DC CONTROL BATTERY SYSTEM PROTECTION & COORDINATION

Robert L. Smith, Jr., Life Fellow, IEEE Volts & vars, h c . PO Box 359 Northville, NY 12134

Abstract - Reliable control battery systems assure proper functioning of well designed, installed and maintained power systems. Battery system failure jeopardizes a power system by eliminating the DC control power source for AC system circuit breakers and protective devices. Failure to protect DC system components also could result in disastrous consequences for the battery system itself. T i paper reviews protection of control hs battery system components including the battery, battery charger and individual circuits. It discusses optimum battery system protective device coordination. Battery selection and charger selection are not discussed. References [q,[7], and [SI discuss these topics.
DC System Failure DC system failure results in the loss of tripping power for major portions of a distribution system. Serious bum-downs can occur if AC power system protective equipment fails to operate for fault conditions because of contol power failure. References [l], [2] and [lo] as well as incidents brought to the attention of the author indicate the following basic causes for DC system failure: o Operating errors AC charger switch open Control bus disconnect open Charger misadjusted o Batterv deterioration Poor maintenance Discharges into fault 10 to 15 secs. or more Overcharging Low or high ambient temperature o Faults (short circuits. ground faults, open circuits) Battery Charger DC distribution system Load Most of the basic causes of failure result from neglect. This neglect probably stems from the following myths associated with battery application:
1. The battery is a "fault free" zone. 2. The installation is "maintenance free". 3. No battery overcurrent protection is required.

DC system failures occur in one of three modes: o Control power loss with no externally apparent damage to any DC system component. o Control power loss with damage to DC control power system components. o Control power loss with damage to the DC control power system adjacent equipment. Table 1 relates failure modes to possible causes.

Failure Mode
No apparent external

U u l Cause sa
Operating errors Battery deterioration Load faults isolated DC system faults isolated isolated

DC system component

Table 1 DC System Failure Modes

Battery Faults While less frequent than feeder faults, battery faults do occur. References [1],[2], and [lo] detail the disasterous results of some such faults. Table 2 shows causes and effects of battery events which may ultimately result in battery faults. Bartev Protection Overcument protection is of limited use in detecting internal battery faults. Figure 1 shows three arrangements of fuses or circuit breakers used for large installations. The disadvantages of these systems arise from the inability of overcurrent devices to detect intemal faults since the only source of short-circuit current is the battery itself (chargers usually are supplied with current-limit protection which means they do not provide enough current to trip a circuit breaker or blow a fuse in the battery circuit). Mid-point, between cell, fusing [fig. I(%)] may provide some degree of protection for internal faults but does not interrupt the flow of short-circuit current within one section of the battery. Using more than one "mid-point" fuse [fig. l(c)] raises the rating question.

