Fault Current Calculations

and
System Protection
 WHY ARE FAULT CALCULATIONS NEEDED?

„ Used to Determine the Proper Interrupting

Ratings for Breakers/Fuses

„ Breaker/Fuse Coordination
 TYPES OF SHORT CIRCUIT FAULTS

„ Three Phase Grounded or Ungrounded Fault

„ Line to Line Ungrounded Fault (Line to Line)

„ Line to Line Grounded Fault (Double Line to

Ground)

„ Line to Ground Fault (Single Line to Ground)

 Three Phase Fault Condition
Bolted Fault Arcing Fault

Systems must be designed However, the majority of faults

for worst case conditions. will be arcing type.
 Frequency of Faults

TYPE OF FAULTS INCIDENCE % FAULT MAGNITUDE

Three-phase bolted - .05% Approaches total fault current

Single-phase bolted - 5% 30-60% of fault current
Line-to-line arcing - 15% Low to medium (less than 30%)
Line-to-ground arcing - 80% Very low to low (less than 10%)
Location of Faults Within a Circuit
UTILITY

Least Likelihood
of Fault

Greatest Likelihood
of Fault

M M
 HOW IS FAULT CURRENT CALCULATED ?

Ishort circuit = Etotal / Ztotal

• Z is the circuit Impedance

• E is the Voltage
 WHAT IS IMPEDANCE ?

• Unit of Opposition to Current Flow in any

Alternating Current Circuit
• Composed of Resistive, Inductive Reactance,
and Capacitive Reactance
• Measured in OHMS
 SERIES IMPEDANCE CALCULATIONS

• Break Individual Impedance into Resistive and

Reactive Components
• Sum All Circuit Resistive (R) Components
• Sum All Circuit Reactive (X) Components
• Zcircuit = √(Rtotal² + Xtotal²)
 EXAMPLE
SERIES IMPEDANCE CALCULATIONS

Z1 = R1 + jX1
= 2 + j6
Zt = (R1+R2)+j(X1+X2)
= (2+5) + j(6+4)
Z2 = R2 + jX2
= 7 + j10
= 5 + j4
= √(7)² + j(10)²
= √(49 + 100)
= 12.2 Ω
 PARALLEL IMPEDANCE CALCULATIONS

• Break Individual Impedance into Resistive and

Reactive Components
• 1/Ztotal = 1/Z1 + 1/Z2 where 1/Z = G + B
• G=R/(R² + X²) B=X/(R² + X²)
• Sum All Circuit G and B
• Rtotal = G/(G² + B²)
• Xtotal = B/(G² + B²)
• Zcircuit = √(Rtotal ² + Xtotal ²)
 EXAMPLE
PARALLEL IMPEDANCE CALCULATIONS

Z1 = R1 + jX1 Z2 = R2 + jX2 Zt = Rt + jXt

= 2 + j6 = 5 + j4 = √((1.89)² + j(2.71)²)
= √(3.57 + 7.34)
= 3.30 Ω
1/Zt = 1/Z1 + 1/Z2
Z 1/Z Sum of
ELEMENT R X G B Square
Z1 2 6 ⇒ 0.05 0.15 ⇒ 40
Z2 5 4 ⇒ 0.122 0.097 ⇒ 41
Zt 1.89 2.71 ⇐ 0.172 0.247 ⇒ 0.091
 System Short Circuit Calculations
Unlimited Fault Current Note:
Obtain specific impedance
12,470V∆ 2,500 kVA, Z = 5.75% values for each system.
Do not assume the values
Calculated Fault shown here will be typical.

12 Feet, 3,200A Copper Feeder Busway

480Y/277V
52,296 3,200A
3,200A Bus
Bus Plug
200A 200A 150A 100 Feet
60 Feet
(3) 1-Conductor (3) 1-Conductor
#4/0 Copper #2 Copper
THW Insulation THW Insulation
Steel Conduit Steel Conduit

26,634 10,968
Main
Control
Calculated at 100% Motor Contributions Panel
 Short Circuit Calculations

Unlimited Fault Current

12,470V∆
2,500 kVA, Z=5.75%

Calculated Fault 52,296A

480Y/277V

Isc = ___kVA____ = 2,500 × 1,000 × 100 = 52,296 Amps

Vphase-neutral × Z 480 × √3 × 5.75%
 Example
Cable Fault Current Calculations
Find Cable Impedance: Table A45, CH Consulting Guide
#4/0 Copper in Steel Conduit

