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Power Quality Troubleshooting

Introduction

Table of Contents Page While we’ve enjoyed enormous problems. But before grabbing
benefits from the evolution of that meter, please read the
Safety ............................................................ 2 solid state technology, the fact following cautionary notes:
is that the microelectronics at 1. Suggested measurements
Getting Started ............................................... 3
the heart of that technology should only be made by
First Steps ..................................................... 3 requires clean power. Faster qualified personnel who have
speeds and lower voltages been trained to make these
Part I: Facility Distribution System mean that there is less and less measurements in a safe
Section 1: Receptacle Branch Circuit ................... 4 tolerance for anything less than manner, using proper
quality power. procedures and test tools
Section 2: Service Panels ...................................... 8 Power Quality (PQ) covers a rated for work on electrical
Section 3: Transformers ....................................... 10 wide range of issues, from volt- power circuits.
age disturbances like sags,
Section 4: Electrical Noise and Transients ........ 16 2. To the best of our knowledge,
swells, outages and transients,
Section 5: Lightning Protection .......................... 21 to current harmonics, to perfor- recommended solutions are
mance wiring and grounding. consistent with the National
Part II: Three-Phase Loads The symptoms of poor PQ in- Electric Code (NEC), but in
clude intermittent lock-ups and any case, NEC requirements
Section 6: Polyphase Induction Motors ............. 22 must not be violated.
resets, corrupted data, prema-
Section 7: AC Adjustable Speed Drives ............. 25 ture equipment failure, over- 3. We have tried to make the
Section 8: Commercial Lighting .......................... 30 heating of components for no information accurate and
apparent cause, etc. The ulti- current, but it is not intended
A Lineup of Power Quality Culprits ............... 31 mate cost is in downtime, to be a substitute for the
decreased productivity and specialized knowledge and
Test Tools ....................................... Back cover experience of professional
frustrated personnel.
This application note gives power quality practitioners.
you information on how to What this application note offers
troubleshoot PQ problems. It is a “starter kit,” not the final
also gives you information on word on PQ troubleshooting.
how to start fixing those

IEC 61010 establishes interna- IEC 61010 requires increased


International Safety tional safety requirements for protection against the hazards
Standards for Test Tools low voltage (1000V or less) of transient overvoltages. Tran-
electrical equipment for mea- sients can cause an arc-over
surement, control and labora- inside an inadequately pro-
Overvoltage
Summary Description tory use. The low voltage power tected meter. When that arc-
Category distribution system is divided over occurs in a high energy
CAT IV* Three-phase at utility connection, any into four categories, based on environment, such as a three-
outdoors conductors (under 1000V) the proximity to the power phase feeder circuit, the result
CAT III Three-phase distribution (under 1000V), source. Within each category can be a dangerous arc blast.
including single-phase commercial lighting
and distribution panels
are voltage listings—1000V, The potential exists for serious
600V, 300V, etc. harm to personnel as well as
CAT II Single-phase receptacle connected loads
The key concept to under- damage to the meter. For more
CAT I Electronic stand is that you should use a information, see the Fluke appli-
*CAT IV product specifications are not yet defined in the standard. meter rated to the highest cat- cation note “ABCs of Multimeter
egory, as well as the highest Safety” (document number
voltage, that you might be B0317UEN) and the Fluke video
working in. For PQ trouble- “The ABCs of Digital Multimeter
shooters, that means a meter Safety” (P/N 609104).
rated to CAT III-600V or CAT III-
1000V (the specifications for Independent Testing and
CAT IV have not yet been de- Certification
fined by IEC). We recommend Manufacturers can self-certify
that you do not use CAT II rated that they meet IEC 61010 specs,
meters, scopes or test leads and but there are obvious pitfalls for
probes on CAT III circuits. The the end-user in self-certification.
CAT ratings should be marked Certification by an independent
near the voltage inputs of the testing lab provides assurance
instrument. Meters designed to that the meter meets IEC re-
IEC 348, the previous standard, quirements. Look for a symbol
will typically not meet the more and listing number of an inde-
stringent safety specs of IEC pendent testing lab such as UL,
61010 CAT III-600/1000V. CSA, TÜV, VDE, etc. UL 3111, for
example, is based on IEC 61010.

2 Fluke Corporation Power Quality Troubleshooting


Getting Started

Your job is to understand these


Lighting Panel
system interactions. The more
Lighting complete your documentation,
Load the better off you’ll be.
Utility
XFMR Switch Gear It’s true, however, that the
MV/480Y Motor
M.C.C.
PF
Correction
sites that need the most help
Capacitor are the ones least likely to have
ASD a good record of what’s going
on in their system. Many a con-
sultant has earned his fee by
Induction upgrading the documentation
Motor handed him with what actually
Recept.
XFMR Recept.
exists on-site. So the simple rule
480/208Y L.C. is, at this point in the investiga-
Receptacle tion, do the best you can to get
Load good documentation, but don’t
count on it being available.
2. Do a walk around
Simplified electrical distribution system typical of commercial and industrial facilities. of the site
Sometimes a visual inspection
will offer immediate clues:
Start at the scene to first diagnose the electrical
of the crime infrastructure of the building, • A transformer that’s much
then monitor if necessary. Our too hot
To troubleshoot PQ problems, bottom-up troubleshooting pro- • Wiring or connections discol-
one approach is to start as close cedure is designed to help you ored from heat
to the “victim load” as possible. do this detective work. • Receptacles with extension
The “victim load” is the sensi- strips daisy-chained to exten-
tive load, typically electronic, sion strips
First steps
that is somehow malfunction- • Signal wiring running in the
ing. Poor PQ is suspected, but 1. Make a map: Obtain or same trays as power cables
part of your job is to isolate PQ create a current one-line • Extra neutral-ground bonds
as a cause from other possible It’s tough to diagnose PQ prob- in sub-panels.
causes (hardware, software?). lems without having a working • Grounding conductors con-
Like any detective, you should knowledge of the site being nected to pipes that end in
start at the scene of the crime. investigated. You can start by mid-air.
This bottom-up approach can locating or reconstructing a At a minimum, you will get a
take you a long way. It relies one-line diagram of the site. sense of how the facility is
on making use of a sharp eye The one-line will identify the wired and what the typical
and on taking some basic ac power sources and the loads loads are.
measurements. they serve. The “as built” one-
An alternative is to start at line, the one with red-lines, is 3. Interview affected
the service entrance, using a the one you want. personnel and keep
three-phase monitor, and work If you work on-site, the map an incident log
back to the “victim load.” This is might already exist in your Interview the people operating
most useful if the problems head, but it will be a big help to the affected equipment. You will
originate with the utility. Yet everyone, including yourself, if get a description of the problem
survey after survey has con- it’s on paper. If you’re coming to and often turn up unexpected
cluded that the great majority a work site for the first time, clues. It’s also good practice to
of PQ problems originate in the getting an up-to-date one-line keep a record of when problems
facility. In fact, as a general rule, means identifying new loads or happen and what the symptoms
PQ is best at the service en- other recent changes in the sys- are. This is most important for
trance (connection to utility) tem. Why go to this effort? Sys- problems that are intermittent.
and deteriorates as you move tems are dynamic; they change The goal is to find some pattern
downstream through the distri- over time, often in unplanned that helps correlate the occur-
bution system. That’s because and haphazard ways. Further- rence of the problem in the
the facility’s own loads are more, while some problems are “victim load” to a simultaneous
causing the problems. Another local in origin and effect, there event elsewhere. Logically, this
illuminating fact is that 75% of are many problems that result trouble-logging is the responsi-
PQ problems are related to wir- from interactions between one bility of the operator closest to
ing and grounding problems! part of the system and another. the affected equipment.
For this reason, many PQ
authorities recommend that a
logical troubleshooting flow is

Power Quality Troubleshooting Fluke Corporation 3


Part I: Facility Distribution System

which corresponds to the effec-


Section 1 tive heating value. Equipment is
Receptacle Branch Circuit rated in RMS, not peak, because
their main limitation has to do
with heat dissipation.
Many PQ problems show up at RMS voltage can be too high
the branch circuit level. There’s or too low, but it is usually the
a simple reason for this: that’s low voltage that causes prob-
where most of the sensitive lems. Low RMS voltage com-
loads (and sensitive employees) bined with flat-topping (low
are located. It’s also the “end of peak) is a deadly combination
the line” of the electrical sys- for sensitive loads.
tem, and the place where short- Voltage drop is a function
comings can’t be hidden. Let’s of both the loading of the circuit
assume you’ve been called in and the source impedance,
Figure 1.1 Flat-topped voltage at receptacle.
to solve the problem. You’ve which in effect means the
already talked to the people in- length and diameter (gauge)
volved, have a rough idea of the Our other measurements will of the wire run. The NEC (210-
symptoms (equipment lock-ups, tell us whether this flat-topping 19.a, FPN No. 4) recommends a
intermittent resets or crashes, is excessive. limit of a 3% voltage drop from
etc.) and as much sense of the the branch circuit breaker to
timing and history of the prob- 2. Peak voltage the farthest outlet, and a total
lems as you can get. So it’s time voltage drop of less than 5% in-
The peak value is critical to cluding the feeder and branch
to gather hard evidence: it’s electronic loads because the
time to take measurements. circuit.
electronic power supply charges
Our primary focus with its internal capacitors to the
troubleshooting at the recep- 4. Recording (short-term)
peak value of the line voltage.
tacle level is to determine if the If the peak is too low, it affects The limitation of the above
Line-Neutral (L-N) voltage avail- the ability of the caps to charge measurement is that it is static.
able is of sufficient stability and fully and the ability of the Many loads require more cur-
amplitude to supply the needs power supply to ride through rent, usually referred to as in-
of the load(s). momentary dips in the line volt- rush current, when they are first
age. For an RMS voltage of turned on. This momentary high
Measurement 115V, the peak value would be current may cause a momentary
1.414 x 115V = 162.6V, if the low voltage (sag) because of the
1. Waveform additional IR drop through the
The waveform gives us quick waveform were a sine wave.
However, as we just saw from conductors. Such sags are often
snapshot information. An ideal caused by loads drawing inrush
waveform would be a sine the flat-topped waveform, what
we have is far from a sine wave currents on the same branch
wave. In this case, (see Fig 1.1) circuit, or on the same
the voltage waveform is flat- and will have a lower peak
value. panelboard.
topped, which is typical of a You can measure a worst-
building with many non-linear case sag of 100 ms or more
loads such as computers and 3. RMS voltage
(about 6 cycles at 60 Hz) by us-
other office equipment (see Nominal line voltage is measured ing the MIN MAX function of the
“Flat-topped voltage,” page 5). in RMS (root-mean-square) Fluke 87 while energizing the
load. What if you want to know
Table 1.1 Measurements on receptacle branch circuits. if there are recurring sags? The
Sags & Swells trending feature
Voltage Measurements Look for Instrument of the Fluke 43 Power Quality
1. Waveform Snapshot of severity of 43 PQ Analyzer Analyzer will continuously cap-
voltage distortion 41B Harmonics Analyzer ture sags of as little as single
2. Peak voltage Excessive flat-topping 43 PQA, 41B cycle duration (17 ms). A four-
87 DMM (Peak MIN MAX) minute to a one-hour recording
3. RMS voltage Low rms (steady-state low 43 PQA (Sags/Swells) time (i.e., anywhere from a
rms or intermittent/cyclical 41B (MIN MAX)
sags) 87 DMM (MIN MAX)
single cup of coffee to a lunch
break) may be enough to tell
4. Recording (short-term) Sags, swells, interruptions 43 PQA
while troubleshooter remains (Sags/Swells or Transients)
you if there are recurring sags
on-site (4 minutes to 1 hour and swells.
typical recording time)
5. Recording (long-term) Up to 4,000 sags, swells, VR101S
outages, transients
6. Neutral-ground N-G voltage too high 43 PQA, 87 DMM
(or close to zero)

