ABB Australia

Doc. Title: UniGear ZVC – Application Notes

Doc. No: 1VGA673011 Sheet No: 1 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

Document Type: System Information:

UNIGEAR ZVC 1VGA673011

Application Notes

ABB CONTACT: DOCUMENT STATUS

Jimmy Ong
Sales Application Manager
ABB Australia Pty Limited
Email: [email protected]
Tel: +612 9821 0935 ABB Australia reserves all rights in this document and the information
contained therein. Reproduction, use or disclosure to third parties without
Mob: +61 409 464 618 prior express authority is strictly forbidden.

B Fuses for Trans., CT, Heat Loss included 22 Sep. 08 JO GA GA JO

A Issued for information 19 Sep. 08 JO GA GA JO
Rev. Reason for Issue Date Issuer Check.by Des.Ch.by Appr.by
Issuer: Checked by: Design Checked by: Approved by:

ABB Australia GA GA JO
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 2 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

CONTENTS:

1. FUSE SELECTION

1.1 Transformers
1.2 Motors
1.3 Capacitors
1.4 Selection Charts
1.4.1 6,600V
1.4.2 3,300V
1.4.3 6,600V Project Selection Example
1.5 Motor HV Fuses For Transformer Protection

2. CONTACTOR - FUSE - RELAY CO-ORDINATION

2.1 Standards & Characteristics

2.2 General Considerations
2.3 Maximum Fuse Ratings
2.4 Fuse Characteristic Calculations
2.4.1 ZVC 3.6 400 Maximum Fuse
2.4.2 ZVC 7.2 400 Maximum Fuse

3. HRC FUSE MODELS

3.1 Manufacturers

4. CURRENT TRANSFORMER

4.1 Selection
4.2 Standard Ratings
4.3 High Burden Ratings

5. PANEL HEAT LOSS

5.1 Typical Values

 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 3 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

1. ZVC FUSE SELECTION

1.1 TRANSFORMERS

• Fuse Rated Current

Rated current must be greater than 150% of transformer full load current to allow for normal
overcurrent conditions.

• Inrush Current
- Single Phase Transformers < 100 kVA. Intersection point of 15 times full load current and 0.1
sec. must be to the left side of fuses time current (T.C.) characteristics.

- Other Transformers. Intersection point of 12 times full load current and 0.15 sec. must be to
the left side of fuses time current (T.C.) characteristics.

1.2 MOTORS

• Fuse Rated Current

Rated current must be greater than 130% of rated full load motor current.

• Starting (Inrush) Current

Fuse must meet the requirements for starts per hour at rated run up time. (Note: selection charts
are based on 2 starts in succession - remainder evenly spaced).

1.3 CAPACITORS

• Fuse Rated Current

(a) < 350 kVA

Rated current must be greater than 1.43 times the capacitor rated current where series
reactors are not used.

(b) Other Capacitors

Rated current must be greater than 1.30 times the capacitor rated current where series
reactors are used.

NOTE: Series reactors of 6% or 7% MUST be used for capacitors above 350 kVA.

• Inrush Current

(a) No Series Reactor

Intersection point of 70 times full load current and 0.1 sec. must be to left of T.C.
Characteristics.

(b) Series Reactor

Intersection point of 5 times full load current and 0.1 sec. must be to left of T.C.
Characteristics.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 4 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

1.4 SELECTION CHARTS

1.4.1 FUSE SELECTION: Service voltage 6600V, Ambient Temperature 45oC

TRANSFORMERS MOTORS CAPACITORS

FUSE RATING ADDITIONAL
(A) F.L.C kVA F.L.C kW F.L.C kVAR REQUIREMENTS
(max.) (approx.) (max.) (approx.) (max.) (approx.)
63 40A 400 45A 400 45A 500
80 50A 500 60A 550 60A 600
100 65A 750 75A 710 75A 800
125 80A 800 90A 850 90A 1000
160 100A 1000 120A 1100 120A 1200
200 130A 1250 150A 1400 150A 1600
225 150A 1600 165A 1500 165A 1800
250 165A 1750 185A 1750 185A 2000
315 210A 2000 225A 2100 225A 2000
400 (2x225) 260A 2750 (1)
400 (2x225) 300A 3050 300A 3000 (2)
450 (2x250) 360A 4000 335A 3300 (2)
550 (2x315) 360A 4000 (2)

