AC, 0-600 ampere, time-delay, Class RK5, FUSETRON Dual-Element fuses with interrupting ratings of 200,000 amperes. The KRP-C_SP is a 600 volt AC, 601-6000 ampere, timedelay, Class L, LOW-PEAK YELLOW fuse, with a 300,000 ampere interrupting rating. The DC listed ratings for these fuses are: LPJ LP-CC LP-CC LP-CC 110 to 200SP 0 to 2 3 to 15 20 to 30 300 300 150 300 Vdc Vdc Vdc Vdc LPN-RK LPS-RK LPS-RK FRN-R FRS-R 0 to 600SP 0 to 10SP 35 to 600SP 0 to 600 0 to 600 125 300 300 125 300 Vdc Vdc Vdc Vdc Vdc Column 6 When the sizes shown in Column 5 are not sufficient to start the motor, a larger size is often available by utilizing 430-52(c)(1) Exception No. 2. The sizes in Column 6 are the larger of the sizes allowed by 430-52(c)(1) Exception No. 1, or 430-52(c)(1) Exception No. 2. These sizes will often be required when acceleration times are greater than 5 seconds, when plugging or jogging applications exist, or where there are high inrush currents (such as Design E motors). Sizing for LPJ_SP, LPS-RK_SP, LPN-RK_SP, FRS-R, and FRNR is based on 225% of Column 2 or the next smaller Bussmann size if 225% does not correspond to a Bussmann fuse size. Sizing for LPCC is based on 400% of Column 2 or the next smaller Bussmann size if 400% does not correspond to a Bussmann fuse size. Sizing for KRP-C_SP is based on 300% of column 2, or the next smaller Bussmann size, if 300% does not correspond to a Bussmann size. Sizes shown for the LP-CC can also be used for non-timedelay fuses such as JKS, KTN-R, KTS-R, JJN, JJS, AND KTK-R. Column 7 Horsepower-rated switch sizes given in Column 7 are based on 115% (430-110) of Column 2. Switch sizes need to be increased when, because of starting requirements, the fuses are sized above the rating of the switch shown in this column. A disconnect switch for a Design E motor above 2 HP must be marked for use with a Design E motor or it must have a HP rating not less than 1.4 times the rating of the motor for motors rated 3 through 100 HP or not less than 1.3 times the rating of the motor for motors rated over 100 HP. Column 8 Sizes listed are for general-purpose magnetic controllers (single speed, full-voltage for limited plugging and jogging-duty) as shown in NEMA Standards Publication ICS-2-1993. A motor controller for a Design E motor above 2 HP must be marked for use with a Design E motor or it must have a HP rating not less than 1.4 times the rating of the motor for motors rated 3 through 100 HP or not less than 1.3 times the rating of the motor for motors rated over 100 HP. Column 9 Copper wire sizes are based upon 125% (430-22) of values shown in Column 2 and ampacities listed in Table 310-16 for 75C terminals. Although the NEC allows 60C terminations for equipment rated 100 ampere or less, most equipment terminations have been rated for 75C conductors. If equipment terminations are rated for 60C conductors only, the 60C ampacities must be utilized and therefore larger conductor sizes may be required than those shown in this column. Column 10 These rigid metallic conduit sizes are based upon copper conductors with THHN insulation, Table C8 of Appendix C, and 75C equipment terminals. Conduit sizes are for three conductors per circuit for three phase motors and two conductors per circuit for single phase and DC motors. Conduit sizes may need to be increased if equipment grounding conductors or neutrals are also installed in the conduit. If equipment terminations are rated for 60C conductors only, the 60C ampacities must be utilized and therefore larger conductor sizes and conduit sizes may be required. Conductors operated in a high ambient temperature may need to be derated. (See correction factor table at the bottom of Table 310-16.)

Column 4 Fuses sized in accordance with Column 4 must be used in combination with properly sized overload relays (430-32). This sizing is normally large enough to allow the overload relay to operate on overloads without opening the fuse, but small enough to offer a maximum amount of back-up protection for the motor and motor circuit. Sizing for LPJ_SP is based on 150% of Column 2 or the next larger Bussmann size if 150% does not correspond to a Bussmann fuse size. Sizing for LP-CC is based on 200% of Column 2 or the next larger Bussmann size if 200% does not correspond to a Bussmann fuse size. (In DC circuits, this size is not larger than shown in column 5.) Sizing for LPS-RK_SP and LPN-RK_SP is based on 130% of Column 2 or the next larger Bussmann size if 130% does not correspond to a Bussmann fuse size. Sizing for FRS-R and FRN-R is based on 125% of Column 2 or the next Bussmann size if 125% does not correspond to a Bussmann fuse size. Column 5 Fuses sized in accordance with Column 5 must be used in combination with properly sized overload relays (430-32). This sizing provides the maximum NEC Table 430-152 sizes for general purpose applications. It takes into account 430-52(c)(1) Exception No. 1, which allows the next standard (240-6) size fuse to be used if the maximum percentage in Table 430-152 does not correspond to a standard fuse size. Sizing for LPJ_SP, LPS-RK_SP, LPN-RK_SP, FRS-R, FRN-R, and KRP-C_SP is based on 175% (150% for DC motors) of Column 2 or the next larger standard (240-6) size if 175% (150% for DC motors) does not correspond to a standard fuse size. Sizing for LP-CC is based on 300% (150% for DC motors) of Column 2 or the next larger standard (240-6) size if 300% (150% for DC motors) does not correspond to a standard fuse size. Sizes shown for the LP-CC can also be used for non-timedelay fuses such as JKS, KTN-R, KTS-R, JJN, JJS, and KTK-R. 84

Contents

Index

Next

Previous

Motor Circuit Protection

Single-Phase, 115 Volt Motors & Circuits (110-120V System)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 Nec Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 Nec Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 Minimum Nema Starter Nema ICS 21993 Size 9 Minimum Copper Wire THHN AWG or KCMIL Table 310-16 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-148 430-148 HP AMPS

Type

4.4

LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R

J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5

8 9 6 5 9 12 8 7 12 15 10 9 15 20 15 15 25 30 20 17 25 25 20 30 30 25 40 35 30 60 45 45 90 80 70 125 110 100 150 150 125

10 15 10 10 15 20 15 15 15 25 15 15 20 30 20 20 25 25 25 30 30 30 35 35 35 45 45 45 60 60 60 100 100 100 150 150 150 175 175 175

10 17 10 10 15 20 15 15 15 25 15 15 20 20 20 30 30 30 35 35 35 45 45 45 50 50 50 70 70 70 125 125 125 175 175 175 225 225 225

30

00

14

5.8

30

00

14

7.2

30

00

14

9.8

30

14

13.8

30

14

16

30*

14

20

30*

12

24

30*

10

34

60*

8**

**

56

100*

**

80

100*

3**

1**

10

100

200*

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required. 2 This size is typical. It is not shown in NEMA ICS 2-1993.

85

Contents

Index

Next

Previous

Motor Circuit Protection

Single-Phase, 230 Volt Motors & Circuits (220-240V System)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-148 430-148 HP AMPS

Type

2.2

LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LPCC LPN-RK_SP FRN-R LPJ_SP LPCC LPN-RK_SP FRN-R

J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5

3 4 3 2 4 6 4 4 5 7 5 4 8 10 8 6 12 15 9 9 12 17 12 10 15 20 15 15 20 25 17 15 30 25 25 45 40 35 60 60 50 80 70 70

6 10 6 6 6 10 6 6 10 15 10 10 10 15 10 10 15 25 15 15 15 25 15 15 20 30 20 20 25 25 25 30 30 30 50 50 50 70 70 70 90 90 90

6 10 6 6 6 10 6 6 10 15 10 10 10 17 10 10 15 25 15 15 17 30 17 17 20 20 20 25 25 25 35 35 35 60 60 60 90 90 90 110 110 110

30

00

14

2.9

30

00

14

3.6

30

00

14

4.9

30

00

14

6.9

30

00

14

30

00

14

10

30

14

12

30

14

17

LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5

30*

12

28

60

10**

40

60*

8**

**

10

50

100*

6**

**

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required.

86

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 200 Volt Motors & Circuits
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size Size

HP

AMPS

Type

Class

AMPS1

2.5

LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R

J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5

4 5 3 3 5 7 5 5 8 10 6 6 12 15 9 9 12 17 12 10 17 25 15 15 30 25 25 40 35 35 50 45 45 80 70 70 100 90 80 125 110 100

6 10 6 6 10 15 10 10 10 15 10 10 15 25 15 15 15 25 15 15 20 20 20 35 35 35 45 45 45 60 60 60 90 90 90 110 110 110 150 150 150

6 10 6 6 10 15 10 10 10 15 10 10 15 25 15 15 17 30 17 17 20 20 20 35 35 35 50 50 50 70 70 70 100 100 100 125 125 125 175 175 175

30

00

14

3.7

30

00

14

4.8

30

00

14

6.9

30

00

14

7.8

30

14

11

30

14

17.5

LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5

30*

12

25.3

60

10**

**

10

32.2

60*

8**

**

15

48.3

100

6**

**

20

62.1

100*

4**

25

78.2

100*

3**

1**

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required.

87

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 200 Volt Motors & Circuits (Continued)
1
Motor Size

2
Motor FLA

3
Fuse

4
Optimal Branch Ckt Protection Class AMPS1

5
NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1

6
NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1

7
Minimum Switch Size Sect. 430110 AMPS

10
Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size Size

30

92

LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP LPN-RK_SP FRN-R KRP-C_SP LPJ_SP LPN-RK_SP FRN-R KRP-C_SP LPJ_SP LPN-RK_SP FRN-R KRP-C_SP J RK1 RK5 L J RK1 RK5 L J RK1 RK5 L

150 125 125 200 175 150 225 200 200 300 250 225 350 300 300 450 400 400 600 500 450 600 600

175 175 175 225 225 225 300 300 300 350 350 350 400 400 400 500 500 500 700 800 1000

200 200 200 250 250 250 300 300 300 350 350 350 450 450 450 650 600 600 600 800 1000 1200 1600

200

2**

1**

40

120

200*

1/0

50

150

200*

3/0

60

177

400

4/0

75

221

400*

300

100

285

400*

500

125

359

600*

4/0 2/PHASE

(2)2

150

414

LPN-RK_SP RK1 FRN-R RK5 KRP-C_SP L KRP-C_SP L

600*

300 2/PHASE 500 2/PHASE

(2)2

200

552

1200

76

(2)3

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required.
1

88

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 208 Volt Motors & Circuits
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 Nec Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 Nec Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum Nema Copper Wire Starter THHN AWG or Nema ICS 2KCMIL 1993 Table 310-16 Size2 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

2.4

LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R

J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5

4 5 3 3 5 7 5 4 7 10 6 6 10 15 9 9 12 15 10 10 17 25 15 15 30 25 25 40 35 35 50 45 40 70 70 60 90 80 80 125 100 100

6 10 6 6 10 15 10 10 10 15 10 10 15 20 15 15 15 20 15 15 20 20 20 30 30 30 45 45 45 60 60 60 90 90 90 110 110 110 150 150 150

6 10 6 6 10 15 10 10 10 15 10 10 15 25 15 15 15 30 15 15 20 20 20 35 35 35 50 50 50 60 60 60 100 100 100 125 125 125 150 150 150

30

00

14

3.5

30

00

14

4.6

30

00

14

6.6

30

00

14

7.5

30

14

10.6

30

14

16.7

30*

12

24.2

60

10**

10

30.8

60

**

15

46.2

60*

6**

**

20

59.4

100*

4**

25

74.8

100*

3**

1**

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch.
Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required. 2 These sizes are typical. They are not shown in NEMA ICS 2-1993.
1

89

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 208 Volt Motors & Circuits (Continued)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 Nec Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 Nec Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum Nema Copper Wire Starter THHN AWG or Nema ICS 2KCMIL 1993 Table 310-16 Size2 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

30

88

LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R LPJ_SP LPN-RK_SP FRN-R KRP-C_SP LPJ_SP LPN-RK_SP FRN-R KRP-C_SP LPJ_SP LPN-RK_SP FRN-R KRP-C_SP LPJ_SP LPN-RK_SP FRN-R KRP-C_SP KRP-C_SP

J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 L J RK1 RK5 L J RK1 RK5 L J RK1 RK5 L L

150 125 110 175 150 150 225 200 200 300 225 225 350 300 300 450 400 350 600 450 450 600 600 500

175 175 175 200 200 200 300 300 300 300 300 300 400 400 400 500 500 500 601 700 1000

175 175 175 250 250 250 300 300 300 350 350 350 450 450 450 601 600 600 600 800 1000 1100 1500

200

2**

1**

40

114

200*

1/0

50

143

200*

3/0

60

169

400

4/0

75

211

400*

300

100

273

400*

500

125

343

600*

4/0 2/PHASE

(2)2

150

396

600*

250 2/PHASE 400 2/PHASE

(2)2

200

528

1200

(2)2-2

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch.
Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required. 2 These sizes are typical. They are not shown in NEMA ICS 2-1993.
1

90

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 230 Volt Motors & Circuits (220 - 240V System)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

2.2

LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R LPJ_SP LP-CC LPN-RK_SP FRN-R

J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5

3 4 3 2 5 7 4 4 7 9 5 5 9 12 8 7 12 15 9 9 15 20 15 12 25 20 20 35 30 30 45 40 35 70 60 60 90 80 70 110 90 90

6 10 6 6 6 10 6 6 10 15 10 10 15 20 15 15 15 25 15 15 20 30 20 20 30 30 30 40 40 40 50 50 50 80 80 80 100 100 100 125 125 125

6 10 6 6 7 12 7 7 10 15 10 10 15 20 15 15 15 25 15 15 20 20 20 30 30 30 45 45 45 60 60 60 90 90 90 110 110 110 150 150 150

30

00

14

3.2

30

00

14

4.2

30

00

14

30

00

14

6.8

30

14

9.6

30

14

15.2

LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5

30

14

22

30*

10

10

28

60

10**

15

42

60*

20

54

100*

25

68

100*

4**

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required.

