Smart tricks to improve power supply reliability

White paper series

Power Distribution

Power distribution systems

Janne Paananen
Technology Manager, Large Systems Group
Eaton
Martijn Imming
Business Development Manager Data Centers
Eaton

Executive summary
For data centers, hospitals and other mission-critical applications, the reliability
and resilience of power distribution systems are top priorities and essential to
securing the critical ICT load.

Equally essential are maintaining safety and eliminating risk to personnel and
equipment during both normal and fault conditions.

This white paper looks at how to improve power supply reliability and safety,
including the dangers of arc flash and how to mitigate against it through careful
power system design and the benefits of power distribution monitoring.
Introduction to power distribution Distribution of power to the load
For hospitals, data centers and other mission-critical applications, A distribution configuration is used to deliver power to the load.
power distribution system integrity is essential in securing the critical This configuration usually comprises a main load breaker (LB) and
ICT load. Accordingly, emergency diesel generators and UPSs are multiple branches, each protected by their own breaker as shown
used to ensure the level of integrity required; these can be used in Fig.3. Sometimes the power distribution is integrated into a
in many different ways to achieve reliable power distribution. For single Power Distribution Unit, or PDU. If an electrical problem
UPSs in particular, there are many factors to be included as part such as a short circuit or overload occurs, it should be limited to
of these considerations. the affected branches without reaching others. This containment
can be achieved by designing in selectivity between the branch
Elements of a power distribution system circuit breakers and the upstream protection. Accordingly, it is
important to use circuit breakers that allow discrimination.
For the reasons above, mission critical applications use a dual-sourced
feed for their power input. One source is the utility grid, while
the other is an emergency supply, often a standby generator. Both
supplies are rated for the total load, which comprises the ICT load LB
and services such as cooling essential to keep the load running. The
input configuration must support automatic transfer of the load
to an alternative supply; this function should be implemented as a
complete solution integrated into the input switchgear and should
include a starting signal for the generator set.
Critical Load
Fig.3: Power distribution configuration with upstream
and downstream breakers
G
Power distribution systems that contain UPSs typically include
an input and output configuration with a load distribution part.
Below we look at examples of these, from the most basic to
more complex and sophisticated.

Input Simple input and output configuration

A set of circuit breakers is necessary to protect both the input
to and output from the UPS. These can be packaged with input
Fig.1: Power input configuration switchgear and output switchgear, while combined UPS Input/
RIB BIB RIB
Output switchboards are becoming increasingly common. These BIB MBS
provide a constant feed to the UPS system and include the bypass
Ensuring uninterrupted power arrangement and UPS output. The most basic Input/Output
A UPS is used to ensure power quality and to prevent a power functionality comprises a module input breaker (MIB), module
break during any utility supply disturbance or transition between output breaker (MOB) and a maintenance bypass switch (MBS),
sources. UPS configurations typically comprise one or more as shown in Fig.4.
power modules with oneRectifier
integrated static bypass. Figure 2 Rectifier
shows this arrangement.
Static bypass Static bypass
Battery Battery Input
Input
MIB MBS
Inverter Inverter
Rectifier

Rectifier Static bypass

Battery

Static bypass
Battery Inverter

MOB MOB MBS

Inverter MIS
Output Output
MOB

LBB LB
Distribution
Fig.4: Basic power distribution configuration
Output
Fig.2: UPS configuration overview
Load Bank
Comprehensive UPS configuration
Components can be added to the basic configuration to develop a
more comprehensive solution as appropriate to a particular installation.
UPS abbreviations Additional possibilities include: Critical Loa
Abbreviations as below are often used for UPSs, breakers • Rectifier Input Breaker (RIB)
and modules:
• Static Bypass Input Breaker (BIB)
• UPS Uninterruptible Power Supply
• Maintenance bypass switch (MBS)
• ISB Integrated Static Bypass
• Maintenance isolation switch (MIS)
• SBM Static Bypass Module (often a distributed unit)
• Load Bank Breaker (LBB)
• Load Breaker (LB)

2 EATON Power distribution systems white paper

Fig.5 below shows how this switchgear can be deployed around Detailed description of the 61439 can be found in “Power Switchgear
the UPS, including generators and transformers. and Controlgear, Assemblies and Distribution Boards according to
EN 61439” by Eur.-Phys. And Dipl.-Ing. Alfred Mörx.

