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The Illegal Shift

When it comes to troubleshooting electrical distribution equipment, even the most seasoned
engineers can get stumped. Using a football analogy of an illegal shift, this piece walks
readers through a complex case study that demonstrates how the unauthorized movement
of neutral conductors created a perplexing troubleshooting scenario for one electrical
contractor and a substantial repair bill for a medical facility owner. Using multiple photos to
highlight the host of problems uncovered in the investigation, the article examines selective
coordination requirements and why electrical contractors must use caution when altering,
modifying, and servicing modern switchgear installations.

The Illegal Shift


Mar 19, 2014Thomas McHaffie | Electrical Construction and Maintenance

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What is in this article?:

The Illegal Shift

SIDEBAR: Don't Touch That Dial


Unauthorized movement of neutral conductors creates perplexing troubleshooting scenario for
electrical contractor and substantial repair bill for medical facility owner
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Although football season is over, the anticipation of watching the next batch of
talented athletes coming up through the ranks is thrilling. And with each ensuing
season, new rules of the game are introduced, requiring players to learn how to
comply. Failure to do so results in the refs tossing the yellow hankie at violators.
Mistakes can be costly for individuals and the team alike. For example, an illegal
shift happens when a player changes position, having been previously set in another.
A flag is thrown for failing to follow the specificand technical rules of how to change
your position or stance. The following electrical case study reminded me of an illegal
shift, and I found myself reaching for that yellow hankie.

Photo 1. This terminal unit [216] assembly had been modified by someone in the field.

Todays electrical distribution equipment what the trade calls switchgear is


often a complex, factory-engineered field configuration. Going forward, especially
given the recent expansion of selective coordination requirements, electrical
contractors must use caution when altering, modifying, and servicing modern
switchgear installations. It is a best practice for owners and facility managers to
allow only qualified professionals to access and service sophisticated switchgear
installations. This recommendation is offered in order to avoid equipment
malfunction issues that can result in service disruptions and entirely avoidable,
potentially costly consequences.
This case is precisely about this precaution. For some years now, my firm has
provided electrical services to a large medical specialty practice. Housed in a threestory, 52,000+-square-foot, 10-year-old building, the facility contains state-of-theart medical equipment used for patient care diagnostic services.
During one particular alteration, it is evident that an electrician committed an illegal
shift with respect to the switchgear configuration. This unauthorized move was
evasive to me as I methodically searched for the possible cause(s) of why a certain
branch panel feeder overcurrent protective device (OCPD) would erratically trip. In
each instance, the OCPD ground fault detection feature was responsible for the
panels power loss, resulting in an HVAC service shutdown for the second floor at the
medical facility.

Although I am certain this was an innocent mistake and fortunately one that
proved to be nothing more than a nuisance it ultimately resulted in a substantial
repair bill (paid incrementally over a long span of time) to multiple tradesmen who
searched for the root cause in vain.
Like any good mystery, clues are helpful. Mine was this: The facility manager
explained that the 250A OCPD serving the second floor duct heaters and zone
dampers would randomly trip. At that point in time, though several technicians had
tried, nobody could figure out why. When this OCPD tripped, HVAC service to the
patient care wing on the second floor went down in some instances without
immediate detection. Eventually, staff and patients would complain about the
uncomfortable indoor temperature, prompting the facility manager to check the
breaker.
The buildings electrical service is a 3,000A, 480/277V, 3-phase, 4-wire wye
configuration. The switchgear had been modified on occasion, new breakers had
been mounted into spare slots, and some existing breakers were relocated, changing
the factory-built layout. A not-so-uncommon sight, a black magic marker was used to
scratch out formal identification labels and indicate revised descriptions for where or
what a breaker supplied power to.
I first removed panel covers and observed the existing distribution equipment
configuration. I also asked the facility manager lots of questions. It was revealed that
yet another renovation had just been completed. New MRI imaging equipment,
along with additional HVAC equipment, had been added to the switchgear. I sought
details surrounding the time of day, frequency, and even the seasonal load present
when the breaker would trip. Each time it tripped, the facility manger would reset
the breaker and restore power to the sub-panel. I was advised that there was never
an instance where the OCPD would not reset.
I also familiarized myself with the building automation system, which controlled the
HVAC zones for the second floor. The BAS graphics (floor plan with symbols)
provided real-time status and mode of the second floor terminal unit zones (duct
heater/damper assembly).
These loads cycled as zone sensors would call for set point heat or cooling. The
zone damper would actuate, and either cool or warm air was supplied. It was
important to note that when the zone called for heated air, the electrical load on

