Global Short-Circuit Current Ratings Global Products, Global Solutions

Transcription

1 Global Short-Circuit Current Ratings Global Products, Global Solutions Jeff Battani Business Development Manager Industrial Components Business Rev 5058-CO900B

2 DISCLAIMER This document is intended to provide general technical information on a particular subject or subjects and is not an exhaustive treatment of such subjects. Accordingly, the information in this document is not intended to constitute application, design, software or other professional engineering advice or services. Before making any decision or taking any action, which might affect your equipment, you should consult a qualified professional advisor. ROCKWELL AUTOMATION DOES NOT WARRANT THE COMPLETENESS, TIMELINESS OR ACCURACY OF ANY OF THE DATA CONTAINED IN THIS DOCUMENT AND MAY MAKE CHANGES THERETO AT ANY TIME IN ITS SOLE DISCRETION WITHOUT NOTICE. FURTHER, ALL INFORMATION CONVEYED HEREBY IS PROVIDED TO USERS "AS IS." IN NO EVENT SHALL ROCKWELL BE LIABLE FOR ANY DAMAGES OF ANY KIND INCLUDING DIRECT, INDIRECT, INCIDENTAL, CONSEQUENTIAL, LOSS PROFIT OR DAMAGE, EVEN IF ROCKWELL AUTOMATION HAVE BEEN ADVISED ON THE POSSIBILITY OF SUCH DAMAGES. ROCKWELL AUTOMATION DISCLAIMS ALL WARRANTIES WHETHER EXPRESSED OR IMPLIED IN RESPECT OF THE INFORMATION (INCLUDING SOFTWARE) PROVIDED HEREBY, INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY, AND NON- INFRINGEMENT. Note that certain jurisdictions do not countenance the exclusion of implied warranties; thus, this disclaimer may not apply to you. Excerpts from UL Standard for Safety for Industrial Control Panels, UL508A are copyright Underwriter s Laboratories Inc. Excerpts from the 2011 National Electrical Code are copyright National Fire Protection Association 2

3 Presentation Agenda SCCR Background NEC, UL 508A SB vs. IEC MCS Motor Starter Circuits SMC Soft-Starter Circuits PowerFlex Drive Circuits rockwellautomation.com Web Tool Global SCCR Summary 3

4 Global Short-Circuit Current Ratings Global Products, Global Solutions! Customer Solutions Competitiveness Common Design Coordinated Protection Complete Solutions 4

5 Importance of Short-Circuit Current Ratings Short-Circuit: An over-current fault the exceeds normal full load currents... 10x, 100x, 1,000x of FLC Catastrophic results if SC Faults are not cleared properly SC Faults are critical to: Worker Safety Customer Applications (Critical Care, Continuous Process) Circuit Components, Assemblies & System Installations Productivity & Downtime ($100k s per hour) We forget how much power we are really discussing: 400V 480V 690V Current (A) Available Short Circuit Current (I pa) Non-Current Limiting Peak Let-Thru (I pl) Let-Thru (I 2 t) Time Clearing Time (t c) Normal Load Current Short Circuit Current 5

6 What is a Short-Circuit Current Rating? Short-Circuit Interrupting Rating (Breaking Capacity): The maximum short circuit current at rated voltage that a over-current protective device can safely interrupt and clear (Fuses & Circuit Breakers) Short-Circuit Current Rating SCCR: The maximum available short-circuit current an electrical component can sustain without the occurrence of excessive damage when protected with an over-current protective device Motor Protection Circuit Breaker Protective Device Icu/Ics = 400V Combination Motor Controllers Icu/Ics = 400V IEC Type 2 Coordination

7 Building a Short-Circuit Current Rating Protection Levels: Component Combinations Branch Circuit Panel Assembly Motor Protection Circuit Breaker Icu/Ics = 400V Combination Motor Controllers Icu/Ics = 400V IEC Type 2 Coordination Panel SCCR 400V Branch Circuit SCCR 400V 7

8 Common Global SCCR Requirements Utility V MCB1 480V, 60Hz Determine System Voltage & Frequency Determine Available Fault Currents (AFC) Ensure Control Panel SCCR covers the AFC Mark the Panels Accordingly Main Switchgear SCCR Evaluation Process varies greatly F1 X 22kA AFC X 48kA AFC X 14kA AFC X 35kA AFC 8