G IEC TR 61641 Arc Flash

IEC 61439 does not describe internal Arc, but IEC TR 61641 does.
The 61641 edition 2.0 is a Technical Report and not a product standard;
Input it is not part of IEC 61439 and it is not a mandatory test. It is an
RIB BIB RIB BIB MBS additional set of testing circumstances to increase protection of
people and assemblies. This guideline indicates three classes:
Rectifier Rectifier
• Personal protection
Static bypass Static bypass
Battery Battery • assembly protection
Inverter Inverter
• limited continued operation

MOB MOB MBS

Personal protection, is achieved when criteria 1 to 6 are fulfilled:
MIS
Output 1. Correctly secured doors, covers, etc., do not open
LBB LB
2. Parts (of the ASSEMBLY), which may cause a hazard, do not
Load Bank fly off. (This includes large parts or those with sharp edges,
for example inspection windows, pressure relief flaps,
Critical Load cover plates, etc.)
Fig.5: Power distribution configuration
3. Arcing does not cause holes to develop in the freely
accessible external parts of the enclosure as a result of
Rectifier Input Breaker and Bypass Input Breaker burning or other effects

To protect each device independently, a separate Rectifier Input 4. Vertically arranged indicators do not ignite (indicators ignited
Breaker (RIB) and static Bypass Input Breaker (BIB) can be used as a result of paint or stickers burning are excluded from
instead of a rectifier and static bypass with one common input. this assessment)
The rectifier input typically also carries the battery charging current. 5. The protective circuit for accessible parts of the enclosure
A further benefit of separated breakers is that the load can be is still effective
supplied via the static bypass. 6. The ASSEMBLY is capable of confining the arc to the defined
area where it ignited, and there is no propagation of the
Maintenance Bypass Switch
arc to other areas within the ASSEMBLY
Adding a Maintenance Bypass Switch (MBS) allows an entire UPS
module to be bypassed and taken off line. The MBS is primarily used In addition, if specified by the manufacturer, criterion 7 applies
to allow voltage free maintenance work on the UPS modules without where the ASSEMBLY is to be suitable for limited continued
disconnecting the load. The MBS can comprise two breakers and operation:
a cable connection between the input and output switchboard. 7. After clearing of the fault or after isolation or disassembly
Alternatively, these switchboards can be combined into a single of the affected functional units in the defined area, emergency
unit if only one MBS is required. operation of the remaining ASSEMBLY is possible. This is
verified by a dielectric test with a value of 1.5 times the
Load Bank Breaker rated operational voltage for 1 minute.
For load testing, UPSs have a test mode that feeds battery stored
energy back into the supply grid. However, some applications require 4.1 Classification with regard to the protection characteristic
testing via a load bank. If so, a Load Bank Breaker (LBB) can be According to their characteristics under arcing conditions
added to handle the load bank connection. ASSEMBLIES can be classified by the manufacturer into:
Maintenance Isolation Switch Arcing class A – ASSEMBLY providing personnel protection
under arcing condition by arc tested zones conforming to arcing
A maintenance isolation switch (MIS) can be added to allow UPS conditions in 8.7, criteria 1 to 5, and by arc ignition protected
testing and servicing without affecting the load. zones, if any;
Arcing class B – ASSEMBLY providing personnel and ASSEMBLY
Latest norms for power distribution protection under arcing conditions by arc tested zones conforming
to arcing conditions to 8.7, criteria 1 to 6, and by arc ignition
IEC regulations set standards for safe products. Often, they also protected zones, if any;
provide guidelines on specifications that should be agreed
between power system manufacturers and their users. Arcing class C – ASSEMBLY providing personnel and ASSEMBLY
protection under arcing conditions by arc tested zones conforming
Possible consequences of inadequate specification to arcing conditions with limited operation in 8.7, criteria 1 to 7,
and by arc ignition protected zones, if any;
Mission critical systems place high demands on the power distribution
equipment they use. IEC standards provide a good starting point Arcing class I – ASSEMBLY providing a reduced risk of arcing
for protecting users, however they are open to interpretation. faults solely by means of arc ignition protected zones.
Therefore, expectations should be discussed and agreed between The power switchgear’s manufacturer and user must agree on
the manufacturer and user, to avoid delivery of a system that is low the arcing class.
cost and IEC-compliant, yet not fit for purpose.

