Panelboards
Effective Date: July 2016
Service Entrance Label for Panelboards
50º C Calibration for Molded Case Circuit Breakers
Panelboard Types: PRL1a, PRL2a, PRL3a, PRL3E, Pow-R-Command
Column Types: PRL1a-LX, PRL2a-LX
Select one option only
· Standard Bolted Aluminum, Al or Cu cable (Default selection)
· Aluminum terminal bar with connectors for aluminum or copper cable.
· Ground bar bolts directly to the panelboard box.
· Insulated / Isolated Aluminum, Al or Cu cable
· Aluminum terminal bar with connectors for aluminum or copper cable.
· Includes a ground bar arranged to be insulated and isolated from the panelboard box.
· It also includes a second ground bar that will bolt directly to the box. (Std Bolted Aluminum)
· Standard Bolted Copper, Cu cable only
· Copper terminal bar with connectors for copper cable only.
· Ground bar bolts directly to the panelboard box.
· Insulated / Isolated Copper, Cu cable only
· Copper terminal bar with connectors for copper cable only.
· Includes a ground bar arranged to be insulated and isolated from the panelboard box.
· It also includes a second ground bar that will bolt directly to the box. (Std Bolted Copper)
Panelboard Type PRL4
Select one option only
· Standard Bolted Aluminum, Al or Cu cable (Default selection)
· Aluminum terminal bar with connectors for aluminum or copper cable.
· Ground bar bolts directly to the panelboard box.
· Insulated / Isolated Aluminum, Al or Cu cable
· Aluminum terminal bar with connectors for aluminum or copper cable.
· Ground bar is arranged to be insulated and isolated from the panelboard box.
· Bolted + Insulated / Isolated Aluminum, Al or Cu cable
· Both ground bars (1and 2) are provided
· Standard Bolted Copper, Cu cable only
· Copper terminal bar with connectors for copper cable only.
· Ground bar bolts directly to the panelboard box.
· Insulated / Isolated Copper, Cu cable only
· Copper terminal bar with connectors for copper cable only.
· Ground bar is arranged to be insulated and isolated from the panelboard box.
· Bolted + Insulated / Isolated Copper, Cu cable only
· Both ground bars (4 and 5) are provided
Only 1 metering option is allowed per panelboard.
Metering is not available for any DC voltage
· PRL1a/PRL2a/PRL3a/PRL3E Application Notes –
· Main Metering – IQ35M
· Available feeder space will be effected.
Main & / OR Feeder Metering – BCM (No local display)
· Available for 42 or 84 feeders circuits only.
· Structure width may have to increase
PRL4 Application Notes –
· Main Metering – IQ130/140/150/250/260 & PMX2250/2260/2270/2280/2290
o At 1200 amperes main bus rating, copper bus must be selected (Density Rated Not Available).
o At 800 amperes and below, If Density Rated Bus is required with Metering, Bus Material must be Copper.
o The panelboard must be minimum 36" wide if metering is selected.
Multipoint Metering – Pow-R-Line MPM utilizing Eaton PXMPM Multipoint Metering Components. The PXMP is an advanced smart meter that can be configured to monitor power, energy and demand for as many as 60 meters and fairly allocate utility bills. Its modular design supports a wide variety of configurations. Power Xpert Multi-Point meters help benchmark energy usage in office buildings, shopping malls, industrial sites, universities and campuses, apartments and condominium complexes and can be used for Tenant Sub metering.
o Complete Assembly only for this application.
o Single section panels only for this application (no two-section panels).
o F-frame and K-frame branch breakers utilize fixed mounted CT assemblies (additional X-space required in most cases). Minimum enclosure width is 36” for fixed CT applications.
o Branch breakers >400A requiring metering will not have fixed mounted CTs. For these applications, X-space and enclosure sizing per standard PRL4 requirements.
o For more information: http://www.eaton.com/Eaton/ProductsServices/Electrical/ProductsandServices/PowerQualityandMonitoring/PowerandEnergyMeters/PowerXpertMulti-PointMeters/index.htm
Panelboards are classified by NEC and UL in two general categories:
· Lighting and Appliance Panelboards and Power Distribution Panelboards.