Panel 2MP increased as electric strip heaters (3kW to 5kW) were the source of the
warm air. Thus, the cumulative demand for Panel 2MP varied, depending on how
many of the 20 zones called for terminal/resistance heat.
The nuisance tripping had manifested sporadically, since about a year ago. There was
no particular event associated with the recurring power loss incidents this panel was
experiencing.
It was a curious problem, with no apparent rhyme, reason, or precursor as to why or
when the OCPD would trip. Morning, afternoon, or night there was no pattern.
Weeks would go by without an incident, and then again the problem could occur
twice in the same day.
My initial hunch was that there was a section of skinned insulation, a pinched
neutral conductor, or a sharp edge penetrating the wire jacket somewhere that
created a path for current leakage via a ground path. I diligently searched for a
copper-to-ground connection on the neutral runs. Meticulously often from the
vantage point of a ladder I traced all the EMT circuit runs, opened every junction
box, and inspected the terminal unit control panels and each disconnect. Although I
was certain I was on the right track, I found nothing obvious.
I soon began to doubt my own theory and reminded myself that others had been
down this same road, also failing to resolve the problem. At this point, I decided it
was time to learn more about how this type of electronic trip breaker functions.

Analysis of breaker operation


Each OCPD has a settings panel and a microprocessor LCD screen readout. The LCD
will sleep if a load is absent; the screen will be blank. The microprocessor has a
variety of functions. The readout is advanced by pushing the button, current levels on
the phases, and the neutral can be viewed by scrolling the display.
The display will also indicate the reason the electronic trip mechanism was activated.
The screen will read overload, short circuit, or ground fault, indicating the
reason for the trip.
This OCP, which supplied power to the second floor patient care area electrical panel
(Panel 2MP), displayed a ground fault readout after tripping. The microprocessor
monitors line and neutral (return) currents and processes them to evaluate/detect a

ground fault. The presence of unbalanced phase currents produces a net neutral
current range that the logic is programmed to interpret. An inappropriate (out of the
permissible range) current load detected on the neutral is interpreted as a ground
fault, resulting in a trip. This range is influenced by dial settings, field adjustable
thresholds that must be carefully calculated and selected.
The features of the OCPDs installed in this switchgear provided frontline protection
for the facility electrical distribution equipment and personnel. The fact that the
breaker tripped on detected ground fault was consistent with my hunch that
somewhere there was neutral current path that had inappropriately found a shortcut
to ground.

A refocus on the path


Using my ammeter, I checked to see if any current was flowing through the ground
conductor. There was no detectable current flow on the ground. Furthermore, I
disconnected the ground conductor and measured for a voltage potential between it
and the mechanically grounded metal of the enclosure. There was no electrical
potential detected.
I also checked the feeders from the switchgear (first floor electrical room) to Panel
2MP, paying particular attention to the condition of the neutral conductor. There
were no indications of insulation damage. Hence, everything with regard to Panel
2MP checked out fine there was no clear evidence of a deficiency of any kind.
Next, I carefully inspected all of the concealed conduits containing circuit conductors
from Panel 2MP installed above the drop ceiling of the second floor. The purpose of
this effort was to identify or locate the possibility of a pinched or nicked neutral wire
making contact with any grounded metal component. I checked every branch circuit
pipe run and every junction box. Nothing obvious was revealed. Although I was
disappointed, it at least confirmed that there was no instance where any of the
neutrals had been compromised.