IEC61439- switchgear build Arc flash risk and mitigation

The new IEC 61439 series of international standards establishes The risk of arc flash is always present in LV switchgear. The results of
clear regulations for low-voltage switchgear and control gear an arc flash event can be devastating, in terms of personnel injury or
assemblies. It specifies electrical equipment safety requirements for even death, damage to equipment and extended system downtime.
planners, system engineers, electricians and end users, to define However, the risk can be mitigated by following the steps below.
protection objectives for people and industrial plant with regards
to electrical installations. Annex C of IEC61439-1 “”Items subject Background
to agreement between the assembly manufacturer and the user”
Most LV switchgear have air insulated busbars. Supports maintain a
provides a useful overview of an agreement between the assembly
safe distance between the bars, with a sufficient insulating air gap.
manufacturer and user for power switchgear and control gear
If this insulation value falls below a critical ignition point an arc flash
assemblies. It Lists all user defined functions and characteristics
is initiated, and can continue until the energy source is cut off.
individually and indicates the standard arrangements.

EATON Power distribution systems white paper 3

Arc flashes mostly occur during maintenance. While the probability Eaton switchgear is based on ‘arc-free design’, implementing a
of such an event is low, the consequences can be devastating, with strategy of prevention being better than cure. All risk areas are
extremely severe effects. considered and designed so that no arc flashes can occur. A fault
free zone is created by ensuring that the phases cannot ‘see’ each
Possible consequences of an arc flash other. The complete set of measures employed to create a fault-free
zone between incomer and outgoing protection include:
An arc flash occurring in a 400 VAC switchboard can result in the
load being shut down, with a long period needed for cleaning or • Full insulation by epoxy coating of main busbars.
replacing the switchgear. The arc flash risk has a direct impact on
uptime when switchgear is used in mission-critical applications.
• Epoxy insulated connection bars between main
and distribution busbars.
During an arc flash intense heat and light is emitted, sufficient to
cause burns, and destroy skin and clothes. The heat energy can
• Epoxy powder insulated connection bars between
melt metal parts and blast molten droplets. These can burn skin incomer/buscoupler and main bars.
and clothes, and may cause lung damage. High current arcs also • Phase-to-phase, phase-to-neutral and phase-to-earth screened
produce pressure waves; sufficient to throw human victims and terminations at both busbar and cable side of incoming feeders.
cause injuries through falling or colliding with nearby objects. The
blast may also lead to hearing loss and chronic pain. Arc proof design – functional outgoing unit
Besides the unwanted risk of human damage or injuries, there When an arc occurs behind the short circuit protection device,
are the equipment issues; loss of production, repair costs and consequences are reduced because the energy levels are limited
consequential damage. However, end-customers are seldom aware by the NH-fuses or MCCBs. This decreases the amount of arc energy
of these consequences, and so fail to take adequate arc reduction in outgoing cables. In the design of motor starters the type of fuse
or prevention measures. Education in this area is important, as arc or MCCB applied depends on whether type 1 or type 2 coordination
awareness and prevention increases personnel safety and improves is required. The coordination type determines the combination of
reliability and uptime. Possible measures include minimizing the short circuit protection device with the contactor. Type 2 means that
chance of arc flashes, and providing system redundancies. the short circuit protection device also protects the contactor if a
System redundancy also provides a reduction of downtime if short circuit occurs. (This is not a demand in type1 coordination).
an arc does occur. Limiting-type MCCBs allow for higher short time withstand current
values. They have minimally improved arc limitation functionality
Minimizing personnel danger from arc flash compared to non-limiting MCCB types. Within Eaton low voltage
Some market segments do not accept the risk of arc flash injury switchgear, tests have been performed for both fused and MCCB
to personnel, but will accept the possibility of damage to equipment designs to assure that when an arc occurs, personnel are safe in
and (partial) power supply outage. Their approach is to build strong front of the system as specified in criteria 1-5 IEC TR 61641.
cabinets with top-mounted flaps to create ‘arc-proof’ systems. If an
Arc Flash Reduction Maintenance System
arc flash occurs, humans in front of the cabinet will be safe and
only the equipment is damaged. The same results can be achieved Eaton Magnum and NRX range ACBs offer an Arc Flash Reduction
without needing such elaborate cabinet construction, by using Eaton’s Maintenance System (ARMS™) option. ARMS provides a reduced
‘Arcon’ product, which limits the consequences of an arc and keeps energy protection setting that reduces the arc energy while staff are
people safe. working close to the devices. ARMS is a separate integral analogue
protection circuit that provides an accelerated instantaneous trip to
Preventing arc flash reduce arc flash, allowing the ACB to trip in as little as 18 ms.
Higher market segments do not accept damage to personnel or The operator can pre-select from five levels of protection to optimally
equipment. Such users specify insulated main and vertical busbar balance arc flash reduction against nuisance tripping during planned
systems designed to eliminate the risk of an arc flash completely. startup and maintenance operations, without disturbing the normal
However not all areas can be made arc-free; some must be made operational trip unit settings. Local and remote enabling and indication
arc-proof. An arc occurring in an arc-proof area must be confined to capabilities are provided as well as provision for Lock-out/Tag-out
one functional unit. Switching the system back on and continuing procedures. ARMS is available on Magnum Digitrip 520MC & 1150,
operation after an arc event should be possible. as well as Series NRX Digitrip 520M and 1150.