4 Fluke Corporation Power Quality Troubleshooting


5. Recording (long-term)
Flat-topped voltage For longer term recording, the
VR101S Voltage Event Record-
The flat-topped waveform is supply. This limit is usually ers will record sags, swells, out-
typical of the voltage in a com- described by a concept called ages, transients and frequency
mercial building with computer source impedance, which is the deviations while plugged into
loads. What causes flat-topping? total impedance from the point the outlet (see “Recording at the
The utility supplies ac power, you’re measuring (or the point Receptacle Outlet,” page 7). The
but electronic equipment runs where the load is located) back device can be left on-site, unat-
on dc power. The conversion to the source. There are two tended, for days and weeks, all
of ac into dc is done by a power major contributors to this source the time catching intermittent
supply. The PS has a diode impedance. One is the wiring; events (4000 event buffer). Now
bridge which turns ac into pul- the longer the conductor and you can see why it’s so impor-
sating dc, which then charges a the smaller the diameter (higher tant to ask the user to keep a
capacitor. As the load draws the gauge), the higher the imped- troubleshooting log: correlation
cap down, the cap recharges. ance. The other factor is the of equipment malfunction with
However, the cap only takes internal impedance of the trans- voltage events is hard evidence
power from the peak of the former (or other source equip- of a PQ problem.
wave to replenish itself, since ment). This internal impedance
that’s the only time the supplied is simply a way of saying that a 6. Neutral-to-ground voltage
voltage is higher than its own transformer of a given size/rat-
voltage. The cap ends up draw- Let’s say that you make a
ing can only supply so much
ing current in pulses at each simple L-N measurement at the
current.
half-cycle peak of the supplied outlet and get a low reading.
The source impedance is
voltage. This is happening with You can’t tell if the reading is
naturally greatest at the end
virtually all the electronic loads low because the feeder voltage
of a branch circuit, the farthest
on the circuit. Now that we see is low (at the subpanel), or if the
point from the source. That’s the
what the loads are demanding branch circuit is overloaded. You
same place where all those
from the source, let’s take a look could try to measure the voltage
electronic loads are demanding
at what the source can supply. current at the peak of the wave. at the panel, but it’s not always
If the source were perfectly The result is that the voltage easy to tell which panel feeds
“stiff,” meaning that it had an peak tends to get dragged the outlet you’re measuring and
infinite capacity to supply all down—in other words, flat- it’s also sometimes inconvenient
the current that was required, topped. Maybe you’ve felt the to access a panel.
then there would be no such same way when all the bills N-G voltage is often an easier
thing as flat-topping (or sags come in at the same time of the way of measuring the loading
or any voltage distortion). Think month. The more loads there on a circuit. As the current trav-
of it this way: if you had all the are (the more the bills), the els through the circuit, there is a
money in the world, you greater the flat-topping. Also, certain amount of voltage drop
wouldn’t get distorted either the greater the source imped- in the hot conductor and in the
when the bills came in. But in ance (the less the cash), the neutral conductor. The drop on
the real world there are practi- greater the flat-topping. the hot and neutral conductors
cal limits to what a source can will be the same if they are the
same gauge and length. The to-
tal voltage drop on both con-
ductors is subtracted from the
source voltage and is that much
less voltage available to the
load. The greater the load, the
greater the current, the greater
the N-G voltage.
Think of N-G voltage as the
mirror of L-N voltage: if L-N
voltage is low, that will show
up as a higher N-G voltage
Diode-Capacitor
Input Circuit
Switching
Power Supply
(see Fig. 1.4).

Figure 1.2 Flat-topped voltage.

Power Quality Troubleshooting Fluke Corporation 5


Ø1

Ø2

Ø3

Ø1 Ø2

Receptacle N-G Voltage


Measurement Notes To panel
ground buss
1. A rule-of-thumb used by many in the industry
is that N-G voltage of 2V or less at the recep- Ø3

tacle is okay, while a few volts or more


indicates overloading; 5V is seen as the upper
To transformer
limit. There’s obviously some room for judgment X0
in this measurement.
N-G voltage
2. A high reading could indicate a shared branch
neutral, i.e., a neutral shared between more
than one branch circuit. This shared neutral
simply increases the opportunities for overload-
ing as well as for one circuit to affect another.
3. A certain amount of N-G voltage is normal in a
loaded circuit. If the reading is stable at close
to 0V, suspect an illegal N-G bond in the
receptacle (often due to loose strands of the Figure 1.3. Neutral-to-ground voltage increases with shared neutrals.
neutral touching some ground point) or at the
subpanel. Any N-G bonds other than those at
the transformer source (and/or main panel) 200 ft
60m
should be removed to prevent return currents
flowing through the ground conductors.
4. If N-G voltage is low at the receptacle, you’re in
good shape (see Measurement Note #3 for the 50 ft
exception to the rule). If it’s high, then you still 15m
have to determine if the problem is mainly at
the branch circuit level, or mainly at the panel
level. Remember, assuming there’s no illegal
N-G bond in intervening panels or receptacles,
your ground “test lead” goes all the way back to
the source, so you’re reading voltage drops all
the way to the source. Laser
Printer

N-G voltage exists because Copier


of the IR drop of the current
travelling through the neutral
back to the N-G bond. If the Figure 1.4 Neutral-ground voltage increases as load current goes up.
system is correctly wired, there
should be no N-G bond except
at the source transformer (at Shared neutrals from nonlinear loads, primarily
what the NEC calls the source of Some buildings are wired so third harmonic, will add up
the Separately Derived System, that two or three phases share a arithmetically and return on the
or SDS, which is usually a single neutral. The original idea neutral. In addition to being
transformer). Under this situa- was to duplicate on the branch a potential safety problem
tion, the ground conductor circuit level the four wire (three because of overheating of an
should have virtually no current phases and a neutral) wiring of undersized neutral, the extra
and therefore no IR drop on it. panelboards. Theoretically, only neutral current creates a higher
In effect, the ground wire is the unbalanced current will re- N-G voltage. Remember that
available as a long test lead turn on the neutral. This allows this N-G voltage subtracts from
back to the N-G bond. one neutral to do the work for the L-N voltage available to the
three phases. This wiring short- load. If you’re starting to feel
cut quickly became a dead-end that shared neutrals are one of
with the growth of single-phase the worst ideas that ever got
non-linear loads. The problem translated to copper, you’re not
is that zero sequence current alone.

6 Fluke Corporation Power Quality Troubleshooting


Solutions should, of course, never be vio- Recording at the
lated, but it is also important to receptacle outlet
Performance Wiring vs. understand that the Code’s ob-
Code Minimum By monitoring voltage events at
jective is not to establish stan- the receptacle, you can see ex-
Any experienced PQ trouble- dards to achieve power quality. actly the same voltage that the
shooter will tell you that the However, many facilities are sensitive load sees.
first place to look for most prob- finding that it pays to take the The VR101 is plugged into
lems is in the building wiring extra step and install or even an outlet, and can record up
system (including its grounding retrofit a performance wiring to 4000 events, including:
system). Quality power depends job. As one veteran said, “If
on quality wiring; the term the every building were perfor- • Voltage sags and swells (rms)
industry uses is performance mance wired, I’d be out of • Outages
wiring (See Table 1.2). The ba- business. . . But there’s no fear • Transients (L-N and N-G)
sic intent of performance wiring of that happening.” with peak values
is to maintain or restore L-N • Frequency deviation
voltage to the load. There is a Power conditioning Events are identified by type,
distinction between “perfor- There are also situations where real-time stamp, and duration.
mance wiring” and “code mini- receptacle-installed power con-
mum” wiring. The NEC sets the ditioning devices are a good so- VR101S operation
absolute minimum requirements lution, either as a complement Set up
for a wiring job and is primarily to the wiring changes or as an
concerned with fire prevention Use EventView software to
economically viable alternative configure the device. The unit
and personnel safety. The NEC to some wiring changes. comes with default thresholds,
but users can enter new thresh-
olds. An optical wand, supplied
200 ft
60m with the software, transfers
new configurations to the VR101.
Plug in
50 ft
15m The VR101 is left on-site for as
long as needed. No computer
connection is necessary. It
draws power from the line and
in the event of outages, a built-
in battery saves data.

Laser Download
Printer
The VR101 is taken to the
computer. The optical wand
retrieves its data.
Copier

Analyze
Events are displayed in spread-
Figure 1.5 Performance wiring. sheet format in EventView
software. Charts, graphs and
waveform graphics are also
Table 1.2 Suggestions for performance wiring of branch circuits. provided for report generation.
Recommendation Reason
Check for loose connections. It’s easy to overlook the obvious.
Eliminate shared neutrals. In new Minimize load interaction and source
installations, pull individual neutrals impedance.
for each branch circuit.
Limit the number of receptacles per Minimize loading and load interaction.
branch circuit to three.
Limit length of 120V branch circuits Minimize source impedance.
to 50 ft. (15m).
Install dedicated branch circuits for all Keep victim loads and culprit loads separated.
laser printers and copy machines. Dedicated Conduit prevents coupling between circuits.
circuits should be run in their own conduit.
Install a green wire ground (don’t just Maintain a continuous, low impedance
depend on the conduit connection). ground.
Label all panels, circuit breakers and Strictly speaking, this won’t improve power
receptacles. quality, but it will sure make life easier for
the troubleshooter and the installer.

Power Quality Troubleshooting Fluke Corporation 7


Table 2.1 Service panel measurements.
Section 2 Measurement Look for Instrument
Service Panels 1. Feeder phase current Overloading and balance. 43, 41B, 87 w/80i-400,
True-rms ClampMeter

Check-out the service panel 2. Feeder neutral current High currents from unbal- 43, 41B for spectrum.
anced fundamental and 87 to find dominant
as follows: 3rd harmonics. frequency.
• Visual inspection 3. Feeder N-G voltage High voltage indicates Same
• Feeder conductor current test excessive current, near-zero
indicates possible subpanel
• Neutral conductor current test N-G bond.
(feeder and branch)
4. Branch L-N voltage Low voltage. Same
• Phase-to-neutral voltage test 5. Branch neutral current Shared neutrals. Same
(feeder and branch)
6. Voltage drop across Worn contacts. Breakers in 43, 87
• Neutral-to-ground voltage breaker contacts. need of replacement.
test (feeder) Hot breakers.
• Circuit breaker voltage drop
and current on branch phase
conductors vice panels; or that the understood that any funda-
The service panel is where the quickest way to reduce N-G mental current resulting from
effects of single-phase harmonic voltage was to install a the unbalance of single phase
loads are easy to measure. A jumper, or that the more loads among the three phases
true-rms meter ensures accurate grounds the better. In any will return on the neutral, but
readings of non-linear voltages case, remove all illegal a relatively recent phenom-
and currents (see “Why True- N-G bonds—no exceptions. enon is the third harmonic
rms, page 27). • Look for signs of overheat- (triplen) currents generated by
ing, such as discolored con- nonlinear single-phase loads
Visual inspection necting lugs. Loose con- that all return on the neutral.
nections and excessive load- The 1996 NEC for the first
• Look for an illegal Neutral- ing show up as heat. High time stated that “On a 4-wire,
Ground bond in subpanels. levels of harmonic current 3-phase wye circuit where the
This is a violation of the NEC that were not accounted for major portion of the load con-
as well as of PQ wiring. It is in the original wire sizing sists of nonlinear loads, there
also extremely common. If an can also cause overheating. are harmonic currents present
illegal N-G bond is found in Infrared sensors are the in the neutral conductor, and
one panel at a site, it is likely preferred method for the neutral shall be considered
to be in any number of them. non- contact temperature to be a current-carrying con-
Who knows why they’re measurement. ductor.” (Article 310, “Notes to
there: perhaps the installer • Of particular concern is the Ampacity Tables of 0 to 2000
was thinking that all panels size of the feeder neutral Volts,” Note 10.c). In effect, this
are wired like residential ser- conductor. It has long been requires that the neutral con-
ductor at least equal the size of
the phase conductor. This re-
quirement is based on solid re-
search: a 1990 survey of 146
sites nation-wide found that
22.6% of them had neutral
current in excess of 100% of
Line phase current!
Neutral Many experts would recom-
Ground
mend that the neutral be
N-G double the size of the phase
Bond conductor.
Panel Sub-Panel
• Check for shared branch
neutrals. Count neutral con-
ductors for branch circuits: if
there are fewer than the phase
conductors, there are shared
neutrals.
• Check tightness of conduit
connections, especially if the
conduit is being used exclu-
Figure 2.1 Sub-panel N-G bonds cause load return currents to flow on ground conductors. sively as the grounding con-
This causes corrosion of pipes in grounding system as well as noisy grounds.
ductor (not recommended).

