EEE 327

Power System Protection

LV / LT Circuit Breakers

Prepared by
Dr. Md. Rezwanul Ahsan
Associate Professor, Dept. of EEE
 Lecture Contents

 Classification of CB based on Voltage

 Purpose & Importance of using LV CB
 Classification of LV CB
 Selection criteria
 Technical Info

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 Circuit Breakers
A Circuit Breaker is an automatically operated electromechanical switch designed to
protect an electrical circuit from damage caused by an overload or a short-circuit.
“A short circuit is an over-current but not an overload”
 Basically CB is used to detect fault condition and immediately cut the power supply.
 Unlike fuse, which operates once and then has to be replaced; a circuit breaker can
reset to resume normal operation.

According to the voltage level of installation, the CB can be categorized as

 High voltage CB (> 72 kV)
 Medium voltage CB (1 ~ 72 kV)
 Low voltage CB (< 1 kV)

The low-voltage circuit breakers that are installed in switchgear or distribution

centers can be classified as:
a. Miniature Circuit Breaker (MCB)
b. Molded-Case Circuit Breaker (MCCB) and
c. Air Circuit Breaker (ACB)

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 Breaker Ratings
According to the IEC 62271-100, IEC 62271-1 and IEC 60947-2

 Plain-break air breakers are used in low voltage and medium voltage up to
15 kV.
 For low and medium voltages fuses can be used, but the main disadvantage
is that they must be replaced after fault clearing.
 In medium voltage systems minimum oil, SF6 and vacuum breakers are
also being used.
 For high voltages minimum oil, SF6 and blast-air breakers are used, but
always with multiple interrupters in series.
 The maximum voltage per interrupter is 100 kV for air-blast and SF6
breakers, 170 kV for minimum oil breakers.

Standard Size of CB:

6A, 10A, 16A, 20A, 25A, 32A, 40A, 50A, 63A, 80A, 100A, 125A, 160A, 180A, 200A,
250A, 300A, 350A, 400A, 630A, 800A, 1000A, 1500A 1600A, 2000A, 2500A, 3000A,
3500A, 4000A, 4500A & 5000A
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 Purpose and Importance of using LV switchgear
 Low-voltage switchgear is typically used name for metal-enclosed or metal-
clad low-voltage power circuit breaker switchgear rated for 600 V alternating
current (AC) and below.
 Indoor switchgear consists of a front section containing circuit breakers,
meters, protection relays and controls, bus section, and cable entrance
section. Whereas, the outdoor section is similar to the indoor switchgear
except a structure that is provided around it for weather-proofing.
 Low-voltage switchgear takes on many specific forms and functions that
combine metering, monitoring, control, protection, and distribution.
 Low-voltage switchgear is often found on the secondary (low-voltage) side
of a power distribution transformer. This transformer and switchgear
combination is known as a substation.
 Low-voltage switchgear is typically used to feed low-voltage motor control
centers (LV-MCC), low-voltage switchboards and other branch and feeders.
 It is used to supply electricity for critical power and critical process
applications such as those found in heavy industry, manufacturing, mining
and metals, petrochemical, pulp and paper, utility, water treatment as
well as datacenter and healthcare.
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 Miniature Circuit Breakers (MCB)
MCB or Miniature Circuit Breaker is an electromechanical device that protects an
electric circuit from an overcurrent. The overcurrent in an electrical circuit may
result from short circuit, overload or faulty design.

MCBs are used in residential & commercial areas. It is a better alternative to a

Fuse since it does not require replacement once an overload is detected. Unlike a
fuse, an MCB can be easily operated and thus offers improved operational safety
and greater convenience without incurring a large operating cost. They are used to
protect lower current circuits and have the following specifications:
 Current rating – Amperes (0.5 A to 125 A)
 Short Circuit Rating – Kilo Amperes ( up to 25 kA)
 Operating Characteristics – B, C, D, Z or K Curves

@Rezwan B type C type D type K type Z type

 Miniature Circuit Breakers (MCB)
Construction:
Most MCB designs are of single-pole construction for use in single-phase circuits.
The complete system is housed within a plastic molding and it is made of flame-
retardant high-strength plastic.
 MCBs are fitted with arc chute stack consisting of various arc chutes (metal
plates) which are held by the position by an insulating material.
 The thermal tripping mechanism consists of a thermal-magnetic arrangement
where thermal action is provided by a bimetallic strip and in some cases by a
heater. The tripping mechanism is activated by the deflection of the
bimetallic strip.
 The magnetic tripping mechanism consists of a coil which is wounded
around a tube. The coil is made up of thin wire with many turns for low
rating MCBs and a thicker wire with fewer turns for higher heating MCBs.
 Depending on the required characteristics, the magnetic tripping is set by the
manufacturer

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 Miniature Circuit Breakers (MCB)
Operation:
The working of a miniature circuit breaker in case of overload and short circuit fault
is, (i) For overload protection, they have a Bi-metallic strip (produces thermal
effect) which causes the circuit to open, and (ii) For short circuit protection, it has
an electromagnetic (produces electromagnetic effect) kind of thing.