· Lighting and Appliance Panelboards
Lighting and appliance branch circuit panelboards are defined in NEC Article 384) as “One having more than 10 percent of its overcurrent devices rated 30 amperes or less for which neutral connections are provided.” Article 384 also limits the number of overcurrent devices (branch circuit poles) to a maximum of 42 in any one cabinet. This rule applies to all panelboard types including PRL4 when the panel circuitry comes within the scope of this definition.
When the 42 poles are exceeded, two or more separate panelboards are required.
Note – The NEC 2008 Edition no longer limits the number of overcurrent devices to a maximum of 42 in any one cabinet. In those areas of the country where the 2008 NEC Code has been adopted, the number of overcurrent devices in lighting and appliance panelboards will only be limited by the maximum physical size of the available enclosures.
Power Distribution Panelboards
Distribution panelboards (all others not defined as lighting and appliance branch circuit panelboards) are restricted only to practical physical limitations such as standard box heights and widths.
It is important to note that the NEC requires that the operating handle of the topmost mounted device be no more than 6 feet 7 inches (2006.6 mm) above the finished floor.
Additional boxes and fronts are required when the components required for one panelboard exceed the standard box dimensions.
Multi-Section Panelboards
When more than 42 overcurrent protective devices are required (See Lighting and Appliance Panelboards), two or more separate enclosures are required. Separate fronts for each box are standard.
Interconnecting Multi-Section Panelboards
When a panelboard, for connection to one feeder, must be furnished in more than one section (Box), each section must be furnished with main bus and terminals of the same rating, unless a main overcurrent device is provided in each section.
Sub-feed or through-feed provisions must also be included (and priced) to provide connection capability to the second section.
Note: Sub-feed or through-feed lugs cannot be used on any panelboard that is not protected by a single main overcurrent device either in the panelboard or immediately upstream, i.e., service entrance panelboards with main lugs only using the six disconnect rule.
Sub-Feed Lugs
Sub-feed lugs are one means of interconnecting multi-section panelboards. The sub-feed (second set of) lugs are mounted directly beside the main lugs. These are required in each section except the last panelboard in the lineup. The feeder cables are brought into the wiring gutter of the first section and connected to the main lugs. Another set of the same size cables are connected to the sub-feed lugs and are carried over to the main lugs of the adjacent panelboard (next section).
· Cross connection cables are not furnished by Eaton.
· Sub-feed lugs are only available on main lug only panelboards.
· Sub-feed lugs may not be used on main lug only (six disconnect rule) service entrance panelboards.
Through-Feed Lugs
Through-feed lugs are another method to interconnect multi-section panelboards.
The incoming feeder cables are connected to the main lugs or main breaker in the first panelboard (Section 1). Another set of lugs (through-feed) are located at the opposite end of the main bus. The interconnecting cables are connected to the through-feed lugs in Section 1 and are carried over to the main lugs in the next panelboard (next section).
· Cross cables are not furnished by Eaton.
· Through-feed lugs may not be used on main lug only (six disconnect rule) service entrance panelboards.
Standard Enclosures
Except for column type panelboards, standard Type 1 boxes for indoor use are unpainted galvanized steel. These boxes are optionally available painted ANSI-61 light gray (at an additional charge).
Trims for Type 1 indoor enclosures for all panelboards are painted ANSI-61 light gray.
The trims for PRL1a, PRL2a, PRL3a, PRL3E and Pow-R-Command panelboards include a door with latch and lock assembly.
Type 1 enclosures for these panelboards are available for Surface or Flush mounting.