9 Presentation Agenda SCCR Background NEC, UL 508A SB vs. IEC MCS Motor Starter Circuits SMC Soft-Starter Circuits PowerFlex Drive Circuits rockwellautomation.com Web Tool Global SCCR Summary 9

10 NEC, UL 508A SB vs. IEC Category Products Panels & Machinery North American Markets UL 508 Part I All Equipment UL 508, 489, 1077 Circuit Breakers UL 98 Disconnect Switches UL 508 Part II Mag Motor Controllers UL 508 Part III Man Motor Controllers UL 508 Part IV Comb Motor Controllers UL 508 Part V Reduced Voltage Starters UL 508 Part IV Solid-State AC Motor Control UL 508 Part X Auxiliary Devices UL 1059 Power & Terminal Blocks UL 508C Power Conversion Equipment NFPA 79 Electrical Standard for Industrial Machinery UL 508A (SB) Industrial Control Panels UL 845 Motor Control Centers UL 1558 LV Switchgear International Markets IEC General IEC Circuit Breakers IEC Disconnect Switches IEC Contactors & Starters IEC Soft-Starters IEC Control Circuit Devices IEC Terminal Blocks IEC Variable Freq Drives IEC Electrical Equipment of Industrial Machines IEC LV Control-gear & Switchgear Assemblies IEC Application of SCCR (TR) Electrical Installations NEC (NFPA 70) National Electrical Code CEC Canadian Electrical Code IEC Low-Voltage Electrical Installations for Buildings 10

11 SCCR on UL Industrial Control Panels NEC & UL 508A NEC Articles: 409 Industrial Control Panels General use, 600V or less 440 Air Conditioning & Refrigeration 610 Cranes & Hoists 670 Industrial Machinery Marking: (3) Short-circuit current rating of the industrial control panel based on one of the following: a. Short-circuit current rating of a listed and labeled assembly b. Short-circuit current rating established utilizing an approved method FPN: UL 508A-2001, Supplement SB, is an example of an approved method General Use Industrial Control Panels: Construction Panels Power Circuits Control Circuits Ratings Markings Specific Use IC Panels Supplement SB: SCCR for IC Panels 11 11

12 UL 508A Supplement SB UL 508A Industrial Control Panels Panel Builders Standard Standardized process to determining SCCR for panels Limited traditional analysis methods Evaluates Voltage Ratings (Y/D Systems) Default to minimum assigned ratings Forces all power components to have high fault SCCR ratings Umbrella Testing UL Witnessed all High Fault Tests! 12

13 UL 508A SB Determining SCCR s - 3 Basic Steps UL 508A Supplement SB Short-Circuit Current Ratings for Industrial Control Panels Shall be determined by the following evaluation procedure: SB4.1: Short-Circuit Current Rating (SCCR) a) First, establish the short circuit current ratings of individual power circuit components as specified in SB4.2 b) Second, modify (limit) the available short-circuit current within a portion of a circuit in the panel due to the presence of current limiting components as specified in SB4.3 c) Third, determine the overall panel short-circuit current rating as specified in SB4.4 13

14 UL 508A SB4.2 Individual Power Circuit Components SB4.2.1 All power circuit components, including disconnect switches, branch circuit protective devices, branch circuit fuse holders, load controllers, motor overload relays, terminal blocks, and bus bars, shall have a short-circuit current rating expressed in amperes or kilo-amperes and voltage. Exception No. 1: Power transformers, reactors, current transformers, dry-type capacitors, resistors, varistors, and voltmeters are not required to have a short circuit current rating. Exception No. 2: The S contactor of a wye-delta motor controller is not required to have a shortcircuit current rating. 14

15 UL 508A SB4.3 Feeder Devices that Limit SC Current SB4.3 Feeder components that limit the short-circuit current available: SB4.3.1 For branch circuits supplied by a power transformer with an isolated secondary winding, a power transformer with an isolated secondary SB4.3.2 For branch circuits supplied by a Listed circuit breaker marked current limiting in the feeder circuit, the short circuit current rating SB4.3.3 For branch circuits supplied by a Class CC, G, J, L, RK1, RK5, or T fuse in the feeder circuit, the short-circuit current rating 15