1.4.2 FUSE SELECTION: Service voltage 3300V, Ambient Temperature 45oC

TRANSFORMERS MOTORS CAPACITORS

FUSE RATING ADDITIONAL
(A) F.L.C kVA F.L.C kW F.L.C kVAR REQUIREMENTS
(max.) (approx.) (max.) (approx.) (max.) (approx.)
63 40A 200 45A 200 45A 250
80 50A 250 60A 280 60A 300
100 65A 325 75A 350 75A 400
125 80A 400 90A 425 90A 500
160 100A 500 120A 550 120A 600
200 130A 700 150A 700 150A 800
225 150A 800 165A 750 165A 900
250 165A 900 185A 800 185A 1000
315 210A 1000 225A 1100 225A 1000
350 230A 1250 270A 1300 225A 1000
400 (2x225) 260A 1400 (1)
400 (2x225) 300A 1500 300A 1500 (2)
450 (2x250) 360A 2000 335A 1650 (2)
550 (2x315) 360A 2000 (2)
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 5 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

FUSE RATED CURRENT

Transformer: Fuse rating is 1.5 times max. current

Motors: Fuse rating is 1.3 times max. current
Capacitors: Fuse rating is 1.3 times max. current

INRUSH CURRENT

Transformer: Time current characteristics must be to the right of the point 12 x F.L.C, 0.1sec
Motors: Fuse must meet requirements for starts per hour at rated run up time.
Note: selection charts are based on 2 starts in succession - remainder evenly spaced.
Starting duty check
Fuse must be selected on basis of F.L.C not kW.
Capacitors: Ratings are based on 6% or 7% reactors in series with capacitors.

ADDITIONAL REQUIREMENTS

(1) Coordination check required

2 Fuse per phase
(2) Coordination check required
Ventilation check required
2 Fuse per phase

NOTE: RATIONALISATION FUSE RATINGS TO LIMIT RANGE TO 3 OR 4 RATINGS PER

INSTALLATION (REFER NEXT SECTION)
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 6 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

1.4.3 FUSE SELECTION AND RATIONALISATION FOR A TYPICAL 6.6KV PROJECT

SELECTION
REQUIREMENTS OF LOAD RATIONALISATION
BASED ON LOAD

FULL LOAD STARTING RUN UP STARTS FIRST STARTS SECOND STARTS ADDITIONAL
DEVICE
CURRENT CURRENT TIME PER HOUR SELECTION PER HOUR SELECTION PER HOUR REQUIREMENTS

MOTOR 267A 1300A 15 sec 3 400 (2x225) 6-8 2x250 8-12 *)

MOTOR 209A 1000A 15 sec 3 315 4-6 315 4-6

MOTOR 165A 960A 6 sec 4 225 3-4 250 6-10

MOTOR 68A 400A 6 sec 8 100 2-3 125 8-10

MOTOR 45A 270A 6 sec 8 63 2 125 32

TRANSFORMER 209A 209A - 2 315 2 315 2

*) Remarks:
o Ventilate
o 2 Fuse per phase
o 400 msec delay or earth fault blocking required.

NOTES:

o 3 Fuse Ratings Only Required 315A, 250A and 125A.

o Starts Per Hour Exceed Requirements.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 7 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

1.5 MOTOR HV FUSES FOR TRANSFORMER PROTECTION

The most common application for fused vacuum contactor assemblies is for motor starting
duty.

When a number of starters are assembled together in a motor control center it is not
uncommon to find additional fused vacuum contactor assemblies included in the line-up as
transformer feeders.

The combination of differing applications for the fused vacuum contactor often leads to
uncertainty when selecting appropriate HV fuses. The uncertainty stems from the common
practice of manufacturers of fused vacuum contactor switchgear to recommend motor
starting duty HV fuses in assemblies designated as transformer feeders.

To understand the reason for this practice it is necessary to understand the main functional
components of the fused vacuum contactor assembly. These are;
o a switching apparatus; the vacuum contactor
o an overload protection device; the protection relay
o a short circuit protection device; the HV fuse.

The vacuum contactor is selected for the high number of switching cycles possible with this
apparatus. The overload protection relay is selected for the many and specific protection
functions offered by the device.

