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The Electrical Power Systems Division The Motor Controllers & motor Control
Centers section Number: 2
The defining parameters for low voltage alternating current magnetic contactors/starters:
The defining ratings for low voltage alternating current magnetic contactors/starters are: the NEMA
size, the voltage rating, the maximum HP for single phase and three phase motors (for both non
plugging/non jogging and plugging/jogging applications), the continuous current rating of the
contactor/starter, the service limit, transformer switching capability rating for single and three phase
applications, the capacitive switching capability (in volt and KVAR), the dimensions, the weights, the
overload protective element type and rating.
The defining parameters of l.v. combination starters:
The defining parameters of low full voltage combination starter units: the starter size, the maximum
motor HP at the different standard voltages (200v, 230, 460 and 575v), whether the unit is reversing or
nonreversing, the fuse or circuit breaker size (used as a protection against short circuit or
protection/load break device), the size of the unit in inches or space factor, the weight of the unit,
method of attachment to riser bus bars of MCC (bolton or plug in) and size plus type of motor
overload protection element/relay.
The defining parameters for full voltage 2speed starters:
The defining parameters for full voltage 2speed starter units are: the starter size, the HP (maximum) at
the different nominal voltages, the circuit breaker or fuse size for the short circuit protection, the
dimension in inches or space factor for the 1winding and 2winding motor starter unit, unit weight,
method of attachment to MCC and the type plus size of o/c protection device.
Defining parameters of low voltage, reduced voltage starter units:
The defining parameters of low voltage reduce voltage starter units (applicable to part winding and
autotransformer units): the starter size, the maximum motor HP at the different rated voltages, the
circuit breaker or fuse rating, the dimensions or space factor for the units, the weight, the size plus type
of the o/l element, the installation method in the MCC.
Defining the motor protection circuit breakers:
The table will have the following headings: 3phase motor HP, the motor full load current at the
different nominal voltages, the circuit breaker continuous current, the different adjustments (eg.
7x/11x/13x), the weight and dimension, the adjustable range.
Defining motor protection fuses:
The fuses for motor protection table will have the following: the maximum motor HP rating, the motor
full load current rating, the fuse size for the different voltage classes, the fuse type (50KA interrupting
fuse, HRC200 KA I.c., code fuse 10KA or size L over 600a 200KA), the fuse weight.
Defining m.v. controllers:
The table for a medium voltage controller (contactor and fuse) will have the following headings: the
contactor maximum continuous current, the interrupting capacity (at the specified KV), the
designation, the voltage rating and range, the interrupting capacity of the fuse (in KA and MVA @ the
rated voltage), the maximum HP motor rating for the motor design/p.f./voltage/controller current rating,
the dielectric withstand voltage, the controller type (full voltage, reversing vs nonreversing, reduced
voltage auto transformer vs reactor). The m.v. fuses for controllers can be defined when the following
values are given: the motor locked rotor current, motor full load current x service factor, the maximum
continuous current rating of the fuse inside the compartment, the fuse size, the peak current let through
characteristics.
Control panels:
Control panels can be built in different constructions depending on the environment and may include
any or all of the following devices: c ontactors, breakers, switches, relays, pushbuttons, selector
switches, meters, pilot lights (filament or LED). These panels incorporate the logic (decision making),
input & output devices.
Distribution panels and switchboards:
Most of the codes define a circuit breaker as a device designed to open and close a circuit automatically
at a predetermined overcurrent values (short circuit or overload) without injury to itself when properly
applied within its rating. A molded case circuit breaker irrelevant of the manufacturer comprises of:
the molded case(frame), operating mechanism, arc extinguishers, contacts, trip elements and the
terminals (connectors i.e. mechanical/ compression lugs or solid bar). The function of the molded case
is to provide an insulated housing to assemble and mount all of the circuit breaker components. The
cases are molded from phenolic material. It provides ruggedness and high dielectric strengh to the
breaker in a compact design. Maximum current, voltage and interrupting current determine the size and
strength of the molded case circuit breaker. Different manufacturers build breakers for the same rating
with different physical sizes i.e. noninterchangeable. The faceplate gives all the important data such as:
catalog number, serial number of breaker, interrupting ratings at different voltage classes, standards
registration numbers i.e. for the CSA or UL, calibration temperature for thermal magnetic units, lugs
data &size, electrical accessories, date of manufacturing. The function of the operating mechanism is to
provide a means of opening and closing the breaker. It is of the quickmake, quickbreak mechanism.
