ELECTRICAL CIRCUIT

PROTECTION
S.S.A.RAJAPAKSA MIET,MIEEE
Senior electrical engineer
Miniature circuit breaker
 MCB standards

• IEC 60898

• Circuit breakers for over current protection for

household and similar installations
 MCB specifications
• Preferred current ratings

• 4,6, 10, 16, 20, 25, 32, 40, 50, 63,80, 100, 125
amperes

• Breaking capacity up to 10ka as per IEC60898

• Suitable for domestic and medium size

commercial applications
 MCB specifications
• No; of poles (e.g; single, two, three, four)

• when No; of poles increases toggles are

interconnected by a bridging bar

• Four pole version overload/short circuit

protection for three phases +neutral
 Miniature circuit breakers

1 pole
2 pole
3 pole

4 pole
 MCB tripping characteristics

• Type B 3-5 times rated current and suitable

for lighting loads

• Type C 5-10 times rated current and suitable

for motor loads

• Type D 10-20 times rated current and

suitable for x-ray units, welding plants
MCB tripping characteristics
 Energy limiting class
• Short circuit Energy=JOULES =WATTS.SECONDS=I^2R t
• R is small compare with I therefore energy = I^2t =
A^2.sec
• To protect a cable I^2t of the Mcb shall be less than the
cable I^2t during a short circuit (I^2t=K^2S^2 adiabatic
equation for cables) K=115(PVC) & 145(XLPE) S=cross sectional
area of cable sq; mm
• I^2t values of a Mcb 16 A, 6Ka, type C
• Class 1 – no limit
• Class 2 -120,000 A2sec
• Class 3 -42 ,000 A2sec
 MCBs for DC applications
• DC Mcbs specially designed to quench the
high arc voltage
• AC Mcbs can be used for DC applications
where thermal tripping unchanged but
magnetic tripping increased by 40% . Voltage
/pole is limited eg; 60 v DC/pole
• If the DC voltage required is 110 v two poles
of MCB can be series connected (2x 60= 120
v DC)
 Temperature rise
• The ambient temperature (T) shall not exceed 40deg;C
(average value over a period of 24 hours shall not exceed
35 Deg ;C )
• temperature rise shall not exceed the following above
ambient temp; (eg; final temp= T + temp; rise )
• Terminals- 60 Deg C (final temp= T +60)
• On/off handle -40 Deg;C (final temp= T +40)

• Metallic parts associated with operating handle (if any )- 25

Deg ;C (final temp= T +25)

• Back side of the mcb-60 Deg ;C(final temp= T +60)

 Pollution degree categories
• Degree 1- no pollution –sealed rooms
• Degree 2 – temporary conductivity of air due
to condensation –laboratories
• Degree 3 - conductivity of air due to
condensation –industries
• Degree 4 – conductive dust/rain – out door
use
 Isolation function
• all Mcbs manufactured as per IEC 60898
suitable for isolation.
• Above 4mm gap required to isolate the
contacts at a rated impulse withstand voltage
of 4 Kv
• The leakage current flowing across the open
contacts is measured and shall not exceed 2
mA
 Switching devices

Circuit breakers with

thermal
overload/magnetic short
Disconnector - isolating capabilities (no load switching) circuit release
Load switch – can switch on/off a load, can switch on(making) to a fault
current, cannot switch off(breaking) a fault current
Switch/disconnector – combination of disconnector + switch
Circuit breaker- can switch on/off loads, trips on fault, can switch on/off to a
fault, if designed isolating capabilities available
Mounting on DIN rails
 Calibration temperature
• The temperature at which the thermal over
load device tested /calibrated at the factory
eg- 45 degrees centigrade

• If the ambient temperature increases above

the calibration temperature the mcb will
derated . ( current handling capacity reduced )
MCBs as per IEC 60898-1 and IEC
60947-2
 General specifications for a MCB
• Rated voltage – 230 or 400 v AC
• Rated frequency -50 Hz
• Rated current -6/10/16/20/25/32/40/50/63 amps
• Breaking capacity – 6ka or 10 ka
• Tripping curve –B, C ,OR D
• Calibration temperature -40 deg C
• Terminal capacity-16sq;mm
• Relevant standard – IEC 60898
• Accessories – shunt trip/auxiliary and alarm contacts
Molded case circuit breakers
 What is a MCCB?

