Module 10 Loadcenters
Module 10 Loadcenters
Like the other modules in this series, this one presents small, manageable sections of new
material followed by a series of questions about that material. Study the material
carefully, then answer the questions without referring back to what you’ve just read.
You are the best judge of how well you grasp the material. Review the material as often
as you think necessary. The most important thing is establishing a solid foundation to
build on as you move from topic to topic and module to module.
Glossary items are italicized and underlined the first time they appear.
Every residential and light commercial/industrial building utilizes electricity for lighting,
receptacles, and/or appliance loads. Conductors are used to bring power from the power
lines to the building. A device is needed to divide this power for branch circuits and
to protect these branch circuits from overloads and short circuits. This device is
called a loadcenter.
Electricity moves from the supply source (example, utility) into the building to the
loadcenter and is then distributed through the building’s Branch Circuits to the loads.
Each branch circuit is connected, or Terminated, at the loadcenter.
Each branch circuit is protected by a circuit breaker housed in the loadcenter. In the event
of a short circuit or an overload on a branch circuit, the circuit breaker cuts the power
before any property damage or personal injury can occur.
NOTE: New electrical installations use circuit breakers in the loadcenter, so we will not
discuss Fuses in this training module.
Applications
If a Voltmeter reading is taken between the two hot conductors (“A” and “B”), it will
measure 240 volts. If a reading is taken between a hot conductor and the neutral (“N”), it
will measure 120 volts.
Figure 4. Typical Single-Phase, Three-Wire Loadcenter
This is convenient because 240 volts are needed to power central air conditioners, electric
clothes dryers, and electric range tops. At the same time, 120 volts are required to service
lighting, small appliances, and receptacle loads.
Now, let’s consider the case of a residential distribution panel. Remember that a
distribution panel is a panel used at a point beyond the service entrance and is sometimes
called a subpanel. This means that the distribution panel is typically fed by a service
entrance panel.
You can add on to a loadcenter in two ways. The first way is to use a branch circuit
breaker. The second way is to use Feed-Through Lugs.
Figure 5. A Service Entrance Panel Feeding a Distribution Panel
In the example shown here, the service conductors (the two “hots” and the neutral) run
from the feed-through lugs of the service entrance panel to the Main Lugs of the
distribution panel. In this way, the distribution panel itself is protected by the main
circuit breaker in the service entrance panel . The neutral conductor is isolated. The
importance of this will be discussed later.
Many commercial/industrial service entrance panels are supplied with a different power
system than the residential one. A distribution transformer provides a 120/208 volt,
three-phase, four-wire system to the panel. Four conductors go to the service entrance.
The three mains are ungrounded (“hot”), and the fourth is the neutral. The “hots” are
connected to the main breaker in the loadcenter. The neutral is attached to the neutral bar
and is connected the same way as in the residential application.
If a voltmeter reading is taken between any two hot conductors (“A,” “B” and “C”), it
will measure 208 volts. If a reading between any hot conductor and the neutral (“N”) is
taken, it will measure 120 volts.
Figure 6. Typical Three-Phase, Four-Wire Loadcenter
This system can handle single-phase or three-phase applications. The 120/208 volt
single-phase power is used the same way as in the residential application. The three-
phase, 208-volt power is rarely used in loadcenters. For this reason, we will not discuss
three-phase any further in this module.
The distribution panel is treated the same as the residential distribution panel. It is
typically fed by the service entrance panel and it can be single phase or three phase.
Again, it is important to remember that the neutral is isolated.
Grounding Issues
In the service entrance panel shown in Figure 7, the neutral from the transformer is
connected to the neutral bar in the loadcenter. The neutral bar is then grounded to the
earth.
This is accomplished by running a conductor from the loadcenter’s neutral bar to a cold
water pipe or copper rod buried in the ground (or other suitable grounding electrode.)
Then, a Bonding screw or strap is used to physically “bond” the neutral bar to the metal
enclosure.
In this way, the neutral bar, the neutral of the transformer, and the enclosure are
grounded. When the neutral is grounded in this manner, the equipment ground from the
branch circuits is sometimes allowed to connect to the neutral.
The Equipment Grounding Bus is connected directly to the loadcenter enclosure. For
safety, all equipment (on both the feeder and branch circuits) is connected to the
equipment grounding bus. This requirement keeps the connected equipment at the same
potential as the enclosure itself.
Figure 8. Equipment Grounding Bus
One additional point for service entrance applications: this bonded and grounded neutral
can also be used as the point of connection for equipment grounding.
It is important to remember that the service entrance panel is the only ground
connection point for the neutral . The neutral is both insulated and isolated at any
downstream panels.
In Figure 10, the table lamp has a short circuit. If you trace the thick line back, you will
see how fault current is returned to the source. This is why the downstream loadcenter
contains a branch circuit breaker. It trips, disconnecting power from the load.
A ground fault is simply current leakage from an ungrounded conductor to the Grounding
Path in an electrical system. Consider Figure 11. A piece of insulation covering a
conductor at an electrical outlet has flaked off. This could allow current to pass from the
conductor to the metal outlet box. The box is part of the system ground. If properly
grounded, the current should follow the grounding path to ground, instead of an
unfortunate person’s finger that touched the box.
Because a distribution panel takes its power from the service entrance panel (Figure 9),
the neutral needs to be isolated from the ground. It is considered a branch circuit of the
main service panel, and needs to have its own ground to prevent a ground fault.
If all the loads in a panel are connected evenly between A-N and B-N, no current will
flow in the neutral. However, loads are rarely balanced. As a result, some current usually
flows through the neutral. The amount of current flowing in the neutral conductor at any
one time is the difference between the current flowing through leg A and leg B. This is
why a path to ground is needed.
Loadcenter Components and Installation
Before we go any further in our exploration of the loadcenter, let’s take a moment to
consider the main components and features of a typical loadcenter.
Anatomy of a Loadcenter
1. Front Cover Provides a neat, protective face for the product. Usually
includes a hinged door to allow access to the circuit breaker
handles.
2. Inner Cover or Serves as a protective barrier to prevent contact with energized
Dead Front (“hot”) parts within the unit.
3/4. Inner Cover Used to secure the inner cover tightly against the tops of the
Adjustment circuit breakers. This eliminates any space that might allow
Screws access to “hot” parts inside.
5. Twistouts Removable perforated metal spaces that can be twisted out, to
allow the protrusion of the circuit breaker handles.
6. Pub (or Lists the specifics of the loadcenter, including: circuit breaker
Publication) application, UL information, short circuit ratings, series
ratings, wire connection torque values, unit accessories, and
wiring diagram.
7. Sliding Latch Provided on indoor loadcenters to allow easy opening of the
loadcenter door.
8. Door The hinged part of the front cover which allows access to the
circuit breaker handles.
9/19. Backpan Top and Allows for easy removal of the loadcenter interior assembly.
Bottom Mounting
Screws
10/18. Enclosure Located at top center and bottom center. Whether surface-
Mounting mounted right-side up or inverted, the unit can be easily
Keyholes centered on the wall by hanging the enclosure with the
uppermost keyhole.
11. Drywall Scribe Serve as a guide for mounting the loadcenter flush with the
and Markings drywall between the wall studs.
12. Surface Mounting Once centered for surface mounting, the loadcenter is affixed
Holes (4) with screws through these four holes.
13. Main Lugs or Provide the means for the termination of the power cables
Main Breaker coming from the electric meter. Main lugs simply provide a
safe mechanical connection to the Bus Bars. A main breaker
provides thermal magnetic protection for the loadcenter.
14. Backpan The solid steel piece that supports the loadcenter bus bar
assembly. It also provides the means to affix branch circuit
breakers.
15. Bonding Strap Used to bond the neutral to the enclosure (when required by
code).
16. Bus Bars (2) An extension of the incoming power cables. Provide a
mechanical means of affixing branch circuit breakers. Notches
are added to (or omitted from) the bus bars to limit the number
of branch circuits allowed. Bus bars may be aluminum or
copper.
17. Knockouts Circular indentations in the top, bottom, sides, and back of the
enclosure. When removed, the electrician can bring wire into
and out of the loadcenter without compromising safety.
20. Neutral Bar Provides the termination point for the neutral wires from both
the incoming service and the load circuits. Most loadcenters
have a twin neutral design, positioning terminations on both
sides of the unit. This is a wiring convenience for the
electrician.
Enclosure
The loadcenter enclosure is typically constructed of cold rolled or galvanized steel. It
serves to house the other loadcenter components. It is designed to provide component and
personnel protection.
NEMA This enclosure type is for general purpose, indoor use. It is suitable for most
Type 1 applications where unusual service conditions do not exist. It provides
General protection from accidental contact with enclosed equipment
Purpose
NEMA This enclosure type is intended for outdoor use. It provides protection
Type 3R against falling rain, sleet, and snow.
Raintight
Space savings – Because the box is behind the wall, the room does not sacrifice
too much space.
Appearance – This option is more attractive, as the wiring and box are concealed.
Safety – Except for the trim, the panel does not stick out to possibly catch
clothing or other objects.
The NEC specifies clearances around loadcenters. This is to provide access and working
space. There are three basic rules:
Circuit Breakers
Now, let’s take some time to look at one of the main components of a loadcenter: the
circuit breaker.
Each branch circuit in the loadcenter is protected by a Branch Circuit Breaker (or
Miniature Circuit Breaker). Miniature circuit breakers are covered in much more detail in
Module 9, Miniature Circuit Breakers.
Miniature circuit breakers are also called Plug-In breakers because they are connected by
plugging them into the bus bar Stabs.
The bus bars provide a convenient means of providing electricity to the various loads in a
building. The circuit breakers attach to the bus bars on vertical stabs that alternate
from each “hot” source.
Single Pole and Double Pole circuit breakers are the most commonly used breakers in a
loadcenter. If a double pole breaker is plugged onto two adjacent stabs, 240 volts are
drawn. A single pole breaker is plugged onto a single bus stab and feeds a 120-volt
circuit. To understand how this is possible, consider the physical shape of the bus bars.
Figure 14. Getting 120V and 240V Power from the Bus Bars
On Figure 15, trace the 240-volt “M” circuit. Current comes in on conductor “A,” flows
through the left bus bar and branch circuit breaker, and enters the motor load’s branch
circuit. From there, current passes through another branch breaker and out on conductor
“B.” The circuit is made across both ungrounded legs of the transformer.
Trace the 120-volt “L” circuit. Current comes in on conductor “A,” flows through the left
bus bar and branch circuit breaker, and enters the lighting load’s branch circuit. From
there, current passes out on the neutral “N.” The circuit is made from an ungrounded leg
of the transformer to the transformer’s grounded leg.
A 240-volt circuit typically consists of four wires: two “hots”, one neutral, and one
ground. A 120-volt circuit consists of three wires: one hot, one neutral, and one ground.
Usually, hot wires are both color-coded black, although the second hot could be red.
Neutral wires are always white. Ground wires are either green or bare (uninsulated)
copper.
If the stab is notched, then Half-Size Branch Circuit Breakers can be used. Half-sized
branch circuit breakers allow for two single-pole circuit breakers to be installed in
one space. Each unit is typically only 1/2” wide. These breakers are every bit as
functional as the full-size units and allow the added convenience of a more compact
installation.
Some local inspectors will not allow the use of half-size branch circuit breakers. This
is because there is a possibility of overloading the loadcenter and/or unbalancing the
system.
The number of notched and unnotched stabs in a particular loadcenter – and therefore the
number of breakers that may be installed – is limited by UL requirements. This is to
prevent a panel from being overloaded.
Every circuit breaker has a specific ampere, voltage, and fault current interruption
rating.
Ampere rating –The ampere rating defines the maximum current a circuit breaker can
carry without tripping. The typical for miniature circuit breakers is ratings from 15-150
amps.
Voltage rating – In residential applications, single pole breakers protect 120 volt branch
circuits and two-pole breakers protect 240 volt branch circuits. The rating of a circuit
breaker can be higher than the circuit voltage, but never lower.
Short circuit interrupting rating – This is the maximum available fault current that a
breaker is designed to interrupt. Typical ratings are from 10,000 to 65,000 amps.
The full rating method selects circuit protection devices with ratings equal to or
greater than the available fault current.
Consider a building service entrance with 22,000 amps of fault current available. All
downstream circuit protection devices must be rated at 22,000 amps.
The requirements of the series-rated method are somewhat looser. The building’s main
circuit protection device must have an interrupting rating which is at least equal to
the system’s available fault current. However, the all downstream, series-connected
panels can have lower ratings.
Consider the same building, still with 22,000 amps of available fault current. While the
breaker at the service entrance is rated at 22,000 amps, additional downstream breakers
could be rated at only 10,000 amps.
Figure 18. Full Rating Method (on top) Vs. Series-Rated Method (on bottom)
In the typical single family home, available fault current is normally 10,000 amps.
Loadcenter Types
There are three different types of loadcenters commonly used today. These are:
Main Breaker
Main Lug Only
Convertible
The incoming supply cables of a main breaker loadcenter are connected to the main
breaker, which in turn feeds power to the loadcenter and its branch circuits. Power
from the main is fed through the main breaker to the bus bars, which are an extension of
the utility power cables.
With the main circuit breaker in the “off” position, no power will flow to the bus bars for
the branch circuit breakers. This serves as a quick and simple way to disconnect power to
the entire building.
Figure 20. Simplified Main Breaker Type Loadcenter
With the main breaker in the “on” position, power is allowed to flow from the bus
bars to the branch circuits. Branch circuits run throughout the building to supply power
for lighting and appliances. Because of these features, the main breaker is normally used
as a service entrance panel.
The Main Lug Only (MLO) Loadcenter does not contain a main circuit breaker to protect
the loadcenter itself. Instead, it is protected by a breaker back in an upstream panel. The
supply cables from the upstream panel are connected to the main lugs and bus bars.
This type of loadcenter is used primarily used as a distribution panel.
Convertible Loadcenter
The Convertible Loadcenter is supplied without lugs or breakers. Once the customer
decides to use main lugs or main breakers, the appropriate kit is installed by an
electrician.
In this home, a main breaker loadcenter supplies power to a main lug only loadcenter in
the home’s workshop.
Using a Main Lug Only Loadcenter
Main lug only loadcenters can also be fed from metering equipment when used in
apartment installations.
Selecting a Loadcenter
1. Ask whether this application will involve an indoor or outdoor installation. This
will determine the enclosure type for the loadcenter.
NEMA This enclosure type is for general purpose, indoor use. It is suitable
Type 1 for most applications where unusual service conditions do not exist. It
General provides protection from accidental contact with enclosed equipment.
Purpose
NEMA This enclosure type is intended for outdoor use. It provides protection
Type 3R against falling rain, sleet, and snow.
Raintight
Once this information is obtained, go to the product catalog. These questions should
cover everything needed to recommend products that fit the customer’s application needs.
Sample Application
To assist you in visualizing the product selection process, let’s consider a commonplace
customer application.
Suppose a customer comes to you and wants to add two branch circuit breakers to an
existing loadcenter for a newly remodeled kitchen. How would you go about sizing the
breaker?
First, interview the customer to find out what loads will be on the branch circuits. Let’s
say that one will be dedicated to a dishwasher, and the other will be dedicated to a
garbage disposal.
Next, obtain the amperage requirements of the loads from the customer. Suppose the
dishwasher runs on 12.5 amps and the garbage disposal runs on 9.8 amps.
Based on these numbers alone, you might think that it would be a good idea to
recommend a 15 amp breaker for the dishwasher circuit, and a 10 amp breaker for the
garbage disposal circuit. But this would result in a lot of nuisance tripping.
So, we need to do a little simple math. Figure in a 25% safety margin by multiplying the
amp ratings by 1.25.
This will be sufficient to eliminate nuisance tripping, but the breakers will still trip in the
case of a true overload condition.
Based on these calculations, you would recommend a 20 amp breaker for the dishwasher
circuit, and a 15 amp breaker for the garbage disposal circuit.
Glossary
Bonding The permanent joining of metallic parts to form an electrically
conductive path that will ensure electrical continuity to ground.
Branch Circuit A circuit that supplies power to the electrical loads in a building and
is terminated at a distribution device (panelboard, loadcenter, etc.).
Branch Circuit Also “Miniature Circuit Breaker.” An overcurrent protection device,
Breaker used to protect a branch circuit. After tripping to break the circuit, it
can be reset to protect the branch circuit again.
Bus Bars A component of a distribution device (loadcenter, panelboard, etc.)
that serves as an extension of the main service conductors. Simplifies
the connection of branch circuit breakers to the main service
conductors.
Circuit Breaker An overcurrent protection device. After tripping to break the circuit, it
can be reset to protect the circuit again.
Convertible A loadcenter supplied without main lugs or a main breaker. Once in
Loadcenter the field, it is up to the electrician to install the appropriate main
device.
Distribution A loadcenter used at a point beyond the building’s service entrance. It
Panel is not typically supplied with a main breaker. This type of panel can
be useful when adding additional electrical service to an existing
building. It has an isolated neutral.
Distribution A device that converts utility voltage into a voltage and current supply
Transformer suitable for use in most residential applications.
Double Pole Term used to describe a breaker that draws power from two poles of a
loadcenter or similar device. Double pole means that it disconnects
two wires.
Equipment A bus connected directly to the enclosure. Used for grounding all
Grounding Bus feeder and branch circuit equipment.
Feed-Through A set of lugs in a service entrance panel where feeder cables for a
Lugs distribution panel are terminated.
Flush-Mounted A style of mounting a loadcenter in which the loadcenter is recessed
into a hole in the wall.
Full Rating A method of selecting circuit protection devices for use in a
Method loadcenter. All devices must have ratings equal to or greater than the
available fault current.
Fuse An overcurrent protection device. After tripping to break the circuit, it
must be replaced to restore power to the circuit.
Ground Fault Current leakage from an ungrounded conductor to the grounding path
in an electrical system.
Grounding Path A solid conducting path for electricity to follow to ground.
Half-Size Branch A specialized overcurrent protection device designed to take up only
Circuit Breakers half as much space in a loadcenter as a normal branch circuit breaker.
Can only be installed in loadcenters equipped with notched stabs.
Loadcenter A wall mounted device that delivers electricity from a supply source
to loads in light commercial or residential applications.
Mains Also “Main Service Conductors.” The conductors that bring
electricity into a building from the power source.
Main Circuit An overcurrent protection device designed to protect an entire
Breaker loadcenter, panelboard or switchboard. Power from the main service
conductors is fed through a main breaker to the bus bars.
Main Lugs Component of a loadcenter that is a termination point for a feeder
cable from another loadcenter.
Main Lug Only A loadcenter where power from the mains is fed directly to the bus
(MLO) bars.
Loadcenter
Main Service Also “Mains.” The conductors that bring electricity into a building
Conductors from the power source.
Miniature Circuit Also “Branch Circuit Breaker.” Used to switch and protect the lowest
Breaker common distribution voltage in an electrical system. Generally used
in a loadcenter, panelboard, or similar device.
Plug-In A type of circuit breaker that is literally plugged into the bus bar
stabs. Generally found in residential applications.
Series-Rated A method of selecting circuit protection devices for use in a
Method loadcenter. The main upstream circuit protection device must have an
interrupting rating equal to or greater than the available fault current
of the system. Downstream devices connected in series can be rated at
lower values.
Service Entrance The point at which electrical power enters a building.
Service Entrance The term used to describe a loadcenter used as a service entrance.
Panel
Single Pole Term used to describe a breaker that draws power from one pole of a
loadcenter or similar device. Single pole means that it disconnects one
wire.
Stab A protrusion on the bus bars of a loadcenter which accepts a
miniature circuit breaker.
Surface-Mounted A style of mounting a loadcenter in which the loadcenter is attached
to and projects out from the wall.
Terminated The end connection of a circuit. For example, branch circuits are
terminated at the service entrance panel.
Voltmeter A device used to measure voltage by finding the potential voltage
between two points.