91

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 230 Volt Motors & Circuits (220 - 240V System) (Continued)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

30

80

LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP LPN-RK_SP FRN-R KRP-C_SP LPJ_SP LPN-RK_SP FRN-R KRP-C_SP LPJ_SP LPN-RK_SP FRN-R KRP-C_SP FRN-R KRP-C_SP J RK1 RK5 L J RK1 RK5 L J RK1 RK5 L RK5 L

125 110 100 175 150 150 200 175 175 250 225 200 300 250 250 400 350 350 500 450 400 600 500 450 600

150 150 150 200 200 200 250 250 250 300 300 300 350 350 350 450 450 450 600 600 600 700 1000

175 175 175 225 225 225 250 250 250 300 300 300 400 400 400 500 500 500 700 900 1000 1400

100*

3**

1**

40

104

200*

1**

1**

50

130

200*

2/0

60

154

200*

3/0

75

192

400

250

100

248

400*

350

125

312

400*

3/0 2/PHASE

(2)1

150

360

600*

4/0 2/PHASE 350 2/PHASE

(2)2

200

480

600*

(2)2

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required.
1

92

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 460 Volt Motors & Circuits (440 - 480V System)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

1.1

LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R

J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5

1 2 1 1 2 3 2 2 3 4 2 2 4 6 4 4 5 7 4 4 8 10 6 6 12 17 10 10 17 25 15 15 25 30 20 17 35 30 30 45 40 35 60 45 45

3 6 3 3 3 6 3 3 6 10 6 6 6 10 6 6 6 15 6 6 10 15 10 10 15 25 15 15 20 20 20 25 25 25 40 40 40 50 50 50 60 60 60

3 6 3 3 3 6 3 3 6 10 6 6 6 12 6 6 7 15 7 7 10 15 10 10 15 30 15 15 20 20 20 30 30 30 45 45 45 60 60 60 70 70 70

30 00 14

30 00 14

1.6

30 00 14

2.1

30 00 14

30 00 14

3.4

30 0 14

4.8

30 0 14

7.6

30 1 14

11

30 1 14

10

14

15

21

LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5

30*

10

20

27

60

10**

25

34

60*

8**

**

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60 C conductors only, the 60 C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required.
1

93

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 460 Volt Motors & Circuits (440 - 480V System) (Continued)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

30

40

LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP LPS-RK_SP FRS-R KRP-C_SP LPJ_SP LPS-RK_SP FRS-R KRP-C_SP LPJ_SP LPS-RK_SP FRS-R KRP-C_SP J RK1 RK5 L J RK1 RK5 L J RK1 RK5 L

60 60 50 80 70 70 100 90 90 125 110 100 150 125 125 200 175 175 250 225 200 300 250 225 400 350 300 500 400 400 600 500 500 600 600

70 70 70 100 100 100 125 125 125 150 150 150 175 175 175 225 225 225 300 300 300 350 350 350 450 450 450 600 600 600 700 800 1000 600 1000 1200

90 90 90 110 110 110 125 125 125 150 150 150 200 200 200 250 250 250 350 350 350 400 400 400 500 500 500 700 900 1000 1200 1400 1500 1600

60*

8**

**

40

52

100*

6**

**

50

65

100*

4**

60

77

100*

3**

1**

75

96

200

1**

1**

100

124

200*

2/0

125

156

200*

3/0

150

180

400

4/0

200

240

400*

350

250

302

400*

3/0 2/PHASE

(2)1

300

361

600*

4/0 2/PHASE 300 2/PHASE 350 2/PHASE 400 2/PHASE 500 2/PHASE

(2)2

350

414

LPS-RK_SP RK1 FRS-R RK5 KRP-C_SP L KRP-C_SP FRS-R KRP-C_SP KRP-C_SP L RK5 L L

600* 1200 600 1200 1200

(2)2

400 450 500

477 515 590

6 7 7

(2)2 (2)2 (2)3

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required.

94

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 575 Volt Motors & Circuits (550 - 600V System)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size2 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

0.9

LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R LPJ_SP LP-CC LPS-RK_SP FRS-R

J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5 J CC RK1 RK5

1 1 1 1 2 2 1 1 2 3 2 2 4 5 3 3 4 5 4 3 6 5 5 5 10 15 8 8 15 20 12 12 17 25 15 15 30 25 25 35 30 30 45 40 35

3 3 3 3 3 6 3 3 3 6 3 3 6 10 6 6 6 10 6 6 10 15 10 10 15 20 15 15 20 30 20 20 20 20 20 30 30 30 40 40 40 50 50 50

3 3 3 3 3 6 3 3 3 6 3 3 6 10 6 6 6 10 6 6 10 15 10 10 15 20 15 15 20 20 20 20 20 20 35 35 35 45 45 45 60 60 60

30

14

1.3

30

14

1.7

30

14

2.4

30

14

2.7

30

14

3.9

30

14

6.1

30

14

30

14

10

11

30

14

15

17

LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5

30*

12

20

22

30*

10

25

27

60

10**

**

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60C conductors only, the 60C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required. 2 These sizes are typical. They are not shown in NEMA ICS 2-1993.

95

Contents

Index

Next

Previous

Motor Circuit Protection

Three-Phase, 575 Volt Motors & Circuits (550 - 600V System) (Continued)
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size2 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-150 430-150 HP AMPS

Type

30

32

LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R LPJ_SP LPS-RK_SP FRS-R KRP-C_SP LPJ_SP LPS-RK_SP FRS-R KRP-C_SP LPJ_SP LPS-RK_SP FRS-R KRP-C_SP LPJ_SP LPS-RK_SP FRS-R KRP-C_SP LPS-RK_SP FRS-R KRP-C_SP FRS-R KRP-C_SP

J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 J RK1 RK5 L J RK1 RK5 L J RK1 RK5 L J RK1 RK5 L RK1 RK5 L RK5 L

50 45 40 70 60 60 80 70 70 100 90 80 125 110 100 150 150 125 200 175 175 225 200 200 300 250 250 400 350 350 450 400 400 600 450 450 600 500 500 600 600 600

60 60 60 80 80 80 100 100 100 110 110 110 150 150 150 175 175 175 225 225 225 300 300 300 350 350 350 450 450 450 600 600 600 600 600 600 601 700 800 1000

70 70 70 90 90 90 110 110 110 125 125 125 150 150 150 200 200 200 250 250 250 300 300 300 400 400 400 500 500 500 700 600 600 600 800 1000 1100 1200 1400

60*

40

41

60*

50

52

100*

6**

**

60

62

100*

4**

75

77

100*

3**

1**

100

99

200

1**

1**

125

125

200*

2/0

150

144

200*

3/0

200

192

400

250

250

242

400*

350

300

289

400*

500

350

336

600*

4/0 2/PHASE

(2)2

400

382

600*

250 2/PHASE 300 2/PHASE 350 2/PHASE

(2)2

450

412

600*

(2)2

500

472

600*

(2)2

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60 C conductors only, the 60 C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required. 2 These sizes are typical. They are not shown in NEMA ICS 2-1993.

96

Contents

Index

Next

Previous

Motor Circuit Protection

Direct-Current3, 90 Volt Motors & Circuits
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size2 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-147 430-147 HP AMPS

Type

4.0

LPC_CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5

6 6 5 10 8 7 15 9 9 15 15 12 20 17 17

6 6 6 10 10 10 15 15 15 15 15 15 20 20 20

15 9 9 20 10 10 25 15 15 30 20 20 25 25

30

14

5.2

30

14

6.8

30

14

9.6

30

14

12.2

30

14

Direct-Current3, 180 Volt Motors & Circuits

1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size2 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-147 430-147 HP AMPS

Type

2.0 2.6 3.4

LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LP-CC CC LPS-RK_SP RK1 FRS-R RK5 LP-CC FRS-R LP-CC FRS-R LP-CC FRS-R LP-CC FRS-R CC RK5 CC RK5 CC RK5 CC RK5

2 2 3 3 4 4 10 6 6 8 12 20 15 25 20 40 35

3 3 6 6 6 6 10 10 10 10 15 20 20 25 25 45 45

4 4 6 6 6 7 17 10 10 20 12 30 17 20 35 60 60

30 30 30

1 1 1

14 14 14

1 1 2 3 5

4.8

30

14

6.1 8.3 10.8 16 27

30 30 30 30* 60

1 1 1 1 2

14 14 14 14 10**

LPS-RK_SP RK1 FRS-R RK5

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60 C conductors only, the 60 C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required. 2 This size is typical. It is not shown in NEMA ICS 2-1993. 3 All equipment manufacturers should be consulted about DC voltage ratings of their equipment.

97

Contents

Index

Next

Previous

Motor Circuit Protection

Direct-Current3, 120 Volt Motors & Circuits
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 Minimum NEMA Starter NEMA ICS 21993 Size2 9 Minimum Copper Wire THHN AWG or KCMIL Table 310-16 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-147 430-147 HP AMPS

Type

3.1

LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LP-CC CC LPN-RK_SP RK1 FRN-R RK5 LPN-RK_SP RK1 FRN-R RK5 LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5 LPJ_SP J LPN-RK_SP RK1 FRN-R RK5

6 4 4 9 5 5 10 7 7 15 10 10 15 15 12 20 17 17 30 25 25 35 35 60 50 80 80 125 100 100

6 6 6 10 10 10 10 10 10 15 15 15 15 15 15 20 20 20 30 30 30 40 40 60 60 90 90 125 125 125

12 6 6 15 10 10 20 12 12 30 15 15 20 20 25 25 35 35 50 50 90 90 125 125 125 150 150 150

30

14

4.1

30

14

5.4

30

14

7.6

30

14

9.5

30

14

13.2

30

14

17

30*

12

3 5

25 40

60 60*

1 2

10** 8**

**

58

100*

4**

**

10

76

100*

3**

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60 C conductors only, the 60 C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required. 2 Reduced voltage magnetic controller ratings. 3 All equipment manufacturers should be consulted about DC voltage ratings of their equipment.

98

Contents

Index

Next

Previous

Motor Circuit Protection

Direct-Current3, 240 Volt Motors & Circuits
1 Motor Size 2 Motor FLA 3 Fuse 4 Optimal Branch Ckt Protection Class AMPS1 5 NEC Max for Gen.Applic 430-52(C)(1) Exc. No. 1 AMPS1 6 NEC Max for Heavy Start 430-52(C)(1) Exc. No. 2 AMPS1 7 Minimum Switch Size Sect. 430110 AMPS 8 9 Minimum Minimum NEMA Copper Wire Starter THHN AWG or NEMA ICS 2KCMIL 1993 Table 310-16 Size2 Size 10 Minimum Rigid Metallic Conduit Appendix C Table C8 Inches

Table Table 430-147 430-147 HP AMPS

Type

1.6 2.0 2.7

LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LP-CC CC LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 FRS-R LP-CC FRS-R RK5 CC RK5

2 2 2 2 4 3 6 5 5 6 6 9 9 12 20 17 30 30 25 40 40 50 50 80 70 110 100 90 150 125 125 175 150 150 200 175 225 225 300 300 350 350 450 450

3 3 3 3 6 6 6 6 6 10 10 10 10 15 20 20 30 30 30 45 45 60 60 90 90 110 110 110 150 150 150 175 175 175 225 225 300 300 350 350 400 400 600 600

3 3 4 4 6 6 15 8 8 10 10 12 17 25 45 45 60 60 80 80 110 110 150 150 150 200 200 200 225 225 300 300 350 350 450 450 500 500

30 30 30

1 1 1

14 14 14

1 1 2 3

3.8

30

14

4.7 6.6 8.5 12.2

30 30 30 30

1 1 1 1

14 14 14 14

20

LP-CC CC LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPJ_SP J LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5 LPS-RK_SP RK1 FRS-R RK5

30*

12

7 10 15

29 38 55

60 60* 100*

2 2 3

8 8** 4

** **

20

72

100*

3**

25

89

200

2**

1**

30

106

200*

1/0**

40 50 60 75 100

140 173 206 255 341

200* 400 400* 400* 600

4 5 5 5 6

2/0** 4/0** 300** 400** 4/0 2/PHASE

1** 1** 2** 2** (2)1**

*Switch size must be increased if the ampere rating of the fuse exceeds the ampere rating of the switch. 1 Per 430-52(c)(2), if the motor controller manufacturers overload relay tables state a maximum branch circuit protective device of a lower rating, that lower rating must be used in lieu of the sizes shown in Columns 4, 5, or 6. **If equipment terminations are rated for 60 C conductors only, the 60 C conductor ampacities must be utilized and therefore larger conductor sizes or conduit sizes may be required. 2 Reduced voltage magnetic DC controller ratings. 3 All equipment manufacturers should be consulted about DC voltage ratings of their equipment.

99

Contents

Index

Next

Previous

Main, Feeder, and Branch Circuit Protection

Recommendations for Electrician and Maintenance Crews Often, for various reasons, motors are oversized for applications. For instance, a 5 HP motor is installed when the load demand is only 3 HP. In these cases a much higher degree of protection can be obtained by sizing the overload relay elements and/or FUSETRON and LOWPEAK YELLOW dual-element, time-delay fuses based on the actual full-load current draw. * Selection of FUSETRON or LOW-PEAK YELLOW Dual-Element Fuses based upon Motor FULL Load Amps for Optimum Motor Circuit Protection.
FUSETRON or LOW-PEAK YELLOW DualElement Fuse Size Motor Current FRN-R FRS-R Class RK5 LPN-RK_SP LPS-RK_SP Class RK1 LPJ_SP Class J LP-CC Class CC

460V. 5 Amperes

1. Preferable With a clamp-on meter, determine running RMS current when the motor is at normal full-load. (Be sure this current does not exceed nameplate current rating.) The advantage of this method is realized when a lightly loaded motor (especially those over 50 HP) experiences a single-phase condition. Even though the relays and fuses may be sized correctly based on motor nameplate, circulating currents within the motor may cause damage.
READ NAMEPLATE 5 Amperes

460V.

Alternate If unable to meter the motor current, then take the current rating off the nameplate.
FRS-R 61/4

460V.

2. Then size the overload relay elements and FUSETRON or LOWPEAK YELLOW dual-element fuses based on this current. For optimum motor circuit protection offering a high degree of back-up overload protection, use the table that follows to assist in sizing dual-element fuses. 3. Use a labeling system to mark the type and ampere rating of the fuse that should be in the fuse clips, such as FRS-R6. This simple step makes it easy to run spot checks for proper fuse replacement. When installing the proper fuses in the switch to give the desired level of protection, it often is advisable to leave spare fuses on top of the disconnect, the starter enclosure or in a cabinet adjacent to the motor control center. In this way, should the fuses open, the problem can be corrected and proper size fuses easily reinstalled.
*Abnormal installations may require FUSETRON or LOW-PEAK YELLOW dual-element fuses of a larger size than shown providing only short-circuit protection. These applications include: (a) FUSETRON or LOW-PEAK YELLOW dual-element fuses in high ambient temperature environments. (b) A motor started frequently or rapidly reversed. (c) Motor is directly connected to a machine that cannot be brought up to full speed quickly (large fans, centrifugal machines such as extractors and pulverizes, machines having large fly wheels such as large punch presses.) (d) Motor has a high Code Letter (or possibly no Code Letter) with full voltage start. (e) Wye delta open transition start. (f) Motor has a large inrush current, such as a Design B or E motor.