8 Fluke Corporation Power Quality Troubleshooting


Measurements
1. Feeder phase current
Check each phase to make sure
it is not overloaded. Also check Circuit breaker
for excessive unbalance. voltage drop

2. Feeder neutral current


Measure the feeder neutral Feeder
conductor for cumulative neu- phase
tral current. Third harmonic current(s)
currents from all three phases
will add arithmetically in the
neutral.
3. Feeder neutral-to-ground
voltage test
As at the receptacle, excessive Feeder
Branch
N-G voltage indicates overload- neutral
L-N
ing. A N-G voltage at or very current
voltage
near zero indicates the exist-
ence of an illegal N-G bond in a
subpanel.
4. Phase-to-neutral Branch neutral current
voltage test
Phase-to-neutral voltages are N-G voltage
measured and recorded. They
can be compared with recep-
tacle L-N voltages to measure
voltage drop.
5. Branch neutral current
Measure each branch neutral Figure 2.2 Panel with clamps, probes to show measurements.
for overloading. The neutrals
are measured instead of the
phase conductors because they Solutions
might share the return current Table 2.2 Service panel recommendations.
of several phase conductors,
yet they are not protected Recommendation Reason
by breakers. Limit length of 208V feeder runs to 120V Minimize source impedance and chance
subpanels to 200 ft. (65m). of voltage sags.
6. Circuit breaker Don’t cascade (daisy chain) subpanels off Upstream loads can cause voltage sags that
voltage drop of other subpanels if possible, and will affect all downstream loads.
especially if the upstream panel is heavily
The voltage drop across a set loaded or has loads with high inrush
of breaker contacts will give currents.
you a quick measure of the Install a green wire ground conductor Maintain a continuous, low impedance
wear of those contacts. Ideally, (don’t rely on conduit connections). ground.
the voltage drop should be Reduce the load on the panel if necessary. Minimize heat, voltage sags.
zero. In practice, there will be Redistribute branch circuit loads to improve Reduce neutral return current (of the
some voltage drop in the mV balance of the three phases. fundamental current).
range, with the exact value be- Upsize the feeder neutral if necessary, to Prevent overloading and heating of feeder
ing dependent on the load cur- accommodate the third harmonic. This can neutral. Will reduce N-G voltage.
rent. As a general rule, the be done by running another neutral
in parallel.
voltage drop should not exceed
20-100 mV, depending on load. Install 3rd harmonic filter. Reduce neutral current.
Replace worn breakers. Nonlinear load panel. Manufacturer-designed for nonlinear loads.

Power Quality Troubleshooting Fluke Corporation 9


Section 3
Measurements • Compare actual load kVA
1. Transformer loading (kVA) to nameplate kVA rating to
Transformers determine % loading.
If the transformer has a four-
wire wye secondary, which is If the load is balanced, a single
Transformers are subject to the standard configuration for measurement is sufficient. (see
overheating from harmonic cur- commercial single-phase loads, Figure 3.1) Transformers loaded
rents. Transformers supplying actual kVA can be easily at less than 50% are generally
non-linear loads should be determined. (See Figure 3.2) safe from overheating. However,
checked periodically to verify as loads increase, measure-
operation within acceptable • Connect voltage probes on ments should be made periodi-
limits. Transformers are also Phase 1 and Neutral and cally. At some point the
critical to the integrity of the clamp current probe on same transformer may require derat-
grounding system. phase. Repeat for Phase 2 ing (see page 15).
and 3.
• Read kVA of each phase and
sum all three for total trans-
former kVA.

Red

Black

Figure 3.3 Harmonic spectrum.


For a balanced load: kVATOTAL = kVA1 • 3
= (kVA1)(1.732)
2. Harmonic spectrum
The harmonic spectrum of the
secondary (load) current will
give us an idea of the harmonic
Figure 3.1 Measuring transformer load (balanced). orders and amplitudes present:
• In a transformer feeding
single-phase loads, the prin-
ø1 cipal harmonic of concern is
Red the 3rd. The 3rd will add
kVA1
arithmetically in the neutral
and circulate in the delta pri-
mary of a delta-wye trans-
former. The good news is
ø2 that the delta-wye tends to
Red
isolate the rest of the system
kVA2 from the 3rd (though not the
5th, 7th or other non-triplen
harmonics). The bad news is
Black Black
that the transformer pays the
N price with additional heat.
Black
• In a transformer feeding
ø3
three-phase loads which in-
Red
clude drives or UPS systems
with 6-pulse converters, the
5th and 7th harmonic will
kVA3 tend to predominate. Exces-
Unbalanced load: sive 5th is of particular con-
kVATOTAL = kVA1 + kVA2 + kVA3
cern because it is negative
sequence. It will tend to
produce counter-torque and
overheating in polyphase
Figure 3.2 Measuring transformer load (unbalanced).
motors.

10 Fluke Corporation Power Quality Troubleshooting


Table 3.1 Measurements at the distribution transformer. 3. Total Harmonic Distortion
Measurement Look for Instrument
Check for THD of both voltage
1. kVA Transformer loading. If loading 43, 41B and current:
exceeds 50%, check for harmonics
and possible need for derating. • For voltage, THD should
not exceed 5%
2. Harmonic spectrum • Harmonic orders/amplitudes present: Same
3rd harmonic (single-phase loads)
5th, 7th (primarily three-phase loads)
• For current, THD should not
exceed 5-20% (Table 3.2)
• Resonance of higher order harmonics
• Effectiveness of harmonic trap filters IEEE 519 sets limits for harmon-
3. THD Harmonic loading within limits: Same ics at the PCC (Point of Common
Voltage %THD <5% Coupling) between the utility
Current %THD <5-20% (Table 3.2) and customer (EN50160 is the
4. K-factor Heating effect on transformer from Same European standard). IEEE 519
harmonic loads is based on THD measurements
5. Ground currents • Objectionable ground currents are Same taken at the PCC. Technically,
not quantified but are prohibited by True-rms Clamp the PCC is the primary of the
the NEC. utility supply transformer (al-
• Neutral-ground bond in place
• ESG (Electrical Safety Ground) though there are cases where
connector to ground electrode the PCC is at the secondary if
(typically building steel) in place the secondary feeds a number
of customers). In practice, these
measurements are often made
• Harmonic amplitudes • Before-and-after harmonic at the secondary of the
normally decrease as the spectrum measurement is ex- customer’s main transformer,
frequency goes up. If one tremely valuable to deter- since that is the point most eas-
frequency is significantly mine if harmonic mitigation ily accessible to all parties (and
higher in amplitude than techniques, like trap filters, also since that is generally a
lower frequencies, we can which are tuned to specific Low Voltage measurement).
suspect a resonant condition frequencies, are sized prop- Some PQ practitioners have
at that frequency. If such a erly and are working as broadened the concept of PCC
condition is detected, be sure expected. to include points inside the fa-
to take readings at capacitor • Different harmonic frequen- cility, such as on the feeder sys-
banks to see if the caps are cies affect equipment in dif- tem, where harmonic currents
experiencing overcurrent/ ferent ways (see below). being generated from one set
overvoltage conditions. of loads could affect another set
of loads by causing significant
Harmonic Sequences voltage distortion. The emphasis
Name F 2nd 3rd 4th 5th 6th 7th 8th 9th is on improving in-plant PQ,
Frequency 60 120 180 240 300 360 420 480 540 rather than on simply not af-
Sequence + — 0 + — 0 + — 0 fecting utility PQ.
Rule: If waveforms are symmetrical, even harmonics disappear.
3a. Voltage THD
Effects of Harmonic Sequences THD has a long history in the
industry. The underlying con–
Sequence Rotation Effects (from skin effect, eddy currents, etc.)
cept is that harmonic currents
Positive Forward Heating of conductors, circuit breakers, etc. generated by loads will cause
Negative Reverse Heating as above + motor problems voltage distortion (E=IZ) as they
Zero None Heating, + add in neutral of 3-phase, 4-wire system travel through the system
impedance. This voltage
Harmonics are classified as follows: distortion then becomes the
1. Order or number: Multiple of fundamental, hence, 3rd is three times the carrier of harmonics system-
fundamental, or 180 Hz.
wide: if, for example, the
2. Odd or even order: Odd harmonics are generated during normal operation of distorted voltage serves a linear
nonlinear loads. Even harmonics only appear when there is dc in the system.
In power circuits, this only tends to occur when a solid state component(s), load like a motor, it will then
such as a diode or SCR, fails in a converter circuit. create harmonic currents in that
3. Sequence: linear load. By setting maximum
• Positive sequence. Main effect is overheating. limits for voltage distortion, we
• Negative sequence. Create counter-torque in motors, i.e., will tend
set limits for the system-wide
to make motors go backwards, thus causing motor overheating. impact of harmonics.
Mainly 5th harmonic.
• Zero sequence. Add in neutral of 3-phase, 4-wire system.
Mainly 3rd harmonic.

Power Quality Troubleshooting Fluke Corporation 11


Table 3.2 IEEE 519 limits for harmonic currents at the point of common coupling. The SCR (Short Circuit Ratio) is
(All percentages are % of I L, maximum demand load current.) a measure of the electrical size
Odd Harmonics of the customer in relation to
SCR=Isc/IL <11 11-17 17-23 23-35 >35 TDD the utility source. The smaller
<20 4.0% 2.0% 1.5% 0.6% 0.3% 5.0% the customer (higher SCR), the
20-50 7.0% 3.5% 2.5% 1.0% 0.5% 8.0%
less the potential impact on the
utility source and the more gen-
50-100 10.0% 4.5% 4.0% 1.5% 0.7% 12.0% erous the harmonic limits. The
100-1000 12.0% 5.5% 5.0% 2.0% 1.0% 15.0% larger the customer (smaller
>1000 15.0% 7.0% 6.0% 2.5% 1.4% 20.0% SCR), the more stringent the
SC R = Short circuit ratio (Isc/IL)
limits on harmonic currents.
Isc = Available short circuit current at PCC
I L = Maximum demand load current (rms amps) 3c. TDD and THD
TDD = Total demand distortion TDD (Total Demand Distortion) is
Note: IEEE allows these limits to be exceeded for up to one hour per day, while IECthe ratio of the current harmon-
allows them to be exceeded for up to 5% of the time. ics to the maximum load (I L).
The concept of I L , maximum demand load current, is key to using Table 3.2. For existing
It differs from THD in that THD
facilities, I L is calculated by averaging the maximum demand current for 12 consecutive
is the ratio of harmonics to the
months (information available in billing records). For new installations, I L must be esti-
mated. Transformer rating could be used and would be the most conservative estimateinstantaneous load. Why TDD
instead of THD? Suppose you
(i.e., it would result in the lowest SCR), since it assumes that the transformer would be
used at full capacity.
were running a light load (using
a small fraction of system ca-
Voltage distortion, however, For equipment manufactur- pacity), but those loads were
depends on source impedance, ers, IEC 1000-3-2, published nonlinear. THD would be rela-
i.e., on system capacity. It was in 1995, is the applicable stan- tively high, but the harmonic
quite possible for the first (or dard. It specifies maximum currents actually being gener-
second or third) customer to in- current levels out to the 40th ated would be low, and the ef-
ject significant harmonic cur- harmonic. Its expected effective fect on the supply system would
rents into the system and not date is projected to be early in fact be negligible. So who
cause voltage THD to exceed 2001. To certify for CE, a re- cares? TDD acknowledges this,
5%. The entire responsibility for quirement for the European and allows harmonic load to be
harmonic mitigation could fall market, manufacturers will referenced to the maximum
on the last customers unlucky have to meet this standard. This load: if harmonic load is high
enough to push V—THD over edict will have a major effect on at maximum load, then we have
5%, even if their particular har- power supply design. to watch out for the effect on
monic load was relatively For the facility, IEEE 519 is the supply source. So where
small—literally the straw that the standard (EN 50160 in Eu- does that leave current THD
broke the camel’s back. rope). The limits set in IEEE 519 as a useful measurement. The
for harmonic currents depend closer the current THD
3b. Current THD on the size of the customer reading(s) is taken to conditions
To restore some fairness to this relative to the system capacity. of maximum load, the closer it
situation, standards for maxi- (See Table 3.2.) approximates TDD.
mum current harmonics were
added, since current harmonics Table 3.3
were under the control of the Inspection of Transformer Ground Explanation
local facility and equipment
Check for N-G bond. A high impedance N-G bond will cause
manufacturer (remember, har- voltage fluctuation.
monic “loads” act as “genera-
Check for grounding conductor and Fault currents will return to the source via
tors” of harmonics). This integrity of connection to building steel these connections, so they should be as low
emphasis on the mitigation of (exothermic weld). impedance as possible.
current harmonics at the load, Check for tightness of all If the conduit is not itself grounded, it will
including the not-too-distant conduit connections. tend to act as a “choke” for higher frequencies
requirement that the load gen- and limit fault current (remember that fault
erate virtually no harmonics, currents are not just at 60 Hz but have
high-f components).
has become the prevailing
regulatory philosophy. It puts Measure for ground currents on the Ideally there should be none, but there will
grounding conductor. always be some ground current due to
the burden of responsibility on normal operation or leakage of protective
the local site and on the equip- components (MOVs, etc.) connected from phase
ment manufacturers. or neutral to ground. However, anything above
an amp should be cause for suspicion (there is
no hard and fast rule, but experienced PQ
troubleshooters develop a feel for possible
problems).

