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MARCH 2018 || VOLUME 54 || ISSUE 3

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IEC REQUIREMENTS FOR HAZARDOUS LOCATIONS Some suggestions for safer installations. P10

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+ Auxiliary cooling of electric motors + EV-ready homes and residential service + Arbitration on steroids

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from the EDITOR ANTHONY CAPKUN

Can we get an “all-of-the-above” strategy?

CONTENTS MARCH 2018 || VOLUME 54 || ISSUE 3

anada recently announced a “road-mapping process” under the Energy Innovation Program to explore the potential for onand off-grid applications for small modular reactor (SMR) technology in Canada. I don’t know where you sit on the subject of nuclear energy, but I’m OK with it, especially with the prospect of these new SMRs. Nuclear energy has for far too long been needlessly and erroneously vilified, much like our fossil-based resources out West... which is a shame, on both counts. Speaking to the latter, Fort St. John Mayor Lori Ackerman pleaded with her fellow British Columbians in a letter published December 2016:

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cover PHOTo: stock photo

Let’s lead the world in resource extraction, continuous improvements and long-term planning. Let’s be leaders in reliable and renewable energy development. Let’s support Canadian industry and stop buying foreign oil. Let’s grow our economy by meeting our domestic needs and exporting our abundant resources. I strongly encourage you to read the whole letter (tinyurl.com/y9wsfjzu). Maybe you’ll think twice about our fossil resources with which Canada is blessed, and those who work them. What we need, and should demand, is what then U.S. DoE Secretary Moniz called “an all-of-the-above energy strategy” (tinyurl.com/kz6x95x). An all-of-the-above energy strategy quite literally includes everything: fossils, nukes, water, sun, wind, tidal, etc. From what I’ve seen, no form of electricity generation works best everywhere, so why should we limit ourselves? Take our Far North, where at least one territorial electric utility sees the potential in SMRs. “Establishing a pathway for the implementation of SMRs is an important national issue with particular significance for remote communities that are interested in exploring alternative energy options,” said Bruno Pereira, president of Nunavut’s Qulliq Energy. Here’s the part that worries me about NRCan’s SMR road-mapping process. The ministry says it will examine different technologies, and see how they align with Canadian priorities... but who sets those priorities? If our priorities are to develop nothing, over-pay here at home, continue buying energy from elsewhere, not seek out markets for the abundant resources we have, then we’ll continue to argue and stagnate. If, however, we adopt an all-of-the-above strategy, then we’ll be able to follow Mayor Ackerman’s closing advice: Let’s live well now and in the future. acapkun@annexweb.com EBMAG.COM

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Hazloc installations and “controversial” IEC recommendations?

Many of the requirements in the IEC 60079 series of explosive atmosphere standards have been adopted here, but there is some controversy. This article explores some of those changes, and offers some recommendations for safer installations.

Auxiliary cooling of electric motors

For the past century, DC machines over 30 kW or 40 kW have been cooled in the same manner, yet that same solution also forces highly conductive carbon dust directly into the very windings that are the lifeblood of the machine.

Can upsizing the cross-sectional area of a conductor save you money?

Upsizing the cross-sectional area of a current-carrying conductor in power electrical cables can reduce the I2R loss which, in certain cases, can offset the higher material and installation costs.

COLUMNS

DEPARTMENTS

20 Legal Desk Adjudication a.k.a. arbitration on steroids

4 Industry news 4 Letters 8 Personalities 13 Calendar 20 Products & solutions 21 Code conundrum

22 Code File “EV-ready” homes and the impact on residential service

March 2018 · ELECTRICAL BUSINESS

INDUSTRY news

PGC Services and K-Line fined $285K for hydrovac worker electrocution

PGC Services Inc. (Gormley, Ont.) and K-Line Maintenance & Construction Ltd. (Stouffville, Ont.) have been fined a total of $285,000 after a 25-year-old employee of PGC suffered a fatal electrical contact incident in Vaughan, Ont. PGC Services provides hydro-vacuum excavation, while K-Line provides design, procurement, construction and maintenance services for overhead distribution lines. K-Line was retained by the utility owner (PowerStream, now Alectra) to replace the existing overhead powerlines. PGC was subcontracted to excavate holes for the installation of new utility poles. In November 2015, PGC sent two of its hydrovac crews to the site. The excavation area along the road was serviced by nearby existing overhead powerlines, with a phase-to-phase voltage of 27,600 volts. The two crews began setting up their equipment, yet no one was present to monitor the movement of the hydrovac boom arms to ensure they did not encroach upon

the legal safety standard of 3 metres. One of the boom arms was controlled by a remote, which was triggered by coming into contact with, or being caught on, a worker’s body part or piece of clothing. The boom moved and came into contact with the overhead powerline, and caught fire. Meantime, a worker in contact with the truck (via the water hose) was fatally shocked. The court found PGC failed as an employer to ensure no object was brought closer than 3 metres from an energized overhead electrical conductor, as required by section 188(2) of the Construction Regulation, violating section 25(1)(c) of the Occupational Health and Safety Act (OHSA). Meantime, K-Line failed as a constructor to ensure a designated signaller was in place to warn the operator each time any part of the vehicle or equipment approached 3 metres from an energized overhead electrical conductor as required by section 188(8) of the Construction Regulation, violating section 23(1)(a) of the OHSA. Following guilty pleas, K-Line was fined $160,000 and PGC was fined $125,000. The court also imposed a 25% victim fine surcharge as required by the Provincial Offences Act.

Eaton establishes cybersecurity collaboration with UL Eaton (eatoncanada.ca) is collaborating with UL to advance cybersecurity for power management technologies. The company also says its cybersecurity research and testing facility in Pittsburgh,

March 2018 || Volume 54 || Issue 3 ELECTRICAL BUSINESS is the #1 Canadian resource for electrical contractors, maintenance & engineering professionals, distributors, manufacturers and their agents, and associated stakeholders.

Editor Anthony Capkun acapkun@annexbusinessmedia.com Group publisher John MacPherson jmacpherson@annexbusinessmedia.com Account manager Jacquie Rankin jrankin@annexbusinessmedia.com Assistant Editor Ellen Cools ecools@annexbusinessmedia.com Media designer Elena Novinskiy enovinskiy@annexbusinessmedia.com Account Coordinator Kathryn Nyenhuis knyenhuis@annexbusinessmedia.com Circulation manager Urszula Grzyb ugrzyb@annexbusinessmedia.com Tel: 416-442-5600 ext. 3537 COO Ted Markle tmarkle@annexbusinessmedia.com President & CEO Mike Fredericks Published by Annex Business Media 111 Gordon Baker Road, Suite 400 Toronto, ON M2H 3R1 Tel. 416-442-5600 • Fax 416-442-2191

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LETTERS Got something to say?

For taking the time to write to Comment on our news item “Jail time and $50K in fines for illegal work in Milton homes” (EBMag January 2018, p.7), we are sending M.P. of Calgary a token of our appreciation: a prize pack consisting of a 36-pc Shockwave impact driver bit set and Fastback utility knife, courtesy of our friends at Milwaukee Tool (milwaukeetool.com).

Occasionally, Electrical Business will mail information on behalf of industry related groups whose products and services we believe may be of interest to you. If you prefer not to receive this information, please contact our circulation department in any of the four ways listed above. The contents of Electrical Business are copyright ©2018 by Annex Publishing & Printing Inc. and may not be reproduced in whole or part without written consent. Annex Publishing & Printing Inc. disclaims any warranty as to the accuracy, completeness or currency of the contents of this publication and disclaims all liability in respect of the results of any action taken or not taken in reliance upon information in this publication. We acknowledge the [financial] support of the Government of Canada.

