AIR CIRCUIT BREAKER.

Circuit Breakers need a way to operate. This can be locally

(when you stand in front of the CB) or remotelly by giving an
electrical signal commanding the circuit breaker to close.
Before to be able to close CB you have to charge a strong
spring inside CB . This charged spring is used to close CB
contacts internally. So for local operation you manually charge
the spring using a particular lever for that purpose. With a
button mounted on the CB front face, you press it and you
close the CB. When you want remote operation of the CB you
need a kind of motor to charge the internal spring (so we call
this CB motorized). Moreover, for remote operation you need a
couple of electrical reles (coils) such as "close coil" and "open
coil". This coils are capable to be remotelly energized by a
signal and thus can close / open the CB. Since we talk about
open/close coils it is clear that coils need auxiliary power to
operate. If for some reason auxiliary power is lost, then you are
not able to operate the coils (close / open). Imagine that you
have sucessfully closed circuit breaker (by remotely energizing
close coil) but during operation for some stupid reason auxiliary
voltage is lost . As a result you can't open the CB!
UnderVoltage Coil comes to cover this hole. In case auxiliary
power required for the coils to work is lost, the undervoltage trip
coil forces the opening of the circuit breaker. Notice that
undervoltage trip coil is optional. Close and Open coils is
mandatory for remote operation.
Basic Specification
Rated voltage 400V, 690V
Rated current 200A to 1000A
Type Conventional
Nominal Insulation Voltage 400V
Poles Number 3
Detail Description

DW50 air circuit breaker (hereinafter referred as ACB), is suitable for

distribution network of AC 50Hz, with rated voltage of 400V/690V, rated
current of 200A ~ 1000A. It can be used to distribute electric energy, protect
the circuit and power equipment against overload, under-voltage, short-
circuit, single-phase earthing, etc. ACB has intelligent protection function,
accurate fault diagnosis, good selectivity, high sensitivity, and can improve
the reliability and security of power supply. Its easy to operate. Whats more,
the operating mechanism and related accessories produced by our factory is
fully adapted to this product.
II. Working Description of the Operating Mechanism:
The product includes operating modes of manual and electric, and adopts
closing method of spring energy storage (pre-energy storage). Closing speed
has nothing to do with electric and manual operation. The product adopts a
cam to compress a set of springs to achieve the purpose of energy storage,
and has a trip-free function.
The ACB has three operating positions:
a ) Energy storage: electrically operated or manually operated external force
drives the cam to rotate. Energy storage lever is on the cam, the lever
compresses the energy storage spring as the cam rotates. When the cam
rotates to a certain angle, energy storage ends through a series of drive inside
the mechanism.
b) Closing: press the ON button (on the intelligent trip unit or the button
supplied by the user to connect the energy - releasing electromagnet), so that
the energy - releasing tripping Axle rotates, energy storage lever trips. Under
the force of energy storage spring, the spindle rotates driven by a powerful
series of transmission, so that the contact is closed.
c) Disconnect: pressing the OFF button or the signal from overcurrent,
undervoltage and shunt,and test trip signal on the intelligent trip unit, so
breaking trip Axle rotates, and lever trips, linkage mechanism changes, then
the ACB is disconnected rapidly under the reaction force of the contact and
the reset force of the spring.
* Interlocking mechanism: its installed on the right panel of the ACB, stack
assemble the ACB with rod connecting interlock, to flat the ACB(fixed or
drawout type) and interlock it by steel cable, when one of the ACB is on,
another will be off, the interlocking mechanism should be installed by the
user.
III. The Operating Performance

