UL 1008 Short Circuit Testing Requirements for Transfer Switches A tutorial on UL’s short circuit testing requirements regarding transfer switch withstand and closing rating (WCR). Ronald Schroeder Director, Product Management and Applications Engineering UL1008 Short-Circuit Testing What is WCR? History of changes to UL1008 Short-Circuit Testing Requirements UL 1008 - 7th Edition Changes What Now? Conclusion What is WCR? Circuit Breakers (AIC) vs. Transfer Switches (WCR) Ampere Interrupting Capacity (AIC) - Capability to safely interrupt or break short circuit currents and disconnect the power source from the load under overcurrent conditions. Withstand Closing Rating (WCR) - Capability to safely endure and close-on short circuit currents until overcurrent conditions are interrupted. These WCR ratings are based on either: Specific time durations (time based) Coordination with specific circuit breaker or fuse types (series rating) Withstand and Closing Rating (WCR) WCR of an ATS has an inverse relationship to the length of fault time - the longer the fault time, the Current (Amps) lower the current it can withstand and close-on Typical Clearing Times Fuses - 1/4 to 1/2 cycle Thermal Mag Type MCBs - 1.5 to 2 cycles MCCBs w/Electronic Trip – 2 to 3 Cycles Power Breakers – 3 to 30 Cycles Mechanical Design Maximum Current Limit Time Current Curve Maximum ATS WCR Time (Cycles or Seconds) History of Changes to UL1008 Short Circuit Testing Requirements 1972 - Original UL1008 Standard was issued in 1972 with short circuit testing based on fuse and specific breaker ratings only 1989 - 4th Edition: Added an optional “Any Breaker” withstand and closing rating (WCR) 1993 – Selective coordination requirements added to the NEC 2002 - 5th Edition: Added optional “Short-Time Current Rating Test” 2014 - 7th Edition of UL 1008 became effective November 1, 2014 Defined detailed guidelines for extending specific breaker qualifications “Any" circuit breaker ratings were replaced with time duration markings shown in seconds rather than cycles. Short-time ratings (where applicable) were replaced with time duration markings shown in seconds rather than cycles. More descriptive text was added regarding how the ratings should be applied in selecting appropriate over-current protection. History of Changes to UL1008 Short Circuit Testing Requirements 1972 - Original UL1008 Standard was issued in 1972 with short circuit testing based on fuse and specific breaker ratings only 1989 - 4th Edition: Added an optional “Any Breaker” withstand and closing rating (WCR) 1993 – Selective coordination requirements added to the NEC 2002 - 5th Edition: Added optional “Short-Time Current Rating Test” 2014 - 7th Edition of UL 1008 became effective November 1, 2014 Defined detailed guidelines for extending specific breaker qualifications “Any" circuit breaker ratings were replaced with time duration markings shown in seconds rather than cycles. Short-time ratings (where applicable) were replaced with time duration markings shown in seconds rather than cycles. More descriptive text was added regarding how the ratings should be applied in selecting appropriate over-current protection. Changes in UL1008 short-circuit testing requirements and WCR label information ensure transfer switches are adequately tested to safely withstand and close-on the short circuit current shown on the label and therefore can be correctly applied in field applications 1972 Original UL 1008 Short Circuit Testing Requirements Switch Withstand and Closing Current Rating Tested with CL Fuse Original edition of UL1008 required current limiting fuse and “specific breaker” withstand and closing ratings only Breaker qualification typically included testing a single breaker type and additional breakers were approved by comparing published trip curves Tested with Circuit Breaker “Any Fuse” Within designated Classes: J, L, T or RK-5 “Specific Breaker” (Series Rating) 10 10 10 10 0 0.5 1 1.5 3 Test Duration, Cycles (60 Hz) Sample of Label Required on ATS 1989 “Any Breaker” Ratings Added in 4th Edition Switch Withstand and Closing Current Rating Used with CL Fuse Used with Circuit Breaker “Any Fuse” Within designated Classes: J, L, T or RK-5 1989 - 4th Edition became effective and added an optional “Any Breaker” withstand and closing rating (WCR) As description implies, this rating was applicable to “Any Breaker” w/o an adjustable short-time response Test time durations: “Any Breaker” (Time Based) 10 10 10 10 0 “Specific Breaker” (Series Rating) 0.5 1 1.5 3 Test Duration, Cycles (60 Hz) 