0-7803-0937-5/93/$3.00 0 1993 IEEE

175

Event
Physical damage

Cause
Foreign objects, Fire, Water Corrosive fumes, Vibration Impacts, Seismic events Loose connections Charger Misadjustment Ambient Conditions
~~~ ~~~ ~

Effect
Cell leakage Short-circuits Ground faults Intercell open circuit Gassing, Terminal corrosion Hieh internal resistance

Over-charging High Temperature Operation

~~

I Internal grid & plate corrosion

Loose inter-cell connections
High internal resistance

h a d Cycling

Unusual Operation

Table 2 - Battery Fault Causes and Effects

Most battery protection recommendations suggest short-circuit protection. "Standard" handbooks and textbooks as well as references [l] through [9] contain no setting or rating recommendations for battery protection. Short-circuit protection prevents the battery from feeding a DC system short-circuit for more than a few seconds. A practical setting opens the battery circuit between three to six times the battery one minute discharge rate. these criteria. The Rate o Rise Appendix of this f paper shows one method of calculating rate of rise and adds comments on this subject. Undervoltage protection may provide better battery protection than any type of overcurrent protection since an internal battery bank fault probably would produce a significantly reduced terminal voltage. The recommended charger undervoltage protection could perform this function. The Hardware Appendix of this paper shows a representative connection diagram for an AC\DC undervoltage protection system. DC battery undervoltage protection should be set at some voltage about 70 46 nominal voltage since this is the voltage below which circuit breaker trip coils may not operate. The Hardware Appendix lists some of the relays applicable. A time delay of less than 0.5 seconds should be sufficient to over-ride any circuit transients involved provided the demand imposed by charging mechanisms is considered when initially selecting the battery rating. Since loss of the battery or a decrease i the battery n voltage for any more than a very short period means a complete loss of protection for any installation, the common sense approach would be to trip the main breaker to the plant. This, however, would be impossible without any reliable tripping power. An AC alarm with sufficient authority to rouse someone into action may be the only alternative. Perhaps a loud alarm in a manned control room, silenced only from the battery room, is appropriate. Ground fault detection on ungrounded control battery circuits not only protects the system from interruption on the first ground fault but it also detects serious battery events not sensed by overcurrent or undervoltage protection. The

Figure 1 Battery Protection Alternatives

Reference [ 11 suggests a fuse rating no smaller than twice the expected continuous load. The fuse selected also must not be damaged when required to pass the maximum instantaneously applied load. This load may be for tripping several circuit breakers simultaneously or recharging their spring closing mechanisms simultaneously. The fuse also must operate prior to the rate of rise curve of the battery current reaching 0.01 seconds. A fuse less than half the battery short-circuit capability, probably about 150% of the one minute discharge rate, usually meets

176

Hardware Appendix of this paper shows a representative connection diagram for a DC ground detection system. Any ground on the DC battery system requires immediate attention and should be annunciated in a manner demanding immediate action. Batery Charger Faults Most battery charger faults result from either physical damage or misoperation. Physical damage may result in internal short-circuits, ground faults or component failure. Misoperation may produce the same reults. Physical damage includes damage from impacts, vibration, water, dust, foreign objects, corrosive atmosphere, high or low ambient temperature. Misoperation includes overloads and high or low AC or DC voltage with resulting insulation, diode or SCR failure. Battery Charger Protection Most automatic battery chargers are protected with AC and DC circuit breakers, a redundant (backup) DC fuse, a current limit feature and both AC and DC surge protection. The AC and DC circuit breakers and redundant fuse protect the charger for internal short-circuits. The current limit feature protects the charger from feeding a DC system short-circuit with more current than the charger rating. The circuit breakers and fuse are sized for the charger maximum rating and system available short-circuit current. The current limit setting usually is set between 110%to 125% of the charger rating. Additional specified optional system and charger protection can include DC ground