Air Circuit breaker

1. 2. Electrical Circuit Breaker is a switching device

which can be operated manually as well as
automatically for controlling and protection of
electrical power system respectively. As the modern
power system deals with huge currents, the spacial
attention should be given during designing of circuit
breaker to safe interruption of arc produced during
 the operation of circuit breaker. This was the basic
definition of circuit breaker.
2. 3. The modern power system deals with huge power
network and huge numbers of associated electrical
equipment. During short circuit fault or any other
types of electrical fault these equipment as well as
the power network suffer a high stress of fault
current in them which may damage the equipment
and networks permanently. For saving these
equipments and the power networks the fault current
should be cleared from the system as quickly as
possible
3. 4. . Again after the fault is cleared, the system must
come to its normal working condition as soon as
possible for supplying reliable quality power to the
receiving ends. In addition to that for proper
controlling of power system, different switching
operations are required to be performed. So for
timely disconnecting and reconnecting different
parts of power system network for protection and
control, there must be some special type of
switching devices which can be operated safely
under huge current carrying condition. During
interruption of huge current, there would be large
arcing in between switching contacts, so care should
be taken to quench these arcs in safe manner. The
circuit breaker is the special device which does all
the required switching operations during current
carrying condition. This was the basic introduction to
circuit breaker
4. 5. The circuit breaker mainly consists of fixed
contacts and moving contacts. In normal "on"
condition of circuit breaker, these two contacts are
physically connected to each other due to applied
mechanical pressure on the moving contacts. There
is an arrangement stored potential energy in the
operating mechanism of circuit breaker which is
realized if switching signal given to the breaker. The
potential energy can be stored in the circuit breaker
by different ways like by deforming metal spring, by
compressed air, or by hydrolic pressure. But
whatever the source of potential energy, it must be
released during operation. Release of potential
energy makes sliding of the moving contact at
extremely fast manner.
5. 6. All circuit breaker have operating coils (tripping
coils and close coil), whenever these coils are
energized by switching pulse, the plunger inside
them displaced. This operating coil plunger is
typically attached to the operating mechanism of
circuit breaker, as a result the mechanically stored
potential energy in the breaker mechanism is
released in forms of kinetic energy, which makes the
moving contact to move as these moving contacts
mechanically attached through a gear lever
arrangement with the operating mechanism.
6. 7. After a cycle of operation of circuit breaker the
total stored energy is released and hence the
potential energy again stored in the operating
mechanism of circuit breaker by means of spring
charging motor or air compressor or by any other
 means. Till now we have discussed about mechanical
working principle of circuit breaker. But there are
electrical characteristics of a circuit breaker which
also should be consider in this discussion of
operation of circuit breaker.
7. 8. Let's have a discussion on electrical principle of

circuit breaker The circuit breaker has to carry large

rated or fault power. Due to this large power there is
always dangerously high arcing between moving
contacts and fixed contact during operation of circuit
breaker. Again as we discussed earlier the arc in
circuit breaker can be quenching safely if the
dielectric strength between the current carrying
contacts of circuit breaker increases rapidly during
every current zero crossing of the alternating
current.
8. 9. The dielectric strength of the media in between

contacts can be increased in numbers of ways, like

by compressing the ionized arcing media since
compressing accelerates the deionization process of
the media, by cooling the arcing media since cooling
increase the resistance of arcing path or by
replacing the ionized arcing media by fresh gasses.
Hence a numbers of arc quenching processes should
be involved in operation of circuit breaker.
9. 10. According different criteria there are different

types of circuit breaker According to their arc

quenching media the circuit breaker can be divided
as
10. 11. According to their services the circuit breaker

can be divided as 1) Outdoor Circuit Breaker 2)

 Indoor Breaker According to the operating
mechanism of circuit breaker they can be divided as
1) Spring operated Circuit Breaker 2) Pneumatic
Circuit Breaker 3) Hydrolic Circuit Breaker
11. 12. According to the voltage level of installation

types of circuit breaker are referred as 1) High

Voltage Circuit Breaker 2) Medium Voltage Circuit
Breaker 3) Low Voltage Circuit Breaker
12. 13. Before going through details arc quenching or arc

extinction technologies employed in circuit breaker

we should know first what is arc actually. What is arc
? During opening of current carrying contacts in a
circuit breaker the medium in between opening
contacts become highly ionized through which the
interrupting current gets low resistive path and
continues to flow through this path even the
contacts are physically separated. During the flowing
of current from one contact to other the path
becomes so heated that it glows. This is called arc.
13. 14. Arc in Circuit Breaker Whenever, on load current

contacts of circuit breaker open there is an arc in

circuit breaker, established between the separating
contacts. As long as this arc is sustained in between
the contacts the current through the circuit breaker
will not be interrupted finally as because arc is itself
a conductive path of electricity. For total interruption
of current the circuit breaker it is essential to
quench the arc as quick as possible. The main
designing criteria of a circuit breaker is to provide
appropriate technology of arc quenching in circuit
breaker to fulfill quick and safe current interruption.
14. 15. This type of circuit breakers, is those kind of
circuit breaker which operates in air at atmospheric
pressure. After development of oil breaker, the
medium voltage air circuit breaker (ACB) is replaced
completely by oil circuit breaker in different
countries. But in countries like France and Italy,
ACBs are still preferable choice up to voltage 15 KV.
It is also good choice to avoid the risk of oil fire, in
case of oil circuit breaker. In America ACBs were
exclusively used for the system up to 15 KV until the
development of new vacuum and SF6 circuit
breakers.
15. 16. Working principle of Air Circuit Breaker The