16 UL 508A SB4.3 Current-Limiting Components SB4.3.2 For branch circuits supplied by a Listed circuit breaker marked current-limiting in the feeder circuit, the short-circuit current rating on the line side of the circuit breaker shall be one of the following: a) The short-circuit current rating of the feeder circuit breaker when all of the components in the branch circuit have a shortcircuit current rating not less than the published peak letthrough current of the circuit breaker, see Figure SB4.1, and the short-circuit current rating of all branch circuit protective devices on the load side are not less than the short-circuit current rating of the feeder circuit breaker; Feeder CB Current Limiting 65kA SCCR 65kA SCC Available 17kA Ip Let-through b) The smallest short-circuit current rating of any branch circuit protective device on the load side of the feeder circuit breaker, when the conditions of SB4.3.2(a) exist except the short-circuit current rating of the branch circuit protective devices on the load side are less than the short-circuit current rating of the feeder circuit breaker. c Branch Circuit PD 65kA SCCR Motor Controller 18kA SCCR a) 65kA Panel SCCR 16

17 UL 508A SB4.4 Overall SCCR of the Panel 10kA 100kA SB4.4.1 For each branch circuit provided with branch circuit protection within the industrial control panel, the smallest short-circuit current rating of all power circuit components on the load side of a branch circuit protective device and the control circuit over-current protection in SB3.2.1 shall be determined and compared with the short-circuit current rating of the branch circuit protective device. The smaller of the two ratings shall be assigned to the line side of the branch circuit protective device. 65kA 70kA 65kA In other words, use the lowest rating of a component or branch protective device to determine branch rating. 10kA Panel Rating 17

18 UL 508A SB4.4 Panel SCCR Validate Results 1. Panel SCCR will be determined by the smallest SCCR of any feeder or branch over-current protective device or component Available Fault Current: 480V 2. Branch Circuit Protection Devices, BCPDs must cover panel available fault level 3. All components and controllers with SCCR s based on high-fault ratings must be used with the specified branch circuit protective device 4. And finally, the panel SCCR must cover the available fault current supplying the panel! 18

19 UL 508A SB Components Requiring High Fault SCCR High Fault Ratings with Circuit Breakers & Fuses Circuit Breaker & Fuse Solutions! Motor Controllers: Motor Starters Soft-starters Drives Servo Controllers Wiring & Connection Systems: Busbar Mounting Systems Adapter Modules Commoning Links & Feeder Blocks Power Distribution Blocks Terminal Blocks Fuse Holders Feeder Devices: Disconnect Switches Circuit Breakers 19 19

20 140U-D Branch Circuit Protection Device 140U-D MCCB UL 489 Molded Case Circuit Breaker Current Limiting Thermal/Magnetic Protection 2 & 3 Pole A Ir Range 480V, kA Interrupting Ratings 45mm wide Full Line Accessories: Aux, Shunt, Under-voltage Commoning Links & Feeder Block Operating Handles Connection Modules 20

21 MCC & IC Panel Applications 140U-D Vertical Bus 480V) Fuseless & Mission Critical Circuits ACB Main Incomer Motor Branch Circuit Breaker 140U-H..L MCCB (Iq = 480V) Horizontal Bus 480V) Feeder Breaker 140U-H..L MCCB (Iq = 480V) Non Motor Loads Lighting Heaters Metering Transformers Power Supplies Control Circuits PLC Control (Iq = 480V) Branch 140U-D MCCB (Iq = 480V) Eliminates requirement for Series or Cascading Ratings 21

22 IEC Switchgear & Control-gear Application of SCCR per IEC IEC Part 1 - General Rules Covers all Switchgear & Control-gear variants in Series No longer includes TTA or PTTA designations, now satisfied thru verification rules General requirements: Panel must have a SCCR rating that covers the available fault current Same requirement as NEC & UL Panel SCCR is determined by equipment manufacturer per Same requirement as NEC & UL Different process to determine ratings 22