1-1/2 cycles for short-circuit currents < 10 kA and switches rated < 400 Amp 3 cycles for higher short-circuit levels and switches rated > 400 Amp 1989 “Any Breaker” Ratings Added in 4th Edition New “Any Breaker” ratings: More flexibility coordinating ATS with over current protective devices Less concern w/ future changes in overcurrent protection Since the “Any Breaker” rating was optional, not all ATS products had this rating ATS manufacturers (like ASCO) with robust designs enabled them to qualify for “Any Breaker” ratings “Specific Breaker” ratings: Higher WCR but limited to circuit breakers listed on label Need numerous breakers listed for application flexibility. Sample of Label Required on ATS 1989 “Any Breaker” Ratings Added in 4th Edition New “Any Breaker” ratings: More flexibility coordinating ATS with over current protective devices Less concern w/ future changes in overcurrent protection Since the “Any Breaker” rating was optional, not all ATS products had this rating ATS manufacturers (like ASCO) with robust designs enabled them to qualify for “Any Breaker” ratings “Specific Breaker” ratings: Higher WCR but limited to circuit breakers listed on label Need numerous breakers listed for This shows the advantage of having BOTH a specific breaker rating for higher application flexibility. WCR values, AND an “any breaker” rating to allow additional breakers Sample of Label Required on ATS 1993 NEC Adds Selective Coordination Requirements Selective Coordination: localization of an overcurrent condition to isolate outages to the circuit affected by selecting appropriate overcurrent protective devices and settings 1993- First added to the NEC for elevator circuits and (3) subsequent articles were added in 2005 and 2008: 2005-Article 700.27 – Emergency Systems Coordination 2005-Article 701.18 – Legally Required Standby Systems 2008-Article 708.54 - Critical Operations Power Systems (COPS) UL recognized applications where transfer switches would be required to withstand and close-on short-circuit currents for time durations greater than 0.1 secs (6 cycles for 60Hz). * *Source: NEC Handbook 2011 2002 Short-Time Current Rating Test UL 1008, 5th Edition Added to UL1008, June 2002 Switch Withstand and Closing Current Rating Used with CL Fuse “Any Fuse” Within designated Classes: J, L, T or RK-5 “Specific Breaker” (Series Rating) “Any Breaker” (Time Based) X kA @ A cycles 10 10 Test Duration, Cycles (60 Hz) B <<X kA @ C cycles 10 A 10 10 3 10 10 1.5 10 10 1 <X kA @ B cycles 10 10 0.5 10 10 0 Short-Time Current Test Used with Circuit Breaker C 2002 Short-Time Current Rating Test UL 1008, 5th Edition Utility Service ATS Must Withstand and Then Close-On Same Magnitude of Short Circuit Current Fault Current Delivery UL 1008 Standard - Passing Criteria: F2 F1 Emergency Generator Alternate Source Main Contacts Must Exhibit Continuity After Test Enclosure Door Must Remain Closed Phase-to-Enclosure Fuse Must Be Intact ATS Must be Operable by Intended Means No Breakage of Switch Base… Power Cables Can’t Pull Free of Terminal Lugs For Short Time Test: ALL Contacts Must Exhibit Continuity AND Pass Temperature Rise! Must be ‘Like New’! Short Circuit Test (non-short time) Short Time Test 2002 Short-Time Current Rating Test UL 1008, 5th Edition Short time test: Longer short circuit test time = more energy ATS must endure Plus, successful temperature rise test requires minimal main contact damage (‘like new’) Therefore, the short-time WCR < short-circuit WCR ATS manufacturers’ options for short-time WCR compliance: A. Don’t offer short-time ratings B. Qualify existing products for short-time ratings C. Develop a separate transfer switch design to provide short-time ratings ASCO’s robust standard 600-4000Amp switches qualified for short-time ratings. In addition, a separate design family was developed for even higher short-time ratings, including 30 cycles (0.5secs) 2014 UL1008, 7th Edition The 7th Edition of UL 1008 has resulted in significant changes to short-circuit testing ratings shown on the transfer switch: Specific guidelines were added for qualifying additional circuit breakers to be shown on the short circuit label markings. The "Any" circuit breaker ratings were replaced by “time based” ratings shown in seconds rather than cycles. Short-time ratings (where applicable) are also shown in “seconds” instead of “cycles”. More descriptive statements have been added regarding how the ratings should be applied in selecting appropriate over-current protection. 