working principle of this breaker is rather different

from those in any other types of circuit breakers. The
main aim of all kind of circuit breaker is to prevent
the reestablishment of arcing after current zero by
creating a situation where in the contact gap will
withstand the system recovery voltage. The air
circuit breaker does the same but in different
manner. For interrupting arc it creates an arc voltage
in excess of the supply voltage. Arc voltage is
defined as the minimum voltage required maintaining
the arc. This circuit breaker increases the arc
voltage by mainly three different ways,
16. 17. It may increase the arc voltage by cooling the arc

plasma. As the temperature of arc plasma is

decreased, the mobility of the particle in arc plasma
is reduced; hence more voltage gradient is required
to maintain the arc. It may increase the arc voltage
by lengthening the arc path. As the length of arc path
 is increased, the resistance of the path is increased,
and hence to maintain the same arc current more
voltage is required to be applied across the arc path.
That means arc voltage is increased. Splitting up the
arc into a number of series arcs also increases the
arc voltage.
17. 18. There are mainly two types of ACB are available.

1) Plain air circuit breaker 2) Air blast Circuit

Breaker.
18. 19. Operation of ACB The first objective is usually

achieved by forcing the arc into contact with as large

an area as possible of insulating material. Every air
circuit breaker is fitted with a chamber surrounding
the contact. This chamber is called 'arc chute'. The
arc is driven into it. If inside of the arc chute is
suitably shaped, and if the arc can be made conform
to the shape, the arc chute wall will help to achieve
cooling. This type of arc chute should be made from
some kind of refractory material. High temperature
plastics reinforced with glass fiber and ceramics are
preferable materials for making arc chute.
19. 20. The second objective that is lengthening the arc

path, is achieved concurrently with fist objective. If

the inner walls of the arc chute is shaped in such a
way that the arc is not only forced into close
proximity with it but also driven into a serpentine
channel projected on the arc chute wall. The
lengthening of the arc path increases the arc
resistance. The third technique is achieved by using
metal arc slitter inside the arc chute. The main arc
 chute is divided into numbers of small compartments
by using metallic separation plates.
20. 21. These metallic separation plates are actually the

arc splitters and each of the small compartments

behaves as individual mini arc chute. In this system
the initial arc is split into a number of series arcs,
each of which will have its won mini arc chute. So
each of the split arcs has its won cooling and
lengthening effect due to its won mini arc chute and
hence individual split arc voltage becomes high.
These collectively, make the over all arc voltage,
much higher than the system voltage. This was
working principle of air circuit breaker now we will
discuss in details the operation of ACB in practice.
21. 22. The air circuit breaker, operated within the

voltage level 1KV, does not require any arc control

device. Mainly for heavy fault current on low voltages
(low voltage level above 1 KV) ABCs with appropriate
arc control device, are good choice. These breakers
normally have two pairs of contacts. The main pair of
contacts carries 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 circuit breaker is being opened, the main
contacts open first and during opening of main
contacts the arcing contacts are still in touch with
each other.
22. 23. As the current gets, a parallel low resistive path

through the arcing contact during 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. The each of the arc
contacts is fitted with an arc runner which helps, the
arc discharge to move upward due to both thermal
and electromagnetic effects as shown in the figure.
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 air circuit breaker, and therefore the arc
is quenched finally during the current zero.
23. 24. Although this type of circuit breakers have

become obsolete for medium voltage application, but

they are still preferable choice for high current rating
in low voltage application.
24. 25. These types of air circuit breaker were used for

the system voltage of 245KV, 420KV and even more,

especially where faster breaker operation was
required. Air Blast Circuit Breaker has some specific
advantages over oil circuit breaker which are listed
as follows, 1) There is no chance of fire hazard
caused by oil. 2) The breaking speed of circuit
breaker is much higher during operation of air blast
circuit breaker.
25. 26. 3) Arc quenching is much faster during operation

of air blast circuit breaker. 4) The duration of arc is

same for all values of small as well as high currents
interruptions. 5) As the duration of arc is smaller, so
lesser amount of heat realized from arc to current
carrying contacts hence the service life of the
contacts becomes longer. 6) The stability of the
system can be well maintained as it depends on the
 speed of operation of circuit breaker. 7) Requires
much less maintenance compared to oil circuit
breaker.
26. 27. There are also some disadvantages of air blast

circuit breakers 1) In order to have frequent

operations, it is necessary to have sufficiently high
capacity air compressor. 2) Frequent maintenance of
compressor, associated air pipes and automatic
control equipments is