The Myth-Application of 100

Percent Rated Circuit Breakers

by Tony Parga, Gary Gluck and Dave Bradley, PE, LEED AP
With ever increasing building loads, 100
percent rated overcurrent protection devices
are widely used in a number of commercial,
industrial and residential installations. Many
specifications include provisions that breakers
larger than a certain frame size shall be 100
percent rated. Though the application of
these devices might enable the use of smaller
conductor sizes, sound economic analysis
forces one to consider not only the benefits
of design but the costs as well. This paper
will discuss some misconceptions about 100
percent rated breakers and how to properly
apply them.
Myth #1: You can specify either 80 percent
breakers or 100 percent breakers
Wrong. There is no such thing as an 80
percent rated circuit breaker. The term 80
percent doesnt appear in the NEC, on any
circuit breaker, or in manufacturers literature.
There are regular circuit breakers, and there
are 100 percent rated circuit breakers. The
80 percent reference is derived from the
NECs required load calculation in Section
210.20(A) which states in part:
Where a branch circuit supplies continuous
loads or any combination of continuous and
non-continuous loads, the rating of the
overcurrent device shall not be less than the
non-continuous load plus 125 percent of the
continuous load.
Exception:
Where the assembly, including the
overcurrent devices protecting the branch
circuit(s) , is listed for operation at 100
percent of its rating, the ampere rating of the
overcurrent device shall be permitted to be
not less than the sum of the continuous load
plus the non-continuous load.

Technical Brief

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The 80 percent is simply the inverse of the

125 percent of continuous load requirement
and is a common derating factor. Sizing
circuit breakers based on an 80 percent
derating assumes that all the connected
design loads are continuous.
It is up to the engineer to calculate the design
loading of the overcurrent device based on
the profile of its load, which is often a
combination of continuous and noncontinuous loads. It is also up to the
engineer to carefully determine which loads
are continuous and account for the 25
percent margin required. Continuous load, as
defined in NEC article 100, is a load where
the maximum current is expected to continue
for 3 hours or more. The table below
illustrates some examples of continuous and
non-continuous loads:
Continuous Loads

Non-Continuous Loads

Lighting, Computers,
fixed electric heating
loads, old style motorgenerator traction
elevators.

Hydraulic and VFD

driven elevators,
cyclical pumps,
welders, copiers.

Please note that some residential load

calculations are not intended to be
considered continuous loads. For example,
the calculation for the service size at a
residential multi-family building is not
considered a continuous load, but it is used to
establish the minimum size service feeder
capacity and over current protection required.
This is also true on calculations for single
family dwelling units. It is not the intent of
this article to classify different types of load
but to examine options for the overcurrent
protective device.

Myth #2: You cant load a regular circuit breaker to more

than 80 percent of its rated value
Not true. Heres an example of two circuits, each with 18A of load:
Total
ampacity
of loads

Calculation
based on
NEC 210.20(A)

Results

Copier
(16A non-continuous)
Desk Light
(1.6A continuous)

16A
+ 2A
18A

16A (1.0)
+ 2A (1.25)
18.5A

Use 20A
regular
breaker

Computer
(10A continuous)
2 monitors
(6A continuous total)
Pencil sharpener
(2A non-continuous)

10A
+ 6A
+ 2A
18A

10A (1.25)
+ 6A (1.25)
+ 2A (1.0)
22A

Use 25A
regular
breaker

Loads

What is a 100 percent rated breaker? It is a circuit breaker that is

rated to allow the use of the load calculation in the exception to
NEC Section 210.20(A). Years ago, only low voltage power circuit
breakers and bolted pressure switches were 100 percent rated
devices. Today, many models of molded case circuit breakers are
available with this option. Siemens offers both thermal magnetic
and solid state circuit breakers with a 100 percent rating. The
only devices that are not available with a 100 percent rated
option are knife blade fusible switches.
Myth #3: Specifying 100 rated breakers now is good
insurance for the engineer because it will let you add
more load in the future
Not necessarily once again it all depends on the load profile and
the required load calculation. Both a regular breaker and a 100
percent rated breaker can be loaded to their rating if the load is
non-continuous.
Circuit breakers rated 100 percent must be installed in enclosures
or assemblies which meet the requirements for the increased
temperature rise of the breaker, conductor and components.
These assemblies or enclosures are modified in various ways
depending on manufacturers design and need to be taken into
consideration when planning the electrical rooms. Switchboards
and panelboards containing 100 percent rated breakers may be
sized larger than standard units with regular breakers. In many
cases the bus material is increased in capacity and size, and in
some cases, breaker placement on the units may be restricted.
This is due to the increased heat generated by continuous loads.
Unfortunately, there is no free lunch. Specifying 100 percent
rated breakers costs more. These costs could be up to 25 percent
higher than standard, so its advisable to evaluate the increased
cost versus the expected savings from a reduction of the
conductor size.
An example of proper application of a 100 percent rated device
that can result in cost savings is a long run to a large continuous
load. Consider a 700A continuous load fed by a switchboard 100
away. If a regular circuit breaker is used, it must be sized for 125