Fig. Thermal-magnetic circuit breaker trip latch operation: (a) normal and
(b) overcurrent condition
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 Miniature Circuit Breakers (MCB)
Operation:
 The thermal operation of the miniature circuit breaker is achieved with a
bimetallic strip. Whenever continuous over electric current flows through
MCB, the bimetallic strip is heated and deflects by bending. This deflection of
bimetallic strip releases the mechanical latch. As this mechanical latch is
attached with the operating mechanism, it causes to open the miniature circuit
breaker contacts.
 But during short circuit condition, the sudden rising of electric current causes
electromechanical displacement of plunger associated with tripping coil or
solenoid of MCB. The plunger strikes the trip lever causing an immediate
release of latch mechanism consequently open the circuit breaker contacts.

Fig. Thermal-magnetic circuit

breaker trip latch operation: (a)
normal and (b) overcurrent
condition

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 Types of MCB based on Tripping Characteristics

The tripping current and operating time of each of the above MCB types are given
in the table below.

Type Tripping Current Operating Time

Type B 3 To 5 times the full load current 0.04 To 13 Sec

Type C 5 To 10 times the full load current 0.04 To 5 Sec

Type D 10 To 20 times the full load current 0.04 To 3 Sec

Type K 8 To 12 times the full load current <0.1 Sec

Type Z 2 To 3 times the full load current <0.1 Sec

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 Typical Loads by Tripping Curve - MCB

Z Curve: Designed to protect circuits that

need a very low short circuit trip setting
(Ex: Semiconductors)

B Curve: Designed for cable protection

(Ex: Control circuits, lighting)

C Curve: Designed for medium magnetic

startups (Ex: Lighting panels, control
panels)

D and K Curves: Designed to allow for

high inrush loads (Ex: Motor or
transformation circuits)

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 Selection of Right MCB
The decision to use Type B, C or D miniature circuit breakers for final circuit
protection in residential, commercial, industrial or public buildings can be based on
a few simple rules. It should be noted that the primary purpose of circuit protection
devices such as miniature circuit breakers and fuses is to protect the cable
downstream of the device. The essential distinction between Type B, C or D
devices is based on their ability to handle surge currents without tripping. These
are, typically, inrush currents associated with fluorescent and other forms of
discharge lighting, induction motors, battery charging equipment, etc.
 Type B, C, and D are used for overcurrent protection of cables in
accordance with IEC/EN 60898-1
 Type K for the protecting motors and transformers and simultaneous
overcurrent protection of cables with overload tripping based on IEC/EN
60947-2
 Type Z for control circuits with high impedances, voltage converter
circuits, and semi cable protection and simultaneous overcurrent protection
of cables with overload tripping based on IEC/EN 60947-2.

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 MCB Selection Table
The MCB selection table helps to choose the right MCB for protecting the circuit.

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 Selecting the Rating Of MCB at a Particular Circuit
If the proper rating is not selected on a particular circuit, there will be no proper
functions of MCB at overload. Therefore it is very important to select the right
rating of MCB which can be easily calculated as under.

Example
Let’s imagine you have 4 Fans, 1 TV, 4 Tubes, 1 V.C.D., 1 Refrigerator & 1 1.5
Ton Air Conditioner on a particular circuit.

The current in that circuit will be :

(4 x 0.40) + (0.55) + (4×0.20) + (0.22) + (1.6) + (11) = 16 A

Therefore, the suitable rating of MCB will be 20 AMP B Series.

Ref.:
https://studyelectrical.com/2014/07/miniature-circuit-breakers-mcb-types-characteristic-curves.html
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 Molded-Case Circuit Breakers (MCCB)
MCCB is an electromechanical safety device used to protect an electrical circuit
from overload or short circuits. It works by automatically cutting off the power
supply when a fault or overcurrent situation arises, thus preventing any damage to
the electrical system. MCCBs can be used in both low-voltage and high-voltage
systems.