“a mechanical switching
device, capable of making,
carrying and breaking
currents under normal
circuit conditions and also
making , carrying for a
specified time and breaking
currents under specified
abnormal circuit condition
such as those of short
circuits.”
Where are MCCBs used?

ACB ACB

MCCB Fuse Switch

MCB MCB
 What are the standards?
• BS EN 60 947-1 General Rules
• BS EN 60 947-2 Circuit Breakers
• BS EN 60 947-3 Switch Disconnecters

• BS EN 60204-1
Safety of machinery
• BS 7671 :2008
IEE Wiring Regulations 17th Edition
 Short circuit breaking capacity
• short circuit breaking capacity or short circuit breaking
current of circuit breaker is defined as maximum
current can flow through the breaker from time of
occurring short circuit to the time of clearing the short
circuit without any permanent damage in the CB. The
value of short circuit breaking current is expressed in
RMS. During short circuit, the CB is not only subjected
to thermal stress, it also suffers seriously from
mechanical stresses. So during determining short
circuit capacity, the mechanical strength of the CB is
also considered. So for choosing suitable circuit
breaker it is obvious to determine the fault level at that
point of the system where CB to be installed.
 factors to be considered for calculation of
breaking capacity
• Distribution transformer KVA rating (higher the
transformer rating breaking capacity increases -
eg:100 KVA- 3 KA , 1000 KVA- 33 KA)
• Distribution voltage (higher the voltage breaking
capacity specified in kA: decreases)
• Cross sectional area of the cables ( higher the
cross sectional area breaking capacity will not
reduce)
• Length of the cables (higher the length breaking
capacity reduces rapidly )
 Breaking Capacity (Ics)
• In order to define this value, the circuit breakers
under test must be subjected to a test sequence
of:

• Ics = o – t – co - t – co, where:

• o = opening time under fault conditions
• t = time interval before re-closing (not more than
3 minutes)
• c = closing operation on to a fault
 Breaking Capacity (Icu)
In order to define this value, the
circuit breakers under test must be
subjected to a test
sequence of:
Icu = o – t– co.
The rated service breaking capacity (Ics) applies to
short circuit faults that could occur in
practice; whereas the ultimate short circuit capacity
(Icu) is the maximum theoretical fault
value of the installation at the point of connection.
 Breaking capacity
• The standard defines the ratio between the two values. Ics
will be shown as 25%, 50%, 75% or 100% of its Icu value for
Category A devices and 50%, 75% or 100% of Icu for Category
B devices.

• A circuit breaker can remain in service after interrupting a

short circuit up to its rated value of Ics
• However, where two or more faults occur between the Ics and
Icu values, the capability of the device for continued
operation must be verified.
Breaking capasity
 Thermal Magnetic MCCBs
t
Thermal (Ir)
0.63 125A
20sec 8 10
0.8

1 6 12
Magnetic (Im) Ir (x ln) Im (x ln)

I
600%In
 Abnormal conditions faced by circuit
breakers
• Over current -sensed by the bimetallic
thermal overload device or electronic
overload trip unit
• Short circuit - sensed by the electromagnetic
short circuit trip or electronic short circuit
trip unit
 Vocabulary of terms associated with
circuit breakers
• Rated current (In)-The maximum permissible continuous
current rating specified with in the given temperature
limits.
• Breaking capacity -a value of abnormal breaking current
that a circuit breaker is capable of breaking at a stated
voltage.
• Rated ultimate short circuit breaking capacity(Icu)- the
maximum short circuit current can withstand by the circuit
breaker under specified conditions of the manufacturer
• Eg; a short circuit close to the breaker terminals may
cause such maximum currents. After such short circuit the
breaker cannot handle its full rated current.
 Suitability for isolation
• In open contact position the same must
withstand the impulse voltage without
flashover. Contact position shall be indicated
using following method
• Position of the opening handle
• Separate mechanical indicator
• Visible breaking of contacts
 Switching devices

