Applying Circuit Breakers

and
Reducing Arc Flash Hazards

Zone Selective Interlocking

&
Arc Flash Hazards

Kevin J. Lippert, Eaton Electrical

 Topics

Circuit breakers with electronic trip units

Zone Selective Interlocking

What is it?

How does it work?

What does it do for you?

IEEE 1584 Arc Flash Calculations & Issues

Current-limiting circuit breakers

Other technologies for reducing arc flash
energies

Summary

Discussion
 Protecting Electrical Systems

Balance:

Continuity Minimize
of Service Equipment
Damage
 Electronic Trip Units
Many modern circuit breakers have
electronic trip units which make them
more “intelligent”

• Adjustment of time-current curves adds flexibility

• Trip characteristics are independent of ambient temperatures
• Permits incorporation of ground fault protection

• Allows remote monitoring & data acquisition

• Opens communication between devices
 Zone Selective Interlocking (ZSI)
 Zone Selective Interlocking
Breakers in the same zone “talk” to their upstream buddy.

Hi!

Hello?
Zone A
 Zone Selective Interlocking
Breakers in the same zone “talk” to their upstream buddy.

Hi!

Hello?
Zone A
 Zone Selective Interlocking
Breakers in the same zone “talk” to their upstream buddy.

Hi!

Hello?
Zone A
 Zone Selective Interlocking
When a fault occurs at point X...
I sense
trouble!

All is OK here, All is OK here, All is OK here,

so I’m quiet. so I’m quiet. Zone A
so I’m quiet. X
 Zone Selective Interlocking

But with ZSI… since none of my

Without ZSI, I’d downstream buddies are telling me that
normally wait for they sense trouble, I know not to wait at
my Short Delay all, and open as quickly as I can!
time, and then open!

X Zone A
 Zone Selective Interlocking
However, when a fault occurs at point XX...
I sense
trouble!
I sense trouble too! Hey
upstream buddy, hang in
All is OK here, All is OK here,
there, I’ve got it!
so I’m quiet. so I’m quiet.

Zone A

XX
 Zone Selective Interlocking
Breakers further downstream can also “talk” to their
upstream buddy in their zone.

Hi!

Zone B

Hello?
 Zone Selective Interlocking
Breakers further downstream can also “talk” to their
upstream buddy in their zone.

Hi!

Zone B

Hello?
 Zone Selective Interlocking
So, when a fault occurs further downstream at point XX...

I sense
trouble!

Zone B

All is OK here, so
I’m quiet.
XX All is OK here,
so I’m quiet.
 Zone Selective Interlocking
So, when a fault occurs downstream at point XX...
Without ZSI, I’d
wait for MY Short
Delay time, and
then open!

But… with ZSI since none of

MY downstream buddies are
telling me that they sense
trouble, I know not to wait
at all, and I open as quickly
as I can!

Zone B
XX
 Practical example – without ZSI
When a fault occurs at point X...
M1
I have to wait my pre-set
SD= 0.5S Short Delay time to
0.5S give the downstream
devices a chance to clear
the fault.

F1 F2 X F3

SD= SD= SD=

0.3S 0.3S 0.3S

B1 B2

SD= SD=
0.1S 0.1S
 Practical example – WITH ZSI
When a fault occurs at point X...
M1
Since none of my downstream
buddies are telling me that they
SD= sense trouble, I over-ride my pre-set
0.5S
SD time and act as quickly as
possible, clearing in 0.08S!
All is OK here, All is OK here,
All is OK here,
so I’m quiet.
F1
so I’m quiet.
F2 X F3 so I’m quiet.

Zone A
SD= SD= SD=
0.3S 0.3S 0.3S

B1 B2

SD= SD=
0.1S 0.1S
 ZSI with Ground Fault Protection
Provides the same benefit when a ground fault occurs (at point X).
M1
Since none of my downstream buddies
GF= are telling me that they sense trouble,
0.5S I over-ride my pre-set GF time and
act as quickly as possible, clearing in
0.08S!
All is OK here, All is OK here,
so I’m quiet.
F1
so I’m quiet.
F2 X F3
All is OK here,
so I’m quiet.

GF= GF= GF= Zone A

0.3S 0.3S 0.3S

B1 B2
GF= GF=
No No
time time
delay. delay.
 Zone Selective Interlocking
Must have a Coordinated System to start.
M1

SD=
0.5S

F1 F2 F3

SD= SD= SD=

0.3S 0.3S 0.3S

B1 B2

SD= SD=
0.1S 0.1S
 Zone Selective Interlocking

Requires twisted-pair instrumentation cables to serve

as the communication channel between devices.

Can be used in different schemes (main/tie/main,

multiple mains/multiple ties) to provide similar
benefits.
Is available to provide similar benefits using certain
medium voltage devices (MV Digital Relay/FP5000).

Is available to provide similar benefits on certain low

voltage molded case circuit breakers.
 Zone Selective Interlocking Summary

Bypasses the preset short delay time and ground

fault delay time (when available) on the upstream
circuit breaker closest to the fault, which then trips
with no intentional delay.

So, what does this means for reducing arc flash?