1 1 1 1 1 1 1 2 21/4 2 2 3 3 3 4 4 5 5 6 6 7 7 8 9 10 12 15 17 20 25 30 35 40 45 50 60 70 75 80 90 100 110 125 150 175 200 225 250 300 350 400 450 500 600

0-0.08 0.09-0.10 0.11-0.12 0.13-0.16 0.17-0.20 0.21-0.24 0.25-0.32 0.33-0.40 0.41-0.48 0.49-0.64 0.65-0.80 0.81-0.90 0.91-1.00 1.01-1.12 1.13-1.20 1.21-1.28 1.29-1.44 1.45-1.60 1.61-1.80 1.81-2.00 2.01-2.24 2.25-2.40 2.41-2.56 2.57-2.80 3.81-3.20 3.21-3.60 3.61-4.00 4.01-4.48 4.49-4.80 4.81-5.00 5.01-5.60 5.61-6.00 6.01-6.40 6.41-7.20 7.21-8.00 8.01-9.60 9.61-12.00 12.01-14.00 14.01-16.00 16.01-20.00 20.01-24.00 24.01-28.00 28.01-32.00 32.01-36.00 36.01-40.00 40.01-48.00 48.01-56.00 56.01-60.00 60.01-64.00 64.01-72.00 72.01-80.00 80.01-88.00 88.01-100.00 100.01-120.00 120.01-140.00 140.01-160.00 160.01-180.00 180.01-200.00 200.01-240.00 240.01-280.00 280.01-320.00 320.01-360.00 360.01-400.00 400.01-480.00

0.0000-0.0769 0.0770-0.0961 0.0962-0.1153 0.1154-0.1538 0.1539-0.1923 0.1924-0.2307 0.2308-0.3076 0.3077-0.3846 0.3847-0.4615 0.4616-0.6153 0.6154-0.7692 0.7693-0.8653 0.8654-0.9615 0.9616-1.076 1.077-1.153 1.154-1.230 1.231-1.384 1.385-1.538 1.539-1.730 1.731-1.923 1.924-2.153 2.154-2.307 2.308-2.461 2.462-2.692 2.693-3.076 3.077-3.461 3.462-3.846 3.847-4.307 4.308-4.615 4.616-4.807 4.808-5.384 5.385-6.153 6.154-6.923 6.924-7.692 7.693-9.230 9.231-11.53 11.54-13.46 13.47-15.38 15.39-19.23 19.24-23.07 23.08-26.92 26.93-30.76 30.77-34.61 34.62-38.46 38.47-46.15 46.16-53.84 53.85-61.53 61.54-69.23 69.24-76.92 76.93-84.61 84.62-96.15 96.16-115.3 115.4-134.6 134.7-153.8 153.9-173.0 173.1-192.3 192.4-230.7 230.8-269.2 269.3-307.6 307.7-346.1 346.2-384.6 384.7-461.5

0.0-0.6666 0.6667-0.7500 0.7501-0.8333 0.8334-0.9333 0.9334-1.000 1.001-1.066 1.067-1.200 1.201-1.333 1.334-1.500 1.501-1.666 1.667-1.866 1.867-2.000 2.001-2.133 2.134-2.333 2.334-2.666 2.667-3.000 3.001-3.333 3.334-3.733 3.734-4.000 4.001-4.666 4.667-5.333 5.334-6.000 6.001-6.666 6.667-8.000 8.001-10.00 10.01-11.66 11.67-13.33 13.34-16.66 16.67-20.00 20.01-23.33 23.34-26.66 26.67-30.00 30.01-33.33 33.34-40.00 40.01-46.66 46.67-53.33 53.34-60.00 60.01-66.66 66.67-73.33 73.34-83.33 83.34-100.0 100.1-116.6 116.7-133.3 133.4-150.0 150.1-166.6 166.7-200.0 200.1-233.3 233.4-266.6 266.7-300.0 300.1-333.3 333.4-400.0

0.0000-0.2500 0.2501-0.3000 0.3001-0.4000 0.4001-0.5000 0.5001-0.5625 0.5626-0.6250 0.6251-0.7000 0.7001-0.7500 0.7501-0.8000 0.8001-0.9000 0.9001-1.000 1.001-1.125 1.126-1.250 1.251-1.400 1.401-1.500 1.501-1.600 1.601-1.750 1.751-2.000 2.001-2.250 2.251-2.500 2.501-2.800 2.801-3.000 3.001-3.125 3.126-3.500 3.501-3.750 3.751-4.000 4.001-4.500 4.501-5.000 5.001-6.000 6.001-7.500 7.501-8.750 8.751-10.00 10.01-12.50 12.51-15.00

100

Contents

Index

Next

Previous

Protection of Motor Starters

Motor Starter Protection Motor controllers are highly susceptible to damage due to shortcircuits. Even for moderate or low-level faults, extensive damage may occur if the short-circuit protective device is not carefully selected. The most vulnerable parts are the starter contacts and heater elements. Fault currents can weld the contacts and cause the heater elements to vaporize or be critically damaged. The metallided vapors from such damage then can initiate further starter destruction in the enclosure. Often, after a fault, no apparent damage is visible (i.e., the contacts are not welded and the heater elements are not burnt up). However, the heat energy from the fault may have caused too high of a heat excursion for the heater elements or overload relay sensing element to withstand, with the result being a permanently altered and degradated level of overload protection. The question is, what can be done to obtain the highest degree of short-circuit protection for motor controllers? The solution is to use short-circuit protective devices that are current-limiting and size them as close as practical. A current-limiting fuse can cut off the shortcircuit current before it reaches damaging levels. Even for potentially high short-circuit currents, the quick clearing of the fuse can limit the current passed through the starter to safe levels. Dual-element fuses are recommended since they can be sized at 125% of the motor fullload current, rather than 300% sizing for non-time-delay fuses. The branch circuit protective device size cannot exceed the maximum rating shown on equipment labels or controller manufacturers tables. Section 430-53 requires observance of the requirements of 430-52 plus, for circuits under 430-53(c) the motor running overload device and controller must be approved for group installation with a specified maximum rating protective device. Under 430-54 for multimotor and combination-load equipment, the rating of the branch circuit protective device cannot exceed the rating marked on the equipment. Therefore, be sure to check labels, controller overload relay tables, equipment nameplates, etc. In no case can the manufacturers specified rating be exceeded. This would constitute a violation NEC 110-3b. When the label, table, etc. is marked with a Maximum Fuse Ampere Rating rather than marked with a Maximum Overcurrent Device this then means only fuses can be used for the branch circuit protective device. Achieving Short-Circuit Protection In order to properly select an overcurrent device for a motor starter, four areas require particular attention: 1. Withstand rating of the contactor. 2. Wire Damage, 3. Cross-over point of the fuse and relay curve, 4. Motor Damage. Please refer to the following graph. Contactor Withstand Rating The first area of concern is the withstand rating of the contactor. In order to prevent damage to the contactor, the maximum peak letthrough current (Ip) and maximum clearing energy (I2t) (amperes2 seconds) of the fuse must be less than the equivalent ratings for the contactor. The clearing time and let-through characteristics of the fuse must be considered when verifying adequate protection of the contactor. Wire Damage Secondly, motor circuit conductors have a withstand rating that must not be exceeded. If the overcurrent protective device is not capable of limiting the short-circuit current to a value below the wire withstand, the wire may be damaged, or destroyed.
1,000

Motor and Motor Circuit Damage Protection 10 H.P @ 460V

100

Legend: Motor Start Overload Relay

TIME IN SECONDS

10

Motor Damage #12 Wire Damage Thermal Withstand Limit Contactor Breaking Current Contactor Withstand 30Ie2

.1

.01 10,000 10 1,000 100

CURRENT IN AMPERES

Cross Over Point Thirdly, the cross-over point (Ic) is the point where the fuse curve intersects the overload relay curve. For current levels less than the cross-over point the overload relay opens the circuit. For current values greater than the cross-over point the fuses open the circuit and prevent thermal damage to the overload relay, contacts, and the motor circuit. This point of intersection should be approximately 7-10 times Ie. Ideally the fuse should allow the overload relay to function under overload conditions, and operate before the overcurrent reaches the contactors breaking capacity. Motor Damage Finally, all motors have an associated motor damage curve. Single phasing, overworking, and locked rotor conditions are just a few of the situations that cause excessive currents in motor circuits. Excessive currents cause motors to overheat, which in turn causes the motor winding insulation to deteriorate and ultimately fail. Overload relays and dual-element, time-delay fuses, are designed to open the motor circuit before current levels reach the motor damage curve. IEC and U.L. Standards for Allowable Damage IEC 947-4-1 and U.L. 508E currently differentiate between two different types of coordination, or damage levels. Type 1 Considerable damage, requiring replacement. No external damage to the enclosure. Shortcircuit protective devices interrupt intermediate to high short-circuit currents which exceed the withstand rating of the motor starter. A noncurrent-limiting device will interrupt these high currents, but this type of damage will typically result. Type 2 No Damage is allowed to either the contactor or overload relay. Light contact welding is allowed, but must be easily separable. (Note: If access is not possible and the contacts cannot be separated, Type 2 protection cannot be achieved.) This level of protection typically can only be provided by a current-limiting device, that is, one which limits the available shortcircuit current to a significantly lower value.

101

Contents

Index

Next

Previous

Protection of Motor Starters

Five Choices1 Solution IEC Motor Starter Protection Five methods of providing motor starter overcurrent protection are delineated in the five examples that follow. In noting the levels of protection provided by each method, it becomes apparent that the use of dual-element, time-delay fuses (Example 5) is the only one that gives protection at all levels whether it be Type 2, Back-up Overload, Back-up Single-Phase, etc. These examples are based on a typical motor circuit consisting of an IEC Starter, and a 10 HP, 460 volt motor (Service factor = 1.15). These Level of Protection examples reflect the branch circuit protective device operating in combination with the IEC starter overload relays sized at approximately 115% of motor FLA and contactor Ie = 18 amperes.

1,000

Motor Circuit Protector (700% FLA)

1,000

Molded Case Circuit Breaker (250% FLA)

100

Legend: Motor Start Overload Relay

100

Legend: Motor Start Overload Relay

TIME IN SECONDS

10

Crossover Point Ic = 5.5 Ie

Motor Damage #12 Wire Damage Thermal Withstand Limit Contactor Breaking Current Contactor Withstand 30Ie2 MCP (700%)

TIME IN SECONDS

10

Motor Damage #12 Wire Damage Thermal Withstand Limit Contactor Breaking Current Contactor Withstand 30Ie2 MCCB 40A

.1 Level of Protection: Type "2" Single-Phase Back-up Single-Phase Overload Back-up Overload Meets 110-10 Meets 430-52 No Yes No Yes No No Yes

.1 Level of Protection: Type "2" Single-Phase Back-up Single-Phase Overload Back-up Overload Meets 110-10 Meets 430-52 No Yes No Yes No No Yes

.01 10 1,000 100 10,000

.01 10 1,000 100 10,000

CURRENT IN AMPERES

CURRENT IN AMPERES

Example 1

Example 2

1,000

Fast-Acting Fuse (IEC) (300% FLA)

1,000

Dual-Element, Time-Delay Fuse (175% FLA)

100

Legend: Motor Start Overload Relay

100

Legend: Motor Start Overload Relay

TIME IN SECONDS

10

Crossover Point Ic = 10 Ie

Motor Damage #12 Wire Damage Thermal Withstand Limit Contactor Breaking Current Contactor Withstand 30Ie2 Fast-Acting Fuse 45A

TIME IN SECONDS

10

Crossover Point Ic = 10 Ie

Motor Damage #12 Wire Damage Thermal Withstand Limit Contactor Breaking Current Contactor Withstand 30I e2 LOW PEAK, Dual-Element, Time-Delay 25A Level of Protection: Type "2" Single-Phase Back-up Single-Phase Overload Back-up Overload Meets 110-10 Meets 430-52 Yes Yes No Yes No Yes Yes

.1 Level of Protection: Type "2" Single-Phase Back-up Single-Phase Overload Back-up Overload Meets 110-10 Meets 430-52 Yes Yes No Yes No Yes Yes

.1

.01 10 1,000 100 10,000

.01 10 1,000 100 10,000

CURRENT IN AMPERES

CURRENT IN AMPERES

Example 3 102

Example 4

Contents

Index

Next

Previous

Protection of Motor Starters

1,000

Dual-Element, Time-Delay Fuse (125% ) - Class RK1 or J

100

Legend: Motor Start Overload Relay

Guideline for Applying R-Rated Fuses The current-limiting fuse should be selected so that the overload relay curve crosses the minimum melting curve of the fuse at a current greater than 110% of the locked rotor current of the motor being utilized. A preliminary choice is obtained through the following formula: 6.6 Full Load Current = R rating of fuse 100 This value is rounded up to the next R-rating fuse. Example: A 2300 volt motor has a 100 ampere full load current rating and a locked rotor current of 600 amperes. The preliminary choice is 6.6 100 100 = 6.6

TIME IN SECONDS

10

Crossover Point Ic = 8 Ie

Motor Damage #12 Wire Damage Thermal Withstand Limit Contactor Breaking Current Contactor Withstand 30I e2 LOW PEAK, Dual-Element, Time-Delay 17A Level of Protection: Type "2" Single-Phase Back-up Single-Phase Overload Back-up Overload Meets 110-10 Meets 430-52 Yes Yes Yes Yes Yes Yes Yes

.1

.01 10 1,000 100 10,000

CURRENT IN AMPERES

Thus one rounds up to the next standard R-rating, 9R. But this must be checked with the appropriate time-current characteristics curves. The overload relay being used has the time-current characteristic as shown in the adjacent Figure. To choose the proper fuse one must plot 110% of the locked rotor current and the family of fuses on the same graph as the overload relay. 1,000 OVERLOAD RELAY 100 6R 9R 12R JCK 9R

Example 5

MEDIUM VOLTAGE CIRCUITS R-Rated Fuses for Medium Voltage Motor Circuits R-rated medium voltage fuses are back-up current-limiting fuses used in conjunction with medium voltage motors and motor controllers. These fuses are designed for short-circuit protection only and do not protect themselves or other components during extended overloads. Thus, this type of fuse does not have an ampere rating, but rather an R-rating. Current-limiting fuses may be designated as R-rated if they meet the following requirements: 1. The fuse will safely interrupt an currents between its minimum and maximum interrupting ratings, 2. The fuse will melt in a range of 15 to 35 seconds at a value of 100 times the R number (ANSIC37.46). Bussmann R-rated current-limiting fuses are designed for use with medium voltage starters to provide short-circuit protection for the motor and motor-controller. These fuses offer a high level of fault current interruption in a self-contained, non-venting package which can be mounted indoors or in an enclosure. All of the R-rated product comes with blown fuse indication. Some of the product is available with a hookeye option. A hookstick can be used for nonloadbreak isolation. Application Medium voltage motors are efficiently protected by overload relays applied in conjunction with back-up current-limiting fuses which are intended to open the circuit for high fault conditions. The overload relay is chosen to interrupt currents below the minimum interrupting rating of the fuse. Since multiple devices are used to provide protection it is very important that they be properly coordinated. The motor starter manufacturer typically chooses the proper fuse R-rating, overload relay, and contactor. The following guideline can be used to insure proper coordination.