We always welcome your comments, insights and article ideas. Got an itch to write? Scratch it by emailing acapkun@annexbusinessmedia.com, or comment directly on the items you see at EBMag.com. (N.B. letters may be edited for clarity and brevity.) 4

ELECTRICAL BUSINESS · March 2018

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INDUSTRY news

Pa., is the first lab approved to participate in UL’s Data Acceptance Program for Cybersecurity. Through this program, Eaton, UL (ul.com) and other industry organizations work to establish foundational requirements for the testing of network-connectable industrial control systems to enable protection against vulnerabilities and security risk controls.

ABB and Nexans successfully deliver on the Maritime Link Project ABB (new.abb.com) says it achieved a major milestone with the successful testing of the Maritime Link: a 500-MW HVDC (high-voltage direct current) connection enabling Emera Inc. to exchange electricity between The Rock and Nova Scotia for the first time in history. “Our innovative HVDC Light technology will enable the historical Maritime project to integrate and deliver clean renewable energy while enhancing grid stability and enabling power sharing,” said Patrick Fragman, head of ABB’s Grid Integration business. Meantime, Nexans (nexans.ca) announced it has completed delivery of two 200-kV mass impregnated (MI) HVDC submarine cables as part of the project. “We are thrilled to be part of this exciting project and we are happy to have completed the installation of these two submarine cables, the longest in Northern America, after almost 600,000 hours of designing, manufacturing and laying works,” said Nexans’ Geir Korstad. The Maritime Link (tinyurl.com/ycxn8ct3) is the first of its kind in the world with a full voltage source converter (VSC) bipolar configuration to enhance system availability, says ABB. In addition to the two converter stations for the ±200-kV HVDC link, the project scope also includes two 230-kVAC substations in Newfoundland & Labrador, one 345-kV AC substation in Nova Scotia, and two cable transition stations.

AD reports 2017 member sales

AD (adhq.com) reports sales of $37.3 billion in 2017 across its 12 divisions. Total company sales grew by 10%. Purchases from AD suppliers grew by 17%, and distributions to members were up 14%. 6

ELECTRICAL BUSINESS · March 2018

Station in Bottom Brook, N.L. Photo courtesy ABB.

On a same store basis, by industry, electrical sales were up 10% in 2017. By country, same store sales in Canada grew 9%.

outside the industry”. Applications are now being accepted until May 31, 2018. Download the Scholarship brochure (tinyurl.com/y7sb5yu5), then VISIT scholarship.electrofed.com. Electro-Federation Canada (www.electrofed.com) is a national, not-for-profit association whose member companies manufacture, distribute and service electrical and electronics products.

“2017 was a fantastic year for AD and our members,” said Bill Weisberg, AD chair and CEO. “AD programs made a real difference in helping our members compete in their markets.”

Hydro-Quebec selected to provide 9.45 TWh to Massachusetts utilities

EFC Scholarship continues to grow; nearly $157K in funding for 2018

Electro-Federation Canada (EFC) and its members continue to demonstrate their support of university and college students while introducing them to the Canadian electrical industry. This year, $156,250 will be awarded to deserving pupils across 62 scholarships through the 2018 EFC Scholarship Program. SEE ALSO our VIDEO: We all want to have access to young talent (tinyurl.com/ yab6xeb3). “The electrical and electronics industries have great jobs, competitive salaries and benefits, plus aggressive career paths in a sector with cutting-edge innovation,” said EFC’s John Jefkins, adding the scholarship program can also help students engage with EFC member companies offering employment and career opportunities. SEE ALSO: How to pick a (scholarship) winner (tinyurl.com/km4kvgp). Speaking of the manufacturers, distributors and associations who support the scholarship program, Scholarship Committee chair Connie Chabot says, “Their dedication to the program demonstrates a commitment to corporate social responsibility both within and

Hydro-Quebec (hydroquebec.com) reports that, after a competitive solicitation process, Massachusetts utilities have selected the generator’s Northern Pass Transmission project proposal to supply 9.45-TWh of hydropower. The next steps involve negotiating longterm contracts and obtaining regulatory approvals to ensure the delivery of this power for 20 years. Starting in 2020, Quebec hydropower will service about 1 million Massachusetts customers. Hydro-Quebec says a longterm agreement with Massachusetts would be “its most important contract since it began developing its export markets”, representing a “meaningful source of revenue”. Hydro-Quebec developed this proposal alongside Eversource Energy. The project involves the construction of a 79-km, 1090-MW transmission line that will be extended into the States, connecting the Des Cantons substation in Val-Joli to the Franklin substation in New Hampshire. Hydro-Quebec will invest over $680 million for the Quebec portion of the transmission project, and expects to start work on the Quebec-New Hampshire interconnection this Fall. EBMAG.COM

INDUSTRY news

Safety Codes Council puts out call for 2018 award nominations

Alberta’s Safety Codes Council (SCC) (safetycodes.ab.ca) has put out a call for nominations for the Accreditation Award, Certification Award and the Dr. Sauer Award. The Dr. Sauer Award honours a volunteer member at the Council who demonstrates the commitment and energy of Dr. Ken Sauer, member and former Chair of the SCC. Meanwhile, the Certification Award recognizes a safety codes officer who “performs their duties with integrity, demonstrates an ongoing commitment to the profession and is an active leader, mentor and promoter within the safety codes system.” Finally, the Accreditation Award recognizes an accredited municipality, corporation or agency that shows “exemplary behaviour” in safety codes administration, staff engagement and public awareness about the safety codes system. The deadline for nominations is March 30, 2018. Award winners will be invited to attend the Partners’ Dinner on June 1 at he Rimrock Hotel in Banff, Alta. where they will be recognized for their contributions to the safety codes system.

Philips Lighting among those honoured in 2018 IoT Breakthrough Awards

American Tower, a player in wireless infrastructure, and Philips Lighting have been selected as winners of “Overall Smart City Solution Provider of the Year” and “Industrial Smart Lighting Solution of the Year” awards, respectively, in the 2018 IoT Breakthrough Awards. The two companies were recognized for their efforts to co-develop an “aesthetically designed smart light pole that blends seamlessly into the urban landscape, delivering both 4G/5G wireless network 8

ELECTRICAL BUSINESS · March 2018

Personalities

capacity for multiple mobile network operators and quality energy-efficient LED lighting in a single solution”. The smart city solution will also enable new applications, including E911, smart parking, traffic management and more. “The smart light pole solution from American Tower (americantower.com) and Philips Lighting (lighting.philips.ca) stood out from the field of award nominees for delivering a practical solution with maximum positive impact in a range of smart city applications for cities around the world,” said James Johnson, managing director, IoT Breakthrough (iotbreakthrough.com). The IoT Breakthrough Awards program’s mission is to recognize innovators, leaders and visionaries in a range of Internet of Things categories, including Industrial and Enterprise IoT, Smart City technology, Connected Home and Home Automation, Connected Car, and more.