23 IEC Verification of Performance under Short-circuit Conditions Verification by the application of Design Rules, Calculation or Test. Verification based on the Reference Design Original Manufacturer Design Must be Tested Verification not required for the following; Short-circuit Prospective Fault (Icp) or Withstand (Icw) is <10kA Conditional Short-circuit Current where the Ipk is <17kA Auxiliary Circuits are connected to transformers < 10kA All other circuits must be verified 23

24 IEC Reference Design Reference Design based on: Original Manufacturer assembly Focus on the bus structure & connection systems Verification by test for SC Current Withstand! Types of Ratings: Short-time Current Withstand Icw = Rated ka for 1..3 sec. I 2 t & Ipk (Thermal/Dynamic Stress) Conditional Short-circuit Current Reference Design Ue = 415V Icw = 50kA, 1 sec Ipk = 105kA Icc = Rated ka at rated voltage with specified SCPD (CB or Fuses) Ratings can be used for verification by calculation: Acceptability of assembly for installation Evaluation of circuits within the assembly Coordination of SCPD selection System V = 400V f = 50Hz Icp = 25kA Internal Circuits Feeders & BCPD = CB Icu/Ics = 50kA V = 415V Branch Components Icc= 50kA V = 415V 24

25 IEC SC Verification Design Checklist Verification by Design Compares original Reference Design to new variant assembly Design Checklist reviews: Icw, conductor cross-section, spacings, materials, enclosure size & compartment design If all questions answered yes, additional verification not required Additional evaluations: Series or Cascading Ratings Circuit Impedances, Cable Lengths Let-thru Characteristics (I 2 t & Ipk) Withstand Characteristics (ka & tsec) Devices evaluated (power blocks?) 25

26 Presentation Agenda SCCR Background NEC, UL 508A SB and IEC MCS Motor Starter Circuits SMC Soft-Starter Circuits PowerFlex Drive Circuits rockwellautomation.com Web Tool Executive Summary 26

27 Branch Circuit Solutions Branch circuit solutions can be complex: Component selection can be difficult to determine coordinated High Fault SCCR RA Branch Circuit Solutions: Tested at RA Accredited High Current Test Facilities Test Programs approved & witnessed by UL Third Party Certification Ratings included in UL File Reports Ratings are typically attained with standard component sizing, limited oversizing required Provide web tool for customer ease of selection Select product solution Select application parameters Output: SCCR Selection Table and One Line BOM 27

28 Global SCCR Applications 25kA, 690V 50kA, 575V 30kA, 575V 65kA, 460V 65kA, V 65kA, 400V 50kA, V 80kA, 690V 50kA, 380V 65kA, V 50kA, 380V 50kA, 415V 50kA, 400V 50kA, 440V 65kA, 400V 50kA, 525V 65kA, 400V 50kA, 690V 28

29 Presentation Agenda SCCR Background NEC, UL 508A SB vs. IEC MCS Motor Starter Circuits SMC Soft-Starter Circuits PowerFlex Drive Circuits rockwellautomation.com Web Tool Global SCCR Summary 29

30 SCCR for Motor Starter Combinations Global Voltages: V, 415V, 440V, 525V, 690V 50Hz 460/480, 575/600V 60Hz Short Circuit Performance: 50, 65 & 100kA Type 1, Type 2 Branch Protection Devices: Fuses, MCP, MCCB, MPCB Motor Starters: ( A) 2C Starters (MPCB + Contactor) 3C Starters (MCP + Contactor + OLR) 3C Starters (Fuses + Contactor + OLR) 2C Load Feeder (MCCB + Contactor) Motor Overload Protection: Electronic Bimetal

31 Selection Tables & Test Summary Letters 3 Component Starters (MCP + Contactor + OLR) - SCCR: 460V - 3C Starters w/ UL MCP - Type 2 Coordination 31

32 Selection Tables & Test Summary Letters 2 Component Starters (MPCB + Contactor) - SCCR: 400V - 2C Starters w/ MPCB - Type 2 Coordination 32

33 Presentation Agenda SCCR Background NEC, UL 508A SB vs. IEC MCS Motor Starter Circuits SMC Soft-Starter Circuits PowerFlex Drive Circuits rockwellautomation.com Web Tool Global SCCR Summary 33