Trims for PRL4 and PRL5P panelboards for Type 1 indoor enclosures are also painted ANSI-61 light gray. They do not include a door as standard. These Type 1 enclosures are available for Surface mounting only.
Column type panelboards (PRL1a-LX, PRL2a-LX) include a painted box finished in ANSI-61 (matching the trim) as part of the standard offering.
(Column type panelboards are also furnished as a complete assembly for surface mounting only as standard.)
Busway Plug-in Panelboard – Panelboard is provided in a Type 1 enclosure designed for plug-in connection to Pow-R-Way busway.
Optional Enclosures - PRL1a, PRL2a, and PRL3a Panelboards
Type 2 - Standard box is unpainted galvanized steel and trim is painted ANSI-61. Surface mounting only.
Type 3R, 12, and 4 - Boxes and trims are painted ANSI-61 as standard. Surface mounting only.
Type 4X - Boxes and trims are 304 stainless steel. Surface mounting only.
(At 600 ampere bus rating, density rated copper bus is required for Type 3R, 12, 4 and 4X.)
(At 800 ampere bus rating [PRL3a], Type 3R, 12, 4, 4X enclosures are not available.)
(LCL and LA-P main breakers [PRL3a] are not available in Type 3R, 12, 4, 4X enclosures.)
Optional Enclosures – PRL3E Panelboards
Type 2 - Standard box is unpainted galvanized steel and trim is painted ANSI-61. Surface mounting only.
Type 3R and 12 (250A max.) - Boxes and trims are painted ANSI-61 as standard. Surface mounting only.
Optional Enclosures - Pow-R-Command Panelboards
Type 2 - Standard box is unpainted galvanized steel and trim is painted ANSI-61. Surface mounting only.
Type 3R and 12 - Boxes and trims are painted ANSI-61 as standard. Surface mounting only.
(LCL main breakers are not available in Type 3R and 12 enclosures.)
Optional Enclosures - PRL4 Panelboards
Type 1 - Trim with lockable door-in-door. Trim is painted ANSI-61. Surface mounting only.
Type 3R, 12 and 4 - Boxes and trims are painted ANSI-61 as standard. Surface mounting only.
Type 4X - Boxes and trims are 304 stainless steel. Surface mounting only.
Type 3R, 12, 4 and 4X enclosures for PRL4 are only available in 24 or 36 wide construction. The following devices require a 44 wide panel and will not be available in this type construction:
· Any "100% Rated" “N” Frame main or branch mounted breaker.
· Double branch mounted “K” Frame breakers.
· NB-P main or branch breakers.
· Twin 200A fusible switches.
· 400-600A main fusible switch.
· 800-1200 main or branch switch.
· (Type 4 and 4X are not available for any fusible switch configuration).
· (Type 4, 4X and 12 are not available for any 100% rated circuit breaker).
· Optional Enclosures - PRL5P Panelboards
Type 1 - Trim with lockable door over devices. Trim is painted ANSI-61. Surface mounting only.
Type 3R - Box and trim is painted ANSI-61 as standard. Surface mounting only.