detection, AC power failure, AC or DC high and low voltage, charger failure. These features include contacts which may either alarm or shut down the charger. Load Protection Circuits supplied by a station service control battery usually include circuit breaker tripping and closing, emergency lighting and small emergency lubricating pumps for generators. Individual tripping circuits in switchgear lineups usually are protected with 35 ampere Class H (NECS) fuses for short-circuit protection. Fifteen ampere fuses usually provide both overload and short-circuit protection for individual circuit breaker stored energy closing circuits. Twenty ampere circuit breakers usually protect emergency lighting circuits. Probably the largest DC motor supplied from a battery system is about 15 hp, requiring 200 ampere branch circuit protection supplemented with appropriate motor thermal overload relay heaters. DC System Protection Overload and short-circuit protection for the DC

system usually is provided by either circuit breakers or fuses sized to protect the circuit wire or cable. Such protective devices not only protect the circuits involved but also are coordinated with source protective devices and are selective with load protective devices. Figures 2 and 3 show single and dual battery systems with some of the typical protective devices such systems include. Overload and short-circuit protection operates selectively, isolating the faulted circuit. Care must be exercised choosing feeder protective devices to assure proper overcurrent and short-circuit coordination for the system. usually is C O M ~ Z Z ~ ~ ~ Undervoltage protection (#27) to an alarm system. For an undervoltage due to a DC system fault, all the instantaneous undervoltage relays, usually set at about 70% of the nominal battery voltage, drop out. These relays usually light an alarm light and start a timer to sound an audible alarm. If the fault is on a DC feeder circuit, the appropriate feeder protective device operates, isolating the fault. All alarm lights except the one for the circuit involved go out when the fault is removed from the system and nominal voltage is restored to the rest of the system leaving only the faulted circuit alarm light lit. The timer sounds the alarm, which usually can be silenced with a push button. Locating this silencing button in the battery room would compel the operator to investigate a possible destructive event in the battery location. Sample DC Control Battery Systems Three sample battery systems will be discussed: 0 Single battery system 0 Dual battery system 0 Redundant DC control system Each of these nominally 125V DC systems involves typical lead-calcium battery, 60 cells at 2.1 to 2.3 volts per cell. The batteries and automatic charger were selected considering the system demands in accordance with the criteria outlined in references [ ] [7], and [SI. Table 3 compares a few of the 6, advantages and disadvantages of these systems. The single battery system shown in Figure 2 involves one battery, one automatic charger, a distribution panel and distribution circuits. This is the usual system found in industrial plants. The dual batten svstem shown in Figure 3 involves two batteries, one charger, a distribution panel, and distribution circuits. This system provides a redundant battery but is not a redundant system. The main advantage of this system is that adequate protection for internal battery faults can be provided. The redundant svstem is not illustrated with a figure

177

*
I I
I I I
BArrERY CMFOER

Fl

I
I I I I
I I I I

CBI

I I I I I

ca2

*E%j

Figure 2 - Single Battery System

because various degrees of redundancy can be provided according to how much expense can be allocated for redundancy. The dual battery system is redundant for battery failure and does have battery protection which removes a faulted battery from the system. It does not provide redundancy for a fault in the battery leads or any of the rest of the distribution system. Duplicate battery chargers and battery leads to a distribution panel with two main breakers would provide redundancy for battery and battery leads but not for the rest of the battery system. A system with half the load supplied fiom one of the two batteries and a tie breaker provides a false sense of security. It does not allow for faults in the panelboard since closing the tie circuit breaker would only trip the other main cicuit breaker and shut down the DC control system due to the panelboard fault condition. A comdetelv redundant svstem could include duplicate single or dual battery systems, two trip coils on each power circuit breaker and two separate control busses for each power circuit breaker. This would provide continuous tripping power for each circuit breaker but duplicate closing mechanisms are not available on present standard design switchgear