TIME IN SECONDS

10

THERMAL OVERLOAD RELAY CONTACTOR 125% MOTOR F.L.A. MOTOR F.L.A. 100A

1 M

.1 110% LOCKED ROTOR CURRENT 660 1,000 10,000 100 125 10 .01

LOCKED ROTOR CURRENT 600A

CURRENT IN AMPERES The fuse that should be selected is the smallest fuse whose minimum melting characteristic crosses the overload relay at a current greater than 110% of the locked rotor current. In this example, it would be a 2400 Volt 9R fuse. This agrees with the quick selection choice. Depending on the type of installation and starter being used, a JCK-9R, JCK-A-9R, or JCH-9R would be the correct choice.

103

Contents

Index

Next

Previous

Motor Circuit Protection

Motor Circuit Protection Motor circuit protection describes the short-circuit protection of conductors supplying power to the motor, the motor controller, and motor control circuits/conductors. Section 430-52 provides the maximum sizes or settings for overcurrent devices protecting the motor branch circuit. A branch circuit is defined in Article 100 as The circuit conductors between the final overcurrent device protecting the circuit and the outlet(s). NEC CircuitProtection ProtectionRequirements Requirements NECMotor Motr Circuit Table 430-152. Maximum Rating or Setting of Motor Branch Circuit, Short-Circuit and Ground Fault Protective Devices
Percent of Full-Load Current DualElement InstanNon-Time(Timetaneous Inverse Delay Delay) Trip Time Fuse** Fuse** Breaker Breaker* 300 175 800 250

Type of Motor Single-phase motors

AC polyphase motors other than wound-rotor Squirrel Cage: Other than Design E Design E Synchronous 300 300 300 150 175 175 175 150 150 800 1100 800 800 250 250 250 250 150 150

1000A Main Fuse

Wound Rotor

Direct-current (constant voltage) 150

For certain exceptions to the values specified, see Sections 430-52 through 430-54. * The values given in the last column also cover the ratings of non-adjustable inverse time types of circuit breakers that may be modified as in Section 430-52. ** The values in the Non-Time-Delay Fuse Column apply to Time-Delay Class CC fuses. 600A Feeder Fuse Receptacles 20A Branch Breaker MCC Branch Fuse Synchronous motors of the low-torque, low-speed type (usually 450 rpm or lower), such as are used to drive reciprocating compressors, pumps, etc., that start unloaded, do not require a fuse rating or circuit-breaker setting in excess of 200 percent of full-load current.

225A

Feeder Circuit

Branch Circuit

Branch Circuit

Note that the branch circuit extends from the last branch circuit overcurrent device to the load. Table 430-152 lists the maximum sizes for Non-Time-Delay Fuses, Dual Element (Time-Delay) Fuses, Instantaneous Trip Circuit Breakers, and Inverse Time Circuit Breakers. Sizing is based on full load amp values shown in Table 430-147 through 430-150, not motor nameplate values. For example, the maximum time-delay fuse for a 10 HP, 460 volt, 3 phase motor with a nameplate FLA of 13 amps would be based on 175% of 14 amperes, not 175% of 13 amps.

The 1993 NEC required the user to round down if the percentages in Table 430-150 did not correspond to a standard ampere rating. For the example using the 1993 NEC, 1.75 14 = 24.5, with a round down to 20 amps. The 1996 NEC allows the user to round up for the same situation. Using the example with the 1996 NEC, 1.75 14 = 24.5, with a round up to 25 amps. Standard sizes for fuses and fixed trip circuit breakers, per 240-6, are 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 110, 125, 150, 175, 200, 225, 250, 300, 350, 400, 450, 500, 600, 700, 800, 1000, 1200, 1600, 2000, 2500, 3000, 4000 5000, and 6000 amperes. Additional standard fuse sizes are 1, 3, 6, 10, and 601 amperes. The exceptions in 430-52 allow the user to increase the size of the overcurrent device if the motor is not able to start. All Class CC fuses can be increased to 400%, along with non-time-delay fuses not exceeding 600 amperes. Time-delay (dual-element) fuses can be increased to 225%. All Class L fuses can be increased to 300%. Inverse time (thermal-magnetic) circuit breakers can be increased to 400% (100 amp and less) or 300% (larger than 100 amps). Instant trip circuit breakers may be adjusted to 1300% for other than Design E motors and 1700% for Design E motors. 430-52(c)(2) reminds the user that the maximum device ratings which are shown in a manufacturers overload relay table must not be exceeded even if higher values are allowed by other parts of 430-52. 430-52(c)(3) details the requirements that instant-trip cbs and motor short-circuit protectors can only be used if part of a listed combination motor controller.

104

Contents

Index

Next

Previous

Group Motor Protection

GROUP FUSING Section 430-53 covers the requirements for group motor installations. Two or more motors or one or more motors and other loads may be protected by the same branch circuit overcurrent device if (a) all motors are 1 HP or less, protected at not over 20A at 120 volts or at 15A at 600 volts or less, the full load amp rating of each motor does not exceed 6 amperes, the device rating marked on the controller is not exceeded, and individual overload protection conforms to 430-32. or (b) the smallest motor is protected per 430-52 or (c) the complete assembly of overcurrent protective device, controller, and overload is tested, listed, and marked (d) (the ampacity of conductors to motors are no less than the ampacity of the branch circuit conductors) or (the conductors to motors have at least the ampacity of the branch circuit conductors, are protected from physical damage and are not more than 25 feet long before being connected to the motor overload device.)

and

Group Motor Installation (Group Fusing) NEC 430-53

Group Motor Protection

Type of Motor Circuit Single Motor Branch Circuit Must meet 430-52

Branch Circuit Fuse Branch Circuit Conductor Taps Group Motor Application (Group Fusing) [430-53 (d)] Do tapped conductors to each motor have an ampacity of at least of the NO incoming branch circuit conductor?

Must meet 430-53

YES YES
[430-53 (d)] Are tapped conductors to each overload device 25 feet or less?

M
or Smallest motor protected per 430-52. NEC 430-53 (b)

[430-53 (a)] Are all motors 1 HP or less?

All motors are 1 HP or less 20A @ 120V & 15A @ 600V. NEC 430-53 (a)

NO

NO
[430-53 (b)] Is smallest motor protected according to 430-52?

or Controllers must be tested, listed, and marked for Group Motor Installations with a maximum size fuse no larger than the branch circuit fuse used. NEC 430-53 (c) and Tap conductors shall have ampacity of at least that of the ampacity of the branch circuit conductor. Distance to the overload shall not be greater than 25 feet. NEC 420-53(d)

YES

YES
OK to use Group Motor Protection but must still meet Group Switching 430-112. (Motors served by a single disconnecting means)

NO
[430-53 (c)] Is the entire assembly of Branch Circuit Over- YES current Devices and motor controllers tested, listed and marked for a group installation?

NO
Group Motor installation not possible. Each motor branch circuit must be individually protected by a branch circuit overcurrent device.

105

Contents

Index

Next

Previous

Group Switching
Motors Served by a Single Disconnecting Means (Group Switching) Section 430-112 covers the requirements for serving two or more motors with the same disconnecting means. Each motor must be provided with an individual disconnecting means unless: (a) all motors drive parts of a single machine or or (b) all motors are 1 HP or less as permitted by 430-53(a) (c) all motors are in a single room and within sight (visible and not more than 50 feet) of the disconnecting means. Group Switching
Type of Motor Circuit Switching Individual motor disconnecting means Must meet Article 430, Part I (430-109)

Group Switching (Motors served by a single disconnecting means)

Motors Served By a Single Disconnecting Means (Group Switching) NEC 430-112

Disconnect which meets Motor Disconnecting means requirements of NEC Article 430, Part I (430-109)

Must meet 430-112

Branch Circuit Fuse

[430-112 Exc. (a)] Do all motors drive parts of same or single machine? NO [430-112 Exc. (b)] Are all motors 1 HP or less?

YES

YES

OK to use Group Switching

Mini breaker listed for group motor protection with branch circuit fuse above MMP listed for group motor protection with the branch circuit fuse above

Branch circuit fuses in U.L. 512 fuseholder OPM-CC

U.L. 508 Controller Branch Cirucit Fuses OPM-SW Contacts Overload Relays

NO [430-112 Exc. (c)] Are all motors in a YES single room and withing sight of the disconnecting means? NO Group motor switching not possible because these multiple motor circuits may not be served by a single disconnecting means.

Motor controller listed for group motor protection with the branch circuit fuse above

M
All motors drive parts of a single machine, or

M
All motors are 1 HP or less and protected by a single set of fuses per 430-53(a), or

Motor controllers do not need to be listed for group motor protection

All motors are in a single room and within sight of disconnecting means

106

Contents

Index

Next

Previous

Overcurrent Devices for Motor Circuit Protection

OVERCURRENT DEVICES AND DISCONNECTING MEANS FOR MOTOR & MOTOR CIRCUIT PROTECTION Branch Circuit Fuses As listed to the U.L. 248 series of standards. These are fuses which cannot be replaced with a fuse having a lower voltage rating. When installed in rejection style clips, current-limiting branch circuit fuses cannot be replaced with fuses which are not current-limiting. Examples of branch circuit fuses are Class L, RK1, RK5, T, J, K1, K5, G, H, CC, and plug fuses. Interrupting ratings range from 10,000 amperes to 300,000 amperes. Supplemental Fuses As listed to U.L. 248-14 These are fuses which can have many voltages and interrupting ratings within the same case size. Examples of supplemental fuses are 1, 5 20mm, and 1 fuses. Interrupting ratings range from 35 to 100,000 amperes. Branch Circuit vs. Supplemental Fuses Branch circuit fuses can be used everywhere fuses are used, from protection of motors and motor circuits and group motor circuits, to protection of distribution and utilization equipment. Supplemental fuses can only be used where proper protection is already being provided by a branch circuit device, by exception (i.e., 430-72(a)), or if protection is not required. Supplemental fuses can often be used to protect motor control circuits but they cannot be used to protect motors or motor circuits. Disconnect Switches As listed to U.L. 98 These are disconnect switches from 30 through 6000* amperes, which may be used on service equipment, panelboards, switchboards, industrial control equipment, motor control centers, motor branch circuits, etc. These switches may be used as a motor disconnecting means to meet NEC 430-109. They may also be used as a motor controller (on-off function) to meet NEC article 430, part G, and may be used as both a motor disconnecting means and a motor controller (NEC 430-111). When used with properly sized branch circuit fuses, disconnect switches may be used for motor, motor circuit, and group motor protection. *U.L. listing through 4000 amperes. 15149 Class J Pullout Molded Case Switches As listed to U.L. 1087 These switches are very similar to molded case thermal magnetic circuit breakers except that they have no thermal overload protection. They may or may not be equipped with a magnetic instantaneous trip as a self protect mechanism. They may be used on service equipment, panelboards, switchboards, industrial control equipment, motor control centers, motor branch circuits, etc. They are suitable for use as a motor circuit disconnect per NEC 430-109. When used with properly sized branch circuit fuses, molded case switches may be used for motor, motor circuit, and group motor protection. They may be used as a motor controller (On-Off Function) to meet NEC Article 430 Part G, and as both a motor disconnecting means and motor controller to meet NEC 430111. Molded case switches may contain a shunt trip with or without ground fault protection. Disconnect Switches As listed to U.L. 508 These switches may be used as a motor controller (On-Off Function) to meet NEC Article 430 Part G. As motor controllers, they have creepage and clearance distances which are less than those required by U.L. 98. As a result, they cannot be used as a motor disconnecting means to meet NEC 430-109. These switches require properly sized branch circuit fuses and a motor disconnecting means on their line side when used to provide motor, motor circuit, or group motor protection. Pullout Switches As listed to U.L. 1429 These are switches from 30 through 200 amperes at 600 volts or less. Pullout switches with horsepower ratings are suitable for motor disconnecting means to meet NEC 430-109, as motor controllers to meet NEC Article 430 Part G (if rated 100 HP or less), and in general use for panelboards, switchboards, etc. They may be used as both a motor disconnecting means and a motor controller to meet 430-111. Pullout switches with ampere ratings only (no HP ratings) are suitable for general use only, not motor circuits. If they are marked Motor circuit pullout switch they may be used only in a motor circuit. When used with properly sized branch circuit fuses, pullout switches may be used for motor, motor circuit, and group motor protection.

BDCF-30J6 Disconnect Switch

107

Contents

Index

Next

Previous

Overcurrent Devices for Motor Circuit Protection

Supplementary Protectors (Mini-Breakers) As recognized to U.L. 1077 With applications similar to supplemental fuses, these circuit breakers cannot be used as a branch circuit protective device. As such they cannot provide motor, motor circuit, or group motor protection. They can only be used for protecting an appliance or other electrical equipment where branch circuit overcurrent protection is already provided, or is not required. They have creepage and clearance distances which are less than those in U.L. 489, so they cannot be listed as a circuit breaker or used as a motor disconnecting means to meet the requirements of NEC 430-109. Interrupting ratings are quite low. Those devices that are short-circuit tested in series with a fuse must be applied with a fuse on their line side. Some mini-breakers have been tested in a group motor application (as the protected device, not the protective device) so that several of them may be able to be protected by one larger upstream fuse. Bussmann Optima - Overcurrent Protection Module with Disconnect Switch Fuse Holders As listed to U.L. 512 When used with a motor disconnecting means and properly sized branch circuit fuses, fuseholders may provide motor, motor circuit, and group motor protection. They cannot be used alone as a motor disconnecting means to meet NEC 430-109, nor can they be used alone as a motor controller (On-Off Function) to meet NEC Article 430, Part G. IEC Manual Motor Protectors As listed to U.L. 508 These manual motor starters, often called MMPs, combine a magnetic short-circuit trip and adjustable motor overload protection. They provide motor protection per NEC 430-32 and controller function (On-Off) per NEC Article 430, Part G. Creepage and clearance distances are not as great as required in U.L. 489, and therefore they cannot be listed as a circuit breaker or used as a motor disconnecting means. MMPs cannot provide motor circuit (branch circuit) protection. They need a branch circuit overcurrent device and a motor disconnecting means on the line side for both single motor and group motor applications. MMPs do not meet requirements for a motor disconnecting means as required in NEC 430109. Most IEC manual motor protectors have been tested and listed for group motor applications (as the protected device, not the protective device) so that several of them may be able to be protected by one larger upstream fuse. Integrated Starters As listed to U.L. 508 Integrated starters are an assembled combination of an IEC manual motor starter and an IEC contactor. They cannot be listed for motor circuit (branch circuit) protection or used as a motor disconnecting means. They do not provide motor circuit (branch circuit) protection. They do not meet the requirements for a motor disconnecting means as required in NEC 430-109. Integrated starters need a branch circuit overcurrent device and a motor disconnecting means on their line side, for both single motor and group motor applications. Most integrated starters have been tested and listed for group motor applications (as the protected device, not the protective device) so that several of them may be able to be protected by one larger upstream fuse. Self-Protected Starters As listed to U.L. 508 Self protected starters are often called Coordinated protected starters and Type E starters. They provide motor and motor circuit (branch circuit) protection by combining a magnetic short-circuit trip and adjustable motor overload in one package. A Type E starter is a listed combination starter suitable for use without additional branch circuit short-circuit protection.