Elmsdale residents piloting Powerwalls in Nova Scotia Power project

Nova Scotia Power (nspower.ca) has launched a pilot project to learn more about how battery storage can help it deliver “cleaner, affordable and more reliable energy to Nova Scotians”. Known as the Intelligent Feeder, the pilot involves the installation of residential energy storage batteries (Tesla Powerwalls) at 10 homes in Elmsdale, and a much larger grid-sized battery (Tesla Powerpack) at the Elmsdale substation. These batteries will be connected and feed into an electrical line powered, in part, by the nearby Hardwood Lands wind turbines. Sensors will be placed on the powerline to monitor and gather data about local system activity and be fed back to Nova Scotia Power’s control centre for analysis and planning. The 10 Elmsdale families were selected following an open application process. Each household received a Powerwall that will be theirs to keep after the pilot ends. The pilot also involves Mpower Energy Solutions (mpowersolutions.ca), a Tesla Powerwall Certified Installer, and Opus One Solutions (opusonesolutions.com), which is providing the software that monitors and gathers electrical system activity. All 10 Powerwall installations have been completed and initial data collection and monitoring is underway.

Stelpro has promoted Gilles Lalonde to the position of sales manager, Electrical Distribution. Lalonde has been a member of Stelpro since 2006, and possesses over 30 years of experience in the electrical industry. Meantime, after three years at Stelpro, Maxime Galarneau will take over from Lalonde as sales rep, Electrical Distribution, for the Montérégie, Vaudreuil-Soulanges, Valleyfield and Sorel territories. Finally, Olivier Lamoureux moves from the position of customer service agent, Submissions, to sales rep, Electrical Distribution, for the Laval and Lanaudière territories. All three report to Sébastien Durocher, director of sales, Electrical Distribution, for Quebec. The supervisory board of Ledvance has appointed Jacob C. Tarn the new CEO and chair of the management board. He will focus on accelerating the company’s transformation from a traditional lamps manufacturer to a full LED lighting company, says Ledvance. Tarn, most recently served as executive vice president and COO of the LED business unit at Samsung Electronics. Rüdger Tibbe, who served as interim CEO, will continue on as chief transformation officer. Meanwhile, James I. Johnson, Jr. has been named managing director for the company’s Canada and U.S. region. He most recently served as CEO of Osram’s Global Traditional Lamps business. British Columbia’s Electrical Joint Training Committee (EJTC) (ejtc.org) has named Phil Davis managing director, succeeding Andy Cleven, who has served as training director since 2004. Andy will remain as training director emeritus, responsible for special projects until his retirement date of June 29, 2018. EBMAG.COM

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Hazardous Locations

• It was not shown documented evidence of any tests carried out to justify the removal of the previous requirements. • The drop pressure test for cables on the standard’s Annex E (Informative) is not related to cable standards, and is not reasonably practicable.

ELECTRICAL INSTALLATIONS IN

HAZARDOUS LOCATIONS Tackling some controversial IEC recommendations / ESTELLITO RANGEL JR.

he design and installation of electrical equipment for a facility with an explosive atmosphere begins after a detailed area classification is completed. The International Electrotechnical Commission has developed a number of standards that deal with multiple requirements for these areas in the IEC 60079 series of explosive atmosphere standards, many of which have been adopted in North America. Below are some of the changes in recent editions of the IEC 60079 series, plus some recommendations for safer installations.

Requirements

Today’s more powerful LED technology presents real challenges for the safety of products used in hazardous locations.

enclosures bigger than 122 in.3 (2 dm3) imposed the use of barrier glands. The U.K.’s Health and Safety Executive (HSE) took exception to this change, and issued a safety notice in February 20164 cautioning users that there was an increased risk of fire and explosion propagating through the cable sheath, they felt, and that this could be avoided through the use of barrier glands. (It should be noted the U.K. was the only country to take this position.) The HSE endorsed the U.K. Committee proposal to keep the previous edition requirements valid in the U.K.5 regarding the cable glands to Ex d enclosures, considering that:

CABLE GLANDS FOR EX D ENCLOSURES

The fifth edition of IEC 60079-14 1 allows the use of Ex d cable glands certified in accordance with IEC 60079-12 as equipment, and combined with appropriate cables with a minimum length of the connected cable of 3 metres. This was a major change compared to the previous edition’s requirement,3 in which Ex d 10

ELECTRICAL BUSINESS · March 2018

Figure 1. A barrier cable gland.

A barrier gland (Figure 1) ensures that gas migration through the cable is prevented, and also provides a flame barrier should an explosion occur, thereby maintaining the explosion protection integrity of the equipment to which it is connected (as per the “Rapidex catalogue”, CMP Products). INITIAL INSPECTION

IEC 60079-14’s position on initial inspection involves checking whether the equipment has been properly selected in accordance with the standards’ requirements and has been correctly installed before coming into operation.6 Annex C contains schedules for this inspection, related to the type of protection for that equipment. These schedules were originally found in IEC 60079-17,7 but their inclusion in IEC 60079-14 was considered a good change.

Recommendations for safer installations OPTICAL RADIATION TRANSMITTING EQUIPMENT

The second edition of IEC 6007928 was issued in 2015.8 It describes requirements and precautions to be taken when using optical radiation transmitting equipment in explosive gas or dust atmospheres. Today’s more powerful LED technology presents real challenges for the safety of products used in hazardous locations. At the IECEx meeting in Umhlanga, South Africa (September 2016), a detailed report presented the issues involving LEDs and the possible ignition sources caused by powerful light. It was shown that, out of 1000 certificates issued by IECEx for Ex luminaires, less than 10% take into account the risk of optical radiation based on consistent and standardized evaluation in accordance with IEC 60079-28.9 The number of LED luminaires found in applications where flammable EBMAG.COM

Figure 2. The radiation limit.

vapours and combustible particles are present is increasing rapidly. A variety of substances can stick to the surface of the luminaires in industrial applications, such as refineries, chemical plants, ships, etc. When these substances cover the transparent surface of the luminaires, they absorb the optical radiation and can start heating up. The risk of ignition is significant when the optical radiation has not been accounted for in the design of these luminaires. As such, the IECEx certification process for Ex LED luminaires was not considered consistent, and this affects end users who are selecting and accepting products without a careful examination of their certificates. Figure 2 shows a toaster: P = 750W for two pieces of bread. It provides about 5 mW/mm2 of radiation during the toasting process, which is enough energy to toast the bread after a short while, if not completely burn it. That same amount of radiation, 5mW/mm2, is the commonly used limit for safe optical radiation in IEC 60079-28. The wavelength of toaster radiation is different, but I use this example to demonstrate the impact of radiation. So, users need to verify whether the certificates of LED luminaires issued include the IEC 60079-28 requirements’ evaluation. SURGE SUPPRESSORS FOR EX MOTORS ABOVE 1KV

In clause 5.11.5.1, IEC 60079-14 (5th ed.) warns that overvoltage switching can occur when a high-voltage motor is switched off and vacuum circuit breakers or vacuum contactors are being used. The transients depend on various system installation and design factors, such as the arc-extinguishing principle of the contactor or switch, EBMAG.COM

size of the motor, length of the power supply cable and system capacitance, among others. IEC 60079-14 states that, regardless of the motor size and the arc-extinguishing principle of the switch being used, shutting down the motor during startup can cause overvoltages and, also, when vacuum circuit breakers For installers, or vacuum contactors are used for manufacturers motor switching, the motor installation design should consider using an and end appropriate surge suppressor, such as users, the a zinc oxide varistor with spark gap. implementation Under these conditions, the installation of surge suppressors in motor cirof a new cuits above 1kV should be considered standard mandatory, especially because there requires is evidence that ignition can occur skilled during locked rotor tests applied on 10 professionals 4.16kV Ex e induction motors.

to perform SAFETY SIGNAGE a careful An item not covered in IEC 60079evaluation 14 that contributes to a safer plant is safety signage/awareness. Figure of the a safety sign containing consequences. 3theshows “Ex” (“explosive atmosphere”) inside a yellow triangle against a red background.11 It alerts workers, and shares information about the zone, gas group and permissive temperature class. The hazardous location classification drawing’s number facilitates onsite consultation.

installation, refresher training for the workforce will become necessary. These can be expensive tasks. For installers, manufacturers and end users, the implementation of a new standard requires skilled professionals to perform a careful evaluation of the consequences. The current editions of IEC standards regarding installations in hazardous locations involve some additional requirements when compared to earlier editions, and special attention should be paid by installers and manufacturers alike because some of them are controversial.