 IEEE 1584

• The IEEE 1584-2002, “Guide for

Performing Arc Flash Calculations”

 Provides guidance for the calculation of incident energy and

arc flash protection boundaries.
 It presents formulas for numerically quantifying these values.
 The IEEE 1584 Guide also includes an Excel Spreadsheet
“Arc-Flash Hazard Calculator” which performs the actual
calculations using the formulas stated in the Guide.
 Bolted Arc
IEEE 1584 Formulas Fault Fault

• Calculate the arcing current, Ia

which is less than bolted fault current

log I a =K +0.662 log I bf +0.0966 V +0.000526 G +0.5588 V (log I bf ) - . 0.00304 G (log I bf )

where
log is the log 10
I a is arcing current (kA)
K is - 0.153 for open configurations and - 0.097 for box configurations
I bf is bolted fault current for three-phase faults (symmetrical RMS)(kA)
V is system voltage (kV)
G is the gap between conductors, (mm)
 
and convert from log
I a = 10 log I a
 IEEE 1584 Formulas
• Use arcing current to determine incident energy, E

log E n =K 1 +K 2 +1.081 log I a +0.0011 G

where
K 1 is -0.792 for open configurations, -0.555 for enclosed
K 2 is 0 for ungrounded & high resist.; -0.113 for grounded
Ia is arcing current (kA)
G is distance between arcing buses (mm), 25 mm for MCC
 Then En = 10 log En
Finally, convert from normalized: E = Cf En (t/0.2) (610x/Dx)

E is incident energy in cal/cm2

Cf is calculation factor, 1.0 > 1kV; 1.5 <= 1kV
En is incident energy normalized for time & distance t is arcing time (seconds)
D is distance from arc to person (mm); typical to use 455 mm (18”) for MCC
x is distance exponent from IEEE table (based upon equip type-conductor gap); 1.641 for MCC
 Arc Flash Example of ZSI
Using IEEE 1584: 480V-35kA, MCC, 18” from Arc.

Previously shown system Without ZSI = 0.5 S:

M1
43.7 Cal/cm2
SD=
0.5S
Greater than Cat. 4 PPE!
35kA fault current
F1 F2 X F3 FIND ALTERNATIVES!
SD= SD= SD=
0.3S 0.3S 0.3S

B1 B2 With ZSI = 0.08 S:

SD=
0.1S
SD=
0.1S 7.0 Cal/cm2
Cat. 2 PPE
FR Shirt & Pants + Cotton
Underwear
 IEEE 1584 Issues
• At what “point(s)” in the system should arc flash hazard
calculations be performed?
There could be multiple calculations performed depending on the
particular task being undertaken. At a minimum, (either 1 or 2) plus 3
below.**
1. A value shall be calculated either at the incoming point to the
enclosure,
or,
2. If the cables terminate immediately into the main device and are
not readily accessible, calculate at the load terminals of an incoming
overcurrent protective device, OCPD (if one exists).
And,
2. At the load side of OCPDs that are sensibly partitioned/separated
from their line side. (For example; when working inside the bucket of
an MCC.)

 **Author’s recommendation, not contained in IEEE 1584

 IEEE 1584 Issues
• Is the OCPD a fuse?
For certain specific low-voltage fuses, and within a specific tested
range of bolted fault currents:
1 Class RK 1 fuse – 100A
2 Class RK 1 fuse – 200A
3 Class RK 1 fuse – 400A
4 Class RK 1 fuse – 600A
5 Class L fuse – 800A
6 Class L fuse – 1200A
7 Class L fuse – 1600A
8 Class L fuse – 2000A
Input fuse type and bolted fault current.
The calculation automatically takes into account both the current-limiting effect of
the fuse and the actual time of interruption.

This is the most accurate method, and preferred, for these certain types of low-
voltage fuses.
 IEEE 1584 Issues
• What if the fuse is not one of the specific
ones stated?

X
If not one of those specifically stated, or when outside the
model’s tested bolted fault current range…

Input of the fuse’s time/current curve information (total

clearing times = melting time + arcing time) is required.
If the manufacturer shows only the average melt
time, add to that time 15%, up to 0.03 seconds and
10% above 0.03 seconds to determine total clearing
time.

This is a secondary method, for use when the preferred fuse method is not possible.
 IEEE 1584 Issues

• Is the OCPD a circuit breaker?

For circuit breakers, the most accurate calculation method

included in the IEEE 1584 Guide, is to use specific
manufacturer’s time/current information (total clearing times).

 Note: This approach causes concern because commonly published time/current curves
in the instantaneous region have not been a focus of circuit breaker manufacturers, and
are very conservative.
At the present time, this is the most accurate circuit breaker calculation method
included in the IEEE 1584 Guide, and the preferred method, for use when the
manufacturer’s information is available.
 IEEE 1584 Issues
• When entering specific OCPD times (for both low-voltage
fuses and low-voltage circuit breakers) 2 different values are
used; one based upon the arcing current and a second based
upon a “reduced” arcing current.
If the arc current falls on the steep part of the time-current
curve, or falls near a step change, a small variation in arc
current could cause a significant change in OCPD tripping or
operating time.

