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Short-circuit current rating (SCCR) of industrial control panels
Introduction
Article 409 on Industrial Control Panels was added to the NEC in its 2005
edition. This Article requires all Industrial Control Panels to be marked with a
short-circuit current rating. The short-circuit current rating (SCCR)
requirements for UL 508A came into force in April 2006. These changes impact
control panel builders, OEMs and end users in a number of different ways:
● The correct choice of power circuit components of a control panel
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As follows, the NEC defines two acceptable methods for labeling an industrial
control panel’s short circuit current rating:
Thus, the two options for panel designers and builders are:
1. Using the SCCR of a listed and labeled assembly, which requires testing the
individual panel design and then recording the test result for each panel design.
Note: The variety of possible combinations is usually very high, and this option
therefore requires a lengthy test procedure. In addition, testing is a time-
consuming and costly undertaking, since it is “destructive” (testing is conducted
until the product fails). After testing, the results must be recorded in the panel
builder’s file.
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Note: The latest edition of the NEC (NEC Ed. 2014) refers to an “Informational
Note in Article 409,” “Industrial Control Panels,” which addresses the short
circuit current ratings of the standard UL508A Supplement SB, as an example
for an approved calculation method.
For many years, the UL508A Supplement SB has been the approved method
for the calculation and determination of the short circuit current rating for
industrial control panels, and one could proceed without further tests. It is
important to note that the calculation method and the rules in the UL508A
were changed in the latest edition, which was reissued in December 2013. The
calculation method and all the latest changes will be explained step-by-step
below.
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The NFPA 70: National Electrical Code includes Article 409 on the Construction
of Industrial Control Panels operating at 600 volts or less.
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UL508A is the safety standard for industrial control panels. NEC Article 409
references UL508A Supplement SB as an approved method for determining the
SCCR of an industrial control panel. The specific method is outlined in Section
SB4.
Paragraph SB3.2.1 states that the primary short-circuit protective device for the
control circuit is also included in the calculation for the SCCR for the power
circuit. Therefore, the SCCR of the overcurrent protective devices (except for
supplementary protectors recognized according to UL1077 or sets of
supplemental fuses recognized according to UL248-13) are included in
calculation of the SCCR of the control panel. Control circuit components on the
load side of these devices are not included in calculation of the SCCR.
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SB4.2 – Determining the short-circuit current ratings (SCCR) of individual
power circuit components
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NEC 2014 – Section 409.110 Marking
Short-circuit current rating of the industrial control panel based on one of the
following:
Exception to (4): Short-circuit current rating markings are not required for
industrial control panels containing only control circuit components.
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II. Overview of the UL508A Supplement SB for Calculating the SCCR for
Industrial Control Panels
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Which components are relevant?
All power circuit components, including the disconnect switches, branch
circuit protective devices, branch circuit fuse holders, load controllers, motor
overload relays, terminal blocks, and bus bars
Where can the SCCR ratings of the individual power circuit components be
found?
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Option 3: High-capacity SCCR is based on testing a combination of components
per UL508 Supplement SB, so follow those guidelines.
Within the UL508A Supplement SB, the application of previously investigated
and tested assemblies from a supplier of equipment can be utilized as described
in the manufacturer’s procedures to determine the SCCR.
Note: The High Capacity Short Circuit Current Ratings for Siemens components
can be found at:
www.usa.siemens.com/sccr
All the ratings for Siemens components are conveniently summarized in Excel
spreadsheets.
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Important note for tested combinations:
If the specified protective device is a Class CC, G, J, L, RK1, RK5, or T fuse, a fuse
of a different class may be used, provided that the peak let-through current (Ip)
and the peak let-through energy (I2t) is equal to or lower than the specified fuse.
The peak let-through currents and peak let-through energy shall be taken from
Table SB4.2 in the UL508A standard.
UL508A allows the use of one of the following components to limit the available
fault current to components downstream of the current limiting device:
1. Power transformers with an isolated secondary winding
2. Circuit breakers that are marked as “current limiting”
3. Fuses of Class CC, G, J, L, RK1, RK5, CF or T
Note: The current limiting component shall be installed in the Feeder Circuit!