MCCBs are used in high energy requirement regions such as high-power equipment
in industries or for commercial purposes (ranges from 16 A to 3000 A). It is
generally installed on the secondary side of transformer stations (main switch or for
protecting individual branches), in the distribution panel and provide a visible
indication. Unlike an MCB, the trip characteristics of MCCBs are changeable as per
the requirement. Except the mold (covering), the operating principles/working of
MCCB is almost same as MCB. It has the following specifications:
 Current rating – Amperes (64 A to 3000 A)
 Current Setting Range – Amperes
 Short Circuit Rating – Kilo Amperes ( up to 100 kA)
 Operating Characteristics – Normal / Current Limiting Type

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 Molded-Case Circuit Breakers (MCCB)
Construction:
The molded case or frame is the cushion that keeps all parts of the circuit breaker in
place. It is solidly built from ‘glass polyester’ or ‘thermoset composite resin that
gives a great nonconducting strength despite its compressed size.
 A Molded case circuit breaker generally have - a thermal element for overcurrent
and a magnetic element for short circuit release which has to operate faster (same as
MCB). MCCBs are manufactured such a way that end user will not have access to
internal workings of the over-current protection system. Additionally it has an arc
extinguishing device which extinguishes the arc generated upon current interruption.

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 Molded-Case Circuit Breakers (MCCB)
Operation / Working Principles:
The MCCB uses a temperature sensitive device (the thermal element) with a current
sensitive electromagnetic device (the magnetic element) to provide the trip
mechanism for protection and isolation purposes. This enables the MCCB to
provide: A. Overload Protection, B. Electrical Fault Protection against short circuit
currents, and C. Electrical Switch for disconnection.

A. Overload Protection: It is provided by the MCCB via the temperature sensitive

component. This component is essentially a bimetallic contact: a contact which
consists of two metals that expand at different rates when exposed to high
temperature. During the normal operating conditions, the bimetallic contact will
allow the electric current to flow through the MCCB. When the current exceeds the
trip value, the bimetallic contact will start to heat and bend away due to the different
thermal rate of heat expansion within the contact. Eventually, the contact will bend
to the point of physically pushing the trip bar and unlatching the contacts, causing
the circuit to be interrupted. The thermal protection of the MCCB will typically
have a time delay to allow a short duration of overcurrent which is commonly seen
in some device operations (eg. starting of motors).

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 Molded-Case Circuit Breakers (MCCB)
Operation / Working Principles:
The MCCB uses a temperature sensitive device (the thermal element) with a current
sensitive electromagnetic device (the magnetic element) to provide the trip
mechanism for protection and isolation purposes. This enables the MCCB to
provide: A. Overload Protection, B. Electrical Fault Protection against short circuit
currents, and C. Electrical Switch for disconnection.

B. Electrical Fault Protection against short circuit currents: MCCBs provides an

instantaneous response to a short circuit fault, based on the principle of
electromagnetism. The MCCB contains a solenoid coil which generates a small
electromagnetic field when current passes through the MCCB. During normal
operation, the electromagnetic field generated by the solenoid coil is negligible.
However, when a short circuit fault occurs in the circuit, a large current begins to
flow through the solenoid and, as a result, a strong electromagnetic field is
established which attracts the trip bar and opens the contacts.

C. Electrical Switch for disconnection: MCCBs can also be used as manual

disconnection switches in case of emergency or maintenance. An arc can be created
when the contact opens which is quenched by internal arc dissipation mechanisms.
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 Air Circuit Breakers (ACB)
Air Circuit Breaker (ACB) is an electrical device used to provide Overcurrent and
short-circuit protection for electric circuits over 800 Amps to 10K Amps. These are
usually used in low voltage applications below 450V. An air circuit breaker is a
circuit operation breaker that operates in the air as an arc extinguishing medium, at
a given atmospheric pressure.
Air circuit breakers are mainly in use for controlling power stations and industrial
plants. The reason is that they are good at controlling low voltage equipment. These
circuit breakers are used in places with a high possibility of fire or explosion
hazards in most cases.
Not to be confused with Air-Blast Circuit Breakers, which are of high capacity
breakers and can be seen in old substations mainly above 132 kV.

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 Air Circuit Breakers (ACB)
Working Principle:
Air Circuit breakers normally have two pairs of contacts. The main pair of contacts
carry the current at normal load and these contacts are made of copper. The
additional pair is the arcing contact and is made of carbon.