Fuse links for motor circuit protection must satisfy the requirements of IEC 282-1. They
need to withstand all of the normal operating conditions in addition to the rather high starting
currents. The high voltage fuse must also coordinate with other components of the circuit:
o the time current characteristic must be to the right of the motor starting point,
o the minimum breaking current of the fuse link must be smaller than the expected
starting current of DOL (direct-on-line) starting motors,
o the let-through current of the fuse link must, at maximum prospective fault current, not
be higher than the rated short-time withstand current of the switchgear in which it is
installed. (That is, switchgear on the load side of the HV fuse.)

In addition the HV fuse is selected so the time current characteristic is to the left of the
“take-over point” defined by the test for co-ordination with protection devices in IEC 60470,
to ensure the vacuum contactor is not required to switch currents greater than its maximum
breaking capacity.

So the HV fuse is the sole interrupter for fault currents greater than say ten times the full
load current of the motor, that is, currents in the short circuit category. The vacuum
contactor, in response to the protection relay, is the interrupter for currents in the overload,
stalled motor and earth fault category.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 8 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

When fused vacuum contactor assemblies are used as transformer feeders a protection
relay is retained to monitor overload and earth fault conditions and the vacuum contactor
still performs the task of interrupting currents in these categories. The HV fuse remains the
sole interrupter for short circuit currents. It is clear that the HV fuse selected to protect the
contactor from switching short circuit currents when applied as a motor starter will offer the
same protection when the contactor is applied as a transformer feeder.

Often comparison is made with charts published by fuse manufacturers recommending HV

fuses for transformer protection. The fuses are a distribution class fuse and the
recommendation is directed towards fused load break switchgear. Traditionally this class of
switchgear does not include a protection relay so the HV fuse is selected to offer a form of
overload protection for the transformer. However, the principal use of the high voltage fuse
is for short circuit protection of the transformer. IEC 60787 provides guidelines for the
coordination of the high voltage fuse with other components. These are;

1. The time-current characteristics of the high voltage fuse links must be to the right side of
the inrush points of the transformer. Depending on the transformer rated capacity and
the design of the magnetic field, this is considered to be 4 to 12 times the transformer
rated current at 100 msec.
2. The rated current of the fuse link should be sufficiently higher than the transformer rated
current, in order to allow admissible overloads of the transformer.
3. To guarantee optimum protection against thermal overload of the transformer the
melting current of the fuse at 10s should be as small as possible.
4. The high voltage fuse for transformer protection should discriminate with the low voltage
protection device over the whole operating range.

Clearly in fused vacuum contactor switchgear applied as a transformer feeder the HV fuse
must comply with criteria 1 and 4. Criteria 2 and 3 are the primary function of the protection
relay so the HV fuse can be over rated in these criteria.

Motor protection fuses are generally a slower time current characteristic compared to
distribution fuses however in practical terms there is no difficulty in complying with criteria 1
and 4 for transformer application.

Finally, distribution class fuses can be used in fused vacuum contactor switchgear applied
as transformer feeders however in motor control centers that include perhaps one or two
transformer feeders it provides an unnecessary complication to fuse ratings rationalization.
In practical terms it is much more satisfactory to select a motor protection class HV fuse for
transformer protection by completing checks against the four criteria listed above.

For more information refer to UniGear ZVC application notes regarding selection of HV
fuses for motor and transformer applications.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 9 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

2. CONTACTOR - FUSE - OVERLOAD RELAY CO-ORDINATION

2.1 STANDARDS & CHARACTERISTICS

2.1.1. Applicable Standard: AS2232-1,1979 IEC (632) -1,1978

APPENDIX 15

2.1.2. Co-ordination Type: "TYPE C" - "light contact burning is allowed and risk of welding
contacts is accepted".

2.1.3. Characteristics of Apparatus:

- Maximum Prospective Current 40kA RMS, 100kA Peak

- Contactor - Breaking Capacity 6.3kA

- Peak Current withstand 85kA
- Short Time withstand 4kA 12 sec.
8kA 2 sec.
2 2
- I t (A Sec.) 128x106

- Fuse (Max.) - Cut off current peak 70kA

- I2t (A2 Sec.) 8.9x106

2.2 GENERAL CONSIDERATIONS

The contactor can be used to interrupt currents up to its 6kA rated breaking capacity. All currents
above this must be interrupted by the fuse.

