9/6/23, 12:41 PM Everything you need to know about Cascading

Everything you need to know about

Cascading
Boris Fuchs + Follow
Technical Expert at Schneider Electric
Published Sep 25, 2017

Cascading, also known as back-up protection, enhanced breaking capacity in the IEC
world, or series rating by our US colleagues, has been used for the past 30 years at
least, to reduce the cost of low voltage distribution networks.

Although many people believe to have a “good enough” understanding of the

phenomena, sometimes just enough to get them into trouble as the saying goes,
this article is an attempt to demystify this phenomenon to help users better
understand how it works, and especially to understand the consequences of its
implementation.

I believe it is now time for a definition of cascading (since, more often than not,
most people are unable to give a good definition): Cascading is the use an
upstream current limiting device to increase the breaking capacity of the
downstream device.

The upstream device can be either a fuse or a circuit breaker, but if it’s a circuit
breaker, it must be a current limiting circuit breaker. Non-current limiting circuit
breakers cannot provide cascading.

So first of all, what is a current limiting protection device?

Current limiting protection devices are devices that will interrupt short circuit
currents within the first half cycle. This fast interruption reduces (limits) the peak
current and I2t energy of the fault.

Current limitation techniques will mostly rely on the creation of an arc voltage / arc
impedance inside the protection device. For fuses, this is achieved through the
fusing of the internal element, with breakers this is achieved through separation of

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the main contacts. I’ve written an article on this previously, so please refer to that
article for further details on current limitation.

One of the many benefits of current limitation is cascading.

Before we review the effects of cascading, we also need to understand what is the
breaking capacity of a circuit breaker. A circuit breaker’s breaking capacity is the
maximum prospective (theoretical) short circuit level it can interrupt under a specific
test sequence or procedure. Different standards nominate different test procedures.
For example, in the IEC world, IEC60947-2 covers the testing of circuit breakers
intended to be used in commercial/industrial environments, whereas IEC60898 -1
covers the test procedure for circuit breakers intended to be used in residential
applications. To test these devices, the test lab will setup a test circuit capable of
delivering the required theoretical short circuit current on the line side of the circuit
breaker to be tested. If the circuit breaker interrupted the event while complying
with all the requirements of the test procedure, then the device is deemed to have
passed the test, and it’s breaking capacity performance is defined to be equal to the
theoretical short circuit current set at the test bench.

It is essential to note that the circuit breaker does not need to withstand the full
amplitude of the theoretical short circuit current. Current limiting device will
naturally limit the actual flow of current, and these devices may therefore never see
the full magnitude of the theoretical condition.

For example, for a 50kA theoretical short circuit current, the expected theoretical
(unlimited) peak according to IEC60947-2 is 105kA peak. Current limiting circuit
breakers having a breaking capacity of 50kA will limit the actual peak to values
significantly less than 105kA peak, for example a Schneider Electric NSX160N
current limiting circuit breaker will limit the 105 kA peak to no more than 22kA
peak, or approximately a 80% reduction in the peak current.

Current limiting circuit breaker need not be designed to be able to carry the full
theoretical peak current. In effect, current limiting circuit breakers protect
themselves by limiting the stresses the circuit breaker will be exposed to, and, as a
consequence, protect the rest of the installation by reducing the stresses the
installation (upstream and downstream) will be exposed to in the event of a
downstream fault.

It is important to understand that the breaking capacity of a circuit breaker does not
represent the actual current the circuit breaker can handle, but it represents the

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9/6/23, 12:41 PM Everything you need to know about Cascading

maximum prospective (theoretical) short circuit current (or fault level) it is rated for
at its point of installation.

Now that we understand current limitation, fault levels, and breaking capacity, let’s
return to the main purpose of this document, cascading.

As mentioned in the definition of cascading, the upstream device must be a current

limiting device. In fact, the downstream device must also be a current limiting
device, typically a circuit breaker. So we need two current limiting devices in series.
The upstream and the downstream.

Normally, the upstream device will have a higher current rating than the
downstream. For example, a 160A rated device upstream of several 20A devices in a
power distribution environment (switchboard)

Without cascading, if the downstream device were a device with a 10kA breaking
capacity, it should not (by law) be installed where the fault level is greater than
10kA, as exposing the 10kA device to conditions greater than 10kA would
potentially cause it to fail, and possibly lead to fire, injury and even death.

As we’ve seen in the definition of current limiting devices, they are designed to self-
protect themselves under fault condition through the limitation provided by their
own current limitation. So if they can protect themselves, can we also expect them
to benefit from protection from other devices? Absolutely. And this is why
cascading requires an upstream current limiting device to provide additional
limitation, ie additional protection to the downstream device.

And this phenomenon allows, once proven by test, to install circuit breakers under
fault level conditions in excess of their stand-alone breaking capacity.