Bussmann Optima - Overcurrent Protection Module Non-Switch Series Thermal Magnetic (Inverse Time) Circuit Breakers As listed to U.L. 489 These circuit breakers are intended to provide branch, feeder, and main protection, with interrupting ratings from 5,000 to 200,000 amperes. They are suitable for use as a motor disconnecting means per NEC 430-109, as a motor controller (On-Off Function) per NEC Article 430, Part G, and as both a motor disconnecting means and motor controller per NEC 430-111. Properly sized inverse time circuit breakers may provide motor circuit protection. They may be used for group motor protection only when the entire package is tested, listed and marked (430-53(c)). Instantaneous Trip Circuit Breakers (MCPS) As recognized to U.L. 489 These are circuit breakers without overload (thermal) protection capability. They are intended to provide only short-circuit protection for individual motor branch circuits. They may not be used to provide main, motor feeder, motor overload or group motor protection. Because they are recognized, not listed, they cannot be used with loose control. NEC 430-52 requires that they shall only be used as part of a listed combination controller. MCPs are shortcircuit tested only in combination with a combination motor controller. They have no interrupting rating by themselves. Per NEC 430-109 exception 7, they may be used as a motor disconnecting means when part of a listed combination motor controller. 108

Contents

Index

Next

Previous

Motor Circuit Notes

Disconnecting Means for Motor Circuits Notes: 1. In Sight From means that the motor must be visible and not more than 50 feet distant. (Definitions in Article 100.) 2. Controller includes any switch or device normally used to start or stop a motor by making and breaking the motor circuit current (430-81). 3. A disconnecting means must be located in sight of the controller (430-102). For exceptions see 430-102. 4. A switch can serve both as a controller and disconnecting means if properly rated in accordance with 430-111 and 430-83. Switches for Motor Circuits The Code requirements for switches used as controllers and disconnect switches are as follows (430-81, 430-83, 430-109, 430-110, 430-111): For 0 to 300 volt stationary motors: 2 HP or Less Use horsepower rated switch, or general use switch having ampere rating at least twice the ampere rating of the motor, or general use AC (only) snap switch having ampere rating at least 125% of motor current rating. Greater than 2 HP to 100 HP Switch must have horsepower rating. Larger than 100 HP Disconnect purposesswitch must have an ampere rating at least 115% of the motor nameplate rating. Controller purposesswitch must have horsepower rating. For 301 to 600 volt stationary motors: Less than 100 HP Switch must have horsepower rating. Larger than 100 HP Disconnect purposesswitch must have an ampere rating at least 115% of the motor nameplate rating. Controller purposesswitch must have horsepower rating. For portable motors: An attachment plug and receptacle may serve as disconnect on all sizes. HP or Less An attachment plug and receptacle may serve as controller. Larger than HP Controller must meet requirements as outlined for stationary motors (shown above). Size of HP Rated Switches (Switch Size Savings) LOW-PEAK YELLOW and FUSETRON dual-element fuses rather than non-time-delay fuses are recommended for motor branch circuit protection because normally dual-element fuses permit the use of a smaller switch size, give better protection, reduce cost, and require less space. For motors, oversized switches must be used with non-timedelay fuses because this type of fuse has very little time-lag. Nontime-delay fuses are generally sized 300% of the motor rating to hold normal motor starting current. Consequently, the switch also has be be oversized to accommodate these fuses. The dual-element fuse can be sized close to the motor full-load amperes and a smaller switch used, as shown in the following illustrations.
WHEN USING DUAL-ELEMENT, TIME-DELAY FUSES Motor Starter with Overload Relay 200 Amp Switch

M
LPS-RK150SP WHEN USING NON-TIME-DELAY FUSES Motor Starter with Overload Relay 400 Amp Switch

F.L.A. = 100

M
KTS-R 300

F.L.A. = 100

Branch circuit (short-circuit) protection can be provided for the given motor by either a 150 ampere dual-element, time-delay fuse or a 300 ampere non-time-delay fuse. The dual-element fuse selection above provides these advantages: (1) Backup overload protection, (2) smaller switch size, resulting in lower cost, (3) smaller fuse ampere case size, resulting in lower cost, (4) short-circuit protection that is comparable or better than non-time-delay (fast-acting) fuse.

Most switches are listed with two HP ratings. The Standard horsepower rating is based on the largest non-time-delay (nondual-element) fuse rating (1) which can be used in the switch, and (2) which will normally permit the motor to start. The Maximum horsepower rating is based on the largest rated time-delay LOWPEAK YELLOW or FUSETRON dual-element fuse (1) which can be used in the switch, and (2) which will normally permit the motor to start. Thus when LOW-PEAK YELLOW or FUSETRON dualelement fuses are used smaller size switches can be used (430-57 Exception). CONDUCTORS FOR MOTOR BRANCH AND FEEDER CIRCUITS Motor Branch Circuit Conductors The ampacity of branch circuit conductors supplying a single motor must be at least 125% of the motor full-load current rating (430-22a). Exceptions: For conductors supplying motors used for shorttime, intermittent, periodic, or varying duty refer to 430-22a. Any motor application must be considered continuous duty unless the nature of the apparatus it drives is such that the motor will not operate continuously with load under any conditions of use. FEEDER CIRCUITS FOR MOTORS Feeder Conductor Ampacity The ampacity of a conductor supplying two or more motors must be at least equal to the sum of (1) 125% of the largest motor (if there are two or more motors of the largest size, one of them is considered to be the largest), and (2) the total of the full-load ampere ratings for all other motors and other loads. Where different voltages exist, the current determined per the above shall be multiplied by the ratio of output to input voltage. Feeder Fuse Size On normal installations, size FUSETRON dual-element fuses or LOW-PEAK YELLOW dual-element fuses equal to the combined ampere rating of (1) 150% to 175% F.L.A. of the largest AC motor (if there are two or more motors of the same size, one of them is considered to be the largest), and (2) the sum of all the F.L.A. for all other motors. This dual-element fuse size should provide feeder protection without unnecessary fuse openings on heavy motor startings.

109

Contents

Index

Next

Previous

Motor Circuit Notes

Where conditions are severe, as where a high percentage of motors connected must be started at one time, a larger size may be necessary. In that event, use the maximum size permitted by the Code as follows. The Maximum Motor Circuit Feeder Fuse (430-62) 1. For the one motor in the group with the highest starting current Find the largest fuse permitted for branch circuit protection using the Tables (430-152) and [440-22(a)]. The fuse capacity permitted for the motor with the heaviest starting current may be considered for only one motor. If two or more motors can each have a fuse of the same maximum size, only one of them can be considered. 2. The Ampere Rating of All other Motors on that feeder. Feeder Motor Schedule Example
No. of Units HP 1 3 1 5 1 15 1 40 1 75 *Per NEC Table 430-150. Per NEC Table 430-152. Amps* 4.8 7.6 21 52 96 Multiplier 13/4 13/4 13/4 13/4 13/4

MOTOR CONTROL CIRCUIT PROTECTION General A motor control circuit is a circuit of a control apparatus or system that carries the electric signal directing the performance of the controller (430-71). It does not carry the main power current. A control circuit tapped on the load-side of the motor branch circuit fuse which controls the motor on that branch circuit shall be protected against overcurrent as in Section 430-72 Such a circuit is not considered a branch circuit and may be protected by a supplementary fuse or a branch circuit fuse. A new standards requirement pertinent to motor controllers listed for available fault currents greater than 10,000 amperes, states that the control circuit fuse must be a branch circuit fuse with a sufficient interrupting rating. (The use of Buss KTK-R, FNQ-R, JJS, JJN, or LPJ_SP fuses is recommendedthese fuses have branch circuit listing status, high interrupting rating, and small size.)
MOTOR BRANCH CIRCUIT FUSE

M
The Control Fuse may be a Branch Circuit Fuse or a Supplementary Fuse (430-72a). CONTROL CIRCUIT

Calculations: Maximum. 1. Largest motor (96A 175% = 168A) (Round up to 175A) 2. F.L.A. all other motors (85.4A) 3. Total (175A + 85.4A = 260.4A) (Round down to 250A) Choose 250 ampere dual-element fuse. Feeder Circuit-Combination Motor, Power and Lighting Loads Where a feeder supplies motor load and power and/or lighting load, the permitted feeder fuse size calculation is the sum of that calculated for the motor load in accordance with Section 430-62, plus that calculated for the other loads in accordance with Articles 210 and 220 (430-63). The conductor ampacity supplying motors and other loads must be at least the sum of that calculated for the motor load in accordance with Sections 430-22 and 430-24, plus that calculated for the other loads in accordance with Article 220 (430-25). (For exceptions see 430-25.) Example of Sizing of Dual-Element Fuses for Combination Load Feeder Motor Load (Use Motor Schedule in preceding example). Continuous Heating and Lighting Load 135A Non-Continuous Loads 110A Calculations: 1. Motor Load: (Use calculation in preceding example) 260.4A 2. Continuous Non-Motor Load 135A 125% 168.8A 3. Non-Continuous, Non-Motor Load 110.0A Total 539.2A (Round down to 500A) Choose 500 ampere dual-element fuse.

MOTOR CONTROL CIRCUIT CONDUCTORS Control Circuits Tapped on Load-Side of Branch Circuit Fuse (430-72b) 1. Control circuit conductors #18 and larger shall be protected against overcurrent in accordance with Table 430-72b, Column A, as applicable.
MOTOR BRANCH CIRCUIT OVERCURRENT DEVICE

M
Conductors #18 and larger refer, to Column A of Table 430-72(b). CONTROL CIRCUIT

110

Contents

Index

Next

Previous

Motor Control Circuit Protection

Exception No. 1 Control conductors not extending beyond the enclosure shall be considered protected by the branch circuit fuse if in accordance with Table 430-72(b), Column B.
CONTROL ENCLOSURE

Exception No. 4 Control conductors are permitted to be protected by the motor branch circuit overcurrent device where the opening of the control circuit would create a hazard. REMOTE MOTOR CONTROL CIRCUITS (Section 725-12) CLASS 1 CIRCUITS; Voltage Does Not Exceed 600 Volts (725-11b) 1. Control circuit conductors #14 and larger shall be protected from overcurrent in accordance with Section 310-15.
POWER SOURCE CONTROL CIRCUIT FUSE For conductors #14 and larger, refer to Tables 310-16 thru 310-19, without derating factors. Control Circuit

MOTOR BRANCH CIRCUIT FUSE OVERCURRENT DEVICE

CONTROL CONDUCTORS DO NOT EXTEND BEYOND ENCLOSURE

Exception No. 2 For control conductors extending beyond the enclosure, the motor branch circuit overcurrent device shall be considered to protect the conductors if in accordance with Table 430-72(b), Column C.
CONTROL ENCLOSURE MOTOR BRANCH CIRCUIT OVERCURRENT DEVICE Control Circuit

2. Control circuit conductors #18 and #16, shall be protected by a control circuit fuse not to exceed 7 and 10 amperes respectively.
POWER SOURCE CONTROL CIRCUIT FUSE 7 OR 10 AMP; MAX. RESPECTIVELY #18, #16 Control Circuit

Table 430-72(b). Maximum Rating of Overcurrent Protective Device-Amperes

Column A Basic Rule Control Circuit Conductor Size, AWG Alum. or CopperClad Alum. Column B Exception No. 1 Alum. or CopperClad Copper Alum. Column C Exception No. 2 Alum. or CopperClad Copper Alum.

Copper

18 7 25 7 16 10 40 10 14 Note 1 100 45 12 Note 1 Note 1 120 100 60 45 10 Note 1 Note 1 160 140 90 75 larger than Note 1 Note 1 Note 2 Note 2 Note 3 Note 3 10 Note 1: Value specified in Section 310-15, as applicable. Note 2: 400 percent of value specified in Table 310-17 for 60C conductors. Note 3: 300 percent of value specified in Table 310-16 for 60C conductors.

Exception No. 2 Relative to Transformer Protection Refer to Exception 3, (430-72b), covered in preceding paragraphs. Motor Control Circuit Transformers [430-72(c)] Control circuit transformers (600V or less) shall be protected as shown previously in Exception No. 3 under 430-72(b). Exception No. 1 Control circuit transformers rated less than 50VA can be protected by a primary fuse, impedance limiting means, or other inherent means. The transformer must be an integral part of the motor controller, and be located within the controller. Exception No. 2 Allows transformers with primary currents less than 2 amps to be protected with primary fuses at 500% or less of primary full-load amps. Exception No. 3 Allows the control transformer to be protected by the motor branch circuit overcurrent device when the transformer supplies a Class 1 power-limited, circuit [see Section 725-11(a)] Class 2, or Class 3 remote control circuit conforming with the requirements of Article 725 (see Article 725, Part C). Exception No. 4 Allows the control transformer to be protected by the motor branch circuit overcurrent device where protection is provided by other approved means. Exception No. 5 States that overcurrent protection shall be omitted where the opening of the control circuit would create a hazard, as for example, the control circuit of a fire pump motor and the like.

Exception No. 3 Secondary conductors of a single-phase transformer having only a 2-wire secondary are protected by the primary fuse (600 volts or less) if the primary fuse rating is: 1. Not larger than that determined in Table 430-72(b), multiplied by secondary-to-primary voltage ratio and, 2. not more than the following percent of transformer rated primary current:

MOTOR BRANCH CIRCUIT FUSE CONTROL TRANSFORMER

Transformer Primary Current Less than 2 amps 2 to 9 amps 9 amps or more

Primary Fuse Ampacity Must Not Exceed 500% 167% 125%*

* If 125% of rated primary current does

not correspond to a standard fuse rating, then the next higher standard fuse rating is permitted.