Large fuses can carry 6kA for several seconds (e.g. 550 Amp fuse interrupts 6kA in 2-3 seconds).
Therefore it is important to ensure the contactor opening is delayed for a time depending on the
rating of the fuse.

Instantaneous overcurrent protection is provided by fuses in fused contactor units. Therefore relays
which have instantaneous elements should not be used OR the instantaneous element should be
blocked.

Earth fault relays/elements can provide a trip signal to the contactor when the current is above the
contactor breaking capacity. Therefore the earth fault relay must have an adequate time delay
(depending on the rating of the fuse) OR have a blocking facility for currents above the fuse-
contactor takeover current.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 10 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

2.3 MAXIMUM FUSE SIZES

2.3.1 Basic applications:

Contactor Loads
Service opening Max. Approx. Time Current
Volts Time Fuse kW Characteristics

3.3kV 15 mSec. 350A 1300kW A3 24776

300 mSec. 450A 1600kW "
6.6kV 15 mSec. 315A 2300kW A3 24789
300 mSec. 450A 3200kW "

Notes: 1. 15mSec is opening time with a.c. & d.c. switching on contactor.

2. 300mSec is opening time with a.c. only switching on contactor.

3. Earth fault delay of 100 mSec minimum is required.

2.3.2 High current applications:

A Contactor - Relay - Fuse Co-ordination diagram should be produced.

Typical diagrams are:

Service Motor Fuse Protection
Diagram No. Voltage F.L.C. Rating Relay

A324777 3300V 400A 630A SPAM 150C

A324788 6600V 400A 550A SPAM 150C

Notes: 1. Icn > Ito

Icn = Contactors short circuit breaking capacity
Ito = Takeover point between fuse and contactor

2. Earth fault must be delayed to a time greater than the time where the fuse
characteristic (+10% on current) and Icn intersect.

3. Earth fault may be blocked at 4, 6 or 8 x In on SPAM 150C where In = rated

current of relay (1 or 5 amp).
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 11 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

2.4 FUSE CHARACTERISTIC CALCULATIONS

2.4.1 ZVC 3.6 400 MAXIMUM FUSE

• RATED CURRENT:

2 x K81 PEX 350 in parallel

IN = 2 x 350 x 0.9 = 630A

Where 0.9 = the derating factor of the 2 fuses in parallel.

• TIME CURRENT CHARACTERISTICS:

Multiplier for prospective current -

= 630 = 1.8
350

Time (Sec) Prospective Current (Amps)

350A Fuse x 1.8 = 630A Fuse

1000 800 1400

100 1200 2160
10 2050 3690
1 3200 5760
0.1 6000 10800
0.01 11000 19800

2
• I t 40KA RMS PROSPECTIVE:

Pre-arcing = 22 X 540 X 103 = 2160 X 103 Amp2 Sec.

Total = 22 X 3100 X 103 = 12,400 x 103 Amp2 Sec.

Where 22 = Multiplier for two fuses in parallel

540 X 103 etc. = Typical published figures for 1 fuse

• CUT OFF CURRENT @ 40KA RMS PROSPECTIVE:

IF = 40kA IF/2 = 20kA

Where IF = Prospective fault current
IF/2 = " " " per fuse

Cut Off Current for K81 PEX 350 @ 20kA = 25kA Pk.
Cut Off Current for 2 x K81 PEX 350 @ 40kA = 50kA Pk.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 12 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

2.4.2 ZVC 7.2 400 MAXIMUM FUSE

• RATED CURRENT:

2 x K81 SDX 315A Fuses in parallel

Rating 2 x 315 x 0.9 = 567A

Say, 550A

• TIME CURRENT CURVE:

Multiplier for prospective current axis

= 550 = 1.75
315

Time (Sec.) Prospective Current (Amps)

315A Fuse x 1.75 = 550A Fuse

1000 900 1600

100 1500 2600
10 2200 3700
1 3800 6600
0.1 6000 10500

• I2t 40KA RMS PROSPECTIVE:

Pre arcing = 22x587x103 = 2348x103 Amp2Sec.

Total = 22x2230x103 = 8920x103 Amp2Sec.