The proof of cascading is done by the manufacturer, under precise test conditions,
and allow the allocation of an enhanced breaking capacity to the downstream
device linked to the upstream device. It is fundamental to recognise that the
increased performance of the downstream device is linked to the presence of a
specific upstream device. Different upstream devices will provide different enhanced
performance on the downstream device, since they each provide different additional
limitation.

So how does all this work?

The best way to review the phenomena is through an example.

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Let’s consider the scenario of a 6kA rated miniature circuit breaker (MCB)
downstream of a 20kA rated upstream moulded case circuit breaker (MCCB)

First of all, let’s consider the 6kA MCB interrupting a 6kA prospective fault current.

The graph shows an example (in black) of what the actual limited wave form would
look like : prior to contact separation, the actual waveform follows the theoretical
unlimited waveform. At some current threshold, contact separation occurs in the
downstream device, and limitation (ie reduction of the rate of rise of the current
compared to the theoretical rate of rise) occurs, and the actual current is seen to be
much less than the prospective. This is shown in the black curve.

What we can notice is that the actual peak current remains under the peak
withstand of the downstream device, and this is one of the key parameters that
ensures the downstream device is capable of safely interrupting the short circuit
current

Now let’s expose this 6kA rated MCB to a prospective 20kA fault current, without
the benefit of an upstream current limiting device.

The curve is shown in red : contact separation occurs at the same current level,
however the reduction of the rate of rise of the current is not sufficient to prevent
the actual peak current from exceeding the peak withstand of the downstream
device (red dotted line). In this area, it is likely, possible, that the downstream device
could fail catastrophically since it is has been exposed to conditions in excess to
what it is rated for.

Let’s now add in series an upstream current limiting MCCB. If it is selected properly,
we could obtain the wave form shown in green. At some stage, the upstream device
will also start to provide a limiting effect, reducing the rate of rise even further, and
in this case limiting it sufficiently to prevent the peak current from exceeding the
peak withstand of the downstream device.

This allows the downstream to interrupt safely the fault.

This usually means that the current rating of the series connected breaker should be
close enough, as a large difference in current ratings may delay the beginning of the
limiting effect of the upstream until it’s too late for the downstream.

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What cascading also means is that since it is expected that the upstream device
provides this limitation effect, it is likely that it will trip, effectively disconnecting all
the downstream circuits from mains supply, and losing short circuit discrimination.
In fact, with fuses, it is a given that the fuse will blow, but with circuit breakers, it is
possible the upstream circuit breaker, if designed properly, may actually reclose.
This could lead to maintaining short circuit discrimination between the devices.

What are the key benefits of cascading?

Essentially, cascading allows, once proven by testing, to use circuit breakers in

locations where the prospective fault level exceeds the standalone breaking capacity
of the downstream device.

This allows for smaller and cheaper breakers to be used, significantly reducing the
cost the switchboards, and their footprint.

Are there any negative effects to cascading?

As mentioned earlier, cascading will usually require the upstream device to operate
as well, meaning a significant section of the distribution network may be isolated. As
there are mandatory requirements for protection discrimination according to
AS/NZS3000 it should be verified if the cascading effect will compromise, or not the
discrimination effect. Some manufacturers offer enhanced discrimination tables for
which the cascading and simultaneous discrimination performances are
documented.

Since the performance of the downstream device is function of the upstream device,
care should be taken when performing switchboard upgrades and / or
modifications. Upgrading the upstream to a larger or different device may cause the
loss of the cascading effect, and when selecting a new downstream device, it should
be verified it cascades with the upstream device as required. Certain state-based
service rules in Australia require the fitting of labels to switchboards where the
switchgear is involved in cascading to reduce the risk of inadvertent switchgear
modification that could compromise the safety and integrity of the network.

Cascading is a significant benefit to LV distribution networks but understanding of

the physics and the consequences of the association are essential to ensure the
system is correctly designed, installed and maintained throughout its life.

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Sifiso Masilela 4y
Electrical Engineering| Product Management| Business Development| Project Management| Energy Management

Hi Boris,

great article. does this means both circuit breaker upstream & downstream disconnect circuit at
the same time. both breakers trip? at the same time or downstream circuit breaker trips first.

thank you.

Like · Reply

Harsh Vardhan Tripathi 4y

Deputy General Manager-Offer Marketing at Schneider Electric

Hi Boris,
Thanks for this article..will be in touch with you even officailly in Schneider.

Harsh Vardhan Tripathi

Schneider Electric
Prescription Team

Like · Reply

Roger Leyland IEng MIET 4y

Senior Electrical Design Engineer at Ameon Limited

Thanks, clear and concise (ish) for a complex subject. Would be interesting to hear your view on
BS88 domestic cut-outs serving 6kA MCBs.

Like · Reply

QS . 4y
.

Boris great piece on cascading 👍

Like · Reply 1 Reaction

Jithu Raj 5y
Electrical QC Engineer- PMP- ISO9001:2015- CBT- SAP #80011800 Revit-AutoCAD-ETAP-Primavera (Saudi Arabia)

Good explanation. Thanks

Cascading is not possible if down stream CB is not current limiting type?

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