BY RAJIV KUMAR, DOUGLAS REED, ROBERT MORRIS, & SAMUEL TERRY

HE UNDERWRITERS LABORATORIES (UL) 845 standard for low-voltage (LV) motor control centers (MCCs) requires a short-circuit withstand rating on the bus for only three

cycles. The LV power-circuit breakers are typically rated for up to 30 cycles short delay, which can be greater than the UL 845 short-circuit withstand test requirements. The trip settings on these LV power-circuit breakers may include shorttime delay that can result in the MCC-enduring fault currents for much more than the three cycles for which it is rated. In this article, it is proposed that MCC bus designed and tested for higher number of cycles of withstand can address the above potential issue by offering better coordination and safer power distribution design options. Motor Control Centers Typically, the MCC assemblies in the United States are UL listed. UL requires the short-circuit withstand ratings for these MCCs to meet the UL 845 standard that requires a three-cycle, three-phase short-circuit test on a horizontal and vertical bus for predetermined levels of short-circuit current such as 42, 65, and 100 kA [1]. However, MCCs
CREATAS

IEEE INDUSTRY APPLICATIONS MAGAZINE  MAY j JUNE 2011  WWW.IEEE.ORG/IAS

Short-circuit higher-withstand requirement in MCCs

Digital Object Identifier 10.1109/MIAS.2010.939638 Date of publication: 4 March 2011

51
1077-2618/11/$26.002011 IEEE

LVSUB-Bus LVSUB-FDR (Power CB) CBL-01

MCC-Main (MCCB)

MCC-Bus MCC-FDR (MCCB) CBL-02

PNLBD-Main (MCCB) PNLBD-Bus

Panel Board
One line: MCCB configuration.

Current in Amperes 1,000

IEEE INDUSTRY APPLICATIONS MAGAZINE  MAY j JUNE 2011  WWW.IEEE.ORG/IAS

can sometimes be fed from LV power-circuit breakers located in the LV switchgear ahead of or in an MCC line up and, sometimes, without a corresponding main circuit breaker at the MCC. The short-time delay on the power breakers could result in the MCC bus enduring fault currents greater than three cycles, which leads to the question: Is the MCC designed to meet the present UL 845 short-circuit withstand requirement adequate for all the MCC power distribution applications today? It should be noted that, in comparison, the global International Electrotechnical Commission (IEC) standard for LV controlgearMCC products (IEC 60439-1) states that the short-circuit withstand rating is assumed to be as high as 60-cycle duration, unless otherwise stated by the manufacturer [2]. Traditional MCC configurations generally use molded case circuit breakers (MCCBs) with instantaneous trip that are rated for a short-circuit withstand rating of three cycles (per UL Standard 489). Recent revisions to National Electric Code (NEC) require that for certain critical systems all overcurrent protective devices are to be selectively coordinated with all supply-side overcurrent protective devices in the system, which would be difficult to accomplish with MCCB as the associated time delays could exceed the low withstand ratings of MCCB [3]. The required time delays for selective coordination would also exceed the withstand ratings of MCC buses that are designed just to meet the UL 845 withstand requirement. This leads to the question: What type of MCC construction and configuration is suitable for selective coordination needs of critical systems? Limitations of the Existing Withstand Rating
Protective Device Coordination Challenges

MCC-Main (MCCB) 600-A Trip MCCB 100

MCC-FDR (MCCB) 200-A Trip MCCB

LVSUB-FDR (Power CB) 800 A Sensor 800 A Plug LTPU 1, LTD 7 STPU 4, STD 0.2 INST 8

10

PNLBD-Main (MCCB) 200-A Trip MCCB Time (s)