A second calculation is performed based upon a “reduced” arcing fault current, 85% of
the originally calculated arcing current. The highest resulting energy (either based upon
arcing current and arcing operating time, or reduced arcing current and reduced current
operating time) is then automatically used.
Applicable to low-voltage arc currents (under 1 kV)
 IEEE 1584 Issues
• What if the circuit breaker time/current information (opening
times) is not available?
For certain low-voltage circuit breakers within specific continuous current ranges and
within specific ranges of bolted fault currents input CB type and bolted fault current :
9 Molded Case Circuit Breaker, 100-400A
10 Molded Case Circuit Breaker, 600-1200A, Thermo-magnetic trip
11 Molded Case Circuit Breaker, 600-1200A, Electronic trip w/Long Delay
12 Molded Case or Insulated Case Circuit Breaker, 1600-600A
13 LV Power Breaker, 800-6300A, w/Instantaneous trip
14 LV Power Breaker, 800-6300A, w/o Instantaneous (Short Delay only)
(Device Type number 9-14 corresponds to Spreadsheet selection)
Also requires input of the circuit breaker’s instantaneous trip level. Calculation is based
upon interruption times for generic breaker-ratings. Typically worst-case; maximum-
duration times based upon the published time-current curves of many manufacturers.
This method is conservative and calculates high values of arc energy that may mandate
more protection than is necessary.
This is a secondary method, for use only when specific time/current curve information
is not available and the preferred circuit breaker method is not possible!
 IEEE 1584 Issues

• Do any of these calculations account for the

current limiting characteristics of circuit
breakers?

No! Regardless of the selected calculation

method for circuit breakers, the present
IEEE 1584 calculations do not take into
account the current-limiting characteristics
of circuit breakers.
 OCPD Current limitation
Reduced Fault Current
via Current-Limitation

Difficult to create models to accurately predict incident energy created by an arc flash
in a system using OCPDs.

2 active systems occurring simultaneously to reduce the current magnitude.

• An arc occurs on downstream busbars = current magnitude reduction due to the
added impedance of the arc at the busbars.
• Upstream OCPD begins to open. This breaking of the current flow creates
another arc inside the OCPD, and is in series with the busbar arc.

Busbar Arc from

Arc
+ CB contacts
parting
 Current-limiting circuit breakers

There are two major components to consider:

• arc current duration (time) and arc current magnitude.

•The arc current duration is controlled by the actual time of interruption. As previously
stated, commonly published circuit breaker time/current curves in the instantaneous region
have not been a focus of circuit breaker manufacturers, and are very conservative. For the
purpose of calculating arc flash energy, using those instantaneous region conservative
operating times will produce unrealistically high arc flash energy values. Actual operating
times will enable more accurate calculations of arc flash energy.
 
The other major component to consider is the reduction of the arc current magnitude due to
the breaker’s dynamic impedance.
 Initial MCCB current limiting tests
Calorimeters constructed to ASTM Standard.

Preliminary testing done according to the information extracted from

previously published IEEE papers.

Table values based upon 480V, MCC, 18” distance from arc, ungrounded system.
Initial MCCB current limiting test conclusions

MCCB current limiting significantly reduces the energy levels (when in the
instantaneous range).

The IEEE 1584 calculation methods are very conservative when compared with the actual
measurements associated with MCCBs. (Need to correct this situation).

Few test points have been verified.

Although the resultant arc energies are significantly lower, this methodology is
preliminary and still needs to be refined.
Use Of Other Existing Technologies to Reduce Arc
Flash Risk
Retro-fit Kits: Provide Zone Selective Interlocking-type performance for existing trip
units (available soon).
Ground Fault Detection: trips the circuit breaker during the early stages of fault
development and prior to "bolted fault" conditions.

Use “finger-safe” electrical components as much as possible. This can reduce the chance
that an arcing fault will occur.
Use insulated bus for equipment such as motor control centers, switchboards,
switchgear, etc. This will reduce the chance that an arc fault may occur. In addition, it
increases the probability that an arc fault will self-extinguish.

Use High Resistance Grounding Systems. This limits the amount of fault current.

Size the current-limiting branch circuit OCPD as low as possible. Typically, the lower
the ampere rating, the greater degree of current-limitation.
Use remote racking & sensing devices. This increases the distance between personnel
and the electrical equipment.
 Protecting Electrical Systems
Balance More Issues:

Minimize
Equipment
Damage
Continuity +
of Service Lower
Arc Flash
Hazard
 Summary
Use Zone Selective Interlocking to minimize fault stress on
equipment AND to reduce arc flash energies.

The IEEE 1584 Guide provides another advancement in

calculating arc flash energies. However, it is important for the user
to understand the required input information.
• For fuses, where possible, use the “preferred” method which accounts
for their current limiting ability.
• For circuit breakers, where possible, use manufacturer specific
interruption time as the “preferred” method.
• For circuit breakers, neither IEEE 1584 calculation method takes into
account their current-limiting characteristics. This situation continues to
be addressed.
• Take advantage of other existing technologies that reduce the arc flash
hazard risk.