A new clue surfaces


The facility manager then revealed that several new terminal units had been added
on the second floor and that apparently the breaker tripping problem began after
these new terminal units were installed. This new bit of information sent me in a new
direction.

Because I am a certified air conditioning contractor, in addition to holding my


electrical licensure, I was able to expand my investigation to include the mechanical
equipment and components. I embarked upon a careful survey of all electrical supply
connections, control connections, and circuit configurations for the new heaters.
Although I spent a significant amount of time poring over the newest terminal units,
I discovered nothing obvious. I then expanded my inspection to some of the other
terminal units. Another hunch I had was that perhaps a resistance heating coil was
making contact with a metal frame or cabinet enclosure. I found a suspicious
condition in Terminal Unit 216. The assembly had at some point been modified by
someone in the field (Photo 1).
While I wasnt certain that I had located the problem, I wasnt impressed with the
condition of Terminal Unit 216. The rigged heater coil electrical terminal connection
was a field adaptation. I checked for continuity from the coils to the metal cabinet as
well as conducted a thorough visual inspection of the ceramic insulators. There was
no continuity between any of the three coils and the enclosure. Frustrated and
somewhat desperate at this point, I suggested that this unit was the best evidence of
an electrical abnormality discovered thus far. I recommended replacing the unit.
A custom-built unit was ordered (three weeks lead time) and then installed; it was an
identical replacement of the original unit (UL listed and without compromise).
Unfortunately, the day after I installed the new terminal unit the 250A OCPD
tripped. I now had egg on my face and was right back where I had begun. I was not
only embarrassed, but also concerned I had a credibility issue. Fortunately, my client
was most gracious and instructed me to continue my quest to pinpoint the problem.

Calling in additional support


At this point I realized it would be wise for me to place a call to the breaker
manufacturer and tap into their expertise. Seasoned contractors know the value
equipment manufacturers can bring to the table. I called technical support and asked
the manufacturer to explain exactly how these breakers worked specifically how
the microprocessor sensed a ground fault. It was a key question, and the answer
provided me with valuable information about how the detection technology works.
Examining the switchgear, there are labels on both the breaker case and the neutral
terminals that are strategically placed in proximity to one another in the cabinets.

Tech support staff explained that the neutral terminals were coordinated with a
current transformer (CT) whose output is subsequently input to the breaker
microprocessor. This crucial measurement is how neutral current, which varied with
any unbalanced loads on the phases, is measured. This information was extremely
helpful and corrected an erroneous assumption I made in my initial investigation. I
presumed that the breaker somehow sensed current flowing through the feeder
grounding conductor. I traced this to its attachment to the switchgear grounding
terminal and observed no means by which a current flow through the feeder
grounding conductor could be detected. Although my observation was right, my
assumption was wrong.
The electronic trip unit in 3-phase breakers senses four currents: phase currents on
A, B, and C and, via the CT the return current on the system neutral. The phase
current sensors are internal within the breaker case; naturally, the neutral CT is an
external component with harness wire leads connected to terminals on the breaker.
The microprocessor interpolates these four current readings and is programmed to
expect a given current draw range for the neutral, per any unbalanced phase currents
the loads may produce.

Photo 2. Internal switchgear wiring for microprocessor type breaker.

The switchgear frame bears the intricate wiring scheme (neatly laid out and
concealed behind the dead front covers) of this sophisticated distribution design,
location, and layout having been specifically coordinated (Photo 2). Thus, its
important where a sub feed neutral is connected. The designated neutral terminal
corresponds to its affiliated breaker. Contractors are much more familiar with
smaller switchgear assemblies where breaker mounting typically has no specific
locale, and neutral connection points are randomly connected to a neutral bus or
terminal. When working with electronic trip ground fault detection breakers, the
position and order of connection are crucial. Additions to or alterations of the
original switchgear configuration must respect this factory layout. If not, there will
be performance issues.