Type PRL1a
· Bolt-on or Plug-on Circuit Breakers
· Voltage - 240V AC Maximum
· Main Lugs Only - 400 Amperes Maximum
· Main Circuit Breaker - 400 Amperes Maximum
· Branch Circuit Breakers - 100 Amperes Maximum, 1-, 2- and 3-Pole
Type PRL2a
· Bolt-on Circuit Breakers
· Voltage - 240V or 480Y/277V AC; 125/250V DC Maximum
· Main Lugs Only - 400 Amperes Maximum
· Main Circuit Breaker - 400 Amperes Maximum
· Branch Circuit Breakers - 100 Amperes Maximum, 1-, 2- and 3-Pole
Type PRL3a
· Bolt-on Circuit Breakers
· Voltage - 240V, 480V or 600V AC; 250V DC Maximum
· Main Lugs Only - 600 Amperes Maximum
· Main Circuit Breaker - 600 Amperes Maximum
· Branch Circuit Breakers - 225 Amperes Maximum, 1-, 2- and 3-Pole
Type PRL3E
· Bolt-on Circuit Breakers
· Voltage - 240V or 480V AC; 250V DC Maximum
· Main Lugs Only - 600 Amperes Maximum
· Main Circuit Breaker - 600 Amperes Maximum
· Branch Circuit Breakers - 125 Amperes Maximum, 1-, 2- and 3-Pole
Type PRL4
Bolt-on Circuit Breakers or Fusible Switches
Voltage - 240V, 480V or 600V AC; 600V DC Maximum
Main Lugs Only - 1200 Amperes Maximum
Main Circuit Breaker - 1200 Amperes Maximum
Main Fusible Switch - 1200 Amperes Maximum
Branch Circuit Breakers - 1200 Amperes Maximum, 1-, 2- and 3-Pole
Branch Fusible Switches - 1200 Amperes Maximum, 2- and 3-Pole
Type PRL5P
· Plug-on Circuit Breakers
· Voltage - 240V, 480V or 600V AC; 250V DC Maximum
· Main Lugs Only - 1200 Amperes Maximum
· Main Circuit Breaker - 1200 Amperes Maximum
· Branch Circuit Breakers - 1200 Amperes Maximum, 1-, 2- and 3-Pole
Pow-R-Command
Bolt-on Circuit Breakers
· Voltage - 240V or 480Y/277V AC Maximum
· Main Lugs Only - 400 Amperes Maximum
· Main Circuit Breaker - 400 Amperes Maximum
· Branch Circuit Breakers - 225 Amperes Maximum, 1-, 2- and 3-Pole
· Programmable lighting and energy control systems
· Type PRL1a-LX (Column Type)
Bolt-on Circuit Breakers
· Voltage - 240V AC Maximum
· Main Lugs Only - 225 Amperes Maximum
· Main Circuit Breaker - 225 Amperes Maximum
· Branch Circuit Breakers - 100 Amperes Maximum, 1-, 2- and 3-Pole
Type PRL2a-LX (Column Type)
Bolt-on Circuit Breakers
· Voltage - 240V or 480Y/277V AC; 125/250V DC Maximum
· Main Lugs Only - 225 Amperes Maximum
· Main Circuit Breaker - 225 Amperes Maximum
· Branch Circuit Breakers - 100 Amperes Maximum, 1-, 2- and 3-Pole
Type PRL1aF and PRL2aF Fusible Lighting Panelboards
Bolt-on Circuit Breakers with in-line CC fuse holders
· Voltage – PRL1aF - 240V AC Maximum
· PRL2aF - 480Y/277V AC Maximum
· Main Lugs Only - 400 Amperes Maximum
· Main Circuit Breaker - 400 Amperes Maximum
· Branch Circuit Breakers - 30 Ampere, 1-Pole
· Type PRL1R and PRL2R Retrofit Panelboards
· Bolt-on Circuit Breakers
· Voltage – PRL1R - 240V AC Maximum
· PRL2R - 480Y/277V AC Maximum
· Main Lugs Only - 225 Amperes Maximum
· Main Circuit Breaker - 225 Amperes Maximum
· Branch Circuit Breakers - 100 Amperes Maximum, 1-, 2- and 3-Pole
Retrofit Panelboards include a chassis and a trim to fit an existing box for use in renovating and upgrading electrical systems. Used for indoor applications, the chassis includes an integral neutral and is provided with a ground bar and bonding conductor. The chassis includes a telescoping feature to accommodate box depths of 4.5 to 6 inches. The trim mounts directly to the panelboard chassis.
Accessories include:
· Insulated/isolated ground bus for separate mounting
· Separately mounted neutral kits for use when additional connection points are required or the neutral must be separately mounted to meet existing cable locations
· Mounting plate extensions
· Depth adder supports for boxes deeper than 6 inches
· Box collar kit for boxes shallower than 4.5 inches
Service Entrance Label for Panelboards
A Service Entrance Label cannot be applied to a panelboard if any of the following conditions exist:
· The voltage is DC.