Where 22 = Multiplier for two fuses in parallel

540 X 103 etc. = Typical published figures for 1 fuse

• CUT OFF CURRENT @ 40KA RMS PROSPECTIVE

IF = 40kA IF/2 = 20kA

Where IF = Prospective fault current
IF/2 = Prospective fault current per fuse

Cut off current for K81SDX 315 @ 20kA = 27kA Pk.

Cut off current for 2 x K81SDX x 315 @ 40kA = 54kA Pk.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 17 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

THE USE OF HRC FUSES IN PARALLEL

By: P G Nicholls
Engineering Manager, Standard Products
GEC ALSTHOM Industrial Products Division

INTRODUCTION

Occasionally, for some low voltage and high voltage applications, it is necessary for two or more fuses to be
connected in parallel in each phase of a circuit, usually for the purpose of obtaining sufficiently high current
rating. It has been the practice for many years to use fuses in parallel without the need for formal testing of
such combinations, provided that:

* the paralleled fuses are of the same type and rating.

* the individual fuse has been subjected to satisfactory short circuit tests.

As higher current rating fuses contain a number of parallel elements (up to 20 in fuses of GEC ALSTHOM
manufacture), the use of parallel fuses only extends the principle of parallel elements. This article explains
various aspects of parallel arrangement of fuses, and shows how technical data for such arrangements can
be derived from the data available on single fuses.

MAXIMUM INTERRUPTING CURRENT

In general, GEC ALSTHOM fuses have a substantially flat I2t/prospective current characteristic. Therefore
the effect of paralleling fuses is to increase the maximum short circuit capability because fuse performance
is dependent on the current density of the elements in concurrent operation. Conversely, for a given
prospective short circuit current, the duty on parallel fuses is eased, as the current in each fuse is inversely
proportional to the number in parallel.

MAXIMUM ARC ENERGY CONDITION

Single fuses are tested to withstand their maximum arc energy condition, which usually occurs at a level
significantly less than maximum interrupting current. For fuses in parallel, the current required for this
condition increases directly in proportion to the number of fuses. If, for whatever reason, unequal sharing of
this current occurs then the current in each individual fuse moves away from the maximum arc energy
condition, and the duty on each fuse is eased.

ARC VOLTAGE

The arc voltage can be considered independent of the number of fuses in parallel, and is that associated
with a single fuse.

MOUNTING ARRANGEMENT AND RATED CURRENT

For optimum thermal performance, the mounting arrangement needs due consideration (bolted tag fuses
offer more certain connection than ferrule types). An ideal parallel arrangement will give equal current
sharing, but even if completely balanced paths are not achieved, a small degree of self compensation will
occur
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 18 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

A full thermal test on the equipment in its intended environment is ideal but usually impractical. Derating is
necessary because two fuses in close proximity radiate heat less effectively then single fuses. As a general
rule, GEC ALSTHOM recommends a minimum reduction in rated current of 10% for 2 fuses in parallel (20%
for 3 or 4 fuses in parallel) and the combination assigned a rated current of nearest preferred number from
R10 or R20 given in AS2752; for example, 2 x 800A fuses in parallel = 2 x 800A x 0.9 = 1440A (= 1400A
nearest preferred number).

TIME/CURRENT CHARACTERISTICS

On the basis that equal current sharing occurs between fuses in parallel, the time/current characteristics can
be determined by either of the two following methods:

(1) Applying a multiplier to the prospective current axis of the published time/current curve for the single
fuse, equal to the ratio of the parallel fuse arrangement assigned rated current (refer above) divided
by the single fuse rated current. Corresponding pre-arcing times for the parallel fuse arrangement
are then represented by the single fuse curve. This is illustrated by using the above 2 x 800A
parallel fuse example, and for say 3500A load current, then:

Multiplier for 2 x 800A parallel fuses = 1400/800 = 1.75

Equivalent current for each fuse = 3500/1.75 = 2000A
Therefore pre-arcing time for parallel arrangement = 650 sec.

By comparison, for 800A single fuse with 3500A load current, pre-arcing time is 60 sec.