These breakers are also trip free i.e. if the breaker operating handle is pushed and hold in the on
position and there is a fault on the system (or the trip test button is pushed, if available) the breaker
would trip open & stay open.There are three distinct positions for the handle to settle in the ON, OFF,
TRIP (which is midway between the ON and OFF positions). The breaker has to be reset after tripping
by pushing the handle all the way to the OFF position and than pushing it to the ON position. The
function of the arc extinguisher is to confine, divide and extinguish the arc drawn between the breaker
contacts each time the breaker interrupts. The trip element provides the protection in case of prolonged
overloads or short circuits. It actuates the operating mechanism and trip the breaker open. This element
is made up of electromechanical or solid state components. The electromechanical element is referred
to as the thermal magnetic and it includes: the bimetallic element and the electomagnet. The
current(load) flows through or heats the bimetal. When a combination of high current level and a long
duration exists which is sufficient to deflect the bimetal far enough to physically push the trip bar and
unlatch the contacts, the breaker will trip open. There is no field adjustment available for the thermal
element. The magnetic trip action is achieved through the use of an electromagnet connected in series
with the load current. When the short circuit current passes through the coil this causes the
electromagnet to attract the armature (trip bar) and the unlatching action causes the breaker to trip
open. Magnetic trip is adjustable in 250A frame breaker and over. Two adjusting methods are available
one is the independent adjustment of each pole of the breaker thus three adjusting knobs versus one
knob to adjust all poles simultaneously. Thermal magnetic trip elements are temperature sensitive thus
a modified unit to compensate for variations in ambient temperature (with a modified design) can be
applied under specific conditions. An ambient compensated overload trip unit can be used whenever the
breaker (protecting a cable or a down stream device) is located in a different place with different
ambient temperature than the protected device or conductor, thus derating or uprating of breakers
becomes unnecessary. Ambient compensation is obtained by using an additional compensating bimetal
which counteracts the effect of ambient temperature changes on the overload bimetal. There are
various methods of connecting the line and load sides of a circuit breaker: bus bars, panelboard straps,
rear connected studs, plugin adapters, terminals (cable lugs for single or multiconductors for copper
only or copper/aluminum ones). The tripping unit can be made up of solid state components or
microprocessor based elements. These components replace the bimetallic & magnetic elements in a
conventional molded case c.b. Internal current transformers in the breaker are required to feed in the
S.S. trip unit. Each frame size can accomodate a set of rating plugs, these plugs set the rated continuous
current of the breaker. Some types of rating plugs are adjustable between 70100% or 50100% of the
rated current of the plug itself. The breaker characteristic curves are similar to the thermal magnetic trip
curves except that the different tripping actions are more clearly defined and can be adjusted. The
distinct portions of the ch/cs curve are: the long time ampere rating & the long time delay (simulates
the thermal section of a thermal magnetic c.b.) the short time pickup & the short time delay (I2t in or
out), the instantaneous pick up (simulates the magnetic portion in a thermal magnetic curve). These
breakers can come with a builtin ground fault protection (for solid effectivegrounded neutral only)
with adjustment of ground fault pickup and time delay. The timecurrent ch/cs curves for current
limiting type c.b. have basically the same shape as conventional c.b. The only difference is the current
limiting action displayed at higher fault levels. A total interruption time of from 1/4 to 1/2 cycle is
consistent with the current limiting operation. The electromagnetic repulsion created by closely spaced
parallel contact arms carrying current in opposite directions intensified by an O shaped magnet
surrounding the contact arm causes the contacts to blow open in an extremely short period of time.