· The panelboard is a column type (PRL1a-LX, PRL2a-LX).
· The panelboard has main lugs only and more than 6 branch or sub-feed breaker devices.
· The panelboard has main lugs only and either sub-feed lugs or through-feed lugs.
· The main device is a molded case switch.
· The panelboard has a main 1200 ampere fusible switch and the voltage is 480Y/277V 3 Ph 4W.
(Ground fault protection is required by the NEC on the main device and that option is not available for the switch.)
Note: When the panelboard is to have a Service Entrance Label, Ground Fault Protection is required for any service disconnect (Main Breaker) rated 1000 amperes or greater when the service voltage is a grounded wye system of more than 150 volts to ground but not exceeding 600 volts phase to phase (i.e. PRL4 panelboards on a 480Y/277V 3 Ph 4W system).
For PRL4 panelboards requiring an SE label with 1200A main lugs only and rated 480Y/277V 3 Ph 4W containing a maximum of 6 branch devices and one of them is a 1200A frame device, refer to factory.
Standard Construction For Panelboards To Be Applied In
240/120V, 3 Phase, 4 Wire, Delta (Hi-leg) Electrical Supply Systems
While relatively uncommon, panelboards can be applied in a 240/120V, 3 phase, 4 wire, delta electrical supply system. These systems are generally referred to as “hi-leg” systems. The mid-point of one of the windings in the supply transformer is grounded; the result is that one of the phases is at a higher voltage to ground than the other two phases (208V vs. 120V). This phase is typically referred to as the “hi-leg”. Usually, it is the B phase that is at this higher voltage (and thus referred to as “B phase hi-leg”), but sometimes it is the C phase that is at this higher voltage (likewise referred to as “C phase hi-leg”).
Panelboard Connector Arrangement:
Panelboards intended for use in “hi-leg” applications are assembled (same as other 3-phase panelboards) so that the phase sequence is A-B-C starting at the top and left, and progressing all the way throughout the panelboard. This results in the normal “A-B-C, top to bottom, left to right” type arrangement, specified in UL and the NEC. The line connection to the hi-leg phase is marked with an appropriate label to clearly indicate which bus bar is intended to be connected to the hi-leg. They are orange in color (per UL and NEC) and state “B PH. HI-LEG” or “C PH. HI-LEG”.
Circuit Protective Device Arrangement:
The following guidelines are utilized to connect the branch circuit protective devices:
· 3-pole Devices:
o 3-pole circuit protective devices are connected exactly as they are in any other 3 phase panelboard, with one pole connected to A phase, one pole connected to B phase and the other pole connected to C phase.
· 2-pole Devices:
o Only 240V rated 2-pole devices are used in hi-leg type panelboards. Do not use 120/240V (nor 120V) rated 2-pole devices. These 240V rated 2-pole devices are alternately connected to the two “non-hi-leg” phases (connect to A & C phases for B phase hi-leg panels, connect to A & B phases for C phase hi-leg panelboards).
o Since the panelboard is constructed with all three branch connectors in sequence, it is necessary to “skip” every 3rd connector when installing groups of 2-pole devices. The B phase is skipped for B phase hi-leg panels and the C phase is skipped for C phase hi-leg panelboards.
· 1-pole Devices:
o 1-pole devices are never connected to the hi-leg. They are alternately connected to the two “non hi-leg” phases (connect to A & C phases for B phase hi-leg, connect to A & B phases for C phase hi-leg).
o Since the panelboard is constructed with all three branch connectors in sequence, it is necessary to “skip” every 3rd connector when installing groups of 1-pole devices. The B phase is skipped for B phase hi-leg panels and the C phase is skipped for C phase hi-leg panelboards.