A graphic explanation of the feeder circuit and the branch circuit can be seen in
Figure 1.
The following information details how to effectively apply the current limiting
components in the feeder circuit. Three scenarios are detailed.
Three-phase Transformers
In General:
The SCCR on the line side of feeder circuit breaker shall be the interrupting
rating of the breaker if the following two conditions are fulfilled:
1. The components on the load side of the circuit breaker have a SCCR equal to
or higher than the peak let-through current of the feeder circuit breaker.
2. The branch protection devices have an interrupting rating equal or higher
than the interrupting rating of the circuit breaker in the feeder circuit.
If condition 1. is not fulfilled, the lowest SCCR any component on the load side
of the circuit breaker shall be the SCCR for the entire circuit on the line side of
the feeder circuit breaker.
Note: The peak let-through values of the Circuit Breaker need to be provided
by the Circuit Breaker manufacturer. 32
Example: Siemens ED Circuit Breaker, CED 6
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Option 3:
Use of current limiting fuses installed in the feeder circuit Fuses of the Class CC,
G, J, L, RK1, RK5, or T are current limiting. The SCCR on the line side of fuse in
the feeder circuit shall be the interrupting rating of the fuse if the following two
conditions are fulfilled:
1. The components on the load side of the fuse have a SCCR equal to or higher
than the peak let-through current of the fuse in the feeder circuit.
2. The branch protection devices have an interrupting rating equal to or higher
than the interrupting rating of the fuse in the feeder circuit.
If condition 1. is not fulfilled, the lowest SCCR of any component on the load
side of the circuit breaker shall be the SCCR for the entire circuit on the line side
of the feeder circuit breaker.
Note: The peak let-through values of the Fuse shall be taken of the table SB 4.2
in the UL508A Standard for Industrial Control Panels!
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Extract of the table SB 4.2 UL508A , Second Edition
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II. Overview of the UL508A Supplement SB for
Calculating the SCCR for Industrial Control Panels
To do so, establish the overall rating for the industrial control panel, which
cannot exceed the rating of the lowest rated component or circuit, including
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Figure 1: Graphic explanation of branch circuit and feeder circuit
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Figure 2: Graphic explanation of Step 1:
Determination of the SCCR for
individual power circuit components
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Figure 3.1: Graphic explanation / example of Step 2: Use of
current limiting transformers in the feeder circuit
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Figure 3.2: Graphic explanation / example of Step 2: Use of
current limiting fuses in the feeder circuit
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Figure 3.3: Graphic explanation / example of Step 2: Use of circuit breaker
marked as “current limiting” in the feeder circuit
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V. Glossary
Interrupting Rating
(aka Available Interrupting Capacity – A.I.C.) The highest current at rated voltage
that a device is identified to interrupt under standard test conditions.
Overcurrent Protection
A device designed to open a circuit when the current through it exceeds a
predetermined value. The ampere rating of the device is selected for a circuit to
terminate a condition where the current exceeds the rating of conductors and
equipment due to overloads, short circuits, and faults to ground.
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Peak Let-Through Current - IP
The highest instantaneous current passed by the over-current protection device
during the interruption of the current
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In this case, the worst case available fault current level at the transformer’s
secondary is 53,704 amps. Upon inspecting Machine 1, it is determined by the
equipment label that Machine 1’s control panel is rated for 42kA. However, Machine
2 is older equipment and its equipment label does not list an assembly SCCR for
the control panel.
Using the worst case available fault current level, Machine 1 is not compliant (42kA
< 54kA). The facility decides to pursue a more precise available fault current
calculation at Machine 1. There are three 500MCM cables per phase running
approximately 500 feet between the substation transformer and Machine 1. Using
Eaton’s FC2 fault current calculator, they determine the calculated available fault
current to be 27,782 amps. Based on this calculation, the equipment SCCR of
Machine 1 is adequate for the available fault current at its location in the electrical
distribution system (42kA > 27.782kA). There are several options to resolve
Machine 2’s unknown equipment SCCR issue. One is to assume the minimum 5kA
equipment SCCR on the control panel and determine a more precise fault current
level calculation for the point in the electrical distribution system where Machine 2 is
located. In this case, a copper bus runs approximately 100 feet to Machine 2.
