PANELBOARDS

A COMPLETE ANALYSIS

March 2nd, 2004

AREN 4570
Professor Krarti

Jason Groob
Robert Johnson
Ryan Kelley
Matthew Peters

Panelboards

Building Electrical Systems

TABLE OF CONTENTS
EXECUTIVE SUMMARY .............................................................................. 1
ELECTRICAL DISTRIBUTION SYSTEMS.................................................... 1
PANELBOARD DEFINITION ........................................................................ 1
TYPICAL CONSTRUCTION ......................................................................... 2
PANELBOARD RATING AND IDENTIFICATION ......................................... 3
ENCLOSURES ............................................................................................. 5
CATEGORIES OF PANELBOARDS............................................................. 5
TYPES OF PANELBOARDS......................................................................... 5
TRANSFORMER / PANELBOARD CONNECTIONS.................................... 7
SAMPLE PANELBOARD DIMENSIONS AND DETAILS .............................. 8
GROUNDING.............................................................................................. 10
PANEL BOARD MANUFACTURERS ......................................................... 12
COST ANALYSIS........................................................................................ 12
CONCLUSIONS.......................................................................................... 13
REFERENCES............................................................................................ 14

Panelboards

Building Electrical Systems

EXECUTIVE SUMMARY
Panelboards are the glue that holds the United States electrical system together. Needed
to distribute electricity throughout a building, panelboards play a vital role in all electrical
systems. Panelboards house overcurrent protection devices to protect electric devices
from the dangerous short-circuit currents and consolidate general electrical system
components. The manufacturing and installation of panelboards fills a substantial
financial role in the lives of many Americans. To better understand panelboards, the
following report will include details on basic panelboard construction, various types
panelboards, and a cost analysis.

ELECTRICAL DISTRIBUTION SYSTEMS

Whether residential or commercial, distribution systems serve to distribute electrical
power throughout a building. Ranging in size and complexity, distribution systems
consist of several key components, including overcurrent protection devices, metering
devices, switches, conductors, and transformers. To better organize such systems,
panelboards are used to consolidate overcurrent devices, switches, and conductors.
Common residential and commercial electrical system diagrams are shown in Figure 1.

Residential / Commercial Electrical Distribution Systems

Figure 1

PANELBOARD DEFINITION
The National Electric Code (NEC) defines a panelboard as a single panel or group of
panel units designed for assembly in the form of a single panel; including buses,
automatic overcurrent devices, and are equipped with or without switches for the control
of light, heat, or power circuits; designed to be placed in a cabinet or cutout box placed in
or against a wall or partition and accessible only from the front (Article 100-definitions).

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Building Electrical Systems

TYPICAL CONSTRUCTION
Although a wide variety of panelboards exists, most have a similar construction. The
basic construction of a panelboard includes two main parts; the first is known as the can
and the second is the interior. The can houses the interior components of the panelboard
and allows the panelboard to be easily mounted to varying surfaces. The case is normally
constructed of galvanized steel. Figure 2 shows the construction of a typical can.

Typical Can Construction

Figure 2
The can of the panelboard also serves as the means for electrical system grounding. All
panelboards should be grounded to protect the branch circuits and the people who use the
panelboard. As a general rule, grounding provides a path of low resistance in case of a
short circuit. The short-circuit current flows to the earth instead of through the metal
casing of the panelboard. In the case of uncontrolled short-circuit current, system
components can be severely damaged. To ground panelboards, a direct connection from
the can to a grounding bus is needed. To prevent potential damage, all NEC regulations
regarding grounding panelboards should be strictly followed. A diagram showing the
connection of the ground bus to a panelboard is shown in Figure 3.

Grounding Bus Connection

Figure 3
The interior section of a panelboard consists of switches and various overcurrent
protection devices. Fuses and circuit breakers are the two types of overcurrent protection
devices used in panelboards. The NEC limits the number of poles that can be used in one
panelboard to a maximum 42. A pole is defined as a connection of an overcurrent
protection device to one phase. For example, an overcurrent protection device that is
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connected to three phases will use three of the allowable poles. The overcurrent
protection devices are typically mounted directly to bus bars inside the panelboard. If
any pole space is unused, it must be covered by either a filler plate or a spare protection
device. Figure 4 shows the mounting of the interior to the can, Figure 5 shows a detail of
the interior, and Figure 6 shows general panelboard connections.