Notes 1.

IEC 60079-14 “Explosive atmospheres-Part 14: Electrical installations design, selection and erection”, 2013.

IEC 60079-1 “Explosive atmospheres-Part 1: Equipment protection by flameproof enclosures ‘d’.”, 2014.

IEC 60079-14 “Explosive atmospheres-Part 14: Electrical installations design, selection and erection (Ed. 4.0)”, 2007.

“Use of barrier glands in potentially explosive atmospheres to meet IEC 60079:14 2013 (Edition 5)”, HSE, February 2016, tinyurl.com/y8n2gcaw.

BS EN 60079-14, “Explosive atmospheres-Part 14: Electrical installations design, selection and erection”, 2014.

Estellito Rangel Jr., Mauricio F. Oliveira and Alan R.S. Queiroz, “The importance of inspections on electrical installations in hazardous locations”, 61st PCIC Conference Record, San Francisco, 2014, p. 155-161.

IEC 60079-17 “Explosive atmospheres-Part 17: Electrical installations inspection and maintenance, edition 5.0”, 2013.

IEC 60079-28 “Explosive atmospheres-Part 28: Protection of equipment and transmission systems using optical radiation, edition 2.0”, 2015.

Tarmo Rintala, “Is certification of LED luminaires causing higher risks on Ex areas?”, Atexor, July 2017.

10. Estellito Rangel Jr. and Carlos Sanguedo, “New requirements for electrical installations in hazardous locations”, 64th PCIC Conference Record, 2017, Calgary, p. 443-450.

Figure 3. An effective sign for classified locations.

Conclusions When a new edition of a standard is issued, changes to the previous content (especially the addition of new technical requirements) can result in an existing, certified product not meeting the new requirements. Sometimes, entire equipment design may need to be reviewed by the manufacturer. On the other hand, when modifications apply to the

11. Estellito Rangel Jr., “Safety in electrical installations in petroleum industry”, 1st IEEE PCIC Mexico Conference Record, Mexico City, 2013. Estellito Rangel Jr. currently serves as a senior consultant on oil & gas electrical system design, and on workplace electrical safety. Prior to consultancy, he spent 33 years with Petrobras designing electrical systems, performing LV and MV equipment factory acceptance tests, and coordinating hazardous area classification assessments. He is also the first Brazilian member of IEC Technical Committee TC-31 “Equipment for explosive atmospheres”. He can be reached at estellito.consultor@gmail.com. This article is adapted from a paper presented during the International Technical Session at IEEE PCIC 2017 in Calgary. March 2018 · ELECTRICAL BUSINESS

Motor Cooling

AUXILIARY COOLING OF ELECTRIC MOTORS

(AND OTHER EQUIPMENT)

Figure 1. Typical squirrel cage blower.

CHUCK YUNG

lthough the earliest practical DC motor was built by Moritz Jacobi in 1834, it was over the next 40 years that men like Thomas Davenport, Emil Stohrer and George Westinghouse brought DC machines into industrial use. It’s inspiring to realize that working DC motors have been around for over 160 years and, for the past century, DC machines over 30 kW or 40 kW have been cooled in the same manner—by mounting a squirrel cage blower directly over the commutator. End users and repairers alike quickly realized that the air that cooled the motor also forced highly conductive carbon dust directly into the very windings that were the lifeblood of the machine. Doing so still seems contrary to the desire to maintain a high-insulation resistance-to-ground to preserve or extend winding life rather than end it. Even so, DC machines remain popular, largely because of the ability to control speed and torque. A DC motor can be expected to operate over a large speed range, and a shaft-mounted fan can only provide cooling in direct proportion to the speed at which it is turning; thus, the default method of cooling a DC machine is with that darned blower (Figure 1). 12

ELECTRICAL BUSINESS · March 2018

Finding best cooling option

It’s inspiring to realize that working DC motors have been around for over 160 years.

Today, we also have inverter-fed AC machines operating at wide speed ranges, so auxiliary cooling has become an aftermarket consideration. Service centres often can help end users select the best cooling method and correctly size it for a particular application. The rule of thumb for cooling electrical equipment is 100 cfm (2.8 m3/min) per kW of losses. When the

efficiency of the motor is known, the simplified calculation is: hp x 0.746 = kW (1 - efficiency) x kW = losses Losses x 100 = cfm recommendation

Rounding up by as much as 25% is prudent to ensure there is adequate air flow to cool a machine. Recognize, too, that at slower operating speeds, less air flow is available from the factory-integral fan(s), and the winding temperature is likely to be higher (Figure 2).

Most-popular cooling method

Figure 2. Some larger machines may use more than one blower.

For a DC machine, an auxiliary squirrel cage blower mounted on the commutator end remains the most popular cooling method, and the recommended air flow can be determined in the same way as for other electrical equipment. Although DC machine efficiency is not part of the typical nameplate, unlike an AC machine, it can be determined by calculating the losses as a percent of input power. To obtain the input power, convert the field and armature ratings to kW (watts = volts x amps) and add them together. If the output power is given in hp, convert it to kW (recall that hp x 0.746 = kW). For example, consider a 400-hp DC motor (0.746 x 400 = 300 kW), EBMAG.COM

CALENDAR

with a 500V armature circuit rated at 645A (500V x 645A = 322.5 kW), and shunt fields rated for 240V and 3.5A (240V x 3.5A = 0.84 kW). (Note that the armature circuit includes the armature, interpoles and—when present—series fields.)

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Input power = 322.5 kW + 0.84 kW = 323.34 kW

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Out power = 300 kW 323.34 kW input - 300 kW output = 23.34 kW losses, for about 93% efficiency 100 cfm x 23.5 kW losses = 2350, and would require a 2350 cfm blower at 2 in. or 3 in. (5 cm to 8 cm) of water column static pressure.