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Using Eaton’s FC2 calculator, the available fault current is 48,817 amps. This
does not resolve the issue as the assumed 5kA default equipment SCCR is less
than the available fault current (5kA < 48.817kA). Machine 2 is older and will
be replaced in a few years. Management considers a reworking and
recertification of its control panel to be a significant investment for a piece of
equipment that will soon be replaced. Machine 2 has a relatively small load,
so a decision is made to investigate lowering the available fault current level
below 5kA by installing an isolation transformer ahead of Machine 2.
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Now that the existing equipment SCCR has been resolved, the facility
determines its equipment SCCR specifications for any new equipment. The
substation transformer is fairly new and expected to be in service for some
time. However, some portions of the electrical distribution system have aged,
and it is expected some portions may be replaced with busway to lower
energy losses and system impedance. Thus the facility management
determines to standardize on a minimum 55kA equipment SCCR for any new
equipment purchases. This standardized 55kA equipment SCCR will provide
flexibility and accommodate any utility changes or electrical distribution
system upgrades while ensuring the required short-circuit event protection
for personnel.
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The operation of a power system departs from normal after the occurrence of a
fault.
Various types of short-circuit faults that can occur on a transmission line are
depicted in Fig. 6-1; the frequency of occurrence decreases from part (a) to part
(f). Although the balanced three-phase short circuit in Fig. 6-1(d) is relatively
uncommon, it is the most severe fault and therefore determines the rating of
the line-protecting circuit breaker. A fault study includes the following:
1. Determination of the maximum and minimum three-phase short-circuit
currents
2. Determination of unsymmetrical fault currents, as in single
ground, line-to-line, and open-circuit faults
3. Determination of the ratings of required circuit breakers
4. Investigation of schemes of protective relaying
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5. Determination of voltage levels at strategic points during a fault
The short-circuit faults depicted in Fig. 6-1 are called shunt faults; open
circuits, which may be caused by broken conductors, for instance, are
categorized as series faults.
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6.2 SYMMETRICAL FAULTS
3 Vl If
where Vl is the nominal line voltage in kilovolts, and If is the fault current in
kiloamperes.
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An example of a three-phase symmetrical fault is a sudden short at the
terminals of a synchronous generator. The symmetrical trace of a short-
circuited stator-current wave is shown in Fig. 6-2. The wave, whose envelope
is shown in Fig. 6-3, may be divided into three periods or time regimes: the
subtransient period, lasting only for the first few cycles, during which the
current decrement is very rapid; the transient period, covering a relatively
longer time during which the current decrement is more moderate; and
finally the steady-state period. The difference Δi' (in Fig. 6-3) between the
transient envelope and the steady-state amplitude is plotted on a logarithmic
scale as a function of time in Fig. 6-4, along with the difference Ai" between
the subtransient envelope and an extrapolation of the transient envelope.
Both plots closely approximate straight lines, illustrating the essentially
exponential nature of the decrement.
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The currents during these three regimes are limited primarily by various
reactances of the synchronous machine (we neglect the armature resistance,
which is relatively small). These currents and reactances are defined by the
following equations, provided the alternator was operating at no load before
the occurrence of a three-phase fault at its terminals:
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where lEgl is the no-load voltage of the generator, the currents are rms
currents, and O, a, b, and c are shown in Fig. 6-2. The machine reactances
Xs, X’d, and X’’d are known as the direct-axis synchronous reactance, direct-
axis transient reactance, and direct-axis subtransient reactance,
respectively. The currents I, i', and i" are known as the steady-state,
transient, and subtransient currents. From (6.1) through (6.3) it follows
that the fault currents in a synchronous generator can be calculated when
the machine reactances are known.
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Suppose now that a generator is loaded when a fault occurs. Figure 6-5(a)
shows the corresponding equivalent circuit with the fault to occur at point P.