34 SCCR Branch Circuit Solutions SMC Soft-Starters Global Voltages: 220V, V, 415V, 440V, 525V, 690V 50Hz V, 230V, 460V, 575V 60Hz Short Circuit Performance: Standard Fault, 65 & 100kA Type 1, Type 2 Coordination Branch Protection Devices: Fuses & Circuit Breakers Soft-Starters: (1..800A) SMC-3 SMC-50 SMC Flex Starting Modes: Line & Delta Connected Motors Standard & Heavy Duty 34

35 Soft-Starter Circuit Solutions Line & Delta Connected SMC-3 SMC-50 Line Connected Delta Connected Line Connected Delta Connected Fuse SCPD BCPD Fused Disconnect BCPD Fused Disconnect BCPD Fused Disconnect K1M Input K1M Input K1M Input K1M Input Terminal Block SCR Fuse SCR Fuse SCR Fuse SCR Fuse SMC 3 SMC 3 R By pass Starter R By pass Starter SMC 50 SMC 50 K2M Output K2M Output K2M Output K2M Output M 3~ M 3~ M 3~ M 3~ 35

36 SCCR Selection Table SMC-3 w/ Fuses Short-circuit Coordination Starter Type: S.C. Protective Device: Soft-starter - Line Connected Motors Normal Duty Rating - AC53b Fuses + Line Contactors + SMC-3 UL/CSA Class J & L Fuses, Current Limiting Line Contactor: 100-C, 100-D (100S-C, 100S-D) Soft-starter: SMC-3 Smart Motor Controller Rated Operational Voltage: 460V 60Hz (480V Line) Test Voltage: 600V 60Hz Rated Conditional S.C. Current (Iq): 70kA (rms sym.) Level of S.C. Coordination: Type "1" or "2" per IEC UL 508 High Fault SCCR M 3~ Fuse SCPD K1M Input SCR Fuse SMC 3 K2M Output - SCCR: 460V - UL Fuse Protection - Normal Duty Starting - Type 2 Coordination Motor SMC-3 Branch Circuit Protection Device - Fuse Line Contactor SCR Fuse (Optional) IEC Coordination 3 ph 1500 rpm Thermal Utilization Max. Current Disconnect Switch Input/Output Max Current Coordination Cat. No. Setting Category Class Rating Cat. No. Cat. No. Class Rating Type [HP] [A] 1) 2) [A] IEC ) [A] Class J & L Fuses 4) 5) [A] 6) Remark 1/ C3NB AC53b: : 3585 J R-J C09 HSJ / C3NB AC53b: : 3585 J R-J C09 HSJ C3NB AC53b: : 3585 J 3 194R-J C09 HSJ / C3NB AC53b: : 3585 J R-J C09 HSJ C9NB AC53b: : 3585 J 6 194R-J C09 HSJ C9NB AC53b: : 3585 J 8 194R-J C09 HSJ C9NB AC53b: : 3585 J R-J C09 HSJ / C16NB AC53b: : 3585 J R-J C12 HSJ C16NB AC53b: : 3585 J R-J C16 HSJ 25 Type C25NB AC53b: : 3585 J R-J C23 HSJ C30NB AC53b: : 3585 J R-J C30 A70P C37NB AC53b: : 3585 J R-J C37 A70P C43NB AC53b: : 1770 J R-J C43 A70P C60NB AC53b: : 1770 J R-J C60 A70P C85NB AC53b: : 3570 J R-J C72 A70P C85NB AC53b: : 3570 J R-J C85 A70P C135NB AC53b: : 1770 J R-J C97 A70P C135NB AC53b: : 1770 J R-J D140 A70P C201NB AC53b: : 1770 J R-J D180 A70P C201NB AC53b: : 1770 J R-J D180 A70P C251NB AC53b: : 1770 J R-J D250 A70P 630 Type C317NB AC53b: : 1770 J R-J D300 A70P C361NB AC53b: : 1770 J R-J D420 A70P C480NB AC53b: : 1770 L R-L D630 A70P kA C480NB AC53b: : 1770 L R-L D630 A70P kA 36