The manufacturers tech support staff cautioned me to verify that the feeder breaker
for Panel 2MP corresponded with the neutral terminal intended for that breaker
space. This could be easily verified by tracing the CT wiring harness run.
Now that I understood how the breaker technology detected a ground fault, my next
task was to trace neutral terminal connections and wiring harness connections to sub
feed breakers. What I saw when I looked more closely at Breaker No. 12 the 250A
OCPD that fed Panel 2MP took me by surprise.

Photo 3. Notice how someone wrote 2MP on the label. It was mounted in space No. 12.

Notice the sticker 12 in Photo 3. Also note that someone penned in 2MP on the
label. This breaker supplied Panel 2MP and was mounted in space No. 12. These
were the original factory labels. Now observe the wire harness entering the breaker
case. This is where the CT output is delivered to the breaker microprocessor;
following that wiring harness will lead to a neutral terminal bus that runs through a
CT. The system neutral for the sub feed must be connected to that terminal;
otherwise, the microprocessor will sense no neutral current whatsoever.

Photo 4. The processor display shows the CT is currently generating no current.

Next, notice the LCD on the microprocessor digital display. The picture indicates the
neutral current level the processor is sensing. See the zero reading (Photo 4)? The
CT is generating no current, while the phase currents are carrying substantial,
unbalanced loads. How can the neutral current be zero, given the significant loads on
phases A, B, and C? It was now time to locate neutral Terminal No. 12.

Photo 5. Note the manufacturer installed current transformer locations. There is no neutral feeder
connection on CT3. In addition, the neutral feeder to 3MP wasnt moved from CT4 to CT3 when the phase
feeders were moved to breaker No. 3.

My search led me to an orderly layout of neutral terminals positioned in proximity to


nearby breaker slots in each cabinet (Photo 5). I found neutral Terminal No. 12; it
was without a neutral conductor connection bare and unused (Photo 6). No
wonder the microprocessor read zero neutral current. The CT associated with space
No. 12 had nothing to sense! Where then, is the sub feed neutral from Panel 2MP
connected?

Photo 6. Terminal No. 12 (where the neutral for 2MP was supposed to be connected) was bare.

They say hindsight is 20/20. I had gained critical understanding that now aided me
in this diagnostic endeavor. In removing the dead fronts of the switchgear, the
problem was revealed (Photo 7). In fact, now it was clear as day.

Photo 7. Note how Terminal No. 17 has two neutrals connected to it. They did not derive from the same
source.

Terminal No. 17 has two neutrals connected to it, and they dont derive from the
same source of conductor runs. For Terminal No. 17 to have two neutrals, breaker
space/breaker No. 17 would have to be a parallel sub feeder run. It was not, and that
meant we had an illegitimate point of attachment the neutral was connected to
Terminal No. 17.
In short order I discovered that the additional neutral conductor was in fact a bandit
from Panel 2MPs sub feed conductors. The 2MP neutral had been randomly
attached to terminal No. 17, probably out of convenience. Note from the picture that
neither neutral conductor properly identified as such. Finally, the problem had been
identified, and the explanation made perfect sense.
Because Breaker No. 12 (Panel 2MP) had no sensed neutral current input, it was
perpetually zero. Thus, as loads built up on phases A, B, and C, the unbalanced
neutral load that the microprocessor expected was absent, resulting in only one
possible interpretation the presence of a ground fault. The microprocessor would
then, as designed, electronically trip the breaker, open the contacts, and display the
ground fault error message. In other words, the breaker was performing precisely as

designed. The random trip instances were contingent upon the varying demand
(on/off) of the zoned terminal unit heater loads serving the second floor.
After de-energizing the breaker and properly marking the neutral, I removed the
2MP neutral conductor from Terminal No. 17 and connected it to Terminal No. 12.
When I turned on the breaker, the display immediately indicated a load on the
neutral, and the zero reading was gone.
Why did Breaker No. 12 start tripping eight years after the original installation? One
option is that the 2MP panel feeder neutral was improperly connected to Terminal
No. 17 from day one. It is also possible that an electrician moved it at some point in
time after the original installation. It is my opinion that it was moved when the three
new terminal units were installed.