The current flowing before the fault occurs is IL, the voltage at the fault is Vf,
and the terminal voltage of the generator is Vt. When a three-phase fault
occurs at P, the circuit shown in Fig. 6-5(b) becomes the appropriate
equivalent circuit (with switch S closed). Here a voltage E’’g in series with X’’d
supplies the steady-state current IL when switch S is open, and supplies the
current to the short circuit through X’’d and Zext when switch S is closed. If we
can determine E’’g, we can find this current through X’’d ,which will be i".
With switch S open, we have
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which defines E’’g, the subtransient internal voltage. Similarly, for the transient
internal voltage we have
Clearly E’’g and E’g are dependent on the value of the load before the
fault occurs.
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6.3 UNSYMMETRICAL FAULTS AND SYMMETRICAL COMPONENTS
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Short Circuit Fault Calculations
There are three major sources of fault current: an electric utility power
system, a generator, and a motor. Short circuit faults are called shunt faults.
An open-circuit condition is known as a series fault. Any phase/circuit to
ground condition is called a ground fault. Among all faults, a balanced 3-
phase short circuit is the most critical and serious. However, it is one of the
least likely of faults to occur. The elements in a power distribution system
that limit or impede the fault current value include: cables, transformers,
and reactors.
Let's work through a few simple examples to show how you can quickly and
easily calculate fault currents.
We'll first use the concept of admittance to calculate the fault current in the
system shown in Fig. 1. Admittance is a measure of how easily a circuit or
device will allow a current to flow. It is the inverse of impedance, which is
defined as a measure of opposition to current.
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Step 1: Because the electric utility can't provide us with fault information
at this particular site, we assume it to be infinite. We calculate the
maximum amount of power that the transformer (XFMR) will allow to
flow to its secondary (i.e., load side) using this formula.
Step 2: Now we can calculate the cable let-through power. This is defined
as the amount of power that the cable would let through from an infinite
source to the load side of the XFMR. The formula we use for this step is
as follows:
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Step 3: Next, we calculate the total let-through fault power by using the
following formula:
Net fault power = 1 ÷ [(1 ÷ XFMR let through power) + (1 ÷ cable let
through power)]
= 1 ÷ [(1 ÷ 100,000kVA) + (1 ÷ 9,600kVA)]
= 8,759kVA
Step 4: Now we can find the fault current using the following formula:
Fault current = net fault power ÷ (secondary XFMR voltage rating x √3)
= 8,759kVA ÷ (12kV x √3)
= 421A
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Let's work through another sample calculation where the electric utility fault
power level is known. The given value is 50,000kVA. In this situation, we
assume cable length to be minimal and therefore neglect its effect since the
impedance is minimal.
= 40,000kVA
= 22,222kVA
= 26,729A
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For our third and final example calculation, we'll work a problem where
generator data is available to us. When working with generators, we introduce a
new value known as sub-transient reactance, which is referred to as X"d. This
value is typically shown on the generator nameplate or can be obtained directly
from the manufacturer.
Step 1: The short circuit kVA available at the generator is calculated using the
following formula:
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As you can see, simplified short circuit fault calculations can be performed
using a basic understanding of sources of fault power and current and
impedance values that impede the short circuit power flow.
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Electrical networks, machines and equipment are often subjected to various
types of faults while they are in operation. When a fault occurs, the
characteristic values (such as impedance) of the machines may change from
existing values to different values till the fault is cleared.
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Under normal or safe operating conditions, the electric equipment in a
power system network operate at normal voltage and current ratings. Once
the fault takes place in a circuit or device, voltage and current values
deviates from their nominal ranges.
The faults in power system causes over current, under voltage, unbalance of
the phases, reversed power and high voltage surges. This results in the
interruption of the normal operation of the network, failure of equipment,
electrical fires, etc.
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Symmetrical and Unsymmetrical Faults
As discussed above that faults are mainly classified into open and short circuit
faults and again these can be symmetrical or unsymmetrical faults.
Symmetrical Faults
A symmetrical fault gives rise to symmetrical fault currents that are displaced
with 1200 each other. Symmetrical fault is also called as balanced fault. This
fault occurs when all the three phases are simultaneously short circuited.