2014 UL1008, 7th Edition The 7th Edition of UL 1008 has resulted in significant changes to short-circuit testing ratings shown on the transfer switch: Specific guidelines were added for qualifying additional circuit breakers to be shown on the short circuit label markings. The "Any" circuit breaker ratings were replaced by “time based” ratings shown in seconds rather than cycles. Short-time ratings (where applicable) are also shown in “seconds” instead of “cycles”. More descriptive statements have been added regarding how the ratings should be applied in selecting appropriate over-current protection. Qualification of Specific Circuit Breakers Prior to UL1008, 7th Edition The most significant change in the 7th Edition is the addition of a method for qualifying additional circuit breakers to be shown on the WCR label markings. Prior to the 7th Edition, the method for listing specific breakers was not defined in the standard and was based on a comparison of the “published” maximum instantaneous clearing time between the tested breaker and non-tested circuit breakers. If the non-tested circuit breaker’s published clearing time was equal to or less than the tested circuit breaker’s published clearing time, the non tested breaker could be listed. Most switch manufacturers then published a formidable list of specific breaker types on their WCR label at that time. Unfortunately, this method could not guarantee that all listed breakers would coordinate with the ATS to clear the short circuit safely. Qualification of Specific Circuit Breakers Prior to UL1008, 7th Edition Recall Time Current Curve = Max ATS WCR i t earlier the WCR of an ATS is related to the time current curve. Qualification of Specific Circuit Breakers Prior to UL1008, 7th Edition Recall Time Current Curve = Max ATS WCR i 42kA Specific Breaker Rating with Breaker A 42kA Breaker A Test Time = 10ms Pub Clearing Time 22ms t earlier the WCR of an ATS is related to the time current curve. ATS was short circuit tested at 42kA with breaker A which cleared the fault in 10ms but has a “published” clearing time of 22ms. Qualification of Specific Circuit Breakers Prior to UL1008, 7th Edition Recall Time Current Curve = Max ATS WCR i 42kA Specific Breaker Rating with Breakers A and B earlier the WCR of an ATS is related to the time current curve. ATS was short circuit tested at 42kA with breaker A which cleared the fault in 10ms but has a “published” clearing time of 22ms. Breaker B was approved for specific breaker listing based on comparison of the published clearing time of 22ms or less. 42kA Breaker A Breaker B Test Time = 10ms Pub Clearing Time 22ms t Qualification of Specific Circuit Breakers Prior to UL1008, 7th Edition Recall Time Current Curve = Max ATS WCR i 42kA Specific Breaker Rating with Breakers A and B earlier the WCR of an ATS is related to the time current curve. ATS was short circuit tested at 42kA with breaker A which cleared the fault in 10ms but has a “published” clearing time of 22ms. Breaker B was approved for specific breaker listing based on comparison of the published clearing time of 22ms or less. 42kA Breaker A However, there is no guarantee Breaker B will actually clear in 10ms @ 42kA and could possibly take 60% or longer, or 16-25ms. Breaker B Test Time = 10ms Test Time = 16ms Pub Clearing Time 22ms t Qualification of Specific Circuit Breakers Prior to UL1008, 7th Edition Recall Time Current Curve = Max ATS WCR i 42kA Specific Breaker Rating with Breakers A and B X 42kA Breaker A Breaker B Test Time = 10ms Test Time = 16ms Pub Clearing Time 22ms If Breaker B has an actual clearing time of 16ms, ATS would see 60% more energy than it would for 10ms, which may be above the ATS WCR t earlier the WCR of an ATS is related to the time current curve. ATS was short circuit tested at 42kA with breaker A which cleared the fault in 10ms but has a “published” clearing time of 22ms. Breaker B was approved for specific breaker listing based on comparison of the published clearing time of 22ms or less. However, there is no guarantee Breaker B will actually clear in 10ms @ 42kA and could possibly take 60% or longer, or 16-25ms. Notice short circuit energy level with Breaker A was below WCR limit of the ATS, but the potential energy level w/ Breaker B would exceed the rating of the ATS. Qualification of Specific Circuit Breakers Post UL1008, 7th Edition Time Current Curve = Max ATS WCR i 42kA Specific Breaker Rating with Breaker A 42kA Breaker A Test Time = 10ms t Effective 11/1/2014 circuit breakers to be listed must either be shortcircuit tested with the transfer switch per UL1008 requirements or they can be added to the WCR label based on the following paragraph 9.13.3.7(c): “1) The duration of time that current passes through the contacts of the switch shall be measured from the short-circuit withstand and short-circuit closing test data. The shortest duration shall be selected from the evaluation.” Qualification of Specific Circuit Breakers Post UL1008, 7th Edition ??? 