0.10

0.01 0.5 1

10

100

1,000

10,000

100,000

52

2
Device curves: MCCB configuration.

Figure 1 shows an MCC power distribution one line, where the low-voltage substation feeder (LVSUB-FDR) is an 800-A LV power-circuit breaker feeding the MCC, and MCC-bus is a typical three-cycle withstand-rated bus. Circuit breakers MCC-main, MCC-FDR, and panel board (PNLBD)-main are of MCCB type, where MCC-main is the 800-A MCC main circuit breaker; MCC-FDR is the 200-A MCC feeder circuit breaker feeding a downstream panel board, and PNLBD-main is the 200-A main circuit breaker of the panel board. Figure 2 shows the corresponding protective device curves for this configuration. LVSUB-FDR settings include a short-time delay of 0.2 s and an instantaneous setting of eight times the plug setting. It can be seen from the coordination curves in Figure 2 that it can be challenging for the fixed-curve MCCB to coordinate with each other [4]. Also, MCCB can be difficult to coordinate with LV power-circuit breakers due

to MCCB low-withstand ratings, thus requiring an instantaneous dial or an instantaneous override. Typically, the MCCB-adjustable instantaneous setting has a maximum setting of ten times trip rating or is equipped with instantaneous overrides that are approximately 1015 times the frame ampere rating. This limitation, in combination with three-cycle withstand rating of a traditional MCC bus, makes it difficult to achieve selective coordination for this MCC power-distribution scenario. It should be noted that, from a selective coordination standpoint, it is not required by 2008 NEC articles 700.27 701.18 for breakers that are in series with each other in a branch circuit to coordinate, as the load outage impact is the same regardless of which of the breakers in series trips first [3]. So, LVSUB-FDR and MCC-main are not required to coordinate as well as MCC-FDR and PNLBD-main. However, as can be seen from Figure 2, it is difficult to selectively coordinate MCC-FDR and PNLBD-main with MCC-main and LVSUB-FDR due to the nature of MCCB curve characteristics.
NEC-Selective Coordination Requirements

LVSUB-Bus LVSUB-FDR (Power CB) CBL-01

MCC-Main (MCCB)

MCC-Bus MCC-FDR (Power CB) CBL-02

PNLBD-Main (MCCB) PNLBD-Bus

Articles 620.62, 700.27, 701.18, and 517.26 of NEC 2008 Panel Board 3 require the system overcurrent devices for elevators, emergency systems, legally required standby systems, and health-care One line: power breakers configuration. facilities to be selectively coordinated with the supply side overcurrent protective devices [3]. In addition, the Current in Amperes new section 708.54 for critical opera1,000 tions power systems requires selective LVSUB-FDR (Power CB) coordination. The objective of this Sensor 600 A, Plug 600 A NEC requirement is to ensure better LTPU 1, LTD 7 power system reliability for critical STPU 8, STD 0.5 systems, where the safety of human INST Disabled PNLBD_Main (MCCB) life can be compromised upon a power 100 200-A Trip MCC Main (Power CB) outage. Based on the discussions in INST Fixed the previous sections of this article, we Sensor 600 A, Plug 600 A LTPU 0.8, LTD 7 know that it can be difficult to achieve STPU 8, STD 0.4 selective coordination for these critical MCC FDR (Power CB) INST Disabled systems with a traditional MCC power distribution consisting of three-cycle Sensor 200 A, Plug 200 A 10 withstand rated bus and MCCBs conLTPU 1, LTD 24 STPU 14, STD 0.3 nected in series. It should be noted INST Disabled that the NEC-mandated selective coordination over the entire protective device range, in many cases, can significantly increase the level of avail1 able arc-flash energy, with a resulting increase in potential for safety to personnel and damage to equipment.
Time (s)

IEEE INDUSTRY APPLICATIONS MAGAZINE  MAY j JUNE 2011  WWW.IEEE.ORG/IAS

Benefits of Higher Withstand Ratings

Improved Selectivity Using LV Power-Circuit Breakers in MCC

0.10

Figure 3 shows an MCC power distribution one line that is similar to the one-line configuration shown in Figure 1, with the difference being that the MCC-bus is assumed to be rated for 30-cycle withstand, and circuit