178

equipments. Some redundant systems include tie circuit breakers with manual operation permitted to prevent closing on a system fault. Automatic throwuver is not applicable since it could close on a system fault disabling the control system.

Single Battery Sample System Figure 2 shows a sample battery system with assumed protective devices. The D t Appendix lists aa the complete rating for equipment shown. For DC short-circuit conditions, the battery charger contribution is ignored since the current limit feature in modem chargers will limit the contribution to only slightly more than the charger rating. The protective circuit breakers and backup fuses included with the charger will not operate under these conditions. Figures 4(a), (b) and (c) show time current curves for three battery protective devices installed either at the F2 or the battery disconnect switch location. The fuse selected and shown in fig. 4(a) is somewhat large for the battery shown if the assumed rate of rise of short-circuit current is as shown. It is not selective with the 40A circuit breaker shown for

Pal

RELAY -R1
CIRCUITS

STAT ION

" L
CIRCUITS

&ERGL l O m

Figure 3 - Dual Battery System

the trip circuit of the AC circuit breaker. The panelboard main breaker acts only as a disconnect since its instantaneous setting is higher than the available short-circuit current at the panelboard. Figure 4(b) shows the time-current curves with the battery fuse replaced by an instantaneous only molded case circuit breaker set to trip under short-circuit conditions. This selection means that the system will be selective for overloads but not for short-circuits. The battery receives better protection because it will feed the short-circuit for the minumum time any protective device with a practical setting will allow. The main battery leads, however, are not protected in accordance with the NEC which requires instantaneous only circuit breakers to be applied only when they include an overload element. A low set instantaneouscircuit breaker protects these conductors better than the hlgh set instantaneous element in a circuit breaker which includes an overload trip. These important circuits, normally lightly loaded, deserve instantaneous protection to remove faults which could result in severe damage. Figure 4(c) shows the timecurrent curves with the battery fuse replaced by a molded case circuit breaker
179

with a high set instantaneous. This circuit breaker is selective with downstream protective devices (except for the panelboard main breaker) but allows the battery to feed the fault for up to two seconds. While this compromises battery protection, it should not harm the battery. If DC system coordination considers overload selectivity only and considers short-circuits an unavaoidable disaster, an instantaneous only circuit breaker seems the proper choice for a single battery system. Dual Battery Sample System Figure 3 shows a sample dual battery system with assumed protective devices. Under DC short-circuit conditions, the battery charger contribution is ignored. The current limit feature in modem chargers will limit the contribution to a DC shortcircuit from the charger to only slightly more than the charger rating. The protective circuit breakers and backup fuses included with the charger will not operate under these conditions. The time-current coordination curves are shown in figure 5 for parallel battery conditions. Since one battery can feed a

1.w-

--J-

10

100 IN-ES AT 1 CT

1 -

10

100
IN-

1 m

10
cuIT(CyT

11 11
IN Y R U C S

1oou

AT 12UV Dc

hT I t W

CC

Figure 4 - Coordination Curves for Alternate Single Battery Systems

short-circuit in the other battery, an instantaneous only circuit breaker will provide better battery protection without sacrificing overload selectivity. The coordination curves shown in Figure 5 are drawn from the perspective of the panelboard and main switchgear. The instantaneous setting of the battery circuit breakers is shown on this curve at twice nominal pickup setting. When considering the battery protection, the instantaneous setting is about half the short-circuit contribution from one battery to assure positive tripping. Normally, coordination of multi-source systems cannot be adequately visualized by coordination curves. Overcurrent protective devices should be coordinated considering operating time at the multiples of pickup current through a device compared to downsteam device operating time. Ultimate Backup System Protection Tragedy resulting from battery system failure can be prevented by installing DC undervoltage devices on each AC source circuit breaker. Such devices are available for both medium and voltage power circuit breakers. Many engineers are reluctant to specify such devices since this would shut down the entire plant. Such a shut down could be far less expensive than the destruction of a large drive motor, switchgear equipment lineup or important transformer. If the battery fails on a system including large synchronous motors and the field contactor opens, the loss of tripping power can be an unfortunately disastrous event. It only takes one event of this nature to convince any engineer of the advantages of such backup for a battery system.