42kA “3) The circuit breaker time-current characteristic shall be evaluated in the instantaneous trip region at the current measured for the shortcircuit withstand and short-circuit closing tests. If the circuit breaker maximum clearing time, at this current on the time-current characteristic, is less than or equal to the shortest test duration as determined in (1), the circuit breaker is acceptable for addition to the markings as specified in 5.2.5.1.e following:” In this case the max instantaneous clearing time is greater than the actual time durations of shortcircuit tests conducted on the transfer switch and the breaker type is not suitable for listing at the specific breaker rating, but may be acceptable under the time based kA rating Qualification of Specific Circuit Breakers Post UL1008, 7th Edition “3) The circuit breaker time-current characteristic shall be evaluated in the instantaneous trip region at the current measured for the shortcircuit withstand and short-circuit closing tests. If the circuit breaker maximum clearing time, at this current on the time-current characteristic, is less than or equal to the shortest test duration as determined in (1), the circuit breaker is acceptable for addition to the markings as specified in 5.2.5.1.e following:” In this case the max instantaneous clearing time is greater than the actual time durations of shortcircuit tests conducted on the transfer switch and the breaker type is not suitable for listing at the specific breaker rating, but may be acceptable under the time based kA rating Breaker B – 16.7ms Clearing Time in the Instantaneous Trip Region 16.7ms 42kA Qualification of Specific Circuit Breakers Post UL1008, 7th Edition Transfer switch manufacturers now have two choices for listing specific breaker ratings on their WCR label: 1) Test with every specific breaker listed on the WCR label since actual clearing times are typically much faster then the published trip curves indicate 2) Conduct time duration tests which will encompass the published clearing times of all the breakers to be listed. Both breaker qualification methods are expensive and exhaustive Using a breaker for method 2 is no longer practical with the new UL guidelines for qualifying additional breakers, because the actual clearing times are significantly faster than their published clearing times. ASCO has robust power transfer switch designs and has conducted longer time duration tests on our switches to encompass the published clearing times of the breakers to be listed on the WCR label. UL1008, 7th Edition The 7th Edition of UL 1008 has resulted in significant changes to short-circuit testing ratings shown on the transfer switch: Specific guidelines were added for qualifying additional circuit breakers to be shown on the short circuit label markings. The "Any" circuit breaker ratings were replaced by “time based” ratings shown in seconds rather than cycles. Short-time ratings (where applicable) are also shown in “seconds” instead of “cycles”. More descriptive statements have been added regarding how the ratings should be applied in selecting appropriate over-current protection. UL1008, 7th Edition Old Label The 7th Edition replaced the term “ANY" circuit breaker with time duration markings on the WCR label shown in seconds. Time based ratings are more conducive for comparison to the time current curves published by breaker manufacturers New Label The UL specified test time durations are 0.025 secs for short-circuit currents up to 10 kA on switch ratings of 400 amp or less and 0.050 secs for most other short-circuit levels. UL1008, 7th Edition The 7th Edition of UL 1008 has resulted in significant changes to short-circuit testing ratings shown on the transfer switch: Specific guidelines were added for qualifying additional circuit breakers to be shown on the short circuit label markings. The "Any" circuit breaker ratings were replaced by “time based” ratings shown in seconds rather than cycles. Short-time ratings (where applicable) are also shown in “seconds” instead of “cycles”. More descriptive statements have been added regarding how the ratings should be applied in selecting appropriate over-current protection. WCR