Typical Interior Connection

Figure 4

Detail of Interior Connection

Figure 5

Panelboard Connections
Figure 6

PANELBOARD RATING AND IDENTIFICATION

Panelboards are rated by several characteristics. First, the panelboard type and system
type (phase, wire, voltage) are listed. Next, because panelboards are designed
specifically for each particular installation, the necessary total amperage is shown.
With both maximum continuous amperes and available fault current known, the rating of
a panelboard can be found two ways. The first option, known as the full rating method, is
to select circuit protection devices with individual ratings equal to or greater than the
available fault current. The second option, known as the series rating method, is to select
a main upstream circuit protection device that has an interrupting rating equal to or
greater than the available fault current of the system. With this system, all subsequent
downstream circuit protection devices connected in series can be rated at lower values.
All loads must be displayed on the inside of the panelboard door, in the format of NEMA
numbering. Using such a format, the poles are separated into even and odd categories,
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Building Electrical Systems

enabling all circuits to be easily identified. On occasion, an additional listing of circuits,

known as vertical numbering, is needed. Figure 7 displays a sample of NEMA and
vertical numbering.

Circuit Numbering
Figure 7
To display the general panelboard ratings described above, a panelboard label is
necessary. Like the circuit numbering, the identification label is generally found on the
interior of the panelboard door. These labels provide important information about the
system that may be necessary should a problem occur. A sample of a panelboard label is
shown in Figure 8.

Sample Panelboard Identification Label

Figure 8

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Building Electrical Systems

ENCLOSURES
To ensure safety, NEMA has established guidelines for panelboard enclosures. With
several options available, the enclosure of the panelboard is often determined by the
environment in which the panelboard will be installed. Listed below are several
examples of panelboard enclosures, with brief descriptions of the exposed environment.
TYPE 1

General purpose indoor use.

TYPE 3R

Outdoor use to provide a degree of protection against rain, sleet

and external ice formation.

TYPE 4X

Indoor and outdoor use to provide a degree of protection against

corrosion, windblown dust and rain, splashing water, hosedirected water, and ice formation.

TYPE 3R/12 Indoor use to provide a degree of protection against circulating

dust, falling dirt, and dripping non-corrosive liquids.

CATEGORIES OF PANELBOARDS
Two different categories of panelboards have been created by the NEC: lighting &
appliance and power. These categories are determined by the different types of branch
circuits connected to the panelboard. Both categories are shown below, with a brief
description of system details.
Lighting & Appliance Panelboards - contain lighting equipment, appliances,
receptacles, and other small loads.
Power Panelboards - consist of 10% or fewer of its branch
circuits dedicated to lighting or appliances.
Defining characteristics of a lighting & appliance panelboard include that each phase
must be connected to the neutral bus and that the overcurrent protection devices must be
rated less than or equal to 30 A. In most cases, lighting and appliance panelboards are
typically found in residential applications.
Power panelboards are generally defined as those that do not fall under the lighting and
appliance category. Differing from lighting and appliance panelboards, power
panelboards are usually found in commercial buildings.

TYPES OF PANELBOARDS
There are two general types of panelboards, known as main breaker and main lug only. In
main breaker panelboards, a breaker protects the entire panelboard. With a main lug only
panelboard there is no breaker to protect the entire load. Figure 9 displays both types of
panelboards.

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Building Electrical Systems

Types of Panelboards
Figure 9
Main Breaker Type Panelboards
The incoming supply cables are connected to the line side of the main breaker, feeding
power to the panelboard and branch circuits. The panelboard is disconnected from the
source by a main breaker, protecting the system from short circuits and system overloads.
Commonly, the main breakers are bus connected to the main bus bars, providing higher
overall circuit integrity and avoiding overheating. Depending on panelboard orientation,
the main breaker can be mounted horizontally or vertically. Figure 10 displays both
possible orientations of the main breaker with respect to panelboards and branch circuits.

Main Breaker Panelboards

Figure 10
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Building Electrical Systems

Main Lug Only Type Panelboards

In the case of main lug only type panelboards, there is no main circuit breaker. The
incoming supply cables are connected directly to the bus bars and overload protection is
not provided. Generally, main lug only panelboards are used in special cases. One
common use is the addition of another panelboard next to an existing one because extra
poles are needed. In such a case, the main breaker provides adequate protection for the
entire system, and the second, main lug only panelboard provides added space for branch
circuits. Figure 11 displays two common connections between main breaker only and
main lug only type panelboards.

Main Breaker Only/ Main Lug Only Connections

Figure 11

TRANSFORMER / PANELBOARD CONNECTIONS

Panelboards receive power from a variety of sources, each with differences in voltage and
current. Generally, power is supplied by a utility power company at high voltages and
currents. To step down voltages to the desired levels, local transformers are used at the
residential or commercial location. Several different types of step down connections that
are commonly used will be discussed.
13W SYSTEM As one of the most common distribution systems in use, the
panelboard operates at 120V (phase + neutral) and 240V (phase + phase). This system
is most commonly used in residential installations.
34W WYE-CONNECTED SYSTEM More common to commercial applications,
the panelboard operates at 277V (phase +neutral) and 480V (phase + phase).
34W DELTA-CONNECTED SYSTEM Also more common to commercial
applications, the panelboard operates at 120V (phase, A or C + neutral), 208V (phase, B
+ neutral), and 240V (phase +phase)
Figures 12-14 compare the three systems described above.