This manner of construction for 1- and 2-pole devices will result in apparent 1 pole provisions periodically throughout the panel. However, all of the panelboards are marked with a warning not to install 1-pole devices on the hi-leg. Thus, these apparent 1-pole provisions cannot be utilized for 1-pole devices, but they may be utilized, in conjunction with adjacent provisions (resulting from future removal of adjacent devices), as 2- or 3-pole provisions.
This construction may require the panelboard to contain more branch connectors than branch circuit protective devices. UL and the NEC have requirements that “lighting and appliance branch panelboards” contain no more than 42 electrically connected circuits, and include means to prevent future field modification to contain more than 42 circuits. Therefore, if the total branch connectors (including spaces and provisions) exceed 42, the “extra” connectors are plugged with rivets.
Devices specifically designed to carry 100% of their nameplate ampere rating when enclosed and tested in specific equipment are referred to as 100% Rated Devices.
Circuit breakers rated for application at 100% of their frame rating are available for use as main or branch devices in PRL4 panelboards.
The 100% rated breaker types have a prefix C on the type designations and are as follows:
· K Frame (400 ampere frame) Types CKD, CHKD
· L Frame (600 ampere frame) Types CLD, CHLD, CLDC
· M Frame (800 ampere frame)Types CMDL, CHMDL
· N Frame (800 ampere frame) Types CND, CHND, CNDC
· N Frame (1200 ampere frame)Types CND, CHND, CNDC
Application Notes for 100% Rated Breakers:
If any 100% rated breaker is used as a main or branch device in a PRL4 panelboard, copper bus must also be selected. If the device is a 100% rated K or N frame, the bus must be 1200A density rated copper.
If any 100% rated breakers are used as a main or branch device in a PRL4 panelboard, Type 12, 4 and 4X enclosures are not available.
100% rated K frame breakers can not be double branch mounted.
100% rated N frame breakers require a 44" wide enclosure (box).
The conductors for use with 100% rated breakers must be 90° C wire applied at the 75° C ampacity.
All 100% rated breakers have electronic trip units.
100% rated breakers are not available for any DC voltage.
50º C Calibration for Molded Case Circuit Breakers
According to UL Standards, molded case circuit breakers are calibrated to operate in an environment with a maximum ambient temperature of 40º C.
Some molded case circuit breakers can be provided with a special non-UL listed calibration for a maximum 50º C ambient temperature.
This special calibration is limited to devices with thermal-magnetic trips.
This calibration is not available for 100% rated circuit breakers or the following breaker types:
QBGFEP, QPGFEP, BAB-D, HQP-D, QBHGFEP, QPHGFEP, QBAF, QBAG, BABR, BABRS, GHQ, HGHB, GHBS, GHBGFEP, GHDHID, DK, FCL, LCL, FB-P, LA-P, NB-P, EGB, EGS, EGH.
NOTE -Circuit breakers with a 50º C calibration are not UL listed. This special calibration will extend the lead time required for panelboard shipment.
SPD Series
In PRL1a, PRL2a, PRL3a and PRL3E Panelboards, the SPD Series unit is normally direct connected to the panelboard bus.
If cable connected to branch breaker is selected to provide a disconnect device for the SPD Series unit, a 30 ampere (3-pole for 3 phase, 2-pole for single phase) branch circuit breaker must be separately selected and added to the panelboard. This branch device must be located adjacent to the SPD Series unit and be placed on the left-hand side of the panelboard. Unit will be factory cabled to the branch device.
In PRL4 Panelboards, the SPD Series package includes an integral 30 ampere circuit breaker bus connected to the panelboard bus.
NOTE - The NEC now allows a Type 1 SPD (Basic Package) to be connected on the Line Side of the Main Overcurrent device and requires that a Type 2 SPD (Standard Package OR Standard + Surge Counter Package) be connected on the load side of the Main overcurrent device unless fed by an overcurrent protective device and disconnect (Breaker).