Effect of carbon dust Still, the drawback remains: the carbon dust generated by brush wear is blown directly into the very windings we want to preserve. Not too many years ago, one manufacturer addressed this by installing the blower on the drive end (opposite the commutator), but found that this by itself was not enough. To optimize cooling, they also needed to increase the static pressure inside the motor while simultaneously forcing more cooling air through the armature. This was accomplished by installing a flat baffle on the commutator end (Figure 3) positioned just above the risers. This increased the static pressure (denser air cools better), forced more air to pass through the axial vent ducts in the armature backiron, and increased the velocity of the air passing between the baffle and risers. This yielded two additional benefits: first, the faster air flow did a better job of expelling the carbon dust from the motor; second, it increased cooling at the risers and the brush holders. (Ideally, the brush and commutator temperature should be in the 140°F to 210°F [60°C to 100°C] range.) Manufacturers of any equipment keep up with what the competition is doing, especially when it works. Not surprisingly, several other manufacturers have (almost) copied the revised cooling scheme, and now install the EBMAG.COM

For those Figure 3. Baffle required to optimize instances cooling, with blower installed on where the opposite commutator end. OEM does not offer blower on the drive end. As of this writing, though, none have apparently enhanced realized the need for the additional cooling baffle on the commutator end. options, revert to the Improving motor performance 100 cfm per The good news is that if there is a installed on the drive end kW of losses blower rather than the commutator end, a guideline. service centre can improve motor

Manufacturers of any equipment keep up with what the competition is doing, especially when it works.

performance by fabricating a baffle for the commutator end. For AC motors operating from a variable frequency drive (VFD), some manufacturers offer an already-engineered aftermarket blower. Some mount directly to the fan cover with a shaft sized to accept the original external fan. Other kits require removal of the shaft-mounted fan (a squirrel cage blower mounts directly to the fan cover). Either way, a suitable constant volume of air is provided to eliminate the problem of reduced cooling at reduced-speed operation. For those instances where the OEM does not offer enhanced cooling options, revert to the 100 cfm per kW of losses guideline. Competent blower manufacturers offer help in sizing blowers for specific applications, and most service centres can fabricate robust framework to support and properly position the auxiliary blower. For TEFC (IP54) or WP (IP 23 or 24) enclosures, adding an aftermarket blower is relatively simple. For ODP enclosures, the same rule for volume and static pressure applies, but the complexity of execution is much greater. Chuck Yung is a senior technical support specialist with EASA, the Electrical Apparatus Service Association (easa.com).

EV2018 Conference & Tradeshow Electric Mobility Canada April 24-27, Ottawa Visit emc-mec.ca/ev2018ve MEET Show Mechanical, Electrical, Electronic & Technology Show May 2-3, Moncton, N.B. Visit meetshow.ca Lightfair International May 6-10, Chicago, Ill. Visit lightfair.com ECA of Alberta Training Day Electrical Contractors Association of Alberta May 25, Edmonton Visit ecaa.ab.ca SCC Annual Conference Safety Codes Council, Alberta May 27 - June 3, Banff, AB. Visit safetycodes.ab.ca EFC Annual Conference Electro-Federation Canada May 29-31, Vancouver, B.C. Visit electrofed.com Energy Summit Canadian Industry Partnership for Energy Conservation (CIPEC), Excellence in Manufacturing Consortium (EMC) and NRCan May 30-31, Vaughan, Ont. Visit energy2018.ca Skills Canada Nat’l Competition Skills/Compétences Canada June 3-6, Edmonton Visit skillscompetencescanada.com Indicates EB will be there. Visit EBMAG.COM for an extensive list of upcoming industry events.

March 2018 · ELECTRICAL BUSINESS

Cable upsizing

THE ECONOMICS OF

UPSIZING YOUR CONDUCTORS

Duane Grzyb is an electrical engineer (Alberta) with 25 years of consulting engineering experience, and has worked on energy projects all over Western Canada. His specialties include area classification, failure analysis, renewables, VFD applications, power quality, harmonics mitigation and project management. He is also the current president of the Electrical Technical Exchange Group (ETEG) for Northern Alberta. This article is adapted from a paper Duane presented at the IEEE ESTMP Workshop in Calgary, 2014.

Can you save money? If so, under what conditions? / DUANE GRZYB

psizing the cross-sectional area of current-carrying conductors in power electrical cables can reduce the I2R loss which, in certain cases, can offset the higher material and installation costs. As a test case, consider a 100-hp 575V induction motor, running continuously, connected by 250m of cable installed in cable tray by trades who work for a rate of $100/ hr. Where electricity purchased at a rate of $0.10/kWh, a 3C#2/0 AWG cable (instead of a CE Code-recommended 3C#1/0 AWG) could pay for itself in as little as 5.3 years. The U.S. Energy Policy Act (EPAct) of 1992 requires 1-hp to 200-hp general-purpose motors manufactured or imported for sale in the U.S. to meet minimum federally mandated efficiency levels. The 100-hp motor described above, running at 100 hp output consumes 89.7A at 575V, power factor 87.5% and is 95.5% efficient. A typical 1990s electric motor of the same size was about 89% efficient. Since 1997, energy-efficient motors have been mandated to be at least 93.6% efficient. Thus, PF (power factor) = |cos φ|, where φ is the apparent power phase angle. The real power P in watts W is equal to the apparent power |S| in volt-amperes (VA) multiplied by PF. |S(VA)| • PF = P(W) (√3 • VL-L(V) • I(A)) x PF = P(W) (√3 • 575 • 89.7 • 0 .875 ) = 78168 W So for a year of continuous operation at $0.10/kWh, the 100-hp motor consumes: (365.25 • 24 • 78.168 • 0.1) = $68,500 of electricity per year. It becomes apparent that a motor costing 14

ELECTRICAL BUSINESS · March 2018

$10,000 consumes almost 7x its purchase price in energy each year. Cost of ownership has been carefully considered when it comes to large power transformers. IEEE C57.120 “Loss evaluation guide for power transformers and reactors” details methods for establishing the electric power used to supply the losses of a transformer or reactor. Users of this standard can determine the relative economic benefit of a high-first-cost, low-loss unit versus one with a lower-first-cost and higher losses. This standard was first published more than 20 years ago, which supports the validity of examining the total cost of ownership (TCO).While transformer loss evaluation is at the discretion of the purchaser, motor loss prevention has been mandated, regardless of whether the user’s motor runs day in and day out, or rarely (e.g. fire pump motor). Let’s examine the typical 3-5% voltage drop on supply wiring and evaluate opportunities to recover some of those losses. Copper (and aluminum) conductors have resistance. Thicker conductors have lower resistance than thinner ones. Copper that is cool has lower resistance than when it is warm. An identical current passing through a thinner wire wastes more energy in heat than its thicker counterpart. To make matters worse, the additional dissipated energy causes the wire to increase in temperature resulting in a further increase in resistance, resulting in more heat until an equilibrium is reached. This is referred to as the steady-state operating temperature. Traditional thinking guides the design engineer to choose wire sizes to limit the voltage drop (the difference in voltage from supply to load) to 3% for a specific device’s load cable, and an additional 2% for upstream equipment that lies between the utility connection and the break-out point for individual loads. This article examines the TCO of wiring

that supplies loads. To do that, let’s examine delivered power. Induction motors are constant power devices. Unlike a resistive load, an induction motor increases current draw when terminal voltage drops to maintain constant power output. For this analysis—to ensure the motor delivers the same amount of useful work in each evaluated scenario—calculations have been normalized for losses and benefits. Our test case compares copper conductors (#1/0 AWG to #4/0 AWG) supplying a 575V, 100-hp induction motor. The modelled test case uses 250m of 3-conductor Teck 90 aluminum-armoured copper cable installed in cable tray and operated at a 30°C ambient. At this operating current, 250m of cable exhibits slightly less than 3% voltage drop using standard 65°C voltage drop tables. In actual fact, equilibrium steady-state running temperatures are lower than 65°C, and have been calculated for each cable type and included in the evaluation. The base case analysis is then subjected to