*o

100

I000

loow

Figure 5 - Coordination Curves for Dual Battery System

180

system

Advantages
Least expensive

Disadvantages
Questionable internal battery fault protection Control power loss results from most DC system faults More expensive than single battery system Control power loss results f o most DC system faults rm More expensive than single or dual battery systems Questionable internal battery fault protection Control power restoration depends on operator skill Most expensive system Closing power not continuous

Single battery

Dual battery

Good battery fault protection

Redundant single battery

Fast control power restoration

Redundant dual battery

Continuous tripping power

w t double power circuit ih

breaker trip coils

Good battery protection

Table 3 - DC Control Power System Comparisons

References
L.Nailen, "Battery Protection - Where Do We Stand," Trans. IEEE Ind. Appl. Vo1.27, No.4, pp.658-667, Jul./Aug.l991. [2] Henry E. Lhar, Jr., "Application of DC Control Power for Switchgear," IEEE Pulp & Paper ConferenceRecord, pp. 106113, May, 1981. [3] IEEE 446-1987, "Recommended Practices for Emergency and Standby Power Systems for Industrial and Commercial Applications." [4] IEEUANSI C2-1990 National Electrical Safety Code, Section 14. [5] NFPA 70-1993 National Electrical Code, Article 480. [6) E.C. Korbeck, Jr. & J.W. Blankley, "Selection, Use, and Care of Stationary Batteries for Paper Mill Service," Trans. IEEE Ind. & Gen'l Appl., Vol.IGA-7, Nod, pp. 742-749 NovlDec 1971.
[ 11 Richard

[7] B. Bridger, Jr., "Control and Auxiliary Power Systemsfor

Industrial and Commercial Switchgear Installations," Trans.

IEEE Ind. Appl., V0l.W-20, No. 3, pp.667471, May/June

1984. [8] M.W. Migliaro, "Considerations for Selecting and Sizing Batteries," Trans. IEEE Ind. Appl., Vo1.U-23, No. I, ladFeb. 1987. [9] M.W. Migliaro, "Maintaining 'Maintenance-Fme' Batteries," IEEE I&CPS Tech. Conf. Record, pp. 69-73, May, 1989 (89CH2738-3). [lo] Kasper, R.J., "ProvidingReliable Switchgear Control Power," Plant Engineering, Jan. 10, 1980 pp.67-70. [ l l ] "GE Protection & Control - Prcducts Catalog", GEZ-7223A (1/92), GE Meter & Control, 205 Great Valley Parkway, Malvern, PA 19355. [ 121 "Drive Systems Industrial Control Components", GEP-345C, GE Drive Systems,Salem, VA 24153

181

HARDWARE APPENDIX
(SeeReferences [ll] and [12] for other details)

Battery and Charger Undervoltage Protection

1) ? ; ( :

1 125VDC I 100-140VDC I 120V60HZ 1

125V DC 125V DC 48V DC 125V DC 100-140V DC 100-140V DC 40-54V DC 54-86V DC 208V 60HZ 240V 60HZ 120V 60HZ 120V 60HZ

Dropout Calibration

Auxiliary Coil

Rating

Dropout

I/

24V DC 48V DC 125V DC 250V DC

18-24V 38-54V 100-14OV 200-280V

/I

Inst. W Relay (#27) [Drawout Type]

Drawout protective relay including 60hz aux coil and 0.5 sec. time delay drop-out (#27,#27x)

I11
Rating
24V DC 48V DC Dropout Glib. 19-27V 38-54V 100-140V 200-280V 100-140V 38-54V
~

Rating
120V60HZ 208V 60HZ 230V60HZ

Time Adj.

0.25-2secs 0.25-2 secs

11

Contacts

1-N0,l-NC 1-N0,l-NC 1-N0,l-NC 1-N0,l-NC l-N0,2-NC 1-N0,l-NC 1-N0,l-NC 1-N0,l-NC

Back Back Back Back Back

I[

0.25-2 secs

12% DC
25OV DC 125V DC 48V DC
~

Time Delay Dropout Auxiliary Relay (#27) [Non-drawout]

Front
Front
Front

125V DC 250V DC

100-140V 200-280V

Instantaneous Undervoltage [Molded Case]

Relay

(#27)

Instantaneous dropout auxiliary relay (#27X) [Non-drawout]

182

HARDWARE APPENDIX (Cont.)

Representative Connections

t
AC

I I I

27

DC

DC Ground Detector Relays

Rating
(#MG)

Max. R to Grd
to operate 30 ohms

Contacts (2 coils) 1-NO/coil 1-NO/coil 1-NO/coil 1-NO/coil

250V DC 125V DC 48V DC 24V DC

15 ohms
5 ohms

1.25 ohms

Switchgear Type Drawout Relay

Representative Connections

4-4

mi LS

CONNECTED

183

CALCULATION APPENDIX
SHORT-CIRCUIT CALCULATIONS FIGURE 2
Battery R,
=

SHORT-CIRCUIT CALCULATIONS FIGURE 3

Buttery 1 R,
=

10 2' 724A

= 0.1652

1 2 0 ' 724A

= 0.1652

62

0 41061 Conductors R, = 2 x 16fr x 2= 0.0148 61

l@wsc

0 4100 Conductors R, = 2 x 6fr x 2= 0.0049 0 1CJwfr

Circuit Breaker R , = 2 x O.OOO6 0 = 0.0012 61

R, = R,

R,

= 0.1701

RI

R, + R, + R,

0.1812 0