Panelboards

Building Electrical Systems

13W SYSTEM
Figure 12

34W WYE-CONNECTED SYSTEM

Figure 13

34W DELTA-CONNECTED SYSTEM

Figure 14

SAMPLE PANELBOARD DIMENSIONS AND DETAILS

To better understand actual panelboard sizes and details, several Siemens brand
panelboards will be analyzed. Similar in construction and function, the following models
will be compared and contrasted based on rating and size descriptions. The smaller
models, known as P1, SE, and S3 panelboards, all have field convertible mains and
bottom or top feed options. Somewhat larger models, known as the S4/F1 and S5/F2,
offer varying types of overcurrent protection with optional circuit breakers or fusible
switches available.
P1 PANELBOARDS
P1 panelboards are the smallest of the product line offered by Siemens. The P1
panelboard can support up to 42 1-pole branch circuits and are available to operate on
12W, 13W, 33W, and 34W systems with voltages up to 480/277 VAC and 250
VDC. Maximum current is 400 amps while short circuit interruption ratings are up to
200,000 amps. Figure 15 shows both P1 panelboard dimensions and ratings.

Panelboards

Building Electrical Systems

Siemens P1 Panelboard
Figure 15
SE PANELBOARDS
SE panelboards are comparable to P1 panelboards with several exceptions. The SE
panelboard can support up to 42 1-pole branch circuits and are available to operate on
12W, 13W, 33W, and 34W systems with voltages up to 600VAC and 250 VDC.
Maximum current is 600 amps while short circuit interruption ratings are up to 200,000
amps. Figure 16 shows both SE panelboard dimensions and ratings.

Siemens SE Panelboard
Figure 16
S3 PANELBOARDS
S3 panelboards are the largest panelboard in this product line that Siemens offers. The S3
panelboard can support up to 54 1-pole branch circuits and are available to operate on
13W, 33W, and 34W systems with voltages up to 600VAC and 250 VDC.
Maximum current is 600 amps while short circuit interruption ratings are up to 200,000
amps. Figure 17 shows both S3 panelboard dimensions and ratings.

Panelboards

Building Electrical Systems

Siemens S3 Panelboard
Figure 17
S4/F1 AND S5/F2 PANELBOARDS
Although similar in design and features, S4/F1 and S5/F2 power panelboards vary in
available ratings. Both models will accept various circuit breakers and fusible switches
with the S4/F1 panelboard allowing up to a 600 amp main circuit breaker and the S5/F2
panelboard allowing up to a 1200 amp main circuit breaker. Figure 18 below lists
available details of each panelboard model.

Siemens S4/F1 and S5/F2 Panelboards

Figure 18

GROUNDING
Grounding is one of the most important aspects of any electrical system. The National
Electrical Code defines grounding as a conducting connection, whether intentional or
accidental, between an electrical circuit or equipment and the earth, or to some
conducting body that serves in place of the earth.
There are two main objectives to grounding electrical equipment. The first objective is to
keep potential voltage differentials between different parts of a system at a minimum.
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Building Electrical Systems

This reduces the risk of shock. The next objective is to keep impedance of the ground
path to a minimum. The lower the impedance of the ground, the greater the current is in
the event of a fault and the faster the overcurrent device will open. Many parts of an
electrical system are grounded, often beginning with the transformer and continuing
through to the equipment. Figure 19 shows a grounding connection on a wye
transformer.

Grounded Wye Transformer

Figure 19
When dealing with panelboards it is important to bond both the panelboard enclosure and
the neutral wire together. This way the circuit can be grounded at the service entrance
only and the enclosure can still be connected to ground. A panelboard, however, may
also require an equipment grounding bus. Using a grounding bus, all equipment can be
connected to the bus at the same potential as the panelboard. Another method of
grounding the panelboard is to use an insulated neutral wire. This way, when a
downstream panel is used, the enclosure of the panel can be connected to ground through
a grounding conductor back to the service equipment
In addition to ensuring proper grounding methods, ground fault protection is also a
concern. Ground fault protectors are not required on service disconnects that are less
than 1000 amperes, but they can be desirable in all situations. Ground fault protectors
install a sensor around the insulated neutral wire. This way, when an unbalanced current
flows from a line to ground the shunt trip will open the circuit breaker and remove the
load from the line. The sensor of a ground fault protector can also be installed around all
of the conductors. When there is a ground fault, an unbalance of currents results and the
sensor will trip the shunt and open the circuit breaker.