(2) Alternatively, another time/current curve is plotted parallel to the single fuse published time/current
curve, by applying the same multiplier as (1) above to various points on the single fuse curve. The
pre-arcing time and prospective current axis remain unchanged. For example, using the same 2 x
800A parallel fuses, then:

Pre-arcing time Corresponding Corresponding

on published current for current for
800A T/C curve 800A fuse 2 x 800A fuses

10000 sec. 1400A 2450A (say 2500A)

1000 sec. 1800A 3150A (say 3200A)
100 sec. 3100A 5425A (say 5400A)
10 sec. 5500A 9625A (say 9600A)
1,0 sec. 10000A 17500A (say 18000A)
0,1 sec. 18000A 31500A (say 32000A)
0,01 sec. 29000A 50750A (say 51000A)

2
PRE-ARCING AND TOTAL OPERATING I t VALUES

In general, for fuses that have a substantially flat I2t/prospective current characteristic, the minimum pre-
arcing I2t are proportional to the square of the number of fuses in parallel. For the same example of 2 x 800A
parallel fuses, I2t values are:
800A single fuse:
Published pre-arcing I2t = 4400 x 103 A2 sec.
2 3
Published total I t (at 415V) = 9600 x 10 A2 sec.

2 x 800A parallel fuses:

Pre-arcing I2t = 22 x 4400 x 103 A2 sec.
Total I2t (at 415V) = 22 x 9600 x 103 A2 sec.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 19 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

CUT-OFF CURRENT

The cut-off current for two or more parallel fuses is determined by the following method:

* The short circuit prospective rms current IF is divided by number of single fuses in parallel N,
giving IF/N.

* For this value of IF/N, the cut-off current peak for the single fuse is found from the published
cut-off current characteristic.

* This value of cut-off current peak is multiplied by the number of single fuses in parallel N,
giving the cut-off current peak for the parallel fuses.

As an example, for 2 x 800A parallel fuses and 50kA rms prospective current, the cut-off current peak is:

Fault current per fuse = IF/N = 50kA/2 = 25kA rms

For 800A single fuse at 25kA rms, published Ico = 54kA peak
Therefore 2 x 800A parallel fuses at 50kA, Ico = 2 x 54kA = 108kA peak.

By comparison, for the 800A single fuse at 50kA, the published Ico is 64kA. Also, the threshold for
exhibiting cut-off for the 800A single fuse is 24kA rms prospective, compared to 48kA rms
prospective for 2 x 800A parallel fuses.

CONCLUSION

The foregoing information is based on known principles applicable to the paralleling of fuses, and the
examples given are relevant to GEC ALSTHOM type 'T' HRC fuses. A unique computer prediction
programme is used for specific applications requiring more infinite analysis of single or parallel fuse
performance.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 20 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

3. HRC FUSE -MODELS

3.1 MANUFACTURERS

Various fuse models are suitable for UniGear ZVC switchgear. Refer following Table.

UniGear ZVC - HRC Fuse Manufacturers

Rated Maximum Delivery to
Order Code / Current
Manufacturer Size Voltage Breaking Australia
Part No. Range (A)
(kV) Current (kA) (weeks)
SIBA 30 269 56 TA 2 3.6 50 - 315 50 ≥8
SIBA 30 271 56 TA 4 7.2 50 - 315 50 ≤4
GEC ALSTHOM K81PEX TA 2 3.6 100 - 350 40 ≤4
GEC ALSTHOM K81PRX TA 2 3.6 450 40 ≤4
GEC ALSTHOM K81SDX TA 4 7.2 50 - 315 45 ≥8
GE Power Controls K81PEX TA 2 3.6 100 - 350 40 ≤4
GE Power Controls K81PRX TA 2 3.6 450 40 ≤4
GE Power Controls K81SDX TA 4 7.2 50 - 315 45 ≥8
Copper Bussman 3.6WDFHO TA 2 3.6 50 - 125 50 ≥ 10
Copper Bussman 3.6WFFHO TA 2 3.6 160 - 200 50 ≥ 10
Copper Bussman 3.6WKFHO TA 2 3.6 250 - 400 50 ≥ 10
Copper Bussman 7.2WFNHO TA 4 7.2 25 - 315 40 ≥ 10
Copper Bussman 7.2MROSA TA 4 7.2 80 - 315 50 ≥ 10
ABB CMF-BS TA 2 3.6 100 - 250 50 ≥ 10
ABB CMF-BS TA 4 3.6 315 50 ≥ 10
ABB CMF-BS TA 4 7.2 63 - 160 50 ≥ 10
XiRong WDFDF TA 2 3.6 50 - 400 50 ≥ 10
XiRong WFNDF TA 4 7.2 25 - 315 50 ≥ 10
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 21 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

4. CURRENT TRANSFORMER

4.1 SELECTION

The application of a UniGear ZVC fused vacuum contactor to motor starter duty has significant
influence on the parameters used for CT selection.