12 Fluke Corporation Power Quality Troubleshooting


A final word on measuring transformer supplying office Transformer grounding
THD: the one place not to apply loads. The higher ratings tend The proper grounding of the
the specs is at the individual to be packaged into PDUs transformer is critical. (Table
harmonic-generating load. This (Power Distribution Units) 3.3.) NEC Article 250 in general
will always be a worst-case which are specially designed and 250-26 in particular
distortion and a misleading to supply computer and other address the grounding require-
reading. This is because as har- PQ-sensitive installations. ments of the SDS.
monics travel upstream, a cer-
tain amount of cancellation 5. Ground currents • A ground reference is estab-
takes place (due to phase rela- lished by a grounding con-
Two prime suspects for exces- nection, typically to building
tionships which, for practical sive ground current are illegal
purposes, are unpredictable). steel (which, in turn, is re-
N-G bonds (in subpanels, re- quired to be bonded to all
Measure at a PCC, or at the ceptacles or even in equip-
source transformer. cold water pipe, as well as
ment) and so-called isolated any and all earth grounding
ground rods: electrodes). Bonding should
4. K-factor
K-factor is a specific measure of
• Subpanel N-G bonds create be by exothermic weld, not
a parallel path for normal re- clamps that can loosen over
the heating effect of harmonics turn current to return via the time. The “grounding elec-
in general and on transformers grounding conductor. If the trode conductor” itself should
in particular. It differs from the neutral ever becomes open, have as low a high-frequency
THD calculation in that it em- the equipment safety ground impedance as possible (not
phasizes the frequency as well becomes the only return least because fault current
as the amplitude of the har- path; if this return path is has high frequency compo-
monic order. This is because high impedance, dangerous nents). Wide, flat conductors
heating effects increase as the voltages could develop. are preferred to round ones
square of the frequency. (Figure 2.1, page 8.) because they have less in-
A K-4 reading would mean ductive reactance at higher
that the stray loss heating • Separate isolated ground frequencies. For the same
effects are four times normal. A rods almost always create
two ground references at reason, the distance between
standard transformer is, in ef- the “grounding electrode con-
fect, a K-1 transformer. As with different potentials, which in
turn causes a “ground loop” ductor connection to the sys-
THD, it is misleading to make a tem” (i.e., N-G bond at the
K-factor reading at the load or current to circulate in an at-
tempt to equalize those po- transformer) and the ground-
receptacle because there will be ing electrode (building steel)
a certain amount of upstream tentials. A safety and
equipment hazard is also should be as short as pos-
cancellation; transformer K-fac- sible: in the words of the
tor is what counts. Once the created: in the case of light-
ning strikes, surge currents Code, “as near as practicable
K-factor is determined, choose to and preferably in the
the next higher trade size. K- travelling to ground at differ-
ent earth potentials will same area...”
factor rated transformers are
available in standard trade sizes create hazardous potential • The neutral and ground
of K-4, K-13, K-20, K-30, etc. differences. (See page 31.) should be connected at a
K-13 is a common rating for a point on the transformer neu-
tral bus. Although permitted,
it is not advisable to make
480V the N-G bond at the main
panel, in order to maintain
the segregation of normal re-
turn currents and any ground
currents. This point at the
transformer is the only point
on the system where N-G
should be bonded.

Grounding electrode nearby,


preferably structural metal

208Y/120V

Neutral

Figure 3.4 Transformer grounding.

Power Quality Troubleshooting Fluke Corporation 13


Solutions
There are a number of solutions
for transformer-related PQ
problems:
• Install additional distribution
transformers (Separately
Derived Systems)
• Derate transformers
• Install K-rated transformers
• Used forced air cooling
1. Separately Derived
System (SDS)
The distribution transformer is
the supply for a Separately
Derived System (SDS), a term
which is defined in the NEC
(Article 100). The key idea is • A new ground reference is • Hysteresis. When steel is
that the secondary of this trans- established. Part of the defi- magnetized, magnetic dipoles
former is the new source of nition of the SDS is that it all line up, so that the North
power for all its downstream “has no direct electrical con- poles all point one way, the
loads: this is a powerful concept nection, including a solidly South poles the other. These
in developing a PQ distribution connected grounded circuit poles switch with the polarity
system. The SDS accomplishes conductor, to supply conduc- of the applied current. The
several important objectives, all tors originating in another higher the frequency, the
beneficial for PQ: system.” (NEC 100) The op- more often the switching
• It establishes a new voltage portunity exists to segregate occurs, and, in a process
reference. Transformers have the subsystem served by the analogous to the effects of
taps which allow the second- SDS from ground loops and friction, heat losses increase.
ary voltage to be stepped up ground noise upstream from • Eddy currents. Alternating
or down to compensate for the SDS, and vice versa. magnetic fields create local-
any voltage drop on the ized whirlpools of current
feeders. 2. K-rated transformers that create heat loss. This
• It lowers source impedance effect increases as a square
by decreasing, sometimes of the frequency. For example,
drastically, the distance a 3rd harmonic current will
between the load and the have nine times the heating
source. The potential for volt- effect as the same current at
age disturbances, notably the fundamental.
sags, is minimized. • Skin effect. As frequency
• It achieves isolation. Since increases, electrons migrate
there is no electrical connec- to the outer surface of the
tion, only magnetic coupling, conductor. More electrons are
between the primary and using less space, so the effec-
secondary, the SDS isolates tive impedance of the con-
its loads from the rest of the ductor has increased; at the
electrical system. To extend higher frequency, the con-
this isolation to high fre- ductor behaves as if it were a
Figure 3.5 Typical K-factor in commercial
quency disturbances, spe- building.
lower gauge, lower ampacity,
cially constructed “isolation higher impedance wire.
transformers” provide a Harmonics cause heating in The industry has responded
shield between the primary transformers, at a greater rate with two general solutions to
and secondary to shunt RF than the equivalent fundamen- the effects of harmonics on
(radio frequency) noise to tal currents would. This is be- transformers: install a K-factor
ground. Otherwise, the ca- cause of their higher frequency. rated transformer or derate a
pacitive coupling between There are three heating effects standard transformer. Let’s look
primary and secondary in transformers that increase at pros and cons of the K-factor
would tend to pass these with frequency: approach first. K-factor is a
high-frequency signals right calculation based on the rms
through.

14 Fluke Corporation Power Quality Troubleshooting


value, %HD (harmonic distor- 3. Derating standard 4. Or, since the ratio of Peak/
tion) of the harmonic currents, transformers RMS is defined as Crest
and the square of the harmonic Some facilities managers use Factor, this equation can
order (number). It is not neces- a 50% derating as a rule-of- be rewritten as:
sary to actually perform the cal- thumb for their transformers xHDF = 1.414 / CF
culation because a harmonic serving single-phase, predomi- If your test instrument has
analyzer will do that for you. nantly nonlinear loads. This the capability, measure the
The important thing to under- means that a 150 kVA trans- CF of each phase directly. If
stand is that the harmonic order former would only supply 75 the load is unbalanced, find
is squared in the equation and kVA of load. The derating curve, the average of the three
that is precisely where the taken from IEEE 1100-1992 phases and use the average
high- frequency heating effects, (Emerald Book), shows that a in the above formula.
like eddy current losses, are transformer with 60% of its Since a sine wave current
taken into account. loads consisting of SMPS waveform has a CF=1.414, it
K-rated transformers are de- (switched-mode power sup- will have an xHDF=1; there will
signed to minimize and accom- plies), which is certainly pos- be no derating. The more the
modate the heating effects of sible in a commercial office 3rd harmonic, the higher the
harmonics. K-rated transformers building, should in fact be peak, the higher the CF. If the
do not eliminate harmonics derated by 50%. CF were 2.0, then the
(unless additional elements like The following is an accepted xHDF=1.414 / 2 =.71. A CF=3
filters are added). They accom- method for calculating trans- gives us an xHDF =.47. A wave
modate harmonics with tech- former derating for single-phase with CF=3 is about as badly
niques such as the use of loads only. It is based on the distorted a current waveform
a number of smaller, parallel very reasonable assumption as you can expect to see on
windings instead of a single that in single-phase circuits, the a single-phase distribution
large winding: this gives more third harmonic will predominate transformer.
skin for the electrons to travel and cause the distorted current (Caution: This method does not apply to
on. The primary delta winding waveform to look predictably transformers feeding three-phase loads,
is up-sized to tolerate the circu- peaked. where harmonics other than the third tend to
lating third harmonic currents Use a true-rms meter to make predominate and CF is not useful as a simple
without overheating. The neu- predictor of the amount of distortion. A
these current measurements: calculation for three-phase loads is available
tral on the secondary is also in ANSI/IEEE C57.110. However, there is some
up-sized for third harmonics 1. Measure rms and peak cur- controversy about this calculation since it may
(typically sized at twice the rent of each secondary underestimate the mechanical resonant
phase ampacity). phase. (Peak refers to the in- vibrations that harmonics can cause, and that
stantaneous peak, not to the accelerate transformer wear above and
inrush or “peak load” rms beyond the effects of heat alone.)
Application issues with
K-factor transformers current). 4. Forced air cooling
K-rated transformers have been 2. Find the arithmetic average If heat is the problem, cooling is
widely applied, but there are of the three rms readings and the solution. Break out the fan,
certain issues with them. Many the three peak currents and turn it on the transformer and
consultants do not see the need use this average in step 3 use forced air cooling. Some
for using transformers with a (if the load is essentially experienced hands figure that’s
rating higher than K-13 al- balanced, this step is not worth 20-30% on the up side.
though K-20 and higher might necessary). In any case, it can only help.
be supplied as part of an inte- 3. Calculate Xformer Harmonic
grated Power Distribution Unit Derating Factor:
(PDU). Also, early applications xHDF = (1.414 * I RMS) / I PEAK
sometimes overlooked the fact
that K-rated transformers nec-
essarily have a lower internal Transformer Capacity (%)
After Derating for
impedance. Whereas a standard Electronic Load
transformer has an impedance 100
typically in the 5-6% range,
K-rated transformers can go 80
as low as 2-3% (lower as the 60
K-rating increases). In retrofit
40
situations, where a standard
transformer is being replaced by 20
a K-rated transformer of equiva- 0
lent kVA, this may require new 0 20 40 60 80 100
short circuit calculations and Switched-Mode Power Supply Load (% of Overall Load)
re-sizing of the secondary
overcurrent protective devices. Figure 3-6 Transformer derating curve (IEEE 1100-1992).