PROS & CONS TO UPSIZING CABLES Pros • Cooler cables are more efficient • Cooler cables last longer • Carbon tax savings • Long-term electricity savings • Positive public image • End-of-life copper recovery

Cons • Fewer cables per tray • Higher cable cost • Larger conductor lugs • Increased installation labour • Larger teck connectors EBMAG.COM

Cable upsizing

Similarly $TIC00 is the total installed cost of a 3C#2/0 cable, terminations and 1/55th the cost of the tray system. $TIC000 is the total installed cost of a 3C#3/0 cable, terminations and 1/54th the cost of the tray system. $TIC0000 is the total installed cost of a 3C#4/0 cable, terminations and 1/48th of the cost of the tray system. Figure 1

adjustment of the assumptions to determine the sensitivity of outcome as a result of the change in assumption. Sensitivities analyzed include electricity cost, cable cost, cable length, operating hours, termination hardware cost, cable tray fill, carbon tax and labour costs. A summary of the anticipated advantages and disadvantages of installing larger-than-normal electrical cables is presented below. To ensure that a sweet spot analysis was not presented, each cost was increased by a factor of two, then decreased by a factor of two, and analyzed to identify the sensitivity to each. Therefore, where electricity costs $0.20/kWh instead of $0.05/kWh, the user can determine how the difference will affect the outcome. The evaluation is a 100-hp, 575V, 60Hz 3-phase induction motor connected with 250m of 3C#1/0 Teck cable in 24-in. aluminum ladder tray, using compression lugs and teck connectors sized appropriately at each end. The considered cable tray is 240m in length, and has 4 horizontal elbows and 3 vertical elbows (approximating a typical installation). To ensure that the same amount of useful work is delivered by the motor in each calculated scenario—despite the argument that the motor is already a constant-power device—the losses and benefits were based on constant motor terminal voltage. The constant terminal voltage approach is conservative for the purpose of determining time to break even, because decreased motor terminal voltage results in increased supply cable current, which results in increased I2R losses in the cable and motor. This is further compounded by higher amperage, causing increased copper conductor temperatures, thereby increasing resistance and increasing losses. So the results obtained are conservative! Conductor operating temperatures in this examination have been calculated using 30°C free air operation. A cable in free air will 16

ELECTRICAL BUSINESS · March 2018

run cooler than it would in a random-filled tray. An increase in cable temperature using random-filled installation further enhances quicker payback. Thus, the free air assumption is conservative for the purposes of this evaluation. Motor data was supplied courtesy of Teco Westinghouse and cable temperature rise calculations have been performed courtesy of Nexans. Other factors that have considered include: • It costs more to install larger copper cables because they are bigger/heavier. • It takes longer to terminate them. • The termination hardware costs more. • Fewer cables fit into a similar-sized tray.

For interest, some consultants propose minimizing cable size to cut capital costs. Using smaller cables allow more to be put in each tray. So just how long do they save us money? $TIC1 is the total installed cost of a 3C#1 cable, terminations and 1/75th of the cost of the tray system. $TIC2 is the total installed cost of a 3C#2 cable, terminations and 1/85th of the cost of the tray system. The upfront cost ($UFC) that must be recovered to offset the TIC differences between 3C#1/0 and 3C#2/0 cables are: $UFC0-00 = $TIC00 - $TIC0 And, similarly, to upgrade from #1/0 to #3/0

The total cost to install 3C#1/0 cable ($TIC0) is the sum: • cost of 250m of 3C#1/0 Teck 90 cable, • labour cost to install 250m of 3C#1/0 cable, • cost of 2 teck connectors to fit 3C#1/0 cable, • labour cost to install 2 size 3C#1/0 teck connectors, • cost of 6 compression lugs for #1/0 conductor, • labour cost to install 6 compression lugs on #1/0 conductors, • 1/56th* the cost of 240m of a 24-in. cable tray system, and • 1/56th* the cost of labour to install the 240m tray system

$UFC0-000 = $TIC000 - $TIC0 and from 3C#1/0 to 3C#4/0 $UFC0-0000 = $TIC0000 - $TIC0 In the case of downsizing cables to save capital costs (Installed Cost Savings), does running more, smaller cables in a cable tray result in permanent savings, or does the choice have repercussions after a calculable period? $ICS0-#1 = $TIC0 - $TIC#1 $ICS0-#2 = $TIC0 - $TIC#2 The calculation of the payback period to recover capital costs:

* Accounting for differing cable tray capacity has been accomplished by determining the quantity of each cable type that could be installed in a 24-in. cable tray, and using the appropriate proportional cost assigned to each cable’s total installed cost (TIC). Figure 1 is a graphical representation illustrating various cable/tray relationships.

Solving for Y0-00 (which represents recovery time in years): EBMAG.COM

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Cable upsizing

Sensitivities Where D is the per unit value of 1 year or 8766 hours. (Running 50% of the time D would be 0.5) $/kWh is the cost of electricity energy WL0 is the number of watts lost in I2R losses of a 3C#1/0 cable 250m long, operating at 87.73A. WL00 is the number of watts lost in I2R losses of a 3C#2/0 cable 250m long, operating at 87.73A. (WL0 - WL00) / 1000 is the difference in kW (I2R losses) between a 3C#1/0 and a 3C#2/0 cable, each 250m long operating at 87.73A. GL is the average percentage of electricity that is lost in the AIS transmission system. 1 + GL is the ratio of electricity produced to the amount received by the end user. TonC / kWh is the average amount of CO2 emissions in tons/kWh generated based on the heat ratio of the source generator. $ / TonC is an empirical value of a tax that could be levied against end users of fossil fuel energy (i.e. carbon tax). Rates of $15 per metric ton of CO2 produced are typical values.

Results: upsizing from the base case Using the base case, 100-hp motor running continuously—with no carbon tax—using 250m of cable in 24-in. cable tray, installed by trades at the rate of $100/hr, the cost equalization of upsizing from #1/0 AWG conductors to #2/0 AWG conductors is 5.36 years. After the additional capital cost has been recovered, each subsequent year’s operating costs is reduced by $399 per year. Similarly After payback recovery

Payback period

Upsize

Y0-00 = 5.36 years

3c#1/0 AWG to 3c#2/0 AWG

$399/year

Y0-000 = 5.85 years

3c#1/0 AWG to 3c#3/0 AWG

$711/year

Y0-0000 = 6.74 years

3c#1/0 AWG to 3c#4/0 AWG

$954/year

Not every situation is the same. Motors run less, cable and labour costs vary, electricity costs change.The following variables have been adjusted and recalculated to determine their effect: motor operating time 25-100%; electricity price $0.05/kWh to $0.20/kWh; cable and termination hardware prices 50% to 200%; installation labour $50/ hr to $200/hr; carbon tax $15 to $30 per ton; allowable cable tray fill 50% to 100%. The variable having the most significant effect on the payback period is energy cost: the higher it is, the sooner a larger cable pays for itself. Motor operation time is also a key factor in obtaining payback. Motors that are used all the time save energy all the time. High usage contributes to quicker payback. Cable cost is a major factor. Larger conductors have more copper in them, more insulation and more armour. When cable price doubles, the payback period nearly doubles. As for cable termination material cost, increased connection costs at each cable end become more relevant as the overall cable installed length is reduced. Allowable cable tray fill has a small effect on the payback period. Labour cost changes had a small effect on the payback period. The increased labour costs for installing larger, heavier cables, bigger terminations, and additional cable tray was small in comparison to cable and energy cost. As expected, a carbon tax shortens the payback period, and continues to pay dividends in the long term. However, the contribution is comparatively small. Amperage of loads with proportionally sized cables does not appear to affect the outcome of the study. There is a curious relationship between the ratios of cable cost (primarily affected by copper commodity price) and the amount of cable losses that can be recovered for any particular load. Motors from 10-hp to 1000-hp have an eerie similarity of payback periods when upsizing one, two or three sizes from the typically accepted cable size.