Secondary Conductors Protected by 2-Wire Primary Secondary Circuit Control Circuit

111

Contents

Index

Next

Previous

Motor Control Circuit Protection

The following Selection Guide Tables simplify and permit easy application of fuses for the protection of the motor control circuits in accordance within the 1996 National Electrical Code. Apply fuses per Table 1 for control circuit without a control transformer (see Circuit Diagrams 1 and 2). Apply fuses per Table 2 for a control circuit with a control transformer (see Circuit Diagrams 3 and 4). Control Circuit Without Control Transformer (See Table 1)
BCPD (Branch Circuit Protective Device) Copper Control Conductor Remaining Within Enclosure A B BCPD (Branch Circuit Protective Device)

Table 1. Fuse Selection GuideControl Circuit Without Control Transformer (See Circuit Diagrams 1 & 2)
Ampere Rating Circuit 1 Circuit 2 (Control Conductor Not (Control Conductor of Branch Circuit Extending Beyond Extending Beyond Protective Enclosure) Enclosure) Device #18 #16 #14 #12 #18 #16 #14 (BCPD) Wire Wire Wire Wire Wire Wire Wire Fuse Size 7A 10A 15A 20A 7A 10A 15A Requirements For Control Circuit Protection (See footnote data) 7 7 10 12 25 30 40 45 50 60 65 100 110 125 up

Copper Control Conductor Extending Beyond Enclosure

#12 Wire 20A

Circuit 1

Circuit 2

Control Circuit With Control Transformer (See Table 2)

BCPD (Branch Circuit Protective Device) C C Copper Control Conductor Remaining Within Enclosure D C C BCPD (Branch Circuit Protective Device) E Copper Control Conductor Extending Beyond Enclosure

Control circuit fuse protection required. Protection recommended but not mandatory when BCPD is a Class CC, G, J, R, or T fuse. Protection is mandatory when BCPD is a thermal magnetic or a magnetic-only circuit breaker (MCP), and available short-circuit current exceeds the values in the table below.

Circuit 3

Circuit 4

Control Circuit Conductor (AWG Copper) #18 #16 #14 #12

Available Short-Circuit Current At Branch Circuit Protective Device (BCPD) 1 Cycle Clearing Time 660A 1050A 1700A 2700A Cycle Clearing Time 940A 1500A 2400A 3800A

*Thermoplastic Insulation.

Based on ICEA Conductor Withstand Data.

Table 2. Fuse Selection GuideControl Circuit With Control Transformer (See Circuit Diagrams 3 and 4)
Control Xfmr Rating Vpri/Vsec (Volts) Ipri (Amps) Isec (Amps) Fuse C Reqd. If BCPD Exceeds These Amps Values
1 2

Maximum Amps

4,5

Fuse D or E Required if BCPD and Fuse C (When Provided) Exceed These Amp Values #18 #16 #14 Wire Wire Wire

Recommended Amps #12 Wire Time Delay1 Non-Time Delay 3

25 VA

50 VA

100 VA

150 VA

200 VA

480/120 480/24 240/120 240/24 480/120 480/24 240/120 240/24 480/120 480/24 240/120 240/24 480/120 480/24 240/120 240/24 480/120 480/24 240/120 240/24

0.05 0.05 0.10 0.10 0.10 0.10 0.21 0.21 0.21 0.21 0.42 0.42 0.31 0.31 0.62 0.62 0.42 0.42 0.84 0.84

0.21 1.00 0.21 1.00 0.42 2.10 0.42 2.10 0.83 4.20 0.83 4.20 1.25 6.25 1.25 6.25 1.67 8.33 1.67 8.33

6 See 430-72(c) Except. 1

0.5 0.5 1.0 1.0 1.0 1.0 2.0 2.0 1.5 1.5 3.0 3.0 2.0 2.0 4.0 4.0

0.25 0.25 0.50 0.50 0.50 0.50 1.0 1.0 1.0 1.0 2.0 2.0 1.5 1.5 3.0 3.0 2.0 2.0 4.0 4.0

0.25 0.25 0.25 0.25 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 1.0 1.0 1.0 1.0 1.0 1.0 1.0/.359 1.0/.509 2.0 2.0 2.0/.709 2.0/1.09 1.5 1.5 1.5/0.59 3.0 3.0 3.0/1.09 2.0/1.759 2.0 4.0/3.59 2.0

0.25 0.25 0.50 0.50 0.50 0.50 1.0 1.0 1.0 1.0 2.0 2.0 1.5 1.5 3.0 3.0 2.0 2.0 4.0 4.0

0.25 0.25 0.50 0.50 0.50 0.50 1.0 1.0 1.0 1.0 2.0 2.0 1.5 1.5 3.0 3.0 2.0 2.0 4.0 4.0

0.25 1.25 0.25 1.25 0.50 2.5 0.50 2.5 1.0 5.0 1.0 5.0 1.50 7.50 1.50 7.50 2.0 10.0 2.0 10.0

0.60 3.0 0.60 3.0 1.0 6.0 1.0 6.0 2.0 12.07 2.0 12.07 3.50 15.07 3.50 15.07 5.0 20.08 5.0 20.08

Time-Delay Fuses: FNQ, FNW, FNM, FNASupplementary Type; FNQ-R, FRN-R, FRS-R, LPN-RK_SP, LPS-RK_SP, LPJ_SP, LP-CC, SC6 & aboveBranch Circuit Fuses (Rejection Type). For exceptions, see 430-72(c), Exceptions 3, 4, & 5. Non-Time-Delay Fuses: KTK, BAN, BAF, MIN, MICSupplementary Fuses; KTK-R, JJN, JJS, SC-5Branch Circuit Fuses (Rejection Types). 4 These are maximum values as allowed by 430-72(c), Exception 2. Closer sizing at 125%-300% may be possible for better overload protection using time-delay branch circuit fuses. 5 Fuse shall be a rejection type branch circuit fuse when withstand rating of controller is greater than 10,000 amps RMS symmetrical 6 These transformers less than 50VA still need protectioneither primary overcurrent protection, inherent protection, or the equivalent. Note that the primary conductors may be protected as shown in Circuit 1 Table 1. 7 Minimum copper secondary control conductor for this application is #14. 8 Minimum copper secondary control conductor for this application is #12. 9 Smaller value applied to Fuse "E".
2 3

112

Contents

Index

Next

Previous

Motor Control Circuit Protection

Supplementary Fuses (13/ 32 11/ 2) DuaI-Element, Time-Delay Time-Delay Non-Time-Delay

FNA
/ 10-8/ 10A 250V 1-15A 125V* 20-30A 32V**
1

FNM
1

FNQ
1

FNW
12-30A 250V

BAF
1

BAN
2

KTK
1

MIC
1-15A 250V 20-30A 32V**

MIN
1-15A 250V 20-30A 32V**

/ 10-10A 250V 12-15A 125V* 20-30A 32V**

/ 10-30A 500V 10K AIR (FNQ-3 Dual-Element)

/ 2-15A 250V 20-30A 125V*

/ 10-30A 250V

/ 10-30A 600V 100K AIR

Branch Circuit Fuses Class R Dual-Element, Time-Delay

Class G

Class CC Fast-Acting, Time-Delay

LPN-RK_SP
1

FRN-R
/ 10-30A 250V 200K AIR
1

FRS-R
/ 10-30A 600V 200K AIR
1

LPS-RK_SP SC
/ 10-30A 600V 300K AIR
1

KTK-R
/ 10-30A 600V 200K AIR
1

FNQ-R
/ 4-30A 600V 200K AIR
1

LP-CC
/ 2-30A 600V 200K AIR
1

/ 10-30A 250V 300K AIR

/ 2-20A 300V 100K AIR

1

0 to 1 amp35 AIR; 1.1 to 3.5 amp100 AIR; 3.6 to 10 amp200 AIR; 10.1 1/ 2 thru 6 ampere fuses are Non-Time-Delay Type; 8 thru 60 ampere fuses

to 15 amp750 AIR; 15.1 to 30 amps1500AIR *10K AIR. **1K AIR. are Time-Delay Type.

Catalog Number Designations for Fuseblocks.

Ampere Rating 1 FRN-R /10-30A 1 LPN-RK_SP /10-30A 1 FRS-R /10-30A 1 LPS-RK_SP /10-30A Branch Circuit 20A SC 1 /2-15A 1 KTK-R /10-30A 1 FNQ-R /10-30A 1 LP-CC /2-30A *Numbers reflect Catalog Number change only. Fuse Supplementary Single Pole Current* BM6031SQ R25030-1SR R25030-1SR R60030-1SR R60030-1SR BG3011SQ BG3021SQ BC6031S Old 2807 1BR001 1BR001 1BR024 1BR024 2961 2962 2078 Double Pole Current* BM6032SQ R25030-2SR R25030-2SR R60030-2SR R60030-2SR BG3022SQ BG3022SQ BC6032S Old 2808 1BR002 1BR002 1BR025 1BR025 2917 2918 2079

113

Contents

Index

Next

Previous

Fuse Diagnostic Chart

Primary Protection Only Supervised Installations Primary and Secondary Protection Over 600V Nominal

Primary at code max. of 250% or next standard size if 250% does not correspond to a standard rating. Transformer Impedance Less Than or Equal to 6%. Transformer Impedance Greater Than 6% But Less Than 10%. Primary at code max. of 300%

(Note: Components on the secondary still need overcurrent protection.) Secondary at code max. of 250%. Secondary at code max. of 250%. Secondary at code max. of 225%. Secondary at code max. of 250%. Secondary at code max. of 250% or next standard size if 250% does not correspond to a standard rating. Secondary at code max. of 125% or next standard size if 125% does not correspond to a standard rating. Secondary at code max. of 225% or next standard size if 225% does not correspond to a standard rating. Secondary at code max. of 125% or next standard size if 125% does not correspond to a standard rating. Fuse 250V LPN-RK_SP, FRN-R 600V LPS-RK_SP, LPJ_SP, KRP-C_SP, FNQ-R, FRS-R 2475V JCD 2750V JCX 2750/5500V JCW 5500V JCE, JCQ, JCY, JCU, 5.5 ABWNA, 5.5 AMWNA, 5.5 FFN 7200V 7.2 ABWNA, 7.2 SDLSJ, 7.2 SFLSJ 8300V JCZ, JDZ, 8.25 FFN 15500V JCN, JDN, JDM, 15.5 CAVH 17500V 17.5 CAV, 17.5 SDM 24000V 24 SDM, 24 SFM, 24 FFM 36000V 36 CAV, 36 SDQ, 36 SFQ 38000V 38 CAV

Secondary Over 600V Secondary 600V or Below Secondary Over 600V Secondary 600V or Below

Primary at code max. of 300%

Secondary Over 600V Un-Supervised Installations Transformer Impedance Less Than or Equal to 6%. Primary at code max. of 300% or next standard size if 300% does not correspond to a standard rating.

Secondary 600V or Below

Secondary Over 600V Transformer Impedance Greater Than 6% But Less Than 10%. Primary at code max. of 300% or next standard size if 300% does not correspond to a standard rating.

Transformers (N.E.C. 450-3)

Secondary 600V or Below

114
Primary Protection Only (Note: Components on the secondary still need overcurrent protection.) Rated primary current less than 2 amps. Rated primary current greater than or equal to 2 amps but less than 9 amps. Rated primary current greater than or equal to 9 amps. 600V Nominal or Less Without Thermal Overload Protection Primary and Secondary Protection With Thermal Overload Protection Transformer Impedance of 6% or less Rated secondary current less than 9 amps. Rated secondary current 9 amps or greater. Rated secondary current less than 9 amps. Rated secondary current 9 amps or greater. Rated secondary current less than 9 amps. Rated secondary current 9 amps or greater. A B C D E F Transformer Impedance of more than 6% but less than 10%
Based on 1996 N.E.C.

OPTIMUM PROTECTION
(LPN-RK_SP, LPS-RK_SP, FRN-R, FRS-R)

N.E.C. MAXIMUMS (All Fuse Types Shown) Max. 300% or next size smaller. (See N.E.C. 430-72(c) for control circuit transformer maximum of 500%. Max. 167% or next size smaller. Max. of 125% or next larger*. A B C Maximum Fuse Size % of Primary % of Secondary F.L.A. (Or next F.L.A. size smaller.) A B C D E F 250% 250% 600% 600% 400% 400% 167% or next size smaller. 125% or next size larger.* 167% or next size smaller. 125% or next size larger.* 167% or next size smaller. 125% or next size larger.* Fuse 250V LPN-RK_SP, FRN-R 600V KRP-C_SP, LPJ_SP, LPS-RKSP, FNQ-R, FRS-R

125% or next size larger 125% or next size larger 125% or next size larger

Primary and secondary fuses at 125% of primary and secondary F.L.A. or next size larger.

D E F

*When 125% of F.L.A. corresponds to a standard rating, the next larger size is not permitted.

Contents

Index

Next

Previous

Fuse Diagnostic Chart

Above 600V FUSE SIZED FOR: Motor Loads (N.E.C. 430) Protected by Time-Delay Fuses Backup Overload w/ Motor Starter & Short-Circuit Protection Short-Circuit Only Protected by NonTime-Delay Fuses & all Class CC Fuses Short-Circuit Only

Compare the min. melting time-current characteristics of the fuses with the time-current characteristics of the overload relay curve. The size fuse which is selected should be such that short-circuit protection is provided by the fuse and overload protection is provided by the controller overload relays.
125% of motor F.L.A. or next size larger.

Fuse 2400V JCK, JCK-A, JCH 4800V JCL, JCL-A, JCG 7200V JCR, 7.2 WKMSJ

0-250V, FRN-R 251-600V, FRS-R 0-250V LPN-RK_SP, FRN-R 251-600V LPS-RK_SP, FRS-R 0-250V, LPN-RK_SP 251-600V, LPS-RK_SP

125% of motor F.L.A. or next size larger.

130% of motor F.L.A. or next size larger.

600V & Less

175%* of motor F.L.A. or next size larger. If this will not allow motor to start, due to higher than normal inrush currents or longer than normal acceleration times (5 sec. or greater), fuse may be sized up to 225% or next size smaller. Max. of 300%* of motor F.L.A. or next size larger. If this will not allow motor to start due to higher than normal inrush currents or longer than normal acceleration times (5 sec. or greater), fuses through 600 amps may be sized up to 400% or next size smaller. *150% for wound rotor and all DC motors.

0-250V LPN-RK_SP, FRN-R 251-600V LPS-RK_SP, FRS-R 0-600V LPJ_SP 0-250V KTN-R, NON 0-300V JJN 251-600V KTS-R, NOS 301-600V JJS 0-600V LP-CC, LPT, JKS, KTK-R

No Motor Load Feeder Circuits (600 Amps & Less) Mains Feeders Branches Combination Motor Loads and other Loads Motor Loads Main, Branch & Feeder Circuits (601-6000 Amps)

100% of non-continuous load plus 125% of continuous load. 150%* of the F.L.A. of largest motor (if there are two or more motors of same size, one is considered to be the largest) plus the sum of all the F.L.A. for all other motors plus 100% of non-continuous, non-motor load plus 125% of continuous, non-motor load. *A max. of 175% (or the next standard size if 175% does not correspond to a standard size) is allowed for all but wound rotor and all D.C. motors. 150%* of the F.L.A. of largest motor (if there are two or more motors of same size, one is considered to be the largest) plus the sum of all the F.L.A. for all other motors. *A max. of 175% (or the next standard size if 175% does not correspond to a standard size) is allowed for all but wound rotor and all D.C. motors. 150% to 225% of full load current of largest motor plus 100% of full load current of all other motors plus 125% of continuous non-motor load plus 100% of non-continuous non-motor load.