Power Quality Troubleshooting Fluke Corporation 15


Section 4
• The first is that electrical Coupling mechanisms
effects do not require direct
Electrical Noise and Transients connection (such as through There are four basic mecha-
copper conductors) to occur. nisms of noise coupling. It pays
For an electrician who’s been to understand them and how
Electrical noise is the result of
trained to size, install and they differ one from the other
more or less random electrical
test wiring, this may not be because a lot of the trouble-
signals getting coupled into cir-
intuitive. Yet think of light- shooter’s job will be to identify
cuits where they are unwanted,
ning, or of the primary and which coupling effect is domi-
i.e., where they disrupt informa-
secondary of an isolation nant in a particular situation.
tion-carrying signals. Noise oc-
curs on both power and signal transformer, or of the an-
tenna to your radio: there’s 1. Capacitive coupling
circuits, but generally speaking,
it becomes a problem when it no direct, hard-wired con- This is often referred to as
gets on signal circuits. Signal nection, but somehow com- electrostatic noise and is a
and data circuits are particularly plete electrical circuits are voltage-based effect. Lightning
vulnerable to noise because still happening. The same discharge is just an extreme
they operate at fast speeds and electrical rules-of-behavior example. Any conductors sepa-
with low voltage levels. The are in operation for noise rated by an insulating material
lower the signal voltage, the coupling, as will be (including air) constitute a ca-
less the amplitude of the noise explained below. pacitor—in other words, capaci-
voltage that can be tolerated. tance is an inseparable part of
• The second concept is that any circuit. The potential for
The signal-to-noise ratio de- we can no longer stay in the
scribes how much noise a cir- capacitive coupling increases as
realm of 60 Hz. One of the
cuit can tolerate before the valid frequency increases (capacitive
benefits of 60 Hz is that it’s
information, the signal, becomes reactance, which can be
a low enough frequency that
corrupted. thought of as the resistance to
power circuits can be treated
Noise is one of the more mys- capacitive coupling, decreases
(almost) like dc circuits; in
terious subjects in PQ, especially with frequency, as can be seen
other words, basic Ohm’s
since it must be considered in the formula: X C = 1/ 2π fC).
Law will get you most places
with its equally mysterious you need to go. But when it
twin, grounding. To lessen the 2. Inductive coupling
comes to noise, we need to
mystery, there are two key keep in mind that signal cir- This is magnetic-coupled noise
concepts to understand: cuits occur at high frequen- and is a current-based effect.
cies, that noise is typically Every conductor with current
a broad spectrum of frequen- flowing through it has an asso-
cies, and that we need to ciated magnetic field. A chang-
consider the frequency-de- ing current can induce current
pendent behavior of potential in another circuit, even if that
sources of noise. circuit is a single loop; in other
words, the source circuit acts as
a transformer primary with the
victim circuit being the second-
ary. The inductive coupling
effect increases with the follow-
Noise
ing factors: (1) larger current
flow, (2) faster rate of change of
current, (3) proximity of the two
20 - 30V
logic signal
conductors (primary and sec-
ondary) and (4) the more the
adjacent conductor resembles a
coil (round diameter as opposed
to flat, or coiled as opposed to
Noise
straight).
Here are some examples of
how inductive coupling can
cause noise in power circuits:

3 - 5V
logic signal

Figure 4.1 Lower voltage, faster signals increase sensitivity to noise.

16 Fluke Corporation Power Quality Troubleshooting


• Receptacles miswired with
ØA N and G switched
• Equipment with internal solid
ØB state protective devices that
Ø-Ø have shorted from line
or neutral to ground, or that
have not failed but have nor-
N
mal leakage current. This
leakage current is limited by
UL to 3.5 mA for plug-con-
ØC
nected equipment, but there
is no limit for permanently
wired equipment with poten-
tially much higher leakage
currents. (Leakage currents
Noise Coupling Ø-G N-G
are easy to identify because
they will disappear when the
device is turned off).
Ground • Another common example is
the so-called isolated ground
Figure 4.2 Noise coupling. Ground noise measured as ø -G or N-G noise. rod. When it is at a different
earth potential than the
source grounding electrode,
• A transient surge, especially should be run in its own metal a ground loop current occurs.
if it occurs on a high-energy conduit when possible is that is This is still conducted noise,
circuit, causes a very fast in effect magnetically shielded even though the direct con-
change in current which can to minimize inductive coupling nection is through the earth.
couple into an adjacent con- effects.
ductor. Lightning surges are a Both inductive and capacitive • Datacom connections that
worst case, but common provide a metallic path from
coupling are referred to as near one terminal to another can
switching transients or arc- field effects, since they domi-
ing can do the same thing. also conduct noise. In the
nate at short distances and dis- case of single-ended, unbal-
• If feeder cables are posi- tance decreases their coupling anced connections (RS-232),
tioned such that there is a effects. This helps explain one the connection to terminal
net magnetic field, then cur- of the mysteries of noise—how ground is made at each end
rents can be induced into slight physical repositioning of of the cable. This offers a
ground cables that share the wiring can have such major path for ground currents if
raceway. effects on coupled noise. the equipment at each end
• It is well known that signal 3. Conducted noise
is referenced to a different
wires and power conductors power source with a different
should not be laid parallel to While all coupled noise ends up ground.
each other in the same race- as conducted noise, this term is
way, which would maximize generally used to refer to noise 4. RFI (Radio Frequency
their inductive coupling, but that is coupled by a direct, gal- Interference)
instead be separated and vanic (metallic) connection. In- RFI ranges from 10 kHz to the
crossed at right angles when cluded in this category are 10s of MHz (and higher). At
necessary. Input and output circuits that have shared con- these frequencies, lengths of
cables should also be isolated ductors (such as shared neutrals wire start acting like transmit-
from each other in the same or grounds). Conducted noise ting and receiving antennas.
manner. could be high frequency, but The culprit circuit acts as a
Magnetic fields are isolated by may also be 60 Hz. transmitter and the victim circuit
effective shielding. The material These are some common is acting as a receiving antenna.
used must be capable of con- examples of connections that RFI, like the other coupling
ducting magnetic fields (ferrous put objectionable noise currents mechanisms, is a fact of life, but
material as opposed to copper). directly onto the ground: it can be controlled (not without
The reason that a dedicated cir- • Sub-panels with extra N-G some thought and effort, how-
cuit (hot, neutral, ground) bonds ever).

Power Quality Troubleshooting Fluke Corporation 17


RFI noise reduction employs • A low-impedance path can Signal Grounding
a number of strategies: be used to shunt away the To understand the importance of
• Fiber optic cable, of course, noise. This is the principle “clean” signal grounds, let’s dis-
is immune to electrical noise. behind filtering and the use cuss the distinction between
• Shielded cabling (such as of decoupling caps (low im- Differential Mode (DM) vs. Com-
coax cables) attempts to pedance to high frequency, mon Mode (CM) signals. Imag-
break the coupling between but open at power line fre- ine a basic two-wire circuit:
the noise and signal. quencies). But a sometimes- supply and return. Any current
• Balanced circuits (such as overlooked, yet critical, as- that circulates or any voltage
twisted pair) don’t break the pect is that the ground path read across a load between
coupling, but instead take and plane must be capable the two wires is called DM
advantage of the fact that of handling high-frequency (the terms normal mode, trans-
the RFI will be coupled into currents. High-frequency verse mode and signal mode
both conductors (signal and grounding techniques are are also used). The DM signal is
return). This noise (called used to accomplish this. The typically the desired signal (just
Common Mode noise) is then SRG (Signal Reference Grid), like 120V at a receptacle).
subtracted, while the signal first developed for raised Imagine a third conductor, typi-
is retained. In effect, the bal- floor computer room installa- cally a grounding conductor.
anced circuit creates a high tions, is an effective solution. Any current that flows now
impedance for the coupled It is essentially an equipo- through the two original con-
noise. tential ground plane at high- ductors and returns on this third
• Another example of the frequency. (For further infor- conductor is common to both of
high-impedance-to-noise mation on high-frequency the original conductors. The CM
approach is the use of RF grounding, see the refer- current is the noise that the
chokes. Whether used with ences listed on the back page.) genuine signal has to overcome.
data or power cables, RF CM is all that extra traffic on the
chokes can offer effective highway. It could have gotten
high-frequency impedance there through any of the cou-
(X L increases with frequency). pling mechanisms, such as
magnetic field coupling at
power line frequency or RFI at
higher frequencies. The point is
to control or minimize these
A Matter of Life and Death ground or CM currents, to make
life easier for the DM currents.
Sometimes PQ troubleshooting that they had been laid parallel
is a matter of life and death. to the power cord. The coupling Measurement
Dave was the on-site field between signal and power CM currents can be measured
engineer at the hospital. One wires caused the 60 Hz “Heart- with current clamps using the
day he got a call from a very beat” on the EKG machine. zero-sequence technique. The
concerned nurse in the ER. One The moral of the story is to clamp circles the signal pair (or,
of their patients had died. But always isolate the signal and in a three-phase circuit, all
as upsetting as that was, it power conductors—before it three-phase conductors and the
wasn’t the main source of con- becomes a matter of life neutral, if any). If signal and re-
cern. What was really unusual and death. turn current are equal, their
was that this particular corpse equal and opposite magnetic
had a heartbeat. fields cancel. Any current read
Dave soon arrived at the must be common mode; in other
scene. A quick glance told him words, any current read is cur-
that the dead had not come rent that is not returning on the
back to life. The problem lay signal wires, but via a ground
elsewhere. The nurses pointed path. This technique applies to
out what they had seen, a sig- signal as well as power conduc-
nal on the EKG indicating a tors. For fundamental currents, a
heartbeat. But there was some- ClampMeter or DMM + clamp
thing unusual about this signal would suffice, but for higher fre-
(above and beyond the fact that quencies, a high bandwidth in-
it seemed to be coming from a strument like the Fluke 43
dead body). He noticed that the Power Quality Analyzer or
signal was a 60 Hz sine wave ScopeMeter should be used
(slightly flat-topped). A further with a clamp accessory.
look at the signal wires told him

18 Fluke Corporation Power Quality Troubleshooting


Transients Causes
Transients are unavoidable.
They are created by the fast
switching of relatively high cur-
rents. For example, an inductive
load like a motor will create a
Cursor moves to display peak Min/Max values.
kickback spike when it is turned
off. In fact, removing a Wiggy (a
Real-time stamp. Date:hr:min:sec
solenoid voltage tester) from a
high-energy circuit can create a
spike of thousands of volts! A
capacitor, on the other hand,
creates a momentary short cir-
cuit when it’s turned on. After
this sudden collapse of the ap-
plied voltage, the voltage re-
bounds and an oscillating wave
Figure 4.3 Fluke 43 can capture and save up
to 40 transients.
occurs. Not all transients are the
same, but as a general state-
Transients should be distin- ment, load switching causes
guished from surges. Surges are transients.
a special case of high-energy In offices, the laser copier/
transient which result from printer is a well-recognized
lightning strikes (see section 5, “bad guy” on the office branch
“PQ Troubleshooting of Light- circuit. It requires an internal
ning Protection Systems”). Volt- heater to kick in whenever it is
age transients are lower energy used and every 30 seconds or
events, typically caused by so when it is not used. This
equipment switching. • Utility capacitor switching constant switching has two
They are harmful in a transients are an example of effects: the current surge or in-
number of ways: a commonly-occurring high- rush can cause repetitive volt-
energy transient (still by no age sags; the rapid changes in
• They deteriorate solid state means in the class of light- current also generate transients
components. Sometimes a that can affect other loads on
single high energy transient ning) that can affect loads at
all levels of the distribution the same branch.
will puncture a solid state
junction, sometimes repetitive system. They are a well
known cause of nuisance Measurement and recording
low energy transients will ac-
complish the same thing. For tripping of ASDs: they have Transients can be captured by
example, transients which enough energy to drive a DSOs (Digital Storage Oscillo-
exceed the PIV (peak inverse transient current into the dc scopes). The Fluke 43 PQ
voltage) rating of diodes are link of the drive and cause Analyzer, which includes DSO
a common cause of diode an overvoltage trip. functions, has the ability to
failure. Transients can be categorized capture, store and subsequently
by waveform. The first category display up to 40 transient
• Their high-frequency compo- is “impulsive” transients, com- waveforms. Events are tagged
nent (fast rise times) cause with time and date stamps (real
them to be capacitively monly called “spikes,” because
a high-frequency spike pro- time stamps). The VR101S Volt-
coupled into adjoining con- age Event Recorder will also
ductors. If those conductors trudes from the waveform. The
cap switching transient, on the capture transients at the recep-
are carrying digital logic, that tacle. Peak voltage and real time
logic will get trashed. Tran- other hand, is an “oscillatory”
transient because a ringing stamps are provided.
sients also couple across
transformer windings unless waveform rides on and distorts
special shielding is provided. the normal waveform.
Fortunately this same high It is lower frequency, but
frequency component causes higher energy.
transients to be relatively
localized, since they are
damped (attenuated) by the
impedance of the conductors
(inductive reactance increases
with frequency).