Rc = .00696 per 100 ft

Xc = .00489 per 100 ft
X1 = 60ft/100ft x .00696 = .00418
R1 = 60ft/100ft x .00489 = .00293
Z1 = √((.00418)² + (.00293)²) = .0051
 Example
Cable Fault Current Calculations
Calculate Fault Current (Assume no busway losses)
1. Find Phase Voltage
Vphase = 480 / √3 = 277 VAC

2. Find Source Impedance

52,296 Amps / 277 VAC = .0053Ω

3. Find Total Impedance (Source plus Cable)

Zt = .0053 + .0051 = .0104Ω

4. Short Circuit Current

277 VAC / .0104Ω = 26,634 Amps
 Secondary Short Circuit Capacity of
Typical Power Transformers
(Table A25, Page A59 of Cutler-Hammer Consulting Guide)

208 Volts, 3-Phase 240 Volts, 3-Phase 480 Volts, 3-Phase

Transformer Maximum
Rating 3-Phase Short Circuit Short Circuit Current rms
kVA and kVA Available Symmetrical Amps
Impedance from Primary
Percent Combined Transformer and Motor (208V & 240V = 2 x
System Transformer FLA, 480V = 4 x Transformer FLA)
300 Unlimited 18400 17300 8600
5%
500 Unlimited 30600 28900 14400
5%
750 Unlimited 40400 38600 19300
5.75%
1000 Unlimited 53900 51400 25700
5.75%
1500 Unlimited 80800 77200 38600
5.75%
2000 Unlimited 41800 51400
5.75%
2500 Unlimited 52300 64300
5.75%
 Fault Current Calculations - Table Method
1500 kVA Transformer/5.75% Impedance/480 Volts
(chart assumes 100% motor load, see Table A10, page A-27 for equivalent conductors)
Fault Current in Thousands of Amperes (Sym.)

UTILITY KVA
60 500,000

4 - 750 MCM
50 2 - 500 MCM
3 - No.4/0,250 MCM
#1/0 AWG
40 #4 AWG

30

20

10

0
0 2 5 10 20 50 100 200 500 1000 2000 5000
Distance in Feet from Transformer to Breaker Location
CIRCUIT BREAKER OPERATION
Arc Extinguisher

ƒ Contact parting creates arc

ƒ Magnetic field pulls arc
into arc extinguisher
ƒ Arc divided and cooled
by steel plates
ƒ Arc extinguishes, opening
circuit
 Two Types of Trip Units

1. Thermal-Magnetic Trip Units

2. Electronic Trip Units (Cutler-Hammer Digitrip)

 Thermal Magnetic Trip Functions

1. Long Delay Current Pickup

• Thermal Function
• Fixed Setting

2. Long Delay Time

• Thermal Function
• Fixed Setting

3. Instantaneous Pickup
• Magnetic Function
• Adjustable Setting (Larger Frames Only)
 Thermal Long Time Pick Up

ƒ Thermal
characteristic
curve
 Adjustable Instantaneous Current Pick Up

ƒ Adjustable Magnetic
Trip Characteristic Curve

ƒ Graph Shows Three

Possible Instantaneous
(Magnetic) Current
Settings
 Thermal Magnetic Trip Curve

ƒ Thermal magnetic
characteristic curve

ƒ Time-current
characteristic curve
 Electronic Trip Functions
1. Long Delay
• Two to 24 Second Time Adjustment
• .5 to 1.0 Times Amp Rating Current Adjustment

2. Short Delay
• 0 to .5 Second Time Adjustment
• Two to Six Times Amp Rating Current Adjustment

3. Instantaneous Pick-up
• No Time Delay, Instantaneous
• Two to Six Times Amp Rating Current Adjustment

4. Ground Fault
• .1 to 0.5 Second Time Adjustment
• .25 to 1.0 Times Amp Rating Current Adjustment
Long Delay - Current Adjustment
Long Delay - Time Adjustment
Short Delay - Current Adjustment
Short Delay - Time Adjustment
Instantaneous - Current Adjustment
Ground Fault Pick Up Current Adjustment
Ground Fault Time Adjustment
 Electronic Trip Unit Curve
(Long Delay, Short Delay, Instantaneous, Ground Fault)
PROTECTION SYSTEMS
Three Types of Systems

1. Selectively Coordinated System

2. Fully Rated System

3. Series Rated System

1. Selectively Coordinated System
This system allows or selects the breaker closest to the
overcurrent source to open, thus most closely isolating the problem.