Circuit breakers with

thermal
overload/magnetic short
Disconnector - isolating capabilities(not designed for load switching)
circuit release
Load switch – can switch on/off a load, can switch on(making) to a fault
current, cannot switch off(breaking) a fault current
Switch/disconnector – combination of disconnector + switch
Circuit breaker- can switch on/off loads, trips on fault, can switch on/off to a
fault, if designed isolating capabilities available
 Vocabulary of terms associated with
circuit breakers (cont)
• Rated service short circuit breaking
capacity(Ics)- Rated maximum short circuit
current can withstand by the circuit breaker
under specified conditions of the
manufacturer.eg;a short circuit downstream of
the circuit breaker. This is specified as a
percentage of Icu.eg;25%,50%,75%,100%.after
such short circuit the breaker can handle its
rated current.
 Vocabulary of terms associated with
circuit breakers (cont)
• Frame size-the maximum rating for the current
carrying components of the breaker in
amperes.the rated current shall be equal or less
than the frame size.eg;800 AF(800 ampere frame
400AT(ampere thermal) that means 800 ampere
frame size can accommodate a 400 ampere
thermal tripping element
• Endurance – number of mechanical/electrical
operations possible
 TERASAKI TEMBREAK
1Thermal/magnetic settings
 Thermal/magnetic settings
160 ampere mccb
overloaded 640
amperes .what
will be the
tripping time.
Over load
=640/160 = 400%
of rated current

Average trip
time=20
seconds

400%
 Tripping a MCCB
• Electromagnetic trip unit
• Inverse time characteristics
• Time delay (utilization category B) not
available
• bimetallic Over current tripping
• Electromagnetic short circuit tripping
 Tripping a MCCB(electronic trip unit)
• Electronic trip unit
• True RMS sensing for long time delay
• Peak sensing for short circuit/instantaneous
• Time delay for tripping (utilization category B )
available
• Communication capability
• L/S/I curves
• Integral ground fault
• History of last trip
Tripping curve of an electronic MCCB
( TERASAKI -TEMBREAK 1 )
 Electronic trip unit

INSTANTANEOUS MAGNET HOLD TRIGGER

OVERIDE TRIPPING TRIPPING CIRCUIT
CIRCUIT

BRIDGE CONSTANT
RECTIFIER VOLTAGE
BUILT IN CURRENT CIRCUIT TO CIRCUIT
TRANSFORMERS CONVERT AC/DC Magnet hold
FOR 3 PHASES
trigger

ANALOGUE
TO DIGITAL CENTRAL
SIGNAL PROCESSING
CONVERTER UNIT
User interface

USER INTERFACE

BLOCK DIAGRAM OF AN ELECTRONIC TRIP UNIT

Current transformers for all three phases

(only one shown for clarity )
TERASAKI TEMBREAK 2 electronic trip
unit setting dial

Rated current setting combined LTD/STD/INST

pickup with time delay
curves
 endurance
• Electrical endurance- no of switching
cycles (on/off ) on load at 400 volts AC
• Eg; TERASAKI TEMBREAK 2 800 amps-
4000 nos
• Mechanical endurance –no of switching
cycles off load
• Eg; TERASAKI TEMBREAK 2 800 amps-
10,000 nos
 Calibration temperature
• The ambient temperature where the
mcb/mccb thermal trip unit set
• If this rating exceeds the mcb/mccb will trip at
lower than the rated current
• TERASAKI TEMBREAK 2– 45 deg C
• TERASAKI NEW COMPACT – 40 deg C
 Isolation & Direct Opening
•Direct opening action in IEC 60204-1
(Reference made in BS7671,Reg 537.4.1)

“…Measures to minimise risk in the event

of failure…”

“…..Recommendation for the use of switches

having direct opening action…..”
 Switching and Isolation
• Direct opening mark

Ensure all relevant MCCBs incorporate direct opening action

 Internal types
INTERNAL ACCESSORIES

•Click and Fit

Auxiliary Alarm

Bridge -contact types

Auxiliary Alarm

Shunt UVT
 Internal accessories

Shunt trip unit Auxiliary switch

Under voltage trip unit Alarm switch

 Interlocks

Link interlock
Wire interlock
- front mounting ensures
- for form 4 application compact change over-unit