The compact design and dimensions of the switchgear provides limited space for accommodating
current transformers and control and protection devices. The design is targeted at the use of multi-
function microprocessor based control and protection apparatus.

Typical of microprocessor based protection devices is ABB REF542plus digital bay unit.
REF542plus will accept 1.0 amp or 5.0 amp input current. One amp rated current is selected to
minimize voltage drop in the connections between CT and relay and also to optimize CT design to
be compatible with the compact space allocated in the switchgear.

Current transformers are designed to comply with the requirements of IEC 60044-1 standard.

Protection current transformers are specified in terms of composite error, classification, accuracy
limit factor and rated burden, for example, for lowest ratio 50/1A 10P10, 0.75VA
where 10 = composite error selected appropriate to the application from preferred
standard values nominated by the standard
P = classification, i.e. protection
10 = accuracy limit factor selected appropriate to the application from preferred
standard values nominated by the standard
0.75VA = rated value of external burden appropriate to the application connected to
the CT terminals.

A motor starter is a terminal feeder. The common wisdom is that extreme accuracy is not essential
for motor protection and indication functions so a 10% composite error is normally specified to be
consistent with economical design and adequate performance. This selection also provides for a 3%
current error at rated current making it suitable for load indicating purposes.

The CT is not required to operate a short circuit protection device. The high voltage fuse is selected
to interrupt fault currents exceeding the stall current and contactor breaking capacity. Motor overload
and stall currents have values in a range up to a nominal 7 x full load current so an accuracy limit
factor of 10 provides a generous range of performance.

The connected burden comprises the protective relay and the wires connecting the relay to the CT.
The REF542plus multi function relay has a 0.1 ohm internal burden of the input circuit, that is, 0.1VA
burden at 1.0 amp rated current. This burden is linear across the operating range. Connecting wires
between the current transformer terminals and the protection relay terminals are 1.0 mm2 flexible
copper conductors comprising a total route loop length of 2.0 metres. Resistance of this loop is 0.04
ohms representing a lead burden of 0.04VA at 1.0amp rated current.

Therefore the theoretical connected burden on the CT is 0.1 + 0.04 = 0.14VA.

A rated burden of 0.75VA has been nominated for the CT to allow for variations in the loop
resistance, variations in relay burdens across make and models and to provide a reasonable safety
margin of performance beyond the theoretical values.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 22 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

Metering current transformers are specified in terms of composite error, classification, accuracy
limit factor and rated burden, for example, class 3, 3.0VA
where class 3 = accuracy class, i.e. the highest permissible percentage error at rated
current, selected appropriate to the application from preferred standard
values nominated by the standard
3.0VA = rated value of external burden appropriate to the application connected to
the CT terminals.

Traditional practice uses an analogue ammeter to provide visual indication that starting current is
initiated when the motor is switched “on” and then decays to a normal load current. The meter is not
used for reading or recording true values of phase current rather it is used as an indicator of
“normal” condition. Class 3, that is 3% accuracy, of the CT is widely accepted to satisfy the needs of
current indication.

An industrial grade ammeter usually has a burden of approximately 1.0VA. The recommended rated
burden of 3.0VA metering offers adequate design margin for variations in the connected burden
beyond the theoretical values of loop resistance and meter burden.

An increasing trend in modern control philosophy is to delete the analogue ammeter and interrogate
the microprocessor to read phase current values and starting current values. This practice fully
utilizes the features provided by most modern protection relays and eliminates the need for a
dedicated metering current transformer.

UniGear ZVC current transformers are available in the following three winding categories;
50/1A 150-100-75/1A 400-300-200/1A

Typical ZVC current transformer standard design data is given in Section 4.2.

4.2 STANDARD RATINGS

The standard current transformers used in UniGear ZVC are uniquely dimensioned, single-phase,
epoxy resin encapsulated, 660V ring type toroids designed for installation on the cable side spout
bushings.