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Panelboards

Building Electrical Systems

PANEL BOARD MANUFACTURERS

There are several major manufacturers of panelboards in the US. Some of the largest
suppliers are as follows:
-

Square D
Kinney
Murray
Westinghouse
Culter-Hammer
Siemens ITE
General Electric

The first four manufacturers listed provide mostly residential panelboards, while the last
three cater more to the commercial sector.

COST ANALYSIS
Typical costs for residential panelboards are presented in Table 1 and commercial
panelboards presented in Table 2. Phase and total amperage differentiates between the
two. In terms of overall estimates, residential panelboards will total between $850 and
$1450 depending on the total amperage. Multiphase panelboards range from $910 to
$6175 depending on total amperage, voltage, and the presence of a main breaker.
Table 1
Residential Panelboards
Voltage
120/240V
120/240V
120/240V

Ratings
Ampere # Breakers
100
10
150
14
200
18

Material
$410
$645
$840

12

Labor
$265
$305
$350

Cost
Subtotal
$675
$950
$1,190

Total w/ Profit
$850
$1,175
$1,450

Panelboards

Building Electrical Systems

Table 2
Commercial Panelboards
Voltage
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 277/480V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
3W 120/240V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 120/208V
4W 277/480V
4W 277/480V
4W 277/480V
4W 277/480V

Ratings
Ampere # Breakers
100
10
100
14
100
18
100
20
225
24
225
30
225
36
225
38
225
42
100
12
100
16
100
20
100
24
100
30
225
32
225
34
225
36
225
42
100
12
100
20
225
24
225
30
225
36
100
12
100
20
225
30
225
42
400
30
400
42
100
24
100
30
225
32
225
42
400
42
600
42
100
24
100
30
225
30
225
42

Main Breaker
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES

Material
$400
$470
$510
$575
$655
$760
$870
$935
$980
$450
$520
$605
$660
$760
$855
$875
$895
$1,000
$865
$1,275
$1,475
$1,775
$2,075
$555
$710
$1,350
$1,575
$1,875
$2,100
$830
$935
$1,575
$1,725
$2,350
$3,475
$1,700
$2,000
$2,525
$3,100

Labor
$315
$360
$420
$485
$525
$700
$790
$875
$955
$315
$420
$485
$525
$595
$700
$750
$790
$925
$360
$525
$700
$790
$875
$395
$525
$925
$1,200
$1,175
$1,250
$670
$790
$875
$1,125
$1,325
$1,575
$750
$830
$875
$1,125

Cost
Subtotal
$715
$830
$930
$1,060
$1,180
$1,460
$1,660
$1,810
$1,935
$765
$940
$1,090
$1,185
$1,355
$1,555
$1,625
$1,685
$1,925
$1,225
$1,800
$2,175
$2,565
$2,950
$950
$1,235
$2,275
$2,775
$3,050
$3,350
$1,500
$1,725
$2,450
$2,850
$3,675
$5,050
$2,450
$2,830
$3,400
$4,225

Total w/ Profit
$910
$1,050
$1,200
$1,350
$1,500
$1,900
$2,125
$2,325
$2,500
$965
$1,200
$1,400
$1,500
$1,725
$2,000
$2,100
$2,150
$2,475
$1,475
$2,175
$2,675
$3,125
$3,575
$1,200
$1,550
$2,875
$3,525
$3,800
$4,175
$1,900
$2,200
$3,050
$3,575
$4,525
$6,175
$3,000
$3,425
$4,075
$5,100

CONCLUSIONS
Panelboards are an important part of any building electrical system. They serve as a
place to contain all of the overcurrent protection devices and organize the circuitry of the
building.
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REFERENCES

1. Square D. Square D. Oct. 2003. 28 Feb. 2004.

http://www.squared.com
2. Kinney Electrical Manufacturing Company. Kinney Electric. Jan. 2003. 28 Feb.
2004.
http://www.kinneyelectric.com
3. Murray Electric System. Murray Electric System. Apr. 2000. 28 Feb. 2004
http://www.murray-ky.net
4. Siemens Power Panelboards. Siemens Power Panelboards. Jun. 2001. 28 Feb.
2004
http://www.siemens.com/index/panelboards
5. Todays Westinghouse Electrical Company. Todays Westinghouse Electrical
Company. Sep. 2003. 28 Feb. 2004
http://www.westinghouse.com
6. Means Building Construction Cost Data. R.S. Means Co. Kingston, MA. Oct.
2003.

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