0-250V LPN-RK_SP, FRN-R 0-300V JJN 251-600V LPS-RK_SP, FRS-R 301-600V JJS 0-600V JKS, LPJ_SP, KTK-R, LP-CC, LPT 0-250V LPN-RK_SP, FRN-R 251-600V LPS-RK_SP, FRS-R 0-600V LPJ_ SP, LP-CC

115
Solid State Devices (Diodes, SCR-s, Triacs, Transistors) Solenoids (Coils)

0-600V KRP-C_SP 0-130V FWA 0-250V FWX 0-500V FWH 0-600V FWC, KAC, KBC 0-700V FWP, 170M Series, SPP 0-1000V FWJ, 170M Series, SPJ

Short-Circuit Protection Only

F, S, K & 170M Series fuses sized up to several sizes larger than full load RMS or DC rating of device.

Branch Circuit Fuses

0-250V LPN-RK_SP, FRN-R Size at 125% or next size smaller. 251-600V LPS-RK_SP, FRS-R 0-600V LPJ_SP, LP-CC 0-32V MDL 9-30, FNM 20-30 0-125V MDA 25-30, FNM 12-15

Supplementary Fuses Based on 1996 N.E.C.

0-250V MDL -8, MDA -20, FNM -10, FNW 12-30, MDQ -7 Size at 125% or next size larger. 0-500 FNQ -30

Contents

Index

Next

Previous

Fuse Diagnostic Chart

Electric Space Heating Electric Heat (N.E.C. 424)

Size at 125% or next size larger but in no case larger than 60 amperes for each subdivided load.

Electric Boilers with Resistance Type Immersion Heating Elements in an ASME Rated and Stamped Vessel.

Size at 125% or next size larger but in no case larger than 150 amperes for each subdivided load. Fuse Fluorescent Consult fixture manufacturer for size and type. GLR GMF GRF BAF BAN KTK FNM FNQ FNW BAF BAN KTK FNM FNQ FNW Holder Fuse GLQ GMQ KTK-R FNQ-R LP-CC KTQ BBS Holder

Fuse 0-250V LPN-RK_SP, FRN-R, NON 0-300V JJN 0-480V SC 251-600V LPS-RK_SP, FRS-R, NOS 301-600V JJS 0-600V LPJ_SP, LP-CC, FNQ-R, JKS, KTK-R Fuse Holder

HLR

HLQ

Indoor All Other (Mercury, Sodium, etc.) Ballasts Consult fixture manufacturer for size and type.

HPF HPS

HPS-RR HPF-RR HPS-L HPF-L

HPF-EE HPS-EE HPF-JJ SC 20 HPS-JJ HPF-FF SC 25-30 HPS-FF SC 0-15

Outdoor

Mercury, Sodium, etc.

Consult fixture manufacturer for size and type.

HEB HEX HPC-D

KTK-R FNQ-R LP-CC

HEY

On load side of motor running overcurrent device

Protection recommended as shown below, but not required

116

Capacitors (N.E.C. 460)

Protected by Time-Delay Fuses Protected by Non-Time-Delay Fuses

150% to 175% of full load current

Fuse 0-250V LPN-RK_SP, FRN-R 251-600V LPS-RK_SP, FRS-R 0-600V FNQ-R, LPJ_SP, LP-CC 0-250V KTN-R, NON 0-300V JJN 251-600V KTS-R, NOS 0-600V JKS, KTK-R 301-600V JJS

250% to 300% of full load current

Based on 1996 N.E.C.

Contents

Index

Next

Previous

Main, Feeder, and Branch Circuit Fuse Sizing

Guide For Sizing Fuses General guidelines are given for selecting fuse ampere ratings for most circuits. Some specific applications may warrant other fuse sizing; in these cases the load characteristics and appropriate NEC sections should be considered. The selections shown here are not, in all cases, the maximum or minimum ampere ratings permitted by the NEC. Demand factors as permitted per the NEC are not included in these guidelines.
Fuse Recommendations 601 to 6000A LOW-PEAK YELLOWTM Time-Delay Fuse KRP-C_SP 1/10 to 600A LOW-PEAK YELLOWTM Dual-Element, Time-Delay Fuses LPN-RK_SP(250V); LPS-RK_SP(600V) or LPJ_SP (600V) FUSETRON Dual-Element Fuses FRN-R (250V); FRS-R (600V) 7. Motor Branch Circuit With Fuse Protection Only. Where the fuse is the only motor protection, the following Class RK5 fuses provide motor running overload protection and short-circuit protection: a. Motor 1.15 service factor or 40C rise: size the fuse at 110% to 125% of the motor full-load current. b. Motor less than 1.15 service factor or over 40C rise: size fuse at 100% to 115% of motor full-load current. 8. Large Motor Branch Circuit. Fuse larger than 600 amps. For large motors, size KRP-C_SP LOW-PEAK YELLOW time-delay fuse at 175% to 225% of the motor full-load current, depending on the starting method; i.e. part-winding starting, reduced voltage starting, etc. 9. Power Factor Correction Capacitors. Size dual-element fuses as low as practical, typically 150% to 175% of capacitor rated current. 10. Transformer Primary Fuse (without secondary fuse protection). When transformer primary current is equal to or greater than 9 amperes, the dualelement, time-delay fuse should be sized at 125% of transformer primary current or the next size larger. Note: Secondary conductors must be protected from overcurrent damage. 11. Transformer Primary Fuse (with secondary fuse protection). May be sized at 250% of transformer primary current if, 12. The secondary fuse is sized at no more than 125% of secondary fullload current. Note: Secondary conductors must be protected at their ampacities.

10

Fuse Greater Than 2 600 Amps Motor Starter OverLoads Relays

Feeder With No Motor Load

Feeder With All Motor Load

Feeder With Combination Motor And Non Motor Load

11

NON-TIME-DELAY AND ALL CLASS CC FUSES (JKS, KTS-R, KTN-R, JJS, JJN, LP-CC, KTK-R, AND FRQ-R)
1. Main service. Size fuse according to method in 4. 2. Feeder Circuit With No Motor Loads. The fuse size must be at least 125% of the continuous load plus 100% of the non-continuous load. Do not size larger than the ampacity of the wire. 3. Feeder Circuit With All Motor Loads. Size the fuse at 300% of the fullload current of the largest motor plus the full-load current of all other motors. Do not size fuse larger than the conductor capacity. 4. Feeder Circuit With Mixed Loads. Size fuse at sum of: a. 300% of the full-load current of the largest motor plus b. 100% of the full-load current of all other motors plus c. 125% of the continuous, non-motor load plus d. 100% of the non-continuous, non-motor load. 5. Branch Circuit With No Motor Loads. The fuse size must be at least 125% of the continuous load plus 100% of the non-continuous load. Do not size larger than the ampacity of conductor.* 6. Motor Branch Circuit With Overload Relays. Size the fuse as close to but not exceeding 300% of the motor running full load current. Provides ground fault and short-circuit protection only. 7. Motor Branch Circuit With Fuse Protection Only. Non-time-delay fuses cannot be sized close enough to provide motor running overload protection. If sized for motor overload protection, non-time-delay fuses would open due to motor starting current. Use dual-element fuses.

M Large Motor

12

CONDUCTOR AMPACITY SELECTION

1. Feeder Circuit And Main Circuit With Mixed Loads. Conductor ampacity at least sum of: a. 125% of continuous non-motor load plus b. 100% of non-continuous non-motor load plus c. 125% of the largest motor full-load current plus d. 100% of all other motors' full-load current. 2. Feeder Circuit With No Motor Load. Conductor ampacity at least 125% of the continuous load plus 100% of the non-continuous load. 3. Feeder Circuit With All Motor Loads. Conductor ampacity at least 125% of the largest motor full-load amperes plus 100% of all other motors full-load amperes. 4. Feeder Circuit With Mixed Loads. Size according to method 1 above. 5. Branch Circuit With No Motor Load. Conductor ampacity at least 125% of the continuous load plus 100% of the non-continuous load. 6, 7, & 8. Motor Branch Circuits. Conductor ampacity at least 125% of the motor full-load current. 9. Conductor ampacity at least 135% of capacitor rated current. The ampacity of conductors for a capacitor connected to a motor circuit must be 1 / 3 the ampacity of the motor circuit conductors. 10, 11. Conductor ampacity minimum 125% of transformer full-load current. 12. Conductor ampacity per 1 above.
100% of the continuous load can be used rather than 125% when the switch and fuse are listed for continuous operation. Most bolted pressure switches and high pressure contact switches 400A to 6000A with Class L fuses are listed for 100% continuous operation. * Where conductor ampacity does not correspond to a standard fuse rating, next higher rating fuse is permitted when 800 amperes or less (240-3. Exc. 1). In many motor feeder applications dual-element fuses can be sized at ampacity of feeder conductors. Available short-circuit current and the clearing time of the overcurrent device must be considered so that the conductors ICEA (P32-382) withstand rating is not exceeded. NEC allows a maximum of 175% or the next standard size if 175% does not correspond with a standard fuse size, for all but wound rotor and DC motors.

9 Continuous Non Loads Continuous Lighting Loads Heating

M
Continuous Loads

Power Factor Correction Capacitor

DUAL-ELEMENT, TIME-DELAY FUSES (LPJ_SP, LPS-RK_SP, LPN-RK_SP, FRS-R, AND FRN-R)

1. Main Service. Size fuse according to method in 4. 2. Feeder Circuit With No Motor Loads. The fuse size must be at least 125% of the continuous load plus 100% of the non-continuous load. Do not size larger than ampacity of conductor*. 3. Feeder Circuit With All Motor Loads. Size the fuse at 150% of the full load current of the largest motor plus the full-load current of all other motors. 4. Feeder Circuit With Mixed Loads. Size fuse at sum of: a. 150% of the full-load current of the largest motor plus b. 100% of the full-load current of all other motors plus c. 125% of the continuous, non-motor load plus d. 100% of the non-continuous, non-motor load. 5. Branch Circuit With No Motor Load. The fuse size must be at least 125% of the continuous load plus 100% of the non-continuous load. Do not size larger than ampacity of conductor*. 6. Motor Branch Circuit With Overload Relays. Where overload relays are sized for motor running overload protection, the following provide backup, ground fault, and short-circuit protection: a. Size RK5 & RK1 fuses at 125% & 130% of motor full-load current respectively or next higher size.

117

Contents

Index

Next

Previous

Suggested Fuse Specification

General Fuses shall not be installed until equipment is ready to be energized. This measure prevents fuse damage during shipment of the equipment from the manufacturer to the job site, or from water that may contact the fuse before the equipment is installed. Final tests and inspections shall be made prior to energizing the equipment. This shall include a thorough cleaning, tightening, and review of all electrical connections and inspection of all grounding conductors. All fuses shall be furnished and installed by the electrical contractor. All fuses shall be of the same manufacturer. Fuses shall be as follows: A. Main, Feeder, and Branch Circuit Fuses 1. Circuits 601 through 6000 amperes Circuits 601 through 6000 amperes shall be protected by current-limiting BUSSMANN LOW-PEAK YELLOW Time-Delay Fuses KRP-C(amp)SP. Fuses shall employ O rings as positive seals between the end bells and the glass melamine fuse barrel. Fuse links shall be pure silver (99.9% pure) in order to limit the short-circuit current let-through values to low levels and comply with NEC Sections requiring component protection. Fuses shall be time-delay and shall hold 500% of rated current for a minimum of 4 seconds, clear 20 times rated current in .01 seconds or less, with an interrupting rating of 300,000 amperes RMS symmetrical, and be listed by a nationally recognized testing laboratory. Peak letthrough currents and I2t let-through energies shall not exceed the values established for Class L fuses. Larger HP motors shall be protected by these fuses, with ratings as shown on the drawings. 2. Circuits 0 through 600 amperes Circuits 0 through 600 amperes shall be protected by currentlimiting BUSSMANN LOW-PEAK YELLOW Dual-Element, Time-Delay Fuses LPN-RK(amp)SP/LPS-RK(amp)SP or LPJ(amp)SP. All fuses shall have separate overload and short-circuit elements. Fuses shall incorporate a spring activated thermal overload element that has a 284 degrees Fahrenheit melting point alloy. The fuses shall hold 500% of rated current for a minimum of 10 seconds (30A, 250V Class RK1 case size may be a minimum of 8 seconds at 500% of rated current) with an interrupting rating of 300,000 amperes RMS symmetrical, and be listed by a nationally recognized testing laboratory. Peak let-through currents and I2t letthrough energies shall not exceed the values established for Class RK1 or J fuses. Motor Circuits - All individual motor circuits with full-load ampere ratings (F.L.A.) of 461 (or 400) amperes or less shall be protected by BUSSMANN LOW-PEAK YELLOW Dual-Element, Time-Delay Fuses LPN-RK(amp)SP/LPS-RK(amp)SP or LPJ(amp)SP. The following guidelines apply for motors protected by properly sized overload relays: LPN-RK(amp)SP/LPS-RK(amp)SP fuses shall be installed in ratings of 130% [or 150% for LPJ(amp)SP fuses] of motor full-load current (or next size larger if this does not correspond to a fuse size), except where high ambient temperatures prevail, or where the motor drives a heavy revolving part which cannot be brought up to full speed quickly, such as large fans. Under such conditions the fuse may be 175%* of the motor full-load current, or the next standard size larger if 175%* does not correspond to a standard fuse size. If this will not allow the motor to start due to higher than normal inrush currents or longer than normal acceleration times (5 seconds or greater), fuses may be sized up to 225% (or next size smaller). Motor Controllers - NEMA and IEC Style motor controllers shall be protected from short-circuits by BUSSMANN LOW-PEAK YELLOW Dual-Element, Time-Delay Fuses in order to provide testing agency-witnessed Type 2 coordination for the controller. This provides no damage protection for the controller, under low and high level fault conditions, as required by IEC Publication 947-4 and U.L. 508E.
*150% for wound rotor and all DC motors.

