ntroduction Harmonic current is generated by most modem electronic loads, which can be found in all sectors of Industrial, Commercial, and domestic facilities. These electronic loads use power electronic devices which are responsible for generating harmonic currents. Common non-linear loads: Industrial equipment (Soldering machines, Induction furnaces, bridge rectifiers and battery chargers) Variable Speed Drives (VSDs) with AC or DC motors Uninterruptible Power Supplies (UPS) Information Technology Equipment (computers, monitors, servers, copiers, printers, etc.) Domestic equipment (TV sets, microwave ovens, fluorescent lamps, light dimmers, etc.) Distorted wave Fundamental Harmonie. VY Fig. E51 — Appearance of a distorted current waveform due to harmonics Today's electronic loads share a common element: electronic power supplies. The benefits of the electronic power supply are its cost, efficiency and the ability to control its output. For this reason, they are found in a wide variety of common single and three-phase electrical equipment, Harmonic currents are a natural by-product of the manner in which electronic power supplies draw current. In order to be more efficient, these devices draw current for only a small portion of the electrical cycle. Installations where these devices can be found in great number are computer centers, banks, Internet Data Centers etc. Harmonic currents generated by these loads present some problems: Voltage distortion responsible for failure of some types of electrical equipment Increased losses, the rms current being higher than the fundamental design current Risk of resonance when power factor correction capacitors are present. Third harmonic currents (150/180 Hz) or multiple of 3 (triple-n harmonics) are specifically responsible for increased neutral currents in three-phase, four-wire systems That the reason why it's important to select optimum busbar design for office buildings, where neutral conductor overload is a major concern Neutral current in three-phase, four-wire systemsFigure E52 represents the non-linear phase currents and resulting non-linear neutral current, in a three-phase, four-wire system, supplying identical single phase loads. St Fig. E52 - Line and neutral currents absorbed by single-phase non-linear loads connected between phase and neutral Fig. E53 — Examples of applications where the level of harmonics (THD) is either negligible or high, depending ‘on the proportion of loads generating harmonics versus classical loads Workshops supply: * Mix polluting charges (computer hardware, inverters, fluorescent lighting) and clean charges (motors, pumps, heaters, et.) * Low probability of harmonic's presence THD < 33 % Offices supply: * Alot of polluting charges (computer hardware, inverters, fluorescent lighting, et.) * High probabilty of harmanic's presence THD 2 33%The harmonic spectra of the phase and neutral currents are represented in Figure E54 and ESS. It can be seen that the neutral current only includes third or triple-n harmonics (i.e. 3, 9, 15, etc). The amplitude of these currents are equal to three times the amplitude of the phase currents. In the neutral current measurements, third harmonic has the greatest magnitude and the other triple-n’s (9, 15, 21, etc.) decrease significantly in magnitude so do not contribute significantly to the rms value. Onn 3604 300-4 250-4 200+ 150+ 1004 50-4 3.5 7 9 11 13 15 17 19 21 23 25 Harmonic order Fig. E54 - Typical harmonic phase current spectrum for single-phase non-linear loads In this example, the rms value of the neutral current is equal to 1.732 (3) times the rms value of the line current. This theoretical value is only obtained with loads absorbing a current similar to the one represented on Figure E52, When the loads include partially linear circuits (such as motors, heating devices, incandescent lamps), the rms value of the neutral current is strictly less than V3 times the rms value of the phase currents. 250-4 2004 150+} 1004 504 3.8 7 9 tf 13 15 17 19 21 23 26 Harmonic orderFig. E55 - Typical harmonic neutral current spectrum for single-phase non-linear loads Load factor of the neutral conductor Simulations have been carried out to assess the influence of the 3" harmonic level on the neutral conductor current, Figure E56 represents different line current waveforms for different amounts of nor-linear load, The ‘same active power was maintained (linear loads are assumed purely resistive) % ofthe fundamental current) an) oot tin) 0% 30% 100% Fig. E56 — Line current for different ratios of non- linear load The neutral current is then calculated and compared to the line current for different levels of third harmonic. The load factor of the neutral conductor (ratio of the neutral current to the line current) is represented in Figure E57. In installations where there are a large number of single-phase electronic non-linear loads connected to the same neutral, a high load factor can be found in that neutral Neutral conductor load factor: ly I, 0 10 20 30 40 50 60 70 80 90 100 Fig. E57 — Neutral conductor load factor as a function of the 3rd harmonic level. In these installations the neutral current may exceed the phase current and a special attention must be given to sizing the neutral conductor. This prevents the installation of a reduced size neutral conductor, and the current in all four wires should be taken into account.The diversified power absorbed by such a group of loads is generally limited, and even if the neutral current exceeds the line current, then the neutral conductor capacity is only exceeded in extreme circumstances if its size is equal to the line conductors. ‘A.common practice in these conditions is to use a 200 % neutral conductor. This does not form part of the electrical/ building regulations, but is encouraged by organizations such as the Copper Development Association. In high power installations (100 KVA or >150 A), various factors contribute to reduce the neutral conductor load factor: More and more high quality IT equipment (work stations, servers, routers, PC, UPS, etc.) include Power Factor Correction circuits, reducing considerably the generation of 3" harmonic currents ttt Ww Fig. E58 - Double-neutral installation for cable solution is not directly applicable for busway solution, due to their very different thermal dissipation behaviour. HVAC equipment in large buildings are supplied