0.01 0.5 1

10

100

1,000

10,000

100,000

4
Device curves: LV power-circuit breakers configuration.

53

5
Horizontal bus bracing modifications. (Photo courtesy of Eaton Corporation.)

and the instantaneous setting has been turned off for each of these three LV power-circuit breakers, to achieve the desired selective coordination. As can be seen from Figure 4, MCC-FDR and PNLBD_MAIN are selectively coordinated with LVSUB-FDR and MCC-MAIN, and the time delays introduced in the power-circuit breaker settings are within the 30-cycle MCC-bus withstand ratings. It should be noted that MCC-FDR and PNLBD-main do not selectively coordinate, but this is acceptable by NEC as they are in series in the same branch circuit [3].
Safer Power Distribution Configurations for Emergency Systems, Standby Systems, and Health-Care Facilities

breakers MCC-main and MCC-FDR are LV power-circuit breakers, and not MCCB. LVSUB-FDR is a power-circuit breaker feeding MCC-bus, and PNLBD-main is a MCCB, similar to the previous MCCB one-line configuration. Figure 4 shows the corresponding device curves. With a higher withstand bus, LV power-circuit breakers can now be set with higher short time pick up (STPU) and higher short time delay (STD) settings, and the instantaneous settings can be disabled to incorporate the necessary time delays required to achieve better selective coordination. For this power distribution scenario, the STPU and STD for LVSUB-FDR, MCC-main, and MCC-FDR have been set at 8 3 0.2 s, 8 3 0.4 s, and 14 3 0.3 s, respectively,

Based on the discussions in the previous paragraph, an excellent level of selective coordination can be accomplished for emergency systems, standby systems and health-care facilities by using a MCC power distribution configuration that incorporates MCC buses with 30-cycle withstand rating and LV power-circuit breakers.
Improved System Design Flexibility

IEEE INDUSTRY APPLICATIONS MAGAZINE  MAY j JUNE 2011  WWW.IEEE.ORG/IAS

With the never-ending need to reduce the space requirements for electrical equipment, a power systems designer seeks configurations that minimize equipment footprint. When faced with systems that have enough large or critical loads to make LV power-circuit breakers a benefit, LV metal-enclosed switchgear is utilized. Rather than design around completely separate enclosure systems, integrating these assemblies is a natural desire. Under these configurations, the main bus within the MCC may be the path of current flow between two LV switchgear assemblies. To utilize the full withstand capability of the LV power-circuit breakers and the LV switchgear, the MCC must be able to safely carry this 30 cycles of fault current that could potentially flow through it. This is definitely a need when maintie-main configurations are utilized, where the substation transformers are close coupled to the LV switchgear; this places the MCC in the middle of the switchgear between the main and tie. An MCC equipped with a 30-cycle withstand rated bus would meet this need. Test Results
Eighty-Five-Kiloampere 30-Cycle Withstand Test

6
Vertical bus bracing modifications. (Photo courtesy of Eaton Corporation.)

54

A two-section MCC assembly was used for testing the horizontal and vertical bus system for 85-kA, 30-cycle threephase short-circuit withstand rating. The horizontal and vertical bus system assembly for this test was equipped with standard 100-kA bracing, modified by addition of extra bracing as detailed below: 1) Horizontal Bus: Standard 100-kA horizontal bus bracing was modified by adding four braces with one brace added at each end and a pair of braces located equidistant from the centerline of the bus. Reference Figure 5 for horizontal bus bracing modifications. 2) Vertical Bus: A 100-kA vertical bus was provided with two braces every 6 in. Reference Figure 6 for vertical bus bracing modifications. Both the horizontal and vertical bus assemblies successfully passed the 85-kA 30 cycle three phase short-circuit withstand tests. These tests were UL witnessed.