Power Quality Troubleshooting Fluke Corporation 19


Transient voltage surge
suppressors (TVSS)
Fortunately, transient protection Voltage susceptibility profile
is not expensive. Virtually all
electronic equipment has (or The new ITIC profile (Informa- power conditioning equipment
should have) some level of pro- tion Technology Industry Coun- or other remedial action. A ma-
tection built in. One commonly- cil) is based on extensive jor change in ITIC is that the
used protective component is research and updates the ride-through times for outages
the MOV (metal oxide varistor) CBEMA curve. The CBEMA as well as the tolerance for sags
which clips the excess voltage. curve (Computer Business have both been increased.
TVSS are applied to provide Equipment Manufacturers Asso- The field troubleshooter must
additional transient protection. ciation, now ITIC) was the origi- keep in mind that the profiles
TVSS are low voltage (600V) nal voltage susceptibility profile are recommendations and that
devices and are tested and cer- for manufacturers of computers a particular piece of equipment
tified to UL 1449. UL 1449 rates and other sensitive equipment. may or may not match the pro-
TVSS devices by Grade, Class Similar curves are being devel- file. Having said that, the pro-
and Mode. As an example, the oped for 230V/50Hz equipment files are still useful because,
highest rating for a TVSS would and for adjustable speed drives. when recorded events are plot-
be Grade A (6000V, 3000A), Sensitive equipment should be ted against them, they give a
Class 1 (let-through voltage of able to survive events inside the general idea of the voltage
330V max) and Mode 1 (L-N curve. Events outside of the quality at a particular site.
suppression). The proper rating curve could require additional
should be chosen based on the
load’s protection needs: 500

• A lower Grade might result in


a TVSS that lasts one year in-
stead of ten years. The solid
state components in a TVSS
will themselves deteriorate as
Percent of nominal voltage (RMS or peak equivalent)

400
they keep on taking hits from
transients.
• A lower Class might permit too
much let-through voltage that
could damage the load. Class
300
1 is recommended for switch
mode power supplies.
Applicable to 120, 120/208, and
• A Mode 2 device would pass 120/240 nominal voltages
transients to ground, where
they could disrupt electronic
200
circuit operation.

140
120
110 110V
100 Voltage-Tolerance
90 envelope 90V
80
70

40

0
0.001c 0.01c 0.1c 0.5c 1c 10c 100c 1000c
1µs 1ms 3ms 20ms 0.5s 10s Steady
state
Duration of disturbance in cycles (c) and seconds (s)

Figure 4.4 ITIC Curve.

20 Fluke Corporation Power Quality Troubleshooting


Table 5.1 Inspection of lightning protection system.
Section 5 Check Look for Reason
Lightning Protection Surge arrestors • Installed at main service • Lightning is high energy
panel, subpanels and and needs multilevel
Lightning protection plays a critical equipment. protection.
• To minimize high • Lightning has high f
vital part in the overall power frequency impedance, components. Shorter leads
quality of an installation. Light- leads should be short, have less XL and less
ning occurrence varies by geog- with no bends. impedance at high f.
raphy, with Florida being the Grounding electrode • Grounding electrode • Ensure low impedance
lightning capital of the U.S. conductors at service connections are not loose ground to minimize
Lightning does not have to entrance or at SDS or corroded. potential to ground with
• Grounding conductor lightning induced surges.
score a direct hit to be disrup- should not be coiled or • Minimize impedance to
tive. It has so much energy that have unnecessary bends. high frequency
it couples surges into conduc- components of lightning.
tors, both those exposed to air Grounding electrode bonding All grounding electrodes Prevent difference in earth
and those buried in the ground. should be effectively bonded potential between electrodes
together (<0.1Ω). in event of lightning.
Basic lightning protection has
two main requirements: Separately driven Electrode and equipment Same as above—entire
(“isolated”) electrode ground should both be tied grounding system should be
to building steel, and an equipotential ground
1. Effective grounding thereby to the service plane for lightning.
A low impedance of the ground- entrance ground.
ing electrode system to earth is Datacom cabling that runs Surge arrestors on datacom Datacom cabling run
important. But, equally impor- between buildings cabling or use of fiber optic between buildings can be a
tant is that all parts of the cables. path for surge currents, due
to differences between
grounding system be bonded building earth potentials.
together: all ground electrodes
Lightning protection is covered in a number of standards and codes, including:
are bonded (and extraneous NEC: Articles 250 and 280
ground rods removed), structural National Fire Protection Association: NFPA 780
steel is tied to service entrance Lightning Protection Institute: LPI-175
ground, all grounding connec- UL-96 and UL-96A
tions are tight and free of corro-
sion, etc. This minimizes the
phenomenon called “transferred 2. Surge arrestors A surge arrestor at an outside
earth potential,” where large A surge arrestor “is a protective installation is closest to the
surge currents create large volt- device for limiting surge volt- lightning event and must ab-
age differences between two ages by discharging or bypass- sorb the most energy. This is
ground points with different ing surge current...” (NEC 280). considered a Category C loca-
impedances to earth. This same Since the surge current is by- tion (corresponding to CAT IV in
grounding practice is important passed to ground, surge arres- IEC 61010). Category B refers to
for performance reasons, as it tors are only as effective as the feeders and distribution panels
tends to minimize ground loop grounding system. (equivalent to CAT III in IEC
currents that circulate in an Surge arrestors are sized for 61010), and Category A refers to
attempt to equalize ground the location where they are in- receptacle connected surge ar-
potentials. stalled. Three categories are de- restors (equivalent to CAT II).
fined (ANSI/IEEE C62.41-1991).
Surge arrestor or TVSS
A surge arrestor is there to
protect the insulation and, ulti-
Load
Sub mately, prevent failures that
Main Panel
Service Surge
could lead to fires. It is not
Arrestor necessarily designed to protect
Surge sensitive equipment. That’s the
Surge Arrestor job of the TVSS (transient volt-
Arrestor age surge suppressor).

Figure 5.1. Surge arrestors installed at service, panel, load.

Power Quality Troubleshooting Fluke Corporation 21


Part II: Three-Phase Loads

Section 6 Voltage unbalance can be caused by severe load unbalance


Polyphase Induction Motors but it could just as easily be caused by loose connections
and worn contacts.
About two-thirds of the electric Example of voltage unbalance calculation:
power in the U.S. is consumed
by motors, with industrial %VUNBALANCE = Max deviation from average x 100%
three-phase motors above 5 HP Average (of three phases)
(7 kW) being by far the bulk of 1. Make three phase-to-phase measurements:
that load. They are linear loads A-B = 475V A-C = 471V B-C = 470V
and therefore don’t contribute
to harmonics. They are, how- 2. Find the average: (475+471+470) ÷ 3 = 472V
ever, the major contributor to 3. Find the maximum deviation from the average:
reduced Displacement Power This occurs on the A-B phase: 475V-472V = 3V
Factor, which is a measurement 4. Divide maximum deviation by average to find
of the effective use of system % unbalance: 3V/472V <1%
capacity.
Measurements
2. Voltage %THD and 3. Current unbalance
1. Voltage unbalance harmonic spectrum To find current unbalance, mea-
Voltage unbalance should not Voltage THD should not exceed sure amps in all three phases.
exceed 1-2% (unless the motor 5% on any phase. If the voltage Do the same calculation as for
is lightly loaded). Why such a distortion on any phase is ex- voltage unbalance. In general,
small number? Voltage unbal- cessive, it can cause current un- current unbalance should not
ance has a very large effect on balance. The usual culprit is the exceed 10%. However, unbal-
current unbalance, in the neigh- 5th harmonic and therefore the ance can usually be tolerated if
borhood of 8:1. In other words, harmonic spectrum should be the high leg reading doesn’t ex-
a voltage unbalance of 1% can examined for the 5th in particu- ceed the nameplate FLA (Full
cause current unbalance of 8%. lar. The 5th is a negative se- Load Amps) and SF (Service
Current unbalance will cause quence harmonic which creates Factor). The FLA and Service
the motor to draw more current counter-torque in the motor. A Factor are available on the mo-
than it otherwise would. This in motor fed by a voltage with tor nameplate. If the voltage un-
turn causes more heat and heat high 5th harmonic content will balance and the voltage THD
is the enemy of motor life, since tend to draw more current than are within limits, high current
it deteriorates the winding insu- otherwise. This is a major prob- unbalance can be an indication
lation. lem when across-the-line or of motor problems, such as
soft-start motors share the same damaged winding insulation or
bus with ASDs. uneven air gaps.
Current measurement will
Table 6.1 Measurements at the motor. also find single-phasing. If a
Measurement Look for Instrument three-phase motor loses a
1. Voltage unbalance Unbalance <1% 43, 41B, 87
phase (perhaps caused by a
blown fuse or loose connection),
2. Voltage %THD %THD <5% 43, 41B
it may still try to run single
3. Current unbalance Unbalance <10% 43, 41B phase off the remaining two
87 w/80i-400
Single phasing No current on one phase. phases. Since the motor acts
(extreme current like a constant power device, it
unbalance) will simply draw additional cur-
4. Loading • Nameplate data on FLA1 and SF2 : Same rent in an attempt to provide
Current < (FLA x SF). sufficient torque. A voltage mea-
• Overloading or extreme underloading. surement alone will not neces-
80% of rated load is optimal.
sarily find this condition, since
5. Inrush current • Inrush causing voltage sag. 43 voltage is induced by the two
• Inrush causing nuisance trips.
powered windings into the
6. Power factor • Low Displacement PF. 43, 41B non-powered winding.
• Large difference between DPF and PF
(Total Power Factor) indicating harmonics.
1 FLA = Full Load Amps
2 SF = Service Factor
(If the FLA = 100A and the SF=1.15, the motor can be run at 115A continuously.)

22 Fluke Corporation Power Quality Troubleshooting


Flattopping
Effects of inrush current
1. Inrush causes voltage sags if
the source voltage is not stiff
enough:
• Relays and contactor coils
might drop out (typically,
the sag would have to get
Total harmonic distortion < 5% as bad as about 70% of
normal line voltage); or, if
they hold in, their contacts
Figure 6.1. Voltage distortion. might chatter (especially if
the additional load causes
4. Loading 5. Inrush a long-term undervoltage).
Measure current draw of the Motors which are started • Control circuits might reset
motor. If the motor is at or near across-the-line (as opposed to or lock up (at 90% and
its FLA rating (times the Service those using soft-starts or drives) below).
Factor multiplier), it will be draw a current inrush, also
more sensitive to the additional called locked rotor current. This • Drives might trip off-line
(undervoltage trip).
heating from harmonics, as well inrush tapers off to normal run-
as current unbalance. A motor ning current as the motor comes 2. High peak demand periods,
that is only lightly loaded is up to speed. which may cause higher
usually safe from overheating.
On the other hand, its efficiency
• Older motors draw an inrush 3. utility bills.
Cycling loads can cause peri-
of typically 500-600% of the
and DPF are both less than op- running current. Newer en- odic sags, which might show
timal. Most motors reach maxi- ergy efficient designs draw up as flickering lights.
mum efficiency at 60%-80% of brief inrushes as high as 4. If the motor is required to
full load rating. Displacement 1200% of running current, a start up a high torque load,
Power Factor is maximum at direct result of the lower im- the inrush can be relatively
rated load (including S.F.) and pedances which help make prolonged (e.g., 10 to 20
drops off, especially at less than them more energy efficient seconds or more) and this
80% of rated load. This leads to in the first place. can cause nuisance tripping
the conclusion that, to the de- as the overload heaters trip
gree a motor load is constant • High torque, high HP motor
loads require proportionally the motor starter.
and predictable, 80% of rated
load is the most efficient oper- higher inrush.
6. Power Factor
ating range. • Motor loads started at the
same time will have a cumu- To size PF correction capacitors,
lative inrush. it is necessary to measure the
DPF (Displacement PF) and
L1 L2 L3 Another source of inrush is UPS Active Power consumption (kW)
and ASD systems with diode of the motor load. Measurement
One converters. They draw inrush of the DPF and kW of a three-
Open current as their cap banks first phase induction motor is ex-
Fuse charge. plained in the sidebar on the
next page. These measurements
assume that the motor voltage
and current is balanced. There-
fore, before undertaking PF cor-
rection, first make sure that
voltage and current unbalance
are within limits. Either problem
can shorten motor life and
should take priority over DPF
T2 correction.
T1 T3

Single-phasing Figure 6.3. Inrush current (Model 43).

Figure 6.2. Single-phasing.