These faults rarely occur in practice as compared with unsymmetrical faults.
Two kinds of symmetrical faults include line to line to line (L-L-L) and line to line
to line to ground (L-L-L-G) as shown in figure below.
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Protection Devices against Faults
When the fault occurs in any part of the system, it must be cleared in a very
short period in order to avoid greater damage to equipment and personnel and
also to avoid interruption of power to the customers. The fault clearing system
uses various protection devices such as relays and circuit breakers to detect and
clear the fault. Some of these fault clearing or faults limiting devices are given
below.
Fuse
It opens the circuit whenever a fault exists in the system. It consists of a thin
copper wire enclosed in a glass or a casing with two metallic contacts. The high
fault current rises the temperature of the wire and hence it melts. A fuse
necessitates the manual replacement of wire each time when it blows.
Circuit Breaker
It is the most common protection device that can make or break the circuit
either manually or through remote control under normal operating conditions.
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Circuit Breakers
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Protective Relays
These are the fault detecting devices. These devices detect the fault and
initiate the operation of the circuit breaker so as to isolate the faulty circuit.
A relay consists of a magnetic coil and contacts (NC and NO). The fault
current energizes the coil and this causes to produce the field, thereby the
contacts get operated.
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Ch 7: General Methods for
Network Calculations
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General Methods for Network Calculations
In this chapter we develop general solution methods that are amenable to the
computer solution of power system network problems. We begin from the
basic network theorems.
7.1 SOURCE TRANSFORMATIONS
The voltage source of Fig. 7-1(a) may be transformed to the current source of
Fig. 7-1(b) and vice versa, provided that
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7.2 BUS ADMITTANCE MATRIX
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Rearranging these equations and rewriting them in matrix form, we obtain
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Each admittance Yii (i = 1, 2, 3, 4) is called the self-admittance (or driving-point
admittance) of node i and is equal to the algebraic sum of all the admittances
terminating on the node. Each off-diagonal term Yik (i, k = i, 2, 3, 4) is called the
mutual admittance (or transfer admittance) between nodes i and k and is equal to
the negative of the sum of all admittances connected directly between those
nodes. Further, Yik = Yki.
For a general network with N nodes, therefore, Kirchhoff's current law in terms of
node voltages may be written as
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is called the bus admittance matrix, and V and I are the N-element node
voltage matrix and node current matrix, respectively.
In (7.6), the first subscript on each Y indicates the node at which the current is
being expressed, and the second subscript indicates the node whose voltage
is responsible for a particular component of the current. Further, the
admittances along the diagonal are the self-admittances, and the off-diagonal
admittances are the mutual admittances. It follows from (7.5) and (7.6) that
the current entering a node k is given by
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A Short Circuit analysis is used to determine the magnitude of short circuit
current the system is capable of producing and compares that magnitude with
the interrupting rating of the overcurrent protective devices (OCPD). Since the
interrupting ratings are based by the standards, the methods used in
conducting a short circuit analysis must conform to the procedures which the
standard making organizations specify for this purpose. In the United States, the
America National Standards Institute (ANSI) publishes both the standards for
equipment and the application guides, which describes the calculation
methods.
Short circuit currents impose the most serious general hazard to power
distribution system components and are the prime concerns in developing and
applying protection systems. Fortunately, short circuit currents are relatively
easy to calculate. The application of three or four fundamental concepts of
circuit analysis will derive the basic nature of short circuit currents. These
concepts will be stated and utilized in a step-by step development.
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The three phase bolted short circuit currents are the basic reference
quantities in a system study. In all cases, knowledge of the three phase bolted
fault value is wanted and needs to be singled out for independent treatment.
This will set the pattern to be used in other cases.
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Listed here are reference values that will be needed in the calculation of
fault current.
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TRANSFORMER FAULT CURRENT
Calculating the Short Circuit Current when there is a Transformer in the circuit.
Every transformer has “ %” impedance value stamped on the nameplate. Why
is it stamped? It is stamped because it is a tested value after the transformer
has been manufactured. The test is as follows: A voltmeter is connected to the
primary of the transformer and the secondary 3-Phase windings are bolted
together with an ampere meter to read the value of current flowing in the 3-
Phase bolted fault on the secondary. The voltage is brought up in steps until
the secondary full load current is reached on the ampere meter connected on
the transformer secondary.