 When the circuit breaker is being opened, the main contacts open first and
during the opening of main contacts the arcing contacts are still in touch with
each other.
 As the current gets a parallel low resistive path through the arcing contact
during the opening of main contacts, there will not be any arcing in the main
contact.
 The arcing is only initiated when finally the arcing contacts are separated. Each
of the arc contacts is fitted with an arc chute which helps the arc discharge to
move upward due to both thermal and electromagnetic effects.
 As the arc is driven upward it enters in the arc chute, consisting of splitters. The
arc in chute will become colder, lengthen and split hence arc voltage becomes
much larger than system voltage at the time of operation of the air circuit
breaker, and therefore the arc is quenched finally during the current zero.
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 Air Circuit Breakers (ACB)

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Calculation/ Selection of Circuit Breaker
Classification of CB according to Current Ratings:

MCB 6 A – 63 A

MCCB 64 A – 800 A

ACB Above 800 A

Standard Size of CB:

6A, 10A, 16A, 20A, 25A, 32A, 40A, 50A, 63A, 80A, 100A, 125A, 160A, 180A, 200A,
250A, 300A, 350A, 400A, 630A, 800A, 1000A, 1500A 1600A, 2000A, 2500A, 3000A,
3500A, 4000A, 4500A & 5000A

Circuit Breaker Size:-

 CB size depends on the load current.
 Tripping time for HT side CB <3 sec
 Tripping time for LT side CB =(0.01 to 1) sec
 According to NEC. 80% of the rated current is a safe current limit to flow

CB Size = 1.25 x Full load current

Calculation/ Selection of Circuit Breaker

At Feeder 1: TCL is 82 kW. Calculate

current for the load of 82 kW.

Since, 82 kW > 5 kW; therefore it is required to consider 3- ф system

Then, P = √3VICos ϕ. Where V = 415 V, Cos ϕ = 0.8, P = 82kW
∴ I = 142.77 A
CB Size = 1.25 x Full load current = 1.25 x 142.77 = 178.46 A

So, proposed size of the CB = 180A, MCCB

* Thermostatically Controlled Load (TCL), aggregated power
Calculation/ Selection of Circuit Breaker

At Feeder 2: TCL is 130 kW. Calculate

current for the load of 130 kW.

Since, 130 kW > 5 kW; therefore it is required to consider 3- ф system

Then, P = √3VICos ϕ. Where V = 415 V, Cos ϕ = 0.8, P = 130 kW
∴ I = 226.34 A
CB Size = 1.25 x Full load current = 1.25 x 226.34 = 282.92 A

So, proposed size of the CB = 300A, MCCB

* Thermostatically Controlled Load (TCL), aggregated power
Calculation/ Selection of Circuit Breaker

At Feeder 3: TCL is 15 HP. Calculate

current for the load of 15 HP.

Since, 15 HP > 6 HP; therefore it is required to consider 3- ф system

Then, P = √3VICos ϕ. Where V = 415 V, Cos ϕ = 0.8, P = 15 HP x 746 = 11.19 kW
∴ I = 19.48 A
CB Size = 1.25 x Full load current = 1.25 x 19.48 = 24.35 A

So, proposed size of the CB = 25A, MCB

* Thermostatically Controlled Load (TCL), aggregated power
Calculation/ Selection of Circuit Breaker

At Feeder 4: TCL is 2 kW. Calculate

current for the load of 2 kW.

Since, 2 kW < 5 kW; therefore it is required to consider 1- ф system

Then, P = VICos ϕ. Where V = 230 V, Cos ϕ = 0.8, P = 2 kW
∴ I = 10.87 A
CB Size = 1.25 x Full load current = 1.25 x 10.87 = 13.59 A

So, proposed size of the CB = 16A, MCB

* Thermostatically Controlled Load (TCL), aggregated power
Calculation/ Selection of Circuit Breaker

At Feeder 5: TCL is 80 kW. Calculate

current for the load of 80 kW.

Since, 80 kW > 5 kW; therefore it is required to consider 3- ф system

Then, P = √ VICos ϕ. Where V = 415 V, Cos ϕ = 0.8, P = 80 kW
∴ I = 139.28 A
CB Size = 1.25 x Full load current = 1.25 x 139.28 = 174.1 A

So, proposed size of the CB = 180A, MCCB

* Thermostatically Controlled Load (TCL), aggregated power