Power Quality Troubleshooting Fluke Corporation 23


Measuring Displacement Power Factor
on 3-phase Induction Motors
Select which of the two methods to use based on Method #2: Three-wire Source
the transformer configuration supplying the mo- With floating-Y, floating-delta or grounded-delta,
tor. Either method will give the same results. the voltage will be different for at least one of
Method #1 is for the grounded-Y source. It is the phase-to-ground readings. (For the floating
simple and can be applied in most situations, source, the phase-to-ground voltage is unpredictable,
since virtually all of the low voltage motors in since it depends on phase to ground capacitance).
commercial and light industrial facilities are fed Method #2 is known as the Two-Wattmeter method.
from a grounded-Y source. Method #2 is for float-
ing sources sometimes found in heavy industrial Set-up:
facilities. 1. Connect the black voltage probe to any phase.
2. Connect the red voltage probe and the clamp
Method #1: Grounded-Y source (arrow towards the load) together on a second
To check if the source is grounded-Y, measure phase. Record kW1.
voltage of each phase to ground. If the readings 3. Move red probe and clamp to the third phase
are equal, you can use this measurement method. (do not move the black probe). Record kW2.
Set-up: Record kVA (kVA of either phase will be more
1. Clamp the current probe on any phase (with or less equal if the current unbalance is within
arrow on clamp pointing towards the motor). limits).
2. Attach the red voltage probe to the same Active Power: KwMOTOR = kW1 + kW2 (If either
phase and the black probe to ground (not to kW reading is negative, as might happen on a
another phase). very lightly loaded motor, it would be subtracted
Active Power: Read kW and multiply by 3: instead of added)
kWMOTOR = 3 * kW Apparent Power: kVA MOTOR = kVA * 1.73.
Displacement PF: Read DPF. DPF = kWMOTOR / kVA MOTOR
(Not necessary to measure kVA) Example (Two-Wattmeter):
Measurements:
kW1 = + 1.52
kW2 = + 1.74
kVA = 2.41
Load Calculations:
KwMOTOR = kW1 + kW2 = (+ 1.52) + (+1.74) = 3.26 kW
kVA MOTOR = kVA * 1.73. = (2.41) (1.73) = 4.17 kVA
DPF = KwMOTOR / kVA MOTOR = 3.26 / 4.17 = 0.78
red

black
red kW1
kVA

Load

red kW2

black black

Power Factor Using the Two-Wattmeter Method:


kWTOTAL = kW1 + kW2
kVATOTAL = kVA1 • 3
kWTOTAL
PF =
kVATOTAL

24 Fluke Corporation Power Quality Troubleshooting


Section 7
PQ Troubleshooting of Adjustable Speed Drives

AC ASDs can be both a source Voltage distortion be no inrush current and no


and a victim of poor PQ (see If high-voltage distortion shows voltage sag effect on the rest of
“Measurement of Adjustable up as excessive flat-topping, it the system. Secondly, if the
Speed Drives with Fluke will prevent dc link capacitors drive is of the PWM type, with a
Meters,” document number from charging fully and will diode converter front-end, the
G0416UEN, for more information diminish the ride-through Displacement Power Factor is
on drive troubleshooting). capability of the drive. Thus a high (commonly >95% at rated
voltage sag which would not load) and more or less constant
ASDs as Victim Loads normally affect a drive will throughout the range. This
Although ASDs are usually cause the drive to trip on means that drives can reduce
depicted as the culprit in the undervoltage. energy usage and correct for
PQ scenario, there are ways Improper grounding will affect DPF at the same time. It’s a
in which they can be a victim the internal control circuits of good thing too, because drives
load as well. the drive, with unpredictable and PF correction capacitors
Capacitor switching transients results. don’t mix (see “Power System
High-energy (relatively low- Resonance,” page 28). Caps are
frequency) transients that are vulnerable to the higher fre-
ASDs as Culprit Loads quency harmonic currents gen-
characteristic of utility capacitor A drive can definitely be a “cul-
switching can pass through the prit load” and have a major im- erated by drives, since their
service transformer, feeders, impedance decreases as fre-
pact on system PQ. But before quency increases.
and converter front-end of the we talk of problems, let’s put in
drive directly to the dc link bus, a good word for the positive ef- The type of drive has a major
where it will often cause a dc impact on the PQ symptoms, be-
fects of drives on PQ. First of all, cause of the different converter
link overvoltage trip. Input di- they offer built-in soft-start ca-
odes could also be blown out designs (converters or rectifiers
pabilities. This means there will turn ac to dc and are the first
by these transients.
stage of the drive). There are
two major types of converter
Table 7.1 Line-side measurements on ASDs. design.
Measurement Look for Instrument
SCR Convertor with Voltage
Voltage waveform • Voltage notching (SCR converters) 43
Source Inverter/Variable
• Flat-topping
Harmonic spectrum Harmonic orders and amplitudes, before and 43, 41B
Voltage Inverter (VSI/VVI)
after filter application Drives
Displacement PF For PWM drives, DPF should remain high even 43, 41B Commonly called six-step
at low speeds (it will typically decrease slightly) drives, they use SCRs (Silicon -
Voltage unbalance Less than drive manufacturer specs, or current 43, 41B Controlled Rectifiers) in their
overload trips can result. The drive may have a converter front-ends (the fol-
higher limit for unbalance than the motor. lowing discussion applies to
CSI, Current Source Inverter
drives, which also use SCRs).
VSI and CSI drive designs
tended to be applied on larger
Induction drives (>100HP). SCR converters
Motor control the dc link voltage by
switching on (or “gating”) cur-
rent flow for a portion of the ap-
M plied sine wave and switching
off at the zero-crossing points.
Line Unlike diodes, SCRs require
Reactors control circuits for gate firing.

Figure 7.1 Voltage Source Invertor (VSI) ASD

Power Quality Troubleshooting Fluke Corporation 25


Diode Convertor with quired. This “six-pulse” con-
Pulse Width Modulation verter will generate 5th and 7th
(PWM) Drives harmonics. If a 12-pulse con-
The other and more common verter were used, the 11th and
converter design uses diodes 13th harmonics will be gener-
and is used in the PWM drive. ated instead of the 5th and
The diodes require no switching 6th—and, very importantly, for
control circuitry. One of the the same load, the amplitude of
main trends in the industry has the 11th and 13th would be
been the proliferation of PWM considerably less than the 5th
drives, mainly due to the con- and 6th. Therefore, the THD
tinued development of fast- would be less. The vast majority
switching, efficient IGBTs of drives, however, are six-pulse
(Insulated Gate Bipolar Transis- PWM style, which is one reason
Figure 7.2 Voltage Notching. tors) used in the inverter section we see so much 5th harmonic
of the drive (inverters turn dc to on the system.
For the SCR converter, there are
three main issues that affect ac). For all practical purposes,
PWM drives are the industry Harmonics solutions
line-side PQ:
standard. There are a number of solutions
• Commutation notches. SCR For an in-depth discussion of to mitigating drive-generated
switching or commutation is the efffects of PWM-IGBT drives harmonics:
such that there are brief mo- on motors, see “Measurement of
ments when two phases will Harmonic trap filters (Fig. 7.5)
ASDs with Fluke Meters,” docu-
both be “ON.” This causes These are typically LC networks
ment number G0416UEN.
what is in effect a momen- connected in parallel at the
tary short circuit that tends source of the harmonics (in
to collapse the line voltage. other words, at the drive input).
This shows up as “notches” They are tuned to just below
on the voltage waveform. the 5th harmonic (typically 280
These notches cause both Hz) and will tend to sink both
high V-THD and transients. 5th and much of the 7th har-
The solution is to place a re- monic. Obviously, they must be
actor coil or isolation trans- sized to the harmonic-generat-
former in series with the ing load.
drive’s front end to clean up Phase-shift transformers
both problems. This can be as simple as a
• Displacement Power Factor delta-wye transformer feeding
declines as drive speed de- one drive(s) and a delta-delta
creases. This is not as serious feeding another drive(s). There
a problem as it sounds, be- Figure 7.3 Typical ASD Harmonic Spectrum is a 30 degree phase shift effect
cause the power requirement between these two configura-
of the drive-motor-load de- For the diode converter, the tions, which effectively results
creases even more. main PQ issue is harmonics. The in cancellation of harmonics at
actual harmonic orders being the closest upstream PCC (Point
• Harmonic currents, typically generated depend on the num- of Common Coupling). The can-
the 5th and 7th, are gener- cellation effect is optimal when
ated by VSI drives. ber of diodes in the front end.
For three-phase conversion, a both loads are more or less
minimum set of six diodes is re- equal.

Figure 7.4. Pulse Width Modulated (PWM) ASD.

26 Fluke Corporation Power Quality Troubleshooting


12-pulse converter Active PF Correction
If the delta-wye/delta-delta are Another recent solution is for
packaged together (delta pri- manufacturers to offer converter Line Load
mary, delta and wye secondary) front ends using fast switching
and each secondary feeds one technology that generates a
of two paralleled six-pulse con- minimum amount of harmonics
verters, a 12-pulse front-end is and has near unity power factor
created with all the benefits (both Total PF and DPF).
mentioned above. 18-pulse
designs are also available. Be- There is room for discussion
cause of the extra cost, this type on which approach to harmonic
of solution tends to only get mitigation might prove most ef-
used on high HP loads. fective and economical in a par-
Active filters ticular situation. However, what
This relatively new technology is often overlooked by the end-
is based on an elegant concept– user, and what should be clear
using power electronics to solve from the information in this sec-
the problems created by power tion, is that the total cost of a
electronics. It senses the instan- drive system should include
taneous ac sine wave; it then both the cost of the drive itself
actively cancels the harmonics and the harmonic mitigation
it detects by generating equal (whether part of the drive or
and opposite polarity harmon- installed separately).
ics, thus recreating the sine Figure 7.5 Harmonic trap filter.
wave. Commercial packages
might provide voltage regula-
tion as well.

Why True-rms
True-rms test tools are necessary for accurate
measurements of distorted waveforms. For more
information, see the Fluke application note Why
True-rms, document number B0294A.
A comparison of average-responding and true-rms multimeters
Multimeter Reading
Waveform Description Average-sensing True-rms
DMM DMM

Sine wave Correct Correct

Square wave
(flat-top voltage) 10% high Correct

Current to single
phase diode rectifier 40% low Correct

Current to 3 phase
diode rectifier 5-30% low Correct

Power Quality Troubleshooting Fluke Corporation 27


Power system resonance
Hot vibes can result when harmonics and capacitors get together

Is it possible to install “Power Displacement Power Harmonics and Capacitors


Factor Correction Capacitors” Factor
and have PF get worse? It cer- Harmonics have had a dramatic
tainly is, and a starting place to Lower DPF is caused by motor impact on our approach to
understanding this puzzle lies loads which introduce the need Power Factor correction. The
in the distinction between Dis- for Reactive Power (Volt-Amp motor and capacitor loads de-
placement PF (DPF) and Total Reactive or VARs). The system scribed above are all linear and
Power Factor (PF). The penalty has to have the capacity, mea- for all practical purposes gener-
for not understanding the differ- sured in Volt-Amps (VA) to sup- ate no harmonics. Non-linear
ence can be blown capacitors ply both VARs and Watts. The loads such as ASDS, on the
and wasted investment. more VARs needed, the larger other hand, do generate har-
Total PF and Displacement PF the VA requirement and the monic currents.
are the same in one basic smaller the DPF. The cost of Take a plant which is step-
sense: they are the ratio of Real VARs is accounted for in a by-step putting adjustable
Power to Apparent Power, or power factor penalty charge. speed drives on its motor loads.
Watts to VA. DPF is the classic Utilities often levy additional ASDs generate significant har-
concept of power factor. It can charges for DPF below a certain monic currents (5th and 7th on
be considered as the power fac- level; the actual number varies six-pulse converter drives). Sud-
tor at the fundamental fre- widely, but typical numbers are denly the fuses on existing PF
quency. Total Power Factor, 0.90 to 0.95. correction caps start blowing.
abbreviated to Power Factor To reduce VARs caused by Since these are three-phase
(PF), now includes the effects motor loads, power factor cor- caps, only one of the three fuses
of fundamental and of harmonic rection capacitors are installed. might blow. Now you’ve got un-
currents (it is also referred to as Upstream system capacity, both balanced currents, possibly un-
True PF or Distortion PF, in the plant and at the utility balanced voltages. The
Fig. 7.7). It follows that with the level, is released and available electrician replaces the fuses.
presence of harmonics, PF is al- for other uses. (Fig. 7.6) They blow again. He puts in
ways lower than DPF and is Historically, this has been the larger fuses. Now the fuses sur-
also a more accurate description gist of the PF story: a relatively vive, but the capacitor blows.
of total system efficiency than well-known problem with a He replaces the capacitor. Same
DPF alone. relatively straightforward thing happens. What’s going
Strictly speaking, the term solution. on? Harmonics are higher fre-
“Power Factor” refers to Total PF, quency currents. The higher the
but in practice can also be used frequency, the lower the imped-
to refer to DPF. Needless to say, ance of a cap (X C = 1/ 2 πfC).
this introduces some confusion The cap acts like a sink for
into discussions of power factor. harmonic currents.
You have to be clear which one
you’re talking about. Before: PF = 42% After: PF = 100%
1.4A

3.3A

Reactive
Reactive
Active Active 360 VAR
360 VAR
165 Watts 165 Watts

Capacitor
60 µF

1/6 HP Motor 1/6 HP Motor

Figure 7.6 Capacitor corrects Displacement Power Factor (DPF).