Paralleled Batteries

Short-circuit at Panelboard

120v -= 0.1812

662.4

Conductors RI = 2 x 60fr x

0 64062 -= 0.0768 0

low

Rc

2 x 18frx - = 0.0148 0 0.4100

loo?!

R, = R, + R, + R& + R: = 0.2580 0
120v -= 0.2580

Rcb

2 x O.OOO6 0

= 0.0012

Short-circuit a Switchgear = t

465A

RI = R, + R, + R, = 0.0998 62
120v -= 1202.4 0.0998

Max. Panelboard Short-circuit

0 64061 R: = 2 x 603 x 2= 0.0768 61

lowfr

RI = R, + Rc + R, + RI = 0.1766

Mar. Switchgear Short-circuit =

120v -= 680A 0.1766

184

RATEOF-RISE APPENDIX

Figures 1 and 2 shown below are approximate copies of Figures 2 and 4 presented in the Nailen paper (Reference [l]). In this paper, Nailen states that typical battery circuit time constants range from 10 to 80 ms. He states that most battery and fuse manufacturers tend to accept 10 ms as most representative. From Figure 2, offered by the C & D Battery Company, it appears that the subject is more complex than the simple approach in Figure 1. (In Figure 2, E = Voltage, I = Current). Figure 2 implies that the time constant is significantly shorter than 10 ms.
'

5 : 5
2

101

75

so

$
%

2s

K E

n
0

N W E R OF T I N CONSTANTS

The Industrial Power Systems Data Book, published by the General Electric Company in the 1950's, calculates (section .173,pp. 1-2) a "typical" battery time constant to be 0.32 ms, using the Figure 1 type of curve. Conversations with Charley Muller (retired Exide representative) and Felix Garfunkel (engineer Badger Engineers, Boston) informed me that a battery can withstand discharging into a short-circuit at its terminal for almost 10 to 15 secondswithout damage. This could be considered confirmed on page 659 of Reference [l] but no data is given. Molded case circuit breaker instantaneous elements detect and respond to peak current. For AC circuits, they are calibrated in RMS current equivalent to a pure sine wave peak. Fuses and thermal elements detect and respond to the RMS currents i the n protected circuit.

FO-LOWIffi

FWLT

INITIATION

Fig. 1 Rate of Rise of Battery Current per Equations

- ---- - --p--- ----r - -

-1

- - - - - -I

O I
0

EWPD T I Y YILLI-

Fig.2
Another Rate of Rise Concept

185

RATEOF-RISE APPENDIX (Cont.)

To calculate the rate of rise of the DC current, use the following:

For DC faults at the Figure 2 single battery terminals:

i =

_V R

726A

v
V = Battery Voltage

= 120v

R = Circuit Resistance

R = -120 726

Circuit lime Constant =

L R

If T = 1 x 0

lo3seconds = W R
Then:

L = 0.16529 x 10 x
A = Max. Current after t = 0

L = Circuit Inductance
i = Instantaneous Peak Current

= 2.71828

If fuses respond to RMS currents, then the currents shown on the time-current curves for the rate-of-rise of battery short-circuit current should be calculated by:

I,,

j,:

iz dt

t sec

I
726(1

I
amPS

In this equation, t, is the begining of any time constant period and is the end.
From k discussion, it appears that some work should be done to establish standards for control batteries which would allow easier selection criteria for protective equipment than those criteria now extant.

0.01 0.02
00 .3

- E-') 726(1 - E-?

726(1 - C3) 726(1

726 x 0.6321 726 x 0.8647 726 x 0.9502 726 x 0.9817

459 627 690 718

0.04

- 3

186

DATA APPENDIX
Figure 2 Equipment
Conductors Battery to Charger 12 feet 2 - s/c #6 AWG Charger to Panelboard 4 feet 2 slc #6 AWG Panelboard to Switchgear 60 feet 2 s/c #12 AWG

Figure 4(a) Curve Identification

A

Max. avail. panelboard short-circuit = 662 A

B Max. avail. battery short-circuit = 724 A

C CB3 identified above for Fig. 2

Battery 120 V , DC; 50 ampere-hours (8 hour rate) 75 A (1 minute discharge rate) 724 A (Maximum Short-circuit) Interrupting Equipment CB 1, CB2 Ratings selected by charger mfg F1 Ratings selected by charger mfg 100 A Form 101 Fuse F2 100 A TFJ therm. mccb, 1250 A inst. CB3 40 A TEY therm. mccb, 1600 A inst. CB4 CB5, CB6 20 A TEY therm. mccb, 700 A inst. 35 A Class H fuse F3 15 A Class H fuse F4

D F2 identified above for Fig. 2 E CB4 identified above for Fig. 2 F F3 identified above for Fig. 2
Figure 4(b) Curve Identification
Same as Figure 4(a) except:

D Same as CB7 or CB8 identified above for Fig. 3

Figure 4(c) Curve Identification
Same as Figure 4(a) except: D 60 A TEY therm. mccb, 1500 A inst.

Figure 5 Curve Identification

Figure 3 Equipment
Same as Figure 2 above except: Two identical batteries same as figure 2, separated by 6 feet of #6 AWG conductor 150 A TFJ therm. mccb, 1500 A inst. CB3 CB7, CB8 30 A TEC mccb, 390 A inst. only

M x avail. panelboard short-circuit = 1202 A a. B Max. avail. battery slc at C" O . COM. 1400 A =
A

C CB3 identified above for Figure 3

D 30 A TEC mccb, 390 A inst. only E CB4 identified above for Fig. 2
F F3 identified above for Fig. 2

187