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When the secondary ampere meter reads 1,202A and the primary Voltage
Meter reads 793.5V. The percent of impedance value is 793.5 / 13800 =
0.0575. Therefore:
This shows that if there was a 3-Phase Bolted fault on the secondary of the
transformer then the maximum fault current that could flow through the
transformer would be the ratio of 100 / 5.75 times the FLA of the transformer,
or 17.39 x the FLA = 20,903A.
Based on the infinite source method at the primary of the transformer. A quick
calculation for the Maximum Fault Current at the transformer secondary
terminals is
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This quick calculation can help you determine the fault current on the
secondary of a transformer for the purpose of selecting the correct
overcurrent protective devices that can interrupt the available fault current.
The main breaker that is to be installed in the circuit on the secondary of the
transformer has to have a KA Interrupting Rating greater then 21,000A. Be
aware that feeder breakers should include the estimated motor contribution
too. If the actual connected motors are not known, then assume the
contribution to be 4 x FLA of the transformer. Therefore, in this case the
feeders would be sized at 20,904 + (4 x 1202) = 25,712 Amps
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GENERATOR FAULT CURRENT
Generator fault current differs from a Transformer. Below, we will walk through a
1000KVA example.
So, the fault current of a 1000KVA Generator is a lot less then a 1000KVA
transformer. The reason is the impedance value at the transformer and
Generator reactance values are very different. Transformer 5.75% vs. a
Generator 16%
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SYSTEM FAULT CURRENT
Below is a quick way to get a MVA calculated value. The MVA method is fast
and simple as compared to the per unit or ohmic methods. There is no
need to convert to an MVA base or worry about voltage levels. This is a
useful method to obtain an estimated value of fault current. The elements
have to be converted to an MVA value and then the circuit is converted to
admittance values.
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Utility MVA at the Primary of the Transformer
MVAsc = 500MVA
Transformer Data
13.8KV - 480Y/277V
1000KVA Transformer Z = 5.75%
MVA Value
1000KVA / 1000 = 1 MVA
MVA Value = 1MVA / Zpu = 1MVA / .0575 = 17.39 MVA
Use the admittance method to calculate Fault Current
1 / Utility MVA + 1 / Trans MVA = 1 / MVAsc
1 / 500 + 1 / 17.39 = 1 / MVAsc
0.002 + 0.06 = 1/ MVAsc
MVAsc = 1 / (0.002 + 0.06)
MVAsc = 16.129
FC at 480V = MVAsc / (1.73 x 0.48)
FC = 16.129 / 0.8304
FC = 19.423KA
FC = 19, 423 A
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The 480V Fault Current Value at the secondary of the 1000KVA transformer based
on an Infinite Utility Source at the Primary of the transformer as calculated in the
Transformer Fault Current section in this article is 20,904A.
The 480V Fault Current Value at the secondary of the 1000KVA transformer based
on a 500MVA Utility Source at the Primary of the transformer as calculated in the
System Fault Current section in this article is 19,432A.
The 480V Fault Current Value at the secondary of the 1000KVA transformer based
on a 250MVA Utility Source at the Primary of the transformer the calculated value
is 18,790A.
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When the cable and its length is added to the circuit the fault current in a 480V
system will decrease to a smaller value. To add cable into your calculation use the
formula.
Cable MVA Value MVAsc = KV2/ Z cable. Use the cable X & R values to calculate
the Z value then add to the Admittance calculation as shown in this article.
The conclusion is that you need to know the fault current value in a system to
select and install the correct Overcurrent Protective Devices (OCPD). The
available FC will be reduced as shown in the calculations when the fault current
value at the primary of the transformer is reduced. If the infinite method is
applied when calculating fault current and 4 x FLA is added for motor
contributions, then the fault current value that is obtained will be very
conservative. This means the calculated value in reality will never be reached, so
you reduce any potential overcurrent protection device failures due to fault
current.
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