IEC norms and arc flash Customers embrace the ARMS functionality of the Magnum/NRX
ACBs. Door switches connected to the Digitrip with ARMS
Naturally, switchgear must be built according to IEC 61439. Eaton functionality allow for better personnel safety in abnormal
is proud that all its products are verified by testing, which is the most conditions such as maintenance operations.
rigid of IEC’s verification methods.
Yet a potential danger still exists because IEC 61439 does not place Arc detection
any demand on open arc switchgear behavior. Though IEC TR 61641 An arc detection system should only operate when it ‘sees’ an internal
does act as a guideline, unfortunately most end-customers lack arc, preferably in combination with a current surge. The duration of
detailed awareness of this standard. See under ‘Latest norms the arc flash is limited to approximately 100 ms; the time needed
for power distribution’ for more information about IEC TR 61641. to detect and switch off the incoming breaker current. Energy within
the arc flash is equal to l2t. The 100ms reduction decreases the arc
Arc flash free designs flash energy level.
As indicated above, achieving a 100% arc-free low voltage system
is not possible. Some areas such as the incoming cable connections Arc mitigation
and the outgoing functional unit behind the short circuit protection An arc mitigation device should only operate when it ‘sees’ an
device cannot be made arc-free. The rest of the system, including internal arc. Its use will cause limited system damage, but it will
the main and vertical busbars can be made arc-free by using epoxy mean that at least the quenching device must be removed before
coated insulated bars or shrink sleeve covered bars. the system can resume operation after an arc flash. This may be
acceptable in some applications such as hospitals, large commercial
buildings and general industries, but in most cases such a safety
option is viewed as an add-on to an intrinsically safe (arc proof)
design and not as the only way to protect a switchboard.

Arc killer Arcon

Reducing the arc energy reduces the damage to a power distribution
system caused by an internal open arc event. With protection settings
only, arcing time is typically 50 ms. Eaton’s Arcon arc killer product
can reduce the arc time to less than 3 ms, significantly reducing
the arc energy. Less arc energy means reduced damage and a
Fig.6: Examples of insulated bus bars faster recovery time.