General Specification -
Rated Frequency : 50/60 Hz
Rated Secondary Current : 1.0 A
Thermal Rating : 1.2 A
Rated Insulation Level : 0.6/2.0 kV (7.2/20/60 kV installed)
Applicable Standard : IEC 60044-1

Three standard design versions are available to adequately cover the full range of permissible circuit
load currents.
400-300-200/1/1A; Core 1: 10P20, 0.75VA
Core 2: class 3.0, 3.0VA

150-100-75/1/1A; Core 1: 10P20, 0.75VA

Core 2: class 3.0, 3.0VA

50/1/1A; Core 1: 10P10, 0.75VA

Core 2: class 3.0, 3.0VA.

The ratio, class and burden have been selected to adequately match modern microprocessor based
electronic protection and metering devices.
 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 23 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

50/1A is the lowest ratio available and will suit applications with full load current as low as
approximately 15A when coupled with modern microprocessor based electronic protection and
metering devices.

Five ampere secondary windings are not available nor are they suitable when considering remote
metering applications.

The protection core, core 1, is located at the ‘P1” primary end of the toroid and the CT is installed
over the primary conductor with ‘P1” facing the direction of the main busbars and ‘P2’ facing the
cables.

Following are the main design features.

o The primary winding is provided by the conductor embedded in the spout bushing.
o Frame dimensions of the toroid are optimised to suit the space available around the spout bushings.
o An earth screen is embedded in the bore of the toroid to provide a secure screen between the high
voltage primary conductor and the low voltage secondary winding.
o The start, finish and intermediate taps of the secondary winding comprise a 3.0 metre long flying
lead of tinned copper multi-core flexible cable securely anchored in the epoxy encapsulation of the
toroid. No loose joints or broken conductors are possible.
o Flying lead conductors form part of the secondary winding, that is, the start and finish of the winding
is 3.0 metre from the toroid. This feature allows the secondary terminal of the CT to be located in the
LV control compartment. (The secondary terminal usually takes the form of a rail mounted test link).
Voltage drop in conductors connecting CTs to meters and relays is no longer a consideration with
the flying lead concept.
o Internal burden of the CT includes the resistance of the flying leads and all mandatory tests for
accuracy and class are conducted by connecting the test equipment to the free end of the flying
lead. The free end of the flying lead is indelibly marked with the secondary terminal marking
according to the applicable standard.
o 2.5 mm2 (32/0.20) conductor, insulation colour green/yellow, is used for the screen earth wire and
1.0 mm2 (50/0.25) conductor, insulation colour black, is used for the secondary winding taps.
o PVC insulation is used on the flexible flying leads and a PVC sheath covers a multi-core group. All
insulation is halogen free.
o Installation and wiring of the toroids is a simple, tidy and efficient task.

4.3 HIGH BURDEN RATINGS

Please refer document no. VGA671019 for selection.

 ABB Australia
Doc. Title: UniGear ZVC – Application Notes
Doc. No: 1VGA673011 Sheet No: 24 (24)
Factory: Moorebank. NSW. Australia Date: 23 Sep. 08
Designer: ABB Australia Rev. No: B

5. PANEL HEAT LOSS

5.1 TYPICAL VALUES

Values are indicative for 3 phase losses in the power circuit only. LV equipment losses are not
included. Values are based on SIBA HV Fuse Links.

A) 6.6kV Motor

Motor Rating – kW Fuse Rating – Amps 3 Phase Heat Loss - Watts

200 100 10
300 100 22
400 100 38
450 100 48
500 160 27
600 160 39
700 160 53
800 160 69
900 250 51
1000 250 63
1250 250 98
1500 250 141
1800 250 198
2000 315 203
2250 315 251
2500 315 310
3000 2 x 250 338
3500 2 x 250 460
4000 2 x 315 498

B) 3.3kV Motor

Motor Rating – kW Fuse Rating – Amps 3 Phase Heat Loss - Watts

200 100 20
250 160 26
300 160 29
400 160 45
500 250 51
600 250 65
700 250 89
800 250 116
900 250 146
1000 315 148
1100 315 179
1250 315 227
1400 2 x 250 230
1500 2 x 250 260
1600 2 x 250 296
1750 2 x 250 321
1800 2 x 315 354
2000 2 x 315 396