•Even interlocks are field fittable

Current limiting effect of a MCCB
 Utilization Categories
• Category A designates circuit breakers not
specifically intended for selectivity with
devices on the load side. In other words circuit
breakers will discriminate only up to certain
fault levels, above which discrimination with
devices on the load side cannot be
guaranteed.
 Utilization Categories
• Category B designates circuit breakers
intended for selectivity with devices on the
load side. Such circuit breakers will
incorporate some form of time delay.
 General specifications for a MCCB
• Rated voltage – 400 V AC
• Rated frequency -50 Hz
• Ampere frame (AF)- 125/160/250/400/630/800/1000/1250/1600 amps
• Ampere thermal(AT)- 20 upwards
• Rated ultimate short circuit breaking capacity (Icu)@ 400 v ac-up to 100 ka
• Rated service short circuit breaking capacity (Ics) @ 400 vac-50%of Icu
• Utilization category –A or B
• Tripping characteristics –adjustable or fixed thermal/magnetic or electronic
• No of poles -3 or 4
• Rated operational voltage -690 vAC
• Rated insulation voltage – 800v
• Rated impulse withstand voltage -8 kv
• Connection –front or rear or plug in
• Relevant standard –IEC60947-2
• Accessories –shunt/uvt/aux;/alarm 230 v or 400 v ac
Residual current circuit breakers
 Residual Current Circuit Breakers (RCCBs)

Specifications …

• Rated Current up to 100 Amps

• Sensitivity 30/100/300 mA

• Application Types A , AC and B

• Tripping Delay Type S and G

• Comply with IEC 61008 standard

Residual current circuit breakers (continued)

CORE BALANCE TRANSFORMER

 Residual current circuit breakers (continued)

• Specifications …..
• Rated tripping (residual) current -10,30,100,300,500 Ma
• Personal shock protection max; value
• 30mA
• Fire protection max; value 300 Ma
• max; tripping time at rated tripping current – 300 mille
seconds

• Max; tripping time at 5 x rated tripping current – 40

mille seconds
 Leakage currents in a RCD circuit

Each computer has a leakage current of 2 MA

 General specification for a RCCB
• Rated voltage 230(S/P) or 400 (T/P) AC
• Rated frequency -50 hz
• Rated current-25/32/63 amps
• No of poles -02 or 04
• Sensitivity – 30/100/300/500 Ma
• Application type –AC.A,
• Terminal capacity – 25 sq;mm
• Relevant standard –IEC 61008
Earth leakage relays
 Earth Leakage vs Earth Fault
• IEC755 definition
– Earth leakage current are current flowing from the
live parts of the installation to earth in the absence
of an insulation fault.
– Earth fault current are current flowing to earth due
to an insulation fault.
• Earth leakage can be protected by using ELCB
(Earth Leakage Circuit Breaker).
 RCCB vs ELR

RCCB
Earth leakage
protection by
RCD
Circuit
ELR + breaker
 RCCB vs ELR
RCCB
• Fixed sensitivity setting.
• Instantaneous tripping.
• Usually for domestic
applications or
applications with less
than 100A load current.
ELR
• Programmable
sensitivity setting.
• Programmable time
delay.
• Usually for industrial
applications or
applications above
100A load current.
 Earth Leakage Protection
• Residual current circuit breaker (RCCB)
– Mainly for human protection & residential use.

• Earth leakage relay (ELR)

– Normally used for equipment and fire protection.
For commercial & industrial applications.
 Setting for ELR
• Sensitivity
– Leakage current before tripping.
– Typically from 30mA to 3A
– (preferred setting – 500MA)

• Tripping time
– Instantaneous
– Delay time
– (preferred setting 500 Milli sec)
Application of shunt trip for (ELR)
 Application of ELR in LV system
• Usually use Earth leakage relays (ELR) for load
current larger than 100A but less than 300A
• Usually for load current less than 100A, use
RCCB/ELCB
• Usually for load current larger than 300A, use
Earth-Fault relay
 Installation & Wiring 1

ZCT

Cable

L1, L2, L3 – Phase conductor.