percent of the 700A load, or 875A, and would require a 1000A

breaker. NEC 240.4( C) would require that 3 sets of 500kcmil be
used. However, an 800A, 100 percent rated breaker could be
used and would only require 2 sets of 500kcmil. The savings of
100 of conductor and conduit would certainly more than offset
the cost of the 100 percent rated breaker.
Another example with savings in device costs is a service
entrance scenario. Consider the case of a building with a 1000A
main (regular rating), 480Y/277V service entrance with a design
load of 400A of continuous load and 400A of non-continuous
load. The NEC requires a ground fault device for this size main.
An alternative would be to specify an 800A, 100 percent rated
main ground fault protection would be no longer required.
Myth #4: When specifications say All breakers are to be
100 percent rated, it means that 100 percent rated devices
are required.
This note frequently appears on plans and, while possibly
applicable in certain limited situations, normally suggests
confusion between the terms 100 percent rated and fully
rated. While these two terms sound similar, their meanings in a
strict electrical sense could not be more different.
A fully rated system is populated with circuit breakers that are
rated for the available fault current at each point in the system.
In this context, it should be compared to series rated circuit
breakers. By contrast, 100 percent rated circuit breakers have
nothing to do with the fault current rating. In fact, calling for all
breakers to have a 100 percent rating is incorrect since 100
percent rated breakers are only available in mid range and larger
frame sizes, usually 400A or more.
Myth #5: Using 100 percent rated circuit breakers always
results in the use of smaller breaker frame sizes and smaller
conductor sizes.
This is not always the case. Consider the following example:

MCB

CB1

1000A Rolling Mill

Motors
(Continuous)

CB2

150A lighting,
500A process motors
(10min on, 20 min off)

CB3

800A
Busway
800A Circulation Pumps
(On during 8 hour morning
shift only)

Outcome
with standard
circuit breakers

Outcome
with 100% rated
circuit breaker

CB1(load cable)
1000Amp
Continuous load

Minimum req.
ampacity =
1000 x 1.25
=1250A

Minimum req.
ampacity
= 1000A

In this case there

would be savings
in both frame size
and conductor
choice using 100
percent rating

CB2 (load cable)

150A continuous load + 500A
non-continuous

Minimum req.
ampacity =
(150 x 1.25) + 500
= 687A

Minimum req.
ampacity =
150 + 500
= 650

In both cases a
700A breaker
would be selected. A 100% rated
breaker offers no
savings in frame
size or conductor
choice

Circuit

Comments

CB3 (800A load

busway)
800A continuous load

Minimum req.
ampacity =
800 x 1.25
=1000A

Minimum req.
ampacity
= 800A

Busway and
breaker will remain 800A if
100% rated
breaker is used.

MCB

Minimum req.
ampacity =
1250 + 687+1000
= 2937A

Minimum req.
ampacity =
1000 + 650 + 800
= 2450

Significant size
and cost advantages can be realized with 100%
rated overcurrent
devices

If a standard breaker is used as the main, the incoming feeder as

well as the breaker will need to be rated for 3000A. Using a 100
percent rated breaker we can provide a 2500A breaker and
incoming feeder resulting on substantial cost savings.
If our calculations for the 100 percent rated breaker would have
resulted on a value larger than 2500A, then we would have had
to use a 3000A frame breaker (next standard frame size). This
3000A breaker would not have to be 100 percent rated since it
would comply with either calculation and the additional cost for
the 100 percent rating would not be warranted.
On breaker CB3 we can have substantial savings on the feeder
cable as well as on the bus duct cost (bus duct can be loaded
continuously to its rated value) by using a 100 percent rated
800A breaker.
Myth #6: Using 100 percent rated circuit breakers means
using solid state breakers
As mentioned before, thermal-magnetic breakers and some
fusible devices are available in 100 percent rated versions.
Myth #7: All fused switches are 100 percent rated
There is a great deal of confusion when it comes to fuses and the
switches that house them. Fuses follow the same rules for
derating as do circuit breakers. All knife blade switches are
regular rated devices and this governs the application of the fuse.
Bolted pressure (and High Pressure Contact) switches are 100
percent rated devices and, provided that a properly sized
enclosure is selected, the switch/fuse combination can be rated
for 100 percent operation.

Myth #8: Insulated case breakers can be either 80 percent or

100 percent rated
All insulated case (power) circuit breakers are 100 percent rated.
Myth #9: Since 100 percent rated breakers are the same
physical size as regular breakers, they can be installed in
switchboards and panelboards the same way
This varies with each manufacturer. It is best to contact the
manufacturer when sizing a panelboard or switchboard
containing 100 percent rated devices. When 100 percent circuit
breakers are being used, the bussing in a switchboard section acts
as a heat sink and there may be modifications required.
Additionally, the number of 100 percent rated breakers and their
positions may be limited.
Myth #10: A standard rated breaker can be exchanged with a
100 percent rated breaker to attain higher circuit capacity.
Unless the breaker being exchanged is mounted in an enclosure
approved for use with the 100 percent rated breaker nothing is
gained. Replacing a breaker mounted in a panelboard or
switchboard may not allow extra loading either. The breaker is
just a component of the 100 percent rated system. In addition to
the special enclosure requirements, keep in mind that 90 degree
C cable sized for 75 degree C MUST be used when connecting to a
100 percent rated device.
Conclusion:
There may be substantial savings that can be realized from the
proper application of 100 percent rated breakers. However,
application of these breakers needs to be evaluated carefully for
each specific instance. In addition, there are other considerations
such as the effect on equipment dimensions which must be taken
into account when planning the electrical room. The specification
of 100 percent rated breakers isnt a cure-all, but when properly
applied will pay for itself.

Siemens Industry, Inc.

3333 Old Milton Parkway
Alpharetta, GA 30005
1-800-241-4453
info.us@siemens.com
www.usa.siemens.com

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2011 Siemens Industry, Inc.

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