4 EATON Power distribution systems white paper

 Arc flash reduction – 208 V versus 400 V circuits
In a 120V/208 V circuit, arcs tend to self-extinguish. This self-
Form 1
extinguishing is caused by the high impedance in the 208/120 V
supply transformer. By contrast, an accidental short circuit in a
230/400 V system can initiate an arc that does not self-extinguish.
Typically an arc flash propagates from the source at a speed of 100
meters per second, finding its extinguishing point at the far end of
the switchgear.

Internal separation in low voltage switchgear

A low voltage switchgear panel is built up from multiple functional
units. The form of internal separation indicates how these units are
separated from each other. Increasing levels of internal separation
make the switchgear increasingly complicated to build, but
increasingly easy to maintain. In any case, it is beneficial for
maintenance purposes to indicate clearly the form of internal
separation used between the switchgear’s functional units. Fig.6:
Fig.7: Forms of internal separation – examples
Form 1 Form 3a
Implications of internal separation forms
The form of internal separation determines the ease of access to
live parts within the switchgear. If a Form 1 switchgear type (see
IEC 61439-2 below) needs a modification such as connecting a
cable, the complete switchgear assembly must be disconnected.
Higher forms of separation mean that only part of the switchgear
assembly needs disconnecting. For each extension or alteration
the total connected load needs to be de-energized.

Forms of internal separation – IEC 61439-2 definition

IEC 61439-2 clearly indicates the forms of internal separations
between busbar, functional units and terminals for external
conductors as shown in Table 1 below.

Description Form
Form 1separation
No internal Form 3a 1 Form 4a
Separation between busbar and functional units 2a
Separation between busbar and functional units, terminals for external
conductors separate from busbar 2b
Separation between busbar and functional units, separation of functional
units from each other, terminals for external conductors separate from 3a
functional units (not from each other)
Separation between busbar and functional units, separation of functional
units from each other, terminals for external conductors separate from 3b
busbar and functional units (not from each other)
Separation between busbar and functional units, separation of functional
units from each other, terminals for external conductors separate from 4a
functional units and each other.
Separation between busbar and functional units, separation of all functional
units from each other. Terminals for external conductors from the functional 4b
units are separate from busbar, the functional units, and each other.

Table 1 – forms of internal separation Fig.7: Forms of internal separation – examples

Internal separation forms and their implications Form of internal separation according to British Standard
for de-energization
Although IEC 61439-2 clearly indicates the separation between
Different forms of internal separation allow different degrees busbars, functional units and terminals for external conductors, it
of de-energization when performing maintenance work such as does not specify cable glanding. Therefore, the British Standard
connecting a new cable, as shown in Table 2 below. version of IEC 61439 has added types of Form 4b to cover this.

Form De-energize with cable work Form Type De-energize with cable work
1 Whole board, all loads. 1 1 Separation by insulation, Cables may be glanded elsewhere
2a Whole board, all loads. 2a 2 Separation by metal, Cables may be glanded elsewhere
2b Whole board, all loads. 2b 3 Each functional unit has its own integral glanding facility
3a Whole panel, all loads in that panel Separation by metal, Each functional unit has its own integral
3a 4
3b Whole panel, all loads in that panel glanding facility
4a Whole panel, all loads in that panel, or functional unit depending on construction Terminals separated by insulated coverings, and glanded in
3b 5 common cabling chambers
4b Only functional unit
All separation is by metallic or non-metallic rigid barriers or
4a 6 partitions. Cables are glanded in common cabling chamber.
Table 2: Forms of internal separation and de-energizing implications
All separation is by rigid barriers or partitions. The termination for
4b 7 each functional unit has its own integral glanding facility.