Some less-tangible benefits Upsized cable runs cooler and, therefore, has extended life. Cables in proximity to upsized cables operate cooler and have extended life. Energy efficiency and reduction in greenhouse gases may have a goodwill factor with the public. Random-filled cables run hotter and increase the benefits gained by upsizing. Motor terminal voltages will typically be higher in upsized cable installations, which has a positive effect on payback periods and further reduced cable heating.

Results: downsizing from the base case

Conclusions and recommendations

In an effort to reduce capital costs, many variances have been written on mega-projects to reduce cable size by eliminating de-rating factors and stretching allowable voltage drops. Using the same methodology, changing the cable from the base case 3C#1/0 AWG to 3C#1 AWG results in savings for only the first 3.75 years. After which, increased energy cost is continuously paid over the life of the installation. 3.75 years is a conservative analysis, as the mean temperature of a tray of reduced sized conductors operates warmer than a tray of increased-size conductors. As well, no value has been deduced for reduced cable life, decreased cable longevity of surrounding cables or carbon tax costs. Decreasing cable size from #1/0 to #1 costs an additional $517 per year in electricity. Downsizing even further to 3C#2 AWG results in energy cost overtaking savings in 3.72 years. Decreasing to #2 costs $1192 extra in electricity per year.

Upsizing power cables can have meaningful cost savings in just a few years. Look for motors that run most of the time, as the payback for cable upsizing is heavily reliant on long hours of operation. Increases in electricity rates shorten payback times. The relationship is nearly linear. Double the price of electricity results in break-even in half the time. Plus, the yearly after break-even savings increases, too. Double the price of the cables and you add about 80% more time to recover the extra cost. Look for motors (and other loads) that have cable lengths of 50m or more.The additional work and material cost of terminating larger cables can only be offset by savings that grow with the number of metres of cable. Lastly, caution should be exercised when selecting smaller cables in an effort to save money; in certain cases, cost savings can be very short-lived.

ELECTRICAL BUSINESS · March 2018

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DAN LEDUC

Adjudication a.k.a. arbitration on steroids

Leviton says it has “completely reimagined the load centre”

he Ontario government is due the deadline for a decision a further 14 days. to proclaim a new Construction The adjudicator’s decision must be Act (which heavily modifies the reached no later than 60 days from the date current Construction Lien Act), the Notice of Adjudication was delivered. and while a lot of time has been The new Construction Act extends your lien spent discussing new prompt payment pro- rights from 45 days to 60, making it possible visions (justifiably so), of equal to have a dispute adjudicated beimportance is a whole new section fore your lien rights expire. regarding Adjudication. The types The adjudicator’s ruling is A practice borrowed from the binding until a final determinaof disputes United Kingdom—which has tion is made by the Court or an that can be Arbitrator. Any money that is payhad this system in place since 1996—Adjudication will become adjudicated able pursuant to an adjudication a compulsory dispute resolution will include must be paid within 10 days. If not platform premised on a very paid within 10 days of the ruling, anything short turnaround time between party who won the award on arising out the submission to the adjudicator adjudication may suspend work of a “proper until the money is paid (in the and a decision. The types of disputes that invoice” U.K., this model has been referred can be adjudicated will include to as “pay now, argue later”). anything arising out of a “proper The parties still have a right to invoice” (also defined by the new Act), “appeal” an adjudication with a subsequent including value of work claimed, other mon- court or arbitration proceeding; however, in etary claims, change orders/scope, claims in the U.K., challenges by the losing party have relation to security held (bonds), set-offs/ rarely been successful. back charges and delay issues as they relate to payment. The takeaways for Ontario... and It’s difficult to do justice to a whole new Canada dispute resolution mechanism in a brief So what can Ontario contractors take from column, but let me try to summarize some the foregoing? First, make sure your docuof its important features. ments are in order, especially when there’s even the slightest suggestion of a dispute. Adjudication highlights This includes having them organized Again, the process is compulsory, and it chronologically or by issue, having them starts with a Notice of Adjudication. If you properly tabbed and accessible (likely elecare the party initiating the process, you tronically), and ready to be submitted to the get to propose an adjudicator. Your Notice Adjudicator at a moment’s notice. requires the names and addresses of the parYou should also open up a separate cost ties, and a brief description of the dispute, code to track your costs associated with the which includes details of how and when dispute so they are easily identifiable and it arose, the relief you are seeking and the not part of your overall project costs. Get name of your nominated adjudicator. ready for this now. The responding party has two (2) days And what about contractors outside of to agree to your choice of adjudicator; Ontario? There is nothing stopping you if not, the Nominating Body will appoint from adopting the same process. The Adone within five (5) days. (We assume this judication platform is designed to keep cash Nominating Body will either be part of the flow as neutral as possible, even through the Attorney General’s office or nominated dispute. It is available to you and your counthrough the A.G.’s office.) sel, and the U.K. model is easily adaptable to Once appointed, the adjudicator can ask any Canadian project or contract. questions, seek further documentation and information, and even visit the worksite, if re- Dan Leduc is a partner in the law firm of Norton Rose quired.The adjudicator must make a decision Fulbright LLP, and practices exclusively in the area of law. He is always happy to take on new within 30 days of the date they were confirmed construction clients from anywhere in Canada. Contact Dan at as adjudicator, though the parties can extend dan.leduc@nortonrosefulbright.com. 20

ELECTRICAL BUSINESS · March 2018

Leviton says it is has completely reimagined the load centre to make it more attractive, approachable and easier to work with—all while improving homeowner safety. All branch wires terminate at custom lugs in the panel, eliminating the need for pigtails. The entire panel can be terminated at rough-in, and all connections are made at the final insertion of the circuit breaker. The design also enables users to switch out branch circuit breakers without having to rewire. Aesthetics play a key role in the new load centre, says Leviton; its enclosure and optional window create an “approachable interface”. When a breaker trips, the at-a-glance diagnostics make it easy to identify trip condition and type of fault (arc or ground) without having to reset the circuit breakers. And line side-powered electronics ensure LED indicators remain lit, even when tripped. Leviton added its reset lockout technology to both GFCI and AFCI/GFCI breakers, saying this makes them “the only true power-denial” circuit breakers available on the market. This technology ensures ground-fault protection against electric shock is always working. AFCI circuit breakers also feature reset lockout technology when the manual test places the device into the tripped state. The breakers also boast hydraulic-magnetic trip technology, which operates in temperatures ranging from -40°C to 85°C. leviton.com

Eaton Neo-Ray Covera and Converge product lines

Featuring curved WaveStream light-emitting diode (LED) technology and LuxWire technology, Eaton introduces the Neo-Ray Covera and Converge EBMAG.COM

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architectural suspended product families. Eaton’s WaveStream LED technology features AccuAim optics arranged in patterns to provide brightness control while delivering optimal distributions. The LuxWire technology delivers low-voltage power to the luminaires through the same aircraft cables from which it’s suspended. The NeoRay Covera product family is available in 2-ft. or 4-ft. lengths with several mounting options and lumen packages. Meanwhile, the Converge LED family is available in 4-ft. and 8-ft. individual luminaires and for continuous runs, in 4-ft. increments.

on and 6-in. solid wheels for increased manoeuvrability. southwire.ca

Arlington fan/fixture pan box for drywall

CODE conundrum

TACKLE THE CODE CONUNDRUM IF YOU DARE! Answers to this month’s questions in April’s Electrical Business.