28 Fluke Corporation Power Quality Troubleshooting


Power System Resonance which are many times greater Imagine coming to work on
than the exciting current. This a Monday and seeing the insu-
In a worst-case scenario, the so-called “tank circuit” can lation on your cables melted off.
inductive reactance (XL) of the severely damage equipment, How can this happen over a
transformer and the capacitive and it will also cause a drop weekend when there was
reactance (XC) of the PF correc- in power factor. Perversely, this hardly any load on the system?
tion cap form a parallel resonant resonant condition often ap- Has Ohm’s Law been overruled?
circuit: XL = XC at a resonant fre- pears only when the system Not quite. Your power system
quency which is the same as or is lightly loaded, because the just spent the weekend tanked
close to a harmonic frequency. damping effect of resistive loads out on the Harmonics. It was
The harmonic current generated is removed. In other words, we quite a party, but now comes
by the load excites the circuit have what the audio buffs call the clean-up.
into oscillation. Currents then a “high Q” circuit. (Fig. 7.8)
circulate within this circuit Start with Harmonics
Mitigation
The correct solution path starts
A. System Diagram B. Equivalent Circuit with measuring and mitigating
the harmonics generated by the
XS
drives. Harmonic trap filters
would generally be called for.
These trap filters are installed
XT XT locally on the line side of the
XC drive. Their effect is very much
like the traditional PF correction
Harmonic XS cap, in two senses: they reduce
XC source DPF as well as PF, and also they
localize the circulation of the
problem harmonics (generally
the 5th). Harmonics mitigation
Figure 7.8 Resonant circuit when XC = (XT + X S) and traditional DPF correction
should be addressed as one
systems issue. In other words,
manage Total PF, not just DPF.
kvar
(nonwork producing)

VA

Harmonics
(nonwork
producing)

kW
(work producing)

Figure 7.7 Total Power Factor increases with harmonics.

Power Quality Troubleshooting Fluke Corporation 29


Section 8
Troubleshooting Commercial Lighting Loads
Lighting loads are a major load 1. Power consumption 4. Voltage stability
for many large facilities. Evalu- Excessive phase unbalance can The sags and swells mode of
ating these circuits is important cause voltage unbalance, which the Fluke 43 is especially useful
for both energy conservation in turn can affect three-phase for recording repetitive voltage
and power quality. Keep in motor loads. sags which can show up as
mind that commercial lighting flickering lights. Both current
loads are wired single phase, 2. Power Factor and voltage are monitored si-
with the loads connected from Ballast with low PF might have multaneously. This helps us to
phase to neutral. Typically, the lower cost-of-purchase but tell if sags are downstream of
phase-to-phase voltage is higher cost-of-operation. the measuring point (load-
480V, with the phase-to-neu- related) or upstream (source-
tral voltage at 277V. Measure- 3. Total Harmonic Distortion related). For example, if voltage
ments must be taken at the
Current THD should be consid- sags while current swells, a
lighting panel, one phase at a
time, since power consumption ered when selecting ballast, es- downstream current inrush
pecially if there is a possibility likely caused the sag. If both
and Power Factor could vary on
of transformer overloading. voltage and current sag, some
each phase. event upstream caused
the sags.
Table 8.1 Measurements on commercial lighting loads. It could be an upstream
Measurement Look for Instrument load like a motor on a parallel
1. Power Balance among three phases. 43, 41B branch circuit which drew
consumption (kW) down the feeder voltage. Or
2. Power Factor Magnetic ballast will have low DPF. Electronic 43, 41B it could be source voltage-
(DPF and PF) ballast may have low total PF, although new related, for example, a lightning
generations of ballast often have harmonic strike or breaker trip/reclosure
mitigation built-in. on the utility distribution
3. Total Harmonic Current %THD <20% is desirable. 43, 41B system.
Distortion (%THD)
4. Voltage Stability Unstable voltage can cause lights to flicker. 43

480V Phase-to-Phase
Ø1
Ø2
Ø3

Figure 8.2 Fluke 43 trends voltage (top) and


current (bottom) simultaneously. Current
277V Phase-to-Neutral swells/inrush caused voltage sags, indicating
that a load downstream from the measure-
ment point is the cause of the disturbance.

Lighting Panel

Figure 8.1

30 Fluke Corporation Power Quality Troubleshooting


A Lineup of Power Quality Culprits
From utility source to receptacle

Lightning Running power and signal And in a class by themselves


Can be extremely destructive if cables together Isolated ground rods (below)
proper surge protection is not Think of the signal cable as a They’re a safety hazard because
installed. It also causes sags single-wire transformer second- the earth is a high impedance
and undervoltages on the utility ary and the power cable as the path and will prevent enough
line if far away. If close by, it primary. The opportunities for current from flowing to trip the
causes swells and overvoltages. coupling are endless. breaker. They also cause ground
But in the final analysis, light- Loose conduit connections loops; after all, every electron
ning is an act of nature and not and lack of green wire still has to go back where it
in the same category as the grounding conductor came from. One of the great
damage man does to himself. Causes open or high impedance mysteries of PQ is how some
Utility automatic ground circuit. Not good for PQ manufacturers get away with
breaker reclosure or safety. insisting that their equipment
Causes short duration sags/ Shared neutrals on warranty is void unless an iso-
outages, but better than the al- branch circuits lated ground rod is installed. My
ternative, a longer-term outage. Causes load interaction and auto mechanic was so inspired
Utility capacitor switching overloaded neutrals. by this practice that he now
Causes a high-energy voltage warranties every car he works
Laser printers and copiers on unless it’s driven.
disturbance (looks like an oscil- sharing branch circuits with
lating transient riding on the sensitive loads Illegal N-G bonds
wave). If the cap bank is near Guaranteed periodic voltage (Fig. 2.1, page 8)
the facility, this transient can sags and switching transients. Guaranteed to put return cur-
propagate all through the rents on ground. A common
building. Miswired receptacles enough problem that the Union
(N-G swapped) of PQ Consultants wants to
Commercial high rises Hard to believe, but they are out
without enough distribution charge piecework rates—say, a
there in quantity. Guaranteed to dollar for every N-G bond
transformers put return currents on the
Trying to cut corners in the found. They’d all get rich. Not
ground conductor and create only is it a PQ problem, it’s a
wrong places; running 208V a noisy ground.
feeder up twenty stories is plumbing problem. Circulating
not the road to PQ. Data cables connected to ground currents cause corrosion
different ground references of water pipes. That explains
Gen-sets not sized for at each end why you can never find the
harmonic loads Ouch! Shows up as voltage electrician that put in those N-G
Excessive voltage distortion between equipment case and bonds—it’s all being done on
affects electronic control the data cable connector. the sly by the plumbers. Guar-
circuits. If SCR converter loads anteed employment, as if they
are present, notching can Hi-frequency noise
The most effective high fre- needed it.
affect frequency control circuits.
quency grounding technique is
Applying PF correction the installation of a Signal Ref-
capacitors without consider- erence Grid (SRG).
ing the effects of harmonics
Harmonics and caps don’t mix.
Those bulging capacitors are
crying for help. Load Current

Inrush currents from high Neutral Return


Current Error
torque motor loads started
across-the-line
Causes voltage sags if the load Separately
Derived
is too large or the source imped- System
Line Line
ance too great. Staggered motor
Neutral Neutral
starts can help.
Ground Ground
N-G
Undersized neutrals Bond
at panelboard Panel
In the era of the 3rd harmonic,
neutrals can easily carry as
much current or more current
than the phase conductor. Earth Ground “Isolated” Ground,
Keeping them undersized leads Ground Rod, Cold Water Pipe, Etc.
to overheated lugs, potential fire
hazards and high N-G voltage. Isolated ground rod can cause ground loops. Common problem with CNC machine tool installations.

Power Quality Troubleshooting Fluke Corporation 31


A word on test tools

The minimum requirement for • CAT III-600V or higher In addition, instruments with
test tools used in PQ trouble- (CAT III-1000V) safety rating, recording capability, waveform
shooting are: which are appropriate for display and specialized mea-
measurements on power surements (such as harmonics,
• True-rms for accurate mea- circuits sags and swells, transient cap-
surement with harmonics
and distorted waveforms. ture, high frequency noise, etc.)
are needed.

The following Fluke test tools are referred to in this application note.
Model Fluke 43 Fluke 41B Fluke VR101S Fluke 87 Series III Fluke 36
Test Tools Power Quality Harmonic Voltage Event Digital ClampMeter
Analyzer Analyzer Recorder Multimeter
Power kVA, kW, kVAR, PF, DPF kVA, kW, kVAR, PF, DPF
Recording TrendPlot™, PC logging PC logging 4000 voltage events
Real-Time Clock • •
True-rms volts and True-rms volts and
Harmonics To 51st harmonic To 31st harmonic
current current
20 nanoseconds 1 microsecond 250 microsecond
Voltage Transients
with waveform event recording Peak MIN/MAX
Sags & Swells Single cycle MIN/MAX Single cycle 100 millisecond
(Voltage only) with trend event recording MIN/MAX
Sags & Swells
(Simultaneous Voltage Single cycle MIN/MAX
and Current)
Single cycle MIN/MAX Event recording with 100 millisecond
Outages
with trend duration MIN/MAX
Documentation, FlukeView ® FlukeView® 41 EventView™
RS232 Computer Power Quality Software Software Software
Motor In-rush Current Waveform with cursors MIN/MAX MAX Hold
Waveform 20 MHz scope Fundamental
Noise •
Peak • • •
True-rms • • • •

References and
acknowledgments Power Quality Troubleshooting
Learn to measure, diagnose and
• EC&M Practical Guide to Qual- solve PQ problems.
ity Power for Sensitive Elec- Part Number: 800919 - NTSC
tronic Equipment, 2nd Edition. 800927 - PAL
• Dranetz Field Handbook for The ABCs of Digital
Power Quality Analysis. Multimeter Safety Video Tape Fluke. Keeping your world
Learn how proper work up and running.
• Ontario Hydro Power Quality
procedures and equipment
Reference Guide. can protect you from hazards.
• Association of Energy Part Number: 609104
Fluke Corporation
Engineers: Fundamentals For sale at Fluke distributors, PO Box 9090, Everett, WA USA 98206
of Power Quality. or call the appropriate phone
Fluke Europe B.V.
number listed to the right
• IEEE Std 1100-1992: Recom- PO Box 1186, 5602 BD
Eindhoven, The Netherlands
mended Practice for Powering
and Grounding Sensitive Elec- Understanding and
For more information call:
U.S.A. (800) 443-5853 or
tronic Equipment. Managing Harmonics
Fax (425) 356-5116
• EPRI, Electrotek Concepts, Inc.: Part Number: 609096 Europe/M-East (31 40) 2 678 200 or
Fax (31 40) 2 678 222
Power Quality for Utility and
Canada (905) 890-7600 or
Industrial Applications Fax (905) 890-6866
• Power Quality Assurance Other countries (425) 356-5500 or
Fax (425) 356-5116
Magazine Web access: http://www.fluke.com
©1998 Fluke Corporation. All rights reserved.
Printed in U.S.A. 9/98 B0333UEN Rev A
Printed on recycled paper.

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