by a three-phase network, and as such do not produce triple- harmonic currents Fluorescent lighting equipment (with magnetic or electronic ballast) generates triple-n harmonic currents Which are phase shifted with harmonic currents generated by PCs, giving a partial vector cancellation Except in exceptional circumstances, the 3" harmonic level in these installations does not exceed 33 %, so the neutral current does not exceed the line currents. It is not therefore necessary to use an oversized neutral conductor. Effects of harmonic currents on circuit conductors The circulation of harmonic currents produces additional heating within the conductors for several reasons: Heat is produced as a result of the additional high levels of triple-n harmonic currents, compared with the relatively minimal current flowing in the neutral for normal balanced linear loads. ‘Additional heating of all conductors by increase of the skin effect and eddy current losses due to the circulation of all harmonic orders.L1 L2 L3 N L1 L2 13 N aud Unusual Overheating Unusual Overheating Fig. E59 ~ Illustration of the overheating risk with standard busway sizing in presence of high level of 3rd harmonics Modeling separately the power losses created by each harmonic order reveals the impact of harmonic currents in busbar trunking systems, Heat measurements performed on busbar trunking systems with circulation of harmonic currents of different frequencies has been also been considered, The same approach has been used to compare two different type of busbar construction both with the same total ‘cross sectional area (c.s.a.) of active conductors, a 200 % neutral and a standard 100 % neutral. This can be seen in Figure E60, Placed in the same conditions, a busbar trunking system with 4 identical conductors will have a lower temperature rise than a 200 % busbar with the same total c.s.a. Itis then perfectly adapted to this situation. Of course, the selection of the size of the conductors must take the possible current flowing through the neutral conductor into account. 200% Neutral 100% Neutral Cross Section Gross Section Fig. E60 — Cross section architecture of 2 different busbar systemsFig, E61 - The most effective solution = reduce the current density in ALL conductors, by selecting proper busway rating (single-neutral) Simplified selection procedure The first step in the selection procedure for busbar trunking systems is to assess the phase currents and 31° harmonic current level. Note: the 3” harmonic current level has an impact on the neutral current, and consequently on the rating of all ‘components in the installation: Switchboard, Protection and dispatching switchgear, Cables and busbar trunking systems. Depending on the estimated 3 harmonic level, 3 cases are possible: A) 39 harmonic level below 15 % (ih3 < 15 %): ‘The neutral conductor is considered as not loaded. The size of the phase conductors is only dependant on the phase currents. According to IEC rules, the neutral conductor size may be smaller than the phase conductors’ if the cross section area is higher than 16 mm? for copper, or 25 mm? for aluminium. B) 3" harmonic level between 15 and 33 % (15 < ih3 < 33 %) The neutral conductor is considered as current-carrying conductor. The practical current shall be reduced by a factor equal to 84 % (or inversely, select a busbar with a practical current equal to the phase current divided by 0.84. Generally, this leads to the selection of a busbar trunking ‘system, which the current rating is immediately superior to the requested capacity. The size of the neutral conductor shall be equal to that of the phases. C) 3 harmonic level higher than 33 % (ih3 > 33 %) The neutral conductor is considered as a current-carrying conductor. The recommended approach is to adopt circuit conductors with equal size for phase and neutral. The neutral current is predominant in the selection of the size of conductor. Generally, this leads to the selection of a busbar trunking system which current rating is higher than the requested capacity (generally by a factor of two).1000 kTc1000_| KTCt000HRB KTC1350HRB 1950 | KTC1350_ | KTC1350HRB KTC1600HRB 1600 | KTC1600__| KTC1600HRB KTCZ000HRB 2000 | KTC2000 | KTC2000HRB KKTC2S00HRB 2500 | KTC2500 | KTC2S00HRB KTC32001RB 3200 | KTC3200_ | KTC3Z00HRB KKTCA0O0HRB 4000 | KTC4000 | KTCA000HRB 5000 | KTC5000 Conclusions Office buildings are often subject to the circulation of high levels of triple-n harmonies in particular 3rd harmonic current. These are responsible for possible overload of the neutral conductor. ‘The performance of standard construction busbar trunking system with circulation of harmonic currents has been analyzed in depth. ‘A simplified procedure has been proposed for selection of busbar trunking systems adapted to the circulation of harmonic currents, and particularly in the neutral conductor. ‘A200 % neutral conductor is not the optimum solution. Busbar trunking systems with equal size for all conductors are perfectly adapted to harmonic distortion, The design is valid as long as the design for a realistic neutral overioad is taken into consideration and is applied to the whole system, No harmonics With harmonics Standard solution Overheating of conductors. Fig. E62 - Cross sectional view of a standard busway without and with harmonics The raw material and performance optimization for more guarantees Figure E63 shows the comparison between 2 busway constructions. The test conditions are the same for both cases: Phase current: IL = 1600 A 3rd harmonic level: ih3 = 33% Neutral current: IN = 1520 A. Placed in the same conditions, a busbar trunking system with 4 identical conductors will have a lower temperature rise than a 200 % busbar with the same total c.s.a. Itis then perfectly adapted to this situation. Of course, the selection of the size of the conductors must take the possible current flowing through the neutral conductor into account. Fig. E63 — Comparison between double-neutral busway solution and properly selected single-neutral solutionDave neural all the additionnal The double neutral does not deal temperature rise Phase conductor | 63.5 418 average) Neutral conductor | 56 39 Casing (maximum) | 55 39 Even though the total cross-section forall conductors is exaclly the ‘same for the 2 busways solutions Phase conductor | 960 1200 cs.a, (mm?) Neutral cs.a. 1920 1200 (mm) Total cs.a.(mm@) | 4800 4800