Compiled by Ray Yousef, code engineer

with Ontario’s Electrical Safety Authority • esasafe.com

QUESTION 1 Single-phase inverters for an interactive solar photovoltaic system are not permitted to be connected to 3-phase systems, unless: a) designed to provide 3-phase system voltages, that are balanced within the limits of supply authority requirements. b) in compliance with requirements of Rule 84-018. c) in compliance with requirements of Rule 84-008. d) all of the above.

QUESTION 2 Arlington’s 14.4-ci. fan/fixture pan box mounts to a joist in new construction and is UL/ CSA listed with a two-hour fire rating. Designed for 1/2-in. and single or double 5/8-in. drywall — with furring strips or hat channel, the fan bracket installation screws ship captive until ready to use.

Bare or insulated conductors not enclosed in grounded metal shall be used in service rooms accessible only to authorized persons. a) True b) False

QUESTION 3 Where batteries are used as a source of the emergency power supply, the batteries shall be kept in proper condition and charged 50% (minimum) at all times. a) True b) False

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Southwire introduces PVC conduit benders Southwire’s new line of heavy-duty PVC conduit benders includes three PVC conduit benders, which the company says help users increase efficiency when heating and bending PVC conduit. Featuring both motorized and manual conduit-bending options, the conduit benders come with chrome-reflective interiors, which Southwire says allows for maximum return of inferred energy, and a thick, textured, powder-coated exterior. All benders also come with an indicator light to notify the user when the elements are

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Making the cut — Hilti cordless band saw SB 4-A22

The Hilti cordless band saw SB 4-A22 is designed for cutting metal pipes and installation channels, plastic pipes, threaded rods, 1-2-in. EMT pipes and 1-5/8-in. strut. Part of the Hilti 22V cordless tool portfolio, the

ANSWERS Electrical Business, February 2018

Question 1 The minimum ampacity for a feeder supplying power to an industrial building shall be based on a basic load of ___ W/m2 of the area of the outside dimension of the building, plus other special loads and electric vehicle supply equipment loads. c) 25 W/m2. Rule 8-210, CE Code 2018. Question 2 The maximum rating for a circuit breaker protecting exposed wiring for a permanent outdoor lighting circuit is: c) 30 A. Rule 30-1120, CE Code 2018. Question 3 All space within 6 m horizontally in any direction from dip tanks and their drain boards, with the space extending to a height of 1 m above the dip tank and drain board, is considered: a) Zone 1. Rule 20-302, CE Code 2018.

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John MacPherson • jmacpherson@annexbusinessmedia.com Jacquie Rankin • jrankin@annexbusinessmedia.com March 2018 · ELECTRICAL BUSINESS

CODE file NANSY HANNA, P.ENG.

“EV-ready” homes and the impact on residential service

ontinuing our discussion regarding electric vehicle supply equipment (EVSE a.k.a. EV chargers), let’s look at a few examples to understand the load impact on the service size for a typical house, and how changes in the 2018 CE Code facilitate such installations.

Single-dwelling house, 232 m2 • 232 m2 plus 116 m2 basement • Total living area is 321 m2 (100% of ground and upper floor[s] plus 75% of basement, as per Rule 8-110) • AC/heat (20A @ 240V) @ 100% = 4800W • Level 2 EV charger (50A-plug @ 240V) 32A @ 100% = 7700W

Based on the above example and CE Code Rule 8-200(1), the minimum-required service size for this house is 125A with the EVSE installed. Without it, the service size would only need to be 100A. That said, a 100A service may still be acceptable were an Electric Vehicle Energy Management System to be deployed (as permitted by Rule 8-500), because the EVEMS adjusts the draw of the charging current based on available capacity on the service. When EVSE is added to an existing house—based on provisions in Rule 8-106—it is permitted to use a detailed (demonstrated) load as obtained from the local distribution company (LDC), which indicates the existing peak demand over the

Load designation

Watts

Basic 90 m (5000W)

5000

Next 90 m2 or portion thereof (1000W x 3)

3000

12.5

Electric range (12 kW)

6000

Amps

Dryer (5000W @ 25%)

1250

A/C @ 100%

4800

20 @ 100%

Sub-total (without EVSE)

20,050

83.5

EV charger (32A @ 100%)

7700

32 @ 100%

Total (with EVSE)

27,750

115.6

Load designation

Watts

Amps

Basic 90 m (5000W)

5000

Next 90 m2 or portion thereof (1000W x 1)

1000

4.2

Electric range (12 kW)

6000

Dryer (5000W @ 25%)

1250

A/C @ 100%

4800

20 @ 100%

Table 1: Single-dwelling house, 232 m2

EV charger (32A)

7700

Total

25,750

108.2 with A/C

Table 2: Townhome, 111 m2

last 12 months plus the nameplate rating of the charger to calculate the new demand. A utility bill along with information from the supply authority for an existing 279-m2 (3000-sf) house with a 100A service (including A/C, hot tub and electric stove) revealed the peak amperage is around 30A, so the new peak demand is: 30A + 32A = 62A. Although the Rules of Section 8 need to be followed for new houses, this case study reveals there may be sufficient capacity on a typical house service.

Townhome, 111 m2 • 111 m2 plus 46 m2 basement • Total living is 147 m2 • AC/heat (20A @ 240V) @ 100% = 4800W • Level 2 EV charger (50A-plug @ 240V) 32A @ 100% = 7700W

Service supply, 6-unit townhomes of 111 m2 (with and without A/C) When calculating the minimum ampacity of the feeder, calculate the feeder/service based on Rule 8-202(3)(a). Assume the base load is calculated by % and the A/C is considered 100% load. Based on 8-202(3), EV loads are not required to be included as 100%, similar to A/C load, but are permitted to be included in the base calculation with demand factors applied. The minimum ampacity for the service conductors for these six units shall be based on a 415.2A load. Similarly, when EVEMS are employed as per the 2018 CE Code, the supply service size for the six units’ townhomes could be reduced. Information on the EVEMS used will be required at the design stage to determine whether a reduction of the service size is permitted. Always consult your AHJ for more specific interpretations.

Unit

Calculation

Amps

Amps with A/C

First

100%

108.2

108

Next 2

65% of base + 100% A/C

2 x (.65[88.2]+20)

155

Next 2

40% of base + 100% A/C

2 x (.40[88.2]+20)

110

Next 1 unit

25% of base + 100% A/C

1 x (.25[88.2]+20)

Total

42 415.2

Nansy Hanna is the director for Engineering & Program Development at Electrical Safety Authority (ESA) where, among other things, she is responsible for product safety, code development, improving harmonization and alternative compliance, worker safety, and aging infrastructure programs. She is a LEED-Accredited Professional and a member of CSA CE Code-Part I, Sections 24, 32, 46, 50 and 64. Nansy can be reached at nansy.hanna@electricalsafety.on.ca.

Table 3: Service supply, 6-unit townhomes of 111 m2 (with and without A/C) 22

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