N – Neutral conductor.
PE – Earth conductor.
 Installation & Wiring 2
Cable

ZCT

 Ensure that the cable maintain at the

center of the ZCT when routed through
the ZCT.
 General specification for a ELR

• Mounting-panel or din rail

• Display-numerical or analogue
• sensitivity range-30 ma-30 amps or programmable
• Time delay range -0-3 sec or programmable
• Leakage level indication 25%,50%.75%
• Zero current transformer internal dia;-40/60/80/120
mm
• Pre fault out put contact -50%
• Relevant standard –IEC 60755
• Auxiliary power supply -180-270 v ac
 Earth Fault Relay

Specifications …

• Microprocessor based type

• Low /high set earth fault setting

• Adjustable Trip Time Delay for low/high setting

• Sensing Using Current Transformers

• C;T; Secondary current 5 amps

• 04 no current transformers required for a 3p & n system

 Earth Fault Protection

• Earth fault current may be limited

• Sensitivity and speed requirements may not be met by
overcurrent relays
– Use dedicated EF protection relays
• Connect to measure residual (zero sequence) current
– Can be set to values less than full load current
• Co-ordinate as for OC elements
– May not be possible to provide co-ordination with fuses
 Earth Fault Relays Current Setting

• Solid earth system

– Used in LV system
– 30%-40% setting of Ifull load adequate
– Or 30% of minimum earth fault current
 Preferred settings
 Low set current – 1 amp( 20%)
 Delay time - .5 sec
 High set current – 10 x low set current
Earth fault relay
 General specifications for a EFR
• Rated secondary current-5 amps
• Aux; power supply-200-260 v ac
• Supply frequency-50hz
• Low set setting-.2%- 40% or 2%-100%
• Low set time multiplier -.05-1.0
• High set –up to 10 times of low set
• High set delay-inst;
• Display indicators –pick up,trip,aux;supply
• Current transformers -
400,500,800,1000,1200,1600,2000,3000,4000 amps/5
amps
 Cable entry/leaving
• Top cable entry/top cable leaving
• Top cable entry/bottom cable leaving
• bottom cable entry/top cable leaving
• bottom cable entry/bottom cable leaving
 Forms of separation
• Form 1 - no separations
 Forms of separation (cont)
• Form 2 –separation of bus bars from the
functional elements -2a terminals not
separated -2b –terminals separated type 1
insulated type 2 partitioned bus bars
 Forms of separation ( cont )
• Form 3 - functional units separated from
other functional units -3a –terminals not
separated from bus – 3b – terminals for
external conductors in a separate
compartment
 Forms of separation
• Form 4 - terminals for external conductors
separated each other -4a -terminals within
the functional unit – 4b –terminals in a
separate compartment
 Flat Copper bus bars
• Current rating depends on ambient
temperature and maximum temperature rise
allowed (eg; ambient -40 deg C. temp rise-50
deg C=total rise 90 deg C)
 External 8 Finish of the enclosure
• Epoxy powder coated finish
• RAL color index eg ; RAL 7035 light grey
DEGREE OF PROTECTION ( IPCODE )
 Control equipment
• Phase failure relays – to detect phase failures
• Earth leakage/fault relays –to detect earth
leakage/faults
• Shunt trip /under voltage trip – to trip the
circuit breaker on an external signal
• Energy analyzers – to indicate electrical
parameters such as
kw/kva/hz/amps/voltage/kwh
Single line diagram
 16

Thermal imaging inspection windows

 23
Thermal images in a electrical
distribution system
 international standards
• IEC 60439 –low voltage switchgear and control
gear assemblies - superseded/withdrawn
• IEC 61439 - low voltage switchgear and
control gear assemblies –now applicable
• Part 1 –general rules
• Part 2 – power switchgear and control gear
assemblies
Any Clarifications or Questions ?