CONTINUITY OF SERVICE
„ High continuity.

PROTECTION
„ All breakers fully rated.

COST
„ Most costly of all three systems.
Time-Current Curve Coordination Study
4.16 kV 250 MVA
MOTOR A B C D E
1,000
E

Ansi 3-Phase D
Through Fault 250A
100 Protection
Curve 1,000
(More kVA 4,160 V ∆
Phase Than 10 5.75% 480Y/277 V
Protection In Lifetime) 19,600A
Time in Seconds

10

C 1,600A
A B
24,400A

1 B 1,000A

Transformer
Inrush
20,000A
.1 A 175A

Ground
Protection
100 HP-
.01 M 124A FLC
.5 1 10 100 1,000 10,000
Scale X 100 = Current in Amperes at 480 Volts = Available fault current
including motor contribution.
„ Electronic Trip Unit
„ Zone Selective Ground Fault Setting:
Interlocking Zone 1
1,200A Pickup
0.5 Sec. Time Delay
- Short Time Delay Breaker 1

- Ground Fault Ground Fault Setting:

600A Pickup
Time Delay Zone 2 0.3 Sec. Time Delay
Breaker 2
- Instantaneous Zone Interlock Wiring

Trip Regardless Fault 1 Ground Fault Setting:

of Short Time 300A Pickup
Zone 3 No Time Delay
Delay
- Minimize Fault 2

Damage LOAD
Coordination

„ Circuit breakers with thermal magnetic trip units will

also coordinate well under the same conditions.
„ Trip unit settings need to be determined by carrying
out a coordination study.
„ Fuses cannot do zone selective interlocking.
2. Fully Rated System
In this system, all of the breakers must be fully rated for the
system’s available fault current. This allows for quick selection
of equipment, but allows for less continuity of service in general.

CONTINUITY OF SERVICE
„ Lower than selectively coordinated system.
„ Usually higher than series connected system.
PROTECTION
„ All breakers fully rated.
COST
„ Lower than selectively coordinated system.
„ Usually higher than series rated system.
3. Series Rated System
This is a system of series connected breakers which have
been tested in combination and shown to effectively protect the system.
Downstream breakers are not fully rated for the system’s available fault
current but the upstream breaker, which is tested
in combination, protects the downstream breaker by operating
before damage occurs.

CONTINUITY OF SERVICE
„ Continuity of service may suffer.
PROTECTION
„ Downstream breakers not fully rated.
COST
„ Usually the least costly system.
Series Ratings
Fuses Circuit Breakers

100 kA 65 kA

14 kA 14 kA
100 kA 100 kA
14 kA 14 kA
100 kA 100 kA
14 kA 14 kA
100 kA 100 kA
14 kA 14 kA
100 kA 100 kA

FULLY RATED SERIES RATING

Series ratings can Circuit breakers are
not be done with fuses- tested as a component and
there’s no advantage. tested in an assembly.
The Issues

… Practical
„ Safety. „ Size.
„ Monitoring and „ Economics.
communications. „ Cost.
„ Testability.
„ Accessorization.
The Issues

…Practical …The Advantages of Using Breakers

„ Testability „ Electronic trip units are field testable.

„ Fuses are not field testable.
„ Push to test in the field.
„ Verify each unit off the assembly line.
The Issues

…Practical …The Advantages of Using Breakers

„ Size „ Smaller devices allow for more room

in an assembly.
„ Assemblies with fusible devices are larger.
„ Space saving in control panel.
Practical Issues
„ Space and Cost Comparisons
PRL 4F Fusible
PRL 4B
SAVINGS…
Breaker
1200A 400A „ 59% Wall Space
FDP FDPW
Wall
„ Equipment Cost
VERT.
1200A ND
400A
Space 400A KD FDPW
400A
400A KD
400A KD
FDPW Savings
73.5” 400A KD 90”

„ Installation Time
400A
FDPW

Thru-Feed
Lugs „ Cost of Fuses and
Labor for Replacement
36” 72”
$1,410 Additional for Fuses
„ Downtime
PLUS Spares

Floor
Space
11.3” 2.83 Sq. Ft. 18” 9 Sq. Ft. „ 69% Floor Space