3. Switchboards, Panelboards, Load Centers The manufacturer shall supply equipment utilizing fully rated and listed components. This equipment shall be tested, listed and labeled for the available short-circuit current. (Where series-rated fuse/circuit breaker systems are acceptable, the systems shall utilize tested, recognized components. The manufacturer shall supply switchboards, panelboards and load centers which have been tested, listed, and labeled for the available shortcircuit current, and those combinations specified on the drawings.) 4. Marking Fuses shall be LOW-PEAK YELLOW in color. LOWPEAK YELLOW NOTICE labels to alert the end user of the engineered level of protection of the electrical equipment shall be field installed by the electrical contractor. They shall be marked with the proper fuse rating, per the specifications, and placed in a conspicuous location on the enclosure. These labels are available upon request from Bussmann. B. Supplementary - Light Fixture Protective Fuses 1. Fluorescent fixtures shall be protected by BUSSMANN GLR or GMF Fuses in HLR Holders. These fixtures shall have individual protection on the line side of the ballast. A fuse and holder shall be mounted within, or as part of, the fixture. Size and type of fuse to be recommended by the fixture manufacturer. 2. All other ballast-controlled light fixtures shall be protected by BUSSMANN KTK or FNQ Fuses in HEB, HPF, or HPS Holders. These fixtures shall have individual protection on the line side of the ballast. Fuse and holder shall be mounted in a location convenient for changing fuses. Holder shall be mounted in protected location or be an in-line waterproof holder (HEB, HEX, or HEY). Size and type of fuse to be recommended by the fixture manufacturer or as indicated on plans. C. Spares Upon completion of the building, the electrical contractor shall provide the owner with spare fuses as shown below: 1. 10% (minimum of 3) of each type and rating of installed fuses shall be supplied as spares. 2. BUSSMANN spare fuse cabinets - Catalog No. SFC - shall be provided to store the above spares. A supply of LOW-PEAK YELLOW NOTICE Labels shall be provided along with the spare fuses in the spare fuse cabinet. D. Substitution Approvals The electrical contractors proposal shall be based upon the fuses specified, using the manufacturers catalog numbers as called for in the specification or on the drawings. Coordination and current limitation requirements for protection of each part of the electrical system have been engineered on the basis of the type, class and manufacturer specified. In the event that the electrical contractor wishes to furnish materials other than those specified, a written request, along with a complete short-circuit and selective coordination study, shall be submitted to the engineer for evaluation at least two weeks prior to bid date. If the engineers evaluation indicates acceptance, a written addendum will be issued listing the other acceptable manufacturer.

118

Contents

Index

Next

Previous

Glossary of Terms
Ampere The measurement of intensity of rate of flow of electrons in an electric circuit. An ampere is the amount of current that will flow through a resistance of one ohm under a pressure of one volt. Ampere Rating The current-carrying capacity of a fuse. When a fuse is subjected to a current above its ampere rating, it will open the circuit after a predetermined period of time. Ampere Squared Seconds, l2t The measure of heat energy developed within a circuit during the fuses clearing. It can be expressed as Melting l2t, Arcing l2t or the sum of them as Clearing l2t. l stands for effective let-through current (RMS), which is squared, and t stands for time of opening, in seconds. Arcing Time The amount of time from the instant the fuse link has melted until the overcurrent is interrupted, or cleared. Breaking Capacity (See Interrupting Rating) Cartridge Fuse A fuse consisting of a current responsive element inside a fuse tube with terminals on both ends. Class CC Fuses 600V, 200,000 ampere interrupting rating, branch circuit fuses with overall dimensions of 1. Their design incorporates a rejection feature that allows them to be inserted into rejection fuse holders and fuse blocks that reject all lower voltage, lower interrupting rating 1 fuses. They are available from amp through 30 amps. Class G Fuses 480V, 100,000 ampere interrupting rating branch circuit fuses that are size rejecting to eliminate overfusing. The fuse diameter is while the length varies from 1 to 2. These are available in ratings from 1 amp through 60 amps. Class H Fuses 250V and 600V, 10,000 ampere interrupting rating branch circuit fuses that may be renewable or non-renewable. These are available in ampere ratings of 1 amp through 600 amps. Class J Fuses These fuses are rated to interrupt a minimum of 200,000 amperes AC. They are labelled as Current-Limiting, are rated for 600 volts AC, and are not interchangeable with other classes. Class K Fuses These are fuses listed as K-1, K-5, or K-9 fuses. Each subclass has designated I2t and lp maximums. These are dimensionally the same as Class H fuses, and they can have interrupting ratings of 50,000, 100,000, or 200,000 amps. These fuses are current-limiting. However, they are not marked current-limiting on their label since they do not have a rejection feature. Class L Fuses These fuses are rated for 601 through 6000 amperes, and are rated to interrupt a minimum of 200,000 amperes AC. They are labelled current-limiting and are rated for 600 volts AC. They are intended to be bolted into their mountings and are not normally used in clips. Some Class L fuses have designed in time-delay features for all purpose use. Class R Fuses These are high performance fuses rated - 600 amps in 250 volt and 600 volt ratings. All are marked current-limiting on their label and all have a minimum of 200,000 amp interrupting rating. They have identical outline dimensions with the Class H fuses but have a rejection feature which prevents the user from mounting a fuse of lesser capabilities (lower interrupting capacity) when used with special Class R Clips. Class R fuses will fit into either rejection or non-rejection clips. Class T Fuses An industry class of fuses in 300 volt and 600 volt ratings from 1 amp through 1200 amps. They are physically very small and can be applied where space is at a premium. They are fast-acting and time-lag fuses, with an interrupting rating of 200,000 amps RMS. Classes of Fuses The industry has developed basic physical specifications and electrical performance requirements for fuses with voltage ratings of 600 volts or less. These are known as standards. If a type of fuse meets the requirements of a standard, it can fall into that class. Typical classes are K, RK1, RK5, G, L, H, T, CC, and J. Clearing Time The total time between the beginning of the overcurrent and the final opening of the circuit at rated voltage by an overcurrent protective device. Clearing time is the total of the melting time and the arcing time. Current-Limitation A fuse operation relating to short-circuits only. When a fuse operates in its current-limiting range, it will clear a short-circuit in less than cycle. Also, it will limit the instantaneous peak let-through current to a value substantially less than that obtainable in the same circuit if that fuse were replaced with a solid conductor of equal impedance. Dual-Element Fuse Fuse with a special design that utilizes two individual elements in series inside the fuse tube. One element, the spring actuated trigger assembly, operates on overloads up to 5-6 times the fuse current rating. The other element, the short-circuit section, operates on short-circuits up to their interrupting rating. Electrical Load That part of the electrical system which actually uses the energy or does the work required. Fast Acting Fuse A fuse which opens on overload and short circuits very quickly. This type of fuse is not designed to withstand temporary overload currents associated with some electrical loads. Fuse An overcurrent protective device with a fusible link that operates and opens the circuit on an overcurrent condition. High Speed Fuses Fuses with no intentional time-delay in the overload range and designed to open as quickly as possible in the short-circuit range. These fuses are often used to protect solid-state devices. Inductive Load An electrical load which pulls a large amount of current an inrush current when first energized. After a few cycles or seconds the current settles down to the full-load running current. Interrupting Capacity See Interrupting Rating Interrupting Rating (Breaking Capacity) The rating which defines a fuses ability to safely interrupt and clear short-circuits. This rating is much greater than the ampere rating of a fuse. The NEC defines Interrupting Rating as The highest current at rated voltage that an overcurrent protective device is intended to interrupt under standard test conditions. Melting Time The amount of time required to melt the fuse link during a specified overcurrent. (See Arcing Time and Clearing Time.) NEC Dimensions These are dimensions once referenced in the National Electrical Code. They are common to Class H and K fuses and provide interchangeability between manufacturers for fuses and fusible equipment of given ampere and voltage ratings.

119

Contents

Index

Next

Previous

Glossary of Terms
Ohm The unit of measure for electric resistance. An ohm is the amount of resistance that will allow one ampere to flow under a pressure of one volt. Ohms Law The relationship between voltage, current, and resistance, expressed by the equation E = IR, where E is the voltage in volts, I is the current in amperes, and R is the resistance in ohms. One Time Fuses Generic term used to describe a Class H nonrenewable cartridge fuse, with a single element. Overcurrent A condition which exists on an electrical circuit when the normal load current is exceeded. Overcurrents take on two separate characteristics overloads and short-circuits. Overload Can be classified as an overcurrent which exceeds the normal full load current of a circuit. Also characteristic of this type of overcurrent is that it does not leave the normal current carrying path of the circuit that is, it flows from the source, through the conductors, through the load, back through the conductors, to the source again. Peak Let-Through Current, lp The instantaneous value of peak current let-through by a currentlimiting fuse, when it operates in its current-limiting range. Renewable Fuse (600V & below) A fuse in which the element, typically a zinc link, may be replaced after the fuse has opened, and then reused. Renewable fuses are made to Class H standards. Resistive Load An electrical load which is characteristic of not having any significant inrush current. When a resistive load is energized, the current rises instantly to its steady-state value, without first rising to a higher value. RMS Current The RMS (root-mean-square) value of any periodic current is equal to the value of the direct current which, flowing through a resistance, produces the same heating effect in the resistance as the periodic current does. Semiconductor Fuses Fuses used to protect solid-state devices. See High Speed Fuses. Short-Circuit Can be classified as an overcurrent which exceeds the normal full load current of a circuit by a factor many times (tens, hundreds or thousands greater). Also characteristic of this type of overcurrent is that it leaves the normal current carrying path of the circuit it takes a short cut around the load and back to the source. Short-Circuit Rating The maximum short-circuit current an electrical component can sustain without the occurrence of excessive damage when protected with an overcurrent protective device. Short-Circuit Withstand Rating Same definition as Short-Circuit Rating. Single-Phasing That condition which occurs when one phase of a three-phase system opens, either in a low voltage (secondary) or high voltage (primary) distribution system. Primary or secondary single-phasing can be caused by any number of events. This condition results in unbalanced currents in polyphase motors and unless protective measures are taken, causes overheating and failure. Threshold Current The symmetrical RMS available current at the threshold of the current-limiting range, where the fuse becomes current-limiting when tested to the industry standard. This value can be read off of a peak let-through chart where the fuse curve intersects the A-B line. A threshold ratio is the relationship of the threshold current to the fuses continuous current rating. Time-Delay Fuse A fuse with a built-in delay that allows temporary and harmless inrush currents to pass without opening, but is so designed to open on sustained overloads and short-circuits. Voltage Rating The maximum open circuit voltage in which a fuse can be used, yet safely interrupt an overcurrent. Exceeding the voltage rating of a fuse impairs its ability to clear an overload or short-circuit safely. Withstand Rating The maximum current that an unprotected electrical component can sustain for a specified period of time without the occurrence of extensive damage.

Useful Formulas
To Find Single-Phase Two-Phase Three-Phase Direct Current

Amperes when kVA is known Amperes when horsepower is known Amperes when kilowatts are known Kilowatts Kilovolt-Amperes Horsepower Watts

kVA 1000 kVA 1000 E2 E 1.73 HP 746 HP 746 E 2 % eff. pf E 1.73 % eff. pf kW 1000 kW 1000 E 2 pf E 1.73 pf I E 2 pf I E 1.73 pf 1000 1000 IE2 I E 1.73 1000 1000 I E 2 % eff. pf I E 1.73 % eff. pf 746 746 I E 2 pf I E 1.73 pf Energy Efficiency = Load Horsepower 746 Load Input kVA 1000 Power Consumed = W or kW = cos Power Factor = pf = Apparent Power VA kVA
kW = Kilowatts pf = Power Factor kVA = Kilovolt-Amperes

kVA 1000 E HP 746 E % eff. pf kW 1000 E pf I E pf 1000 IE 1000 I E % eff. pf 746 E I pf

Not Applicable HP 746 E % eff. kW 1000 E IE 1000 Not Applicable I E % eff. 746 EI

I = Amperes HP = Horsepower

E = Volts % eff. = Percent Efficiency

120

Contents

Index

Next

Previous

KRP-C_SP

MDP Feeder For MCC Branch For Large Motor LPJ-RK_SP KRP-C_SP KRP-C_SP LPS-RK_SP Feeder For MLO Lighting Panel LPJ_SP LPS-RK_SP Branch For Resistance Load

Reduced Voltage Starter For Large Motor M LPJ_SP LPS-RK_SP

LP1 20A Circuit Breakers

Resistance Load

LP-CC_SP

Specify the Buss LOW-PEAK Yellow System

Yellow = Safety. Built-in rejection features. Selective coordination with a minimum 2:1 ratio. Maximum current-limiting protection for distribution equipment. Type 2 Protection for motor starters. Only one type of fuse throughout building. Reduces inventory. 300,000 amperes interrupting rating. M

1998 Cooper Bussmann, Inc., P.O. Box 14460, St. Louis, MO 63178-4460 Phone: 314-394-2877 Fax: 800-544-2570 http://www.bussmann.com
3002 49840

Contents

Previous

Index
Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Ambient Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Ballasts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21, 55 Blackouts, Prevention of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 9 Blocks, Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Distribution and Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Box Cover Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Branch Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,19,100 C Values for Conductors & Busways . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Cable Limiters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Circuit Breaker Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Classes of Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Component Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Busway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Ballasts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 HVAC Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Let-through Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-62 Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Wire and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Conductor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Control Circuit Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Control Circuit Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Control Transformer Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Coordination, Selective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Current Limitation, Definition of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Fuse Charts of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-62 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Diagnostic Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114-116 Dimensions, Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Disconnect Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 107 Dual-Element Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,12 E Rated Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Elevator Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Equipment Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Feeder Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 109 Flash Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Fuses, Control Circuit Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Diagonostic Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114-116 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Dual-Element, Time-Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 12 E Rated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Fast Acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 75 Medium Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,23 Non-Time-Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 12 Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13 R Rated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 103 Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Semiconductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Special Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Supplementary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119-120 Fuseholders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ground Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 HVAC Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 High Speed Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Interrupting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Interrupting Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Let-Through Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-62 Medium Voltage Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Mobile Homes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Motor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,104 Motor Circuit Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Type 1 Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Type 2 Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Motor Controller Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54, 110 Motor Protection, Overload Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 MCPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Terminal Magnetic Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Voltage Unbalancing/Single-Phasing . . . . . . . . . . . . . . . . . . . . . 78-83 Group Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Group Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Motor Protection Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-99 Motor Starter Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Overcurrents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Overcurrent Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Overcurrent Protection Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,108 Overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 75 Panelboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Phase Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Plug Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Power Distribution Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Power Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Protection of, Air Conditioning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Ballasts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Conductors, Branch Circuits. . . . . . . . . . . . . . . . . . . . . . . . 17,19,100 Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hazardous Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Mobile Homes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Motor Circuits Overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Short-Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Switches and Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-99 Non-Time-Delay Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 13 Panelboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Refrigeration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Room Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Semiconductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Welders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pullout Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 R Rated Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 103 Ratings, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Interrupting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Room Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SAMI Fuse Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Selection Chart (Fuses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Selective Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 38 Reading Time-Current Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Current Limiting Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Elevator Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Selectivity Ratio Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Short Circuits, Calculations of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Definition of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Impedance and Reactive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Sizing of Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Supplementary Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107, 113 Time-Current Curves, Interpretation of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Transformers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Volt Loss, Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Tables of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Voltage Drop Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-37 Wire & Cable Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Welders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20