TABLE 1. THREE-PHASE SHORT-CIRCUIT WITHSTAND TEST SUMMARY. Applied Short Circuit in Kiloampere Interrupting Current 85 Bracing Assembly Duration (in cycles) 30 Horizontal Bus Standard 100 kA horizontal bus bracing with four additional braces Standard 100 kA horizontal bus bracing Standard 100 kA horizontal bus bracing Vertical Bus 100 kA vertical bus with two braces every 6 in Standard 100 kA vertical bus bracing Standard 100 kA vertical bus bracing

85 100

10 6

Eighty-Five-Kiloampere Ten Cycle and 100-kA Six Cycle Withstand Test

A two-section MCC assembly was used to test the horizontal and vertical bus system with just the standard 100-kA bracing to verify if the withstand ratings greater than the UL 845s three-cycle requirement can be met. The horizontal and vertical bus assemblies were successfully tested for 85-kA ten cycles and 100-kA six cycles. These tests were UL witnessed.
Summary of Test Results

of the equipment will change the breaker trip settings to settings that are favorable to fast faultclearing times 2) using an optical relay detection system that can sense the intense light given off by an arc flash and trip the main breaker instantaneously; a permissive current-detection interlock in the system eliminates nuisance trips. Conclusions Selective coordination can be of high priority in some power distribution configurations and especially for critical systems as required per NEC articles 700, 701, and 517. A higher withstand MCC can enable 30-cycle LV power-circuit breakers to be used in an MCC configuration to achieve selective coordination. A higher withstand MCC also allows the system designer the flexibility of integrating MCC assemblies with 30-cycle rated LV switchgear. While the design objectives for arc-flash safety may appear to be in conflict with selective coordination, there are several solutions available in the market that can enable arc-flash safety in a selectively coordinated power distribution system. Acknowledgments The authors gratefully acknowledge the valuable input provided by Tom Courtney, Chuck Nochumson, Bob Yanniello, Ed Yee, and Neal Rowe in developing the value proposition of higher withstand MCCs. References
[1] Underwriters Laboratories 845 Standard for Motor Control Centers, 2005. [2] IEC MCC Standard, IEC 60439-1, 1999. [3] 2008 National Electric Code, NFPA 70. [4] IEEE Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems, ANSI/IEEE Standard 2421986.

The test results are summarized in Table 1. Impact on Arc-Flash Protection Arc-flash protection requires fast fault-clearing times from the protective devices to minimize the magnitude and time duration of the arc current. This objective does not often align with the selective coordination requirements of the protective devices as selective coordination requires significant trip delays in circuit breakers located upstream of the feeder breaker feeding the faulted branch circuit, to ensure that the load power outage is localized to the faulted branch circuit. There are, however, several solutions available that can enable arc-flash safety in a selectively coordinated power distribution. One manufacturer offers an MCC that includes features such as 1) the ability to connect and disconnect motor starters using a remote racking mechanism with the unit door closed, 2) insulated horizontal and vertical bus, and 3) automatic shutters that isolate the bus when the motor starters stabs disengage from the bus. These safety features can significantly reduce the possibility of an arcflash event occurring in the MCC. Another solution can be to utilize zone-selective interlocking schemes between the LV power-circuit breakers trip units. For example, in the power distribution one line shown in Figure 4, the LV power-circuit breakers are selectively coordinated; however, by employing zone-selective interlocking between the LV power-circuit breakers, the MCC main breaker MCC-main can be interlocked to clear an internal MCC fault almost instantaneously. Other solutions available in the market include 1) using power-circuit breaker trip units equipped with a switch, which when engaged during maintenance

IEEE INDUSTRY APPLICATIONS MAGAZINE  MAY j JUNE 2011  WWW.IEEE.ORG/IAS

Rajiv Kumar (rajivkumar@eaton.com) and Robert Morris are with Eaton Corporation in Fayetteville, North Carolina. Douglas Reed is with MWH Americas in Cleveland, Ohio. Samuel Terry is with Eaton Corporation in Houston, Texas. Kumar, Reed, and Morris are Members of the IEEE. Terry is a Senior Member of the IEEE. This article first appeared as Higher Withstand MCC for Better Selective Coordination at the 2009 Petroleum and Chemical Industry Conference.

55