Tying up loose ends

Photo 8. Someone scratched out the original 3MP marking on this breaker and penned in the word
spare below it.

It will probably come as no surprise that upon closer examination of the breaker
locations and the connected neutral feeder for each branch circuit, another improper
breaker/neutral configuration was revealed. Ironically, the third floor terminal units
panel a 400A load had its neutral connected to the wrong CT terminal as well. I
was given the approval to repair any and all deficiencies present within this
equipment.
As for Breaker No. 3 and Breaker No. 4, the evidence is a bit more conclusive.
Originally, Breaker No. 4 served Panel 3MP, the terminal units on the third floor.

However, the 3MP marking on the breaker label had been scratched out, and the
word spare was penned on the sticker (Photo 8). The original phase conductors
connected to Breaker No. 4 were also moved, at some point, to Breaker No. 3.

Photo 9. This is the neutral conductor terminal point for CT/Breaker space 3. Note that it is empty.

Why Panel 3MPs feeders were moved from Breaker No. 4 to Breaker No. 3 is not
known. But whomever moved them forgot (or didnt know) that the neutral terminal
connection needed to be moved as well (Photos 9and 10).

The neutral feeder conductor for Breaker No. 4 was relocated to the neutral Terminal
No. 4, as should have been done when the breaker was shifted to a new slot in the
switchgear. Current on the neutral was confirmed and indicated in the
microprocessor display window.

Photo 10. This is the neutral conductor terminal point for CT4. Note that it should be empty since the
breaker in slot No.4 is marked spare.

Wrapping it all up
Good electricians know when to stop and go back to the drawing board, having
realized the evidence doesnt support their assumptions. The best decision any
technician can make when youre in over your head is to call tech support. The good

fortune of excellent knowledge and diagnostic guidance from the manufacturers


technical support staff saved the day for me.
I began this case study with a football analogy of an illegal shift. In this electrical
configuration quandary, we ultimately learned the unauthorized move of changing
the position of breakers in sophisticated switchgear cant be done without regard for
the manufacturers design and operational protocol. More than a year after the
reconfiguration was completed, the equipment is performing without incident not
a single instance of a power supply failure to Panel 2MP.
McHaffie is the owner of Thomas McHaffie, LLC, an electrical contracting firm
based in Tallahassee, Fla. He can be reached at tom@thomasmchaffie.com.

The Illegal Shift


Mar 19, 2014Thomas McHaffie | Electrical Construction and Maintenance

EMAIL
INSHARE

COMMENTS 4
What is in this article?:

The Illegal Shift

SIDEBAR: Don't Touch That Dial


Unauthorized movement of neutral conductors creates perplexing troubleshooting scenario for
electrical contractor and substantial repair bill for medical facility owner
Advertisement

SIDEBAR: Don't Touch That Dial


During the electrical troubleshooting efforts in this case, it is worth mentioning that
at one point changing the sensitivity settings on the 250A breaker was proposed to
my client. Although tempting, this is typically a bad idea especially if the
equipment has been performing without problems for a long period of time.
Tampering with sensitivity settings is seldom advised.
When switchgear is designed, the manufacturer ships the equipment with breaker
settings considered appropriate for the intended use and application it is destined
for. It is rarely advisable or necessary to tweak these settings, and if warranted the

adjustment(s) should be made only at the recommendation of a person qualified to


specify this type of change.
One contractor told my client that the 2MP breakers settings were too sensitive.
Thus, he concluded this was the cause of the nuisance tripping. However, as was later
revealed, it would have been a mistake to change these settings.

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