37 Presentation Agenda SCCR Background NEC, UL 508A SB vs. IEC MCS Motor Starter Circuits SMC Soft-Starter Circuits PowerFlex Drive Circuits rockwellautomation.com Web Tool Executive Summary 37

38 SCCR Branch Circuit Solutions PowerFlex Component Drives Global Voltages: 220V, V, 415V, 440V, 525V, 690V 50Hz 230/240V, 460/480, 575/600V 60Hz Short Circuit Performance: 65 & 100kA IEC Type 1 & 2 Coordination Branch Protection Devices: Fuses & Circuit Breakers (MCCB, MPCB) Motor Starters: (1..800A) PowerFlex 525 PowerFlex 4/4M PowerFlex 750 Series Circuit Variables: Circuit Protection Components Power/Line Conditioning Components Control Components 38

39 Drive Circuit Solutions Core Drive Components: Branch Circuit Protection Drive EMC Filter Isolation Transformers Line Reactors (Input/Output) Terminators Reflective Wave Devices Bypass Starter Line Branch circuit Protection Device Fuses or Circuit Breakers Isolation Contactor Line Reactor Control Components: Branch Circuit Protection Isolation Contactors (Input /Output) Bypass Starters SCR Fuse Output Contactor Multi-Motor Controllers (Output) Note: Components require SCCR s per UL 508A SB RWTM Single Motor Multi-motor 39

40 SCCR Selection Table PowerFlex 525 w/ Fuses - SCCR: 460V - UL Fuse Protection - Standard Fuse Sizing (Max) - Normal & Heavy Duty Starting - Type 2 Coordination 40

41 SCCR Selection Table PowerFlex 525 w/ Fuses - SCCR: 460V - UL Fuse Protection - Optimized Fuse Sizing - Normal & Heavy Duty Starting - Type 2 Coordination 41

42 SCCR Selection Table PowerFlex 525 w/ Circuit Breakers - SCCR: 460V - MCCB Circuit Breaker Protection - Normal & Heavy Duty Starting - Type 2 Coordination 42

43 SCCR Selection Table PowerFlex 525 w/ Circuit Breakers - SCCR: 400V - Circuit Breaker Protection - Normal & Heavy Duty Starting - Type 2 Coordination 43

44 Disconnecting Means Branch Circuits Control Connection Systems Branch Circuits Power 44

45 Presentation Agenda SCCR Background NEC, UL 508A SB vs. IEC MCS Motor Starter Circuits SMC Soft-Starter Circuits PowerFlex Drive Circuits rockwellautomation.com Web Tool Global SCCR Summary 45

46 Web Selection Tool Focus on Branch Circuit Solutions: Electromechanical Starters Soft-Starters Component Drives Selection based on: Common Voltage & Frequency Common SCCR Common Level of Coordination Data subject to change: New component introductions Optimized combination ratings Always Use Current Posted Documentation 46

47 Product Category IEC Motor Control 47

48 General Starter Data - Starter Type 2 Component Starters (MPCB + Contactor) 48

49 System Voltage Data Motor Voltage 460V, 60Hz 49

50 Performance Specification 140M C (Type E) 50

51 Available Documents SCCR Selection Table & Test Summary Letter 51

52 Selection Table & Test Summary Letter View, Print or Download 460V, 65kA HP SCCR Selection Table 460V, 65kA HP Test Summary Letter 52

53 productcertifications/ul508a 53

54 Global SCCR Summary High Fault SCCR requirements increasing globally UL 508A SB procedure can be applied to global applications RA customers require solutions for global voltages & faults levels Utilize Complete Branch Circuit Solutions: MCS Starter Circuits SMC Soft-starter Circuits PowerFlex Drive Circuits UL Witnessed & Listed Ratings SCCR Selection Tables One Line BOM Improving Customer Solutions! 54

55 Global Short-Circuit Current Ratings Global Products, Global Solutions Thank you for your time!! Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. Rev 5058-CO900B

56 Presentation Agenda SCCR Background NEC, UL 508A SB vs. IEC MCS Motor Starter Circuits SMC Soft-Starter Circuits PowerFlex Drive Circuits rockwellautomation.com Web Tool Global SCCR Summary 57