Table 3: British Standard for forms of separation and cable glanding

EATON Power distribution systems white paper 5

Remark Power distribution monitoring – Eaton Diagnose system
These forms of separation are not relevant to arc fault containment EATON Diagnose System is specifically designed to provide
which is not the subject of this definition. Arc fault containment is continuous predictive monitoring of switchgear used in mission
subject to a separate agreement between the manufacturer, and critical applications. Diagnose identifies and recognizes hotspot
the client. issues and problems before they progress into a major failure.
It identifies faulty joints or connections by the excess heat they
generate.
Diagnostics
EATON Diagnose System detects problems early through continuous
A low voltage switchgear panel is typically intended to operate monitoring. It provides warnings and information for diagnostics
for 20 or more years. Throughout this extended lifetime, months purposes, helping to record the state of the switchgear and give
may pass between even the most cursory of visual inspections. an insight into its availability. It provides log file records and integrates
But does this provide sufficient diagnostic input to for adequate into existing SCADA systems.
intervention?
The monitoring system is wireless, meaning that no wiring of
Implications of long intervals of inspection the sensors is required, and is quick and easy to install. Permanent
status transmission is established immediately on installation, and
During these long periods, a small problem like a bad connection continuous thermal condition monitoring of critical joints within the
could develop into a major failure. Overheating of a joint increases energized electrical equipment is realized.
the temperature and this increases the resistance, converting the
small problem into a potential switchgear failure. Many maintenance This enables permanent, non-invasive, round the clock detection of
crews have asked for the switchgear to be equipped with IR viewing hotspots at an early stage of their development, so avoiding potential
windows. These IR viewing windows on crucial positions allow downtime resulting from arc flash or power outage incidents.
for periodically checking the connections for temperature behavior.
However there can still be long intervals between checks, and a
strong dependence on load and ambient temperatures. Accordingly,
an efficient diagnostics system that can detect and provide early
warning of such problems is highly desirable if not essential.

G A E
G C C H
G G G G G
G
D H B D
H
H H H H H H H H H H H H
C C C

F F F F F F F F F F F F F F F

Fig.8: EATON Diagnose system overview

6 EATON Power distribution systems white paper

Conclusions About the authors
A Power Distribution system in a mission critical application Janne Paananen is Technology Manager in the Critical Power
typically includes a backup source such as a standby generator, Solutions organization for Eaton EMEA. He is specializing in large
with a UPS to ensure power quality and continuity during utility UPS system solutions for datacenters and special applications. Janne
power problems or changeover between power sources. The UPS has more than 15 years of experience with large three phase UPS
and other devices must be connected into the power distribution products and has been working in after- and pre-sales organizations
system through a suitable set of switches and circuit breakers to providing tailored UPS solutions, support and in-depth product
limit any power outage to the area where the fault occurs, and to trainings for Eaton’s personnel and customers world-wide. Janne
take the UPS safely off line for maintenance. Paananen is also a guest lecturer for educational institutes and
participating in the international standardization work around
data centers.
Alongside reliability and resilience, maintaining safety and
eliminating risk to personnel and equipment are vital parts of an Martijn Imming is Business Development Manager, Power Distribution
overall protection strategy for the power distribution system. There for Eaton EMEA. He is specializing in switchgear solutions for
are IEC regulations that set standards for safe products, which datacenters. Martijn has over 20 years of experience with power
must be met. distribution products both on use, design and manufacturing. During
his work in 6 organizations providing business development expertise,
For instance, many users are unaware of the ever-present risk of technical support and in-depth product trainings for Eaton’s personnel
arc flash in Power Distribution systems – or how dangerous it can and customers in EMEA.
be. This is why mitigation of arc flash is so crucial to system safety
and why adhering to safety standards is critical.

Forms of internal separation is another practical and important

topic, as they indicate how functional units are separated from one
another within low voltage switchgear units. This in turn dictates
the extent to which a system must be de-energized before making
extensions or alterations to the switchgear.

Finally, diagnostics and monitoring is an important step in ensuring

that the system is running as intended and in providing early
warning of any potential risks or failures.

Together, these measures help users to operate and maintain

the power distribution system with maximum safety and
minimal downtime.

Eaton
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Route de la Longeraie 7
1110 Morges, Switzerland
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