Circuits which produce high fault currents typically are associated with low short circuit power factors
(i.e. high X/R ratios). The high speed contact separation enhances the ability of the c.b. to limit both the
peak current and the let through energy. The integral current limiting breaker is similar to the standard
thermal magnetic except that it incorporates a current limiting device. This device consists of 3 current
limiters specially designed to coordinate with the breaker of which they are an integral part. All
normal overloads and s.c. faults are interrupted by the thermal magnetic portion of the c.b. When a
large fault occurs the trigger type current limiters will blow and operate the trip bar to open the breaker,
thus preventing single phasing.
The standard molded case switch, which is a more compact design than the conventional disconnect
switch, has no trip unit. It consists of the standard breaker contacts, bussing and lugs for the highest
ampere rating in each frame size and is manually operated only.
The safety switches can be single throw or double throw. All switches to have visible blades and safety
handles (interlock bypass lever, cross bar and operating spring). There are two types of switch contacts
the butt and the knifeblade/jaw construction. In the former, only one of the blades contact surface is
held in tension against the conducting path, electromagnetic forces due to high current faults will tend
to force the contacts apart therefore arcing and contact burning may be the result. In the latter the jaws
distribute a uniform clamping pressure on both sides of the blade contact surfaces, the electromagnetic
forces due to the high s.c. currents will tend to squeeze the 2 sides of the jaw together onto the blade.
The action of the blade moving in and out of the jaws aids in cleaning the contact surfaces. The
contacts are made of copper and the current carrying parts of the switch are plated, to reduce heating.
Fused switches will have fuse clips/holders plated and either spring reinforced or not, the classes found
on these switches are J, R, or L for 800A and over. The molded case switches and the safety switches
are installed in a variety of enclosures to meet practically all applications. The enclosures are
designated according to Nema standards(1,3R,4,4X,5,...etc.) or CSA(1,2,3,..etc) all the enclosures have
to go through a set of qualifying tests before been given such a designation.
Now,we shall cover panelboards. These types of boards can be classified, broadly,into two categories:
lighting and distribution/ power. Another method of classification is whether the board contains
breakers, switches (fused or unfused) or a combination thereof. The panelboards can also be classified
according to the main, accepting the incoming cable, whether it is a breaker a switch or just a set of
lugs. The rating ranges, for single phase (three wire) or three phase (three or four wire) lighting panels,
from 120/240V to 600V 50A 800A main breaker or main lug. The ratings range for single phase (two
or three wire) or three phase (three or four wire) power panels from 120/240V through 600V a.c or
250V d.c., main breaker or switch or lugs, up to 1200A. The major components of the breaker
panelboards are the boxwhich comes in standard dimensions, the interior which holds the breakers
and comes in standard current carrying capacity & mounting spaces, the solid neutral which is a bare
conducting bar with lugs, the trim either flush or surface which covers the gutters and has the door
that covers the branch/main breakers, finally the breakers plug on or bolted type. For the fusible
panels the components are: the fusible switch unit, the interior assembly, the enclosure the box and the
front trim parts, the cover plates (blanks)and the neutral.
There are metering equipment (centres or sockets) that are used for single phase and three phase
systems. They are units that act as the point of placement for the P.U. to place its detachable meter
(watthour). The single phase 120/240V,3wire units are used in conjunction with the load centre which
is located inside the single family resident. There are three types of meter sockets: the noncircuit
closing, automatic circuit closing and the manual circuit closing. The first means when the watthour
meter is removed the service to the down stream load is interrupted, the second means that a
mechanism to short the line to the load jaws of the socket when the meter is detached is provided, the
third offers the ability of shorting the line to the load jaws of the socket manually through the use of a
slider or lever before removing the meter. All these mechanisms are meant for temporarily shorting the
socket and usually rated 50% of the continuous current carrying capacity of the socket. The jumper bars
are not to be used to make/break current. The 4 jaw meter socket is used on 120/240V a.c.,1 phase, 3
wire. The 5jaw used with single phase loads fed from 3 phase ,4w 120/208V ac system. For 3 phase, 4
wire systems the 7jaw meter socket is used with the proper meter to measure the energy consumption
of the connected loads. The type of socket trim will suit the type of socket installed. These meter
sockets can be assembled together in one lineup to meter different loads in one location like shopping
centers, apartment buildings,...etc. They are built for indoor or outdoor installations.
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