Labelling Changes UL1008, 7th Edition Short-time ratings will still be shown as short-circuit amperes, volts, and time duration markings shown in seconds instead of cycles. UL1008, 7th Edition The 7th Edition of UL 1008 has resulted in significant changes to short-circuit testing ratings shown on the transfer switch: Specific guidelines were added for qualifying additional circuit breakers to be shown on the short circuit label markings. The "Any" circuit breaker ratings were replaced by “time based” ratings shown in seconds rather than cycles. Short-time ratings (where applicable) are also shown in “seconds” instead of “cycles”. More descriptive statements have been added regarding how the ratings should be applied in selecting appropriate over-current protection. UL1008, 7th Edition WCR Label Changes ATS w/o Short-Time Rating Old Label The original text sometimes caused confusion with interpreting the coordination of the short circuit ratings with the overcurrent protection. New Label More descriptive statements have been added regarding how the ratings should be applied in selecting appropriate over-current protection. Notice if the circuit breaker is coordinated with a switch w/o a short time rating, the short-time delay adjustment must be set to zero. UL1008, 7th Edition WCR Label Changes ATS with Short-Time Rating Old Label The original text was also the same on the WCR label even if the switch had a short- time rating. This again caused confusion in interpreting the short circuit ratings. With the 7th Edition, the text is different for a switch with a short-time rating. Note the switch must have a short-time rating, which must be coordinated with the short-time rating of the breaker. New Label What Now? The “Any Breaker” rating has been replaced in the 7th edition by a time based rating of .05 seconds (for switches >400 Amp) or .025 seconds for switches rated 400A and under for short circuit currents <10,000 Amp. This forces the system designer to determine the instantaneous clearing time of the breaker from the published trip curves to confirm it is less than or equal to the time based rating of the transfer switch. Typically .05 seconds is sufficient to cover most breakers available today. If not, or if the breaker has a “short time response”, the short-time rating of the transfer switch must be applied which is typically at a lower kA level. If the transfer switch has no short-time rating, CL fuses w/ faster clearing times may have to be installed ahead of the switch for coordination purposes which adds cost and physical size to the project. What Now? It is important to note the time based short-circuit and short time ratings are both optional for product qualification under UL1008 Not all transfer switch manufacturers offer these two optional ratings These optional ratings offer more convenience and flexibility in selecting an acceptable circuit breaker to coordinate with the transfer switch WCR ASCO 7000 Series Power Transfer Switches now offer four Withstand and Closing Ratings to provide maximum flexibility: Current Limiting Fuse Rating Specific Breaker Rating Time Based Breaker Rating Short Time Rating (600-4000 Amp Switches) ASCO Product Configurations and Ratings WCR Values Standard Product Short-Time Product WCR Values Time Duration and Current (kA) Ampacity and Frames Ampacity and Frames Time Duration and Current (kA) Secs 3 .05 8 .13 18 .3 30 .5 42 150-600 Current (kA) 50 36 85 100 100 85 65 18 .3 30 .5 50 36 30 600-1200 H P 1000-1200 G Q 600-1600 65 50 800-1200 100 65 1600-2000 100 2600-4000 125* 4000 Cycles Secs J ATS 600-800 BPS 6001200 1600-3000 42 3 .05 G G S U 85 Current (kA) Cycles 65 100 * 3.6 cycles ( 0.6 Sec) Duration Conclusion Significant changes in UL 1008 short testing requirements since its inception have had a significant impact on: Short-circuit testing methods Markings on WCR labels Transfer switch product designs 7th Edition now clarifies specific breaker qualification criteria, which will impact the quantity of breakers shown on most switch equipment labels 7th Edition requires additional information on product labels which helps authorities having jurisdiction determine compliance with UL1008 7th Edition aims to mitigate the mis-application of transfer switches based on the incorrect assessment of breaker coordination ASCO 7000 Series Power Transfer Switches: are tested and qualified to both the optional time based short-circuit and the short time requirements specified in UL1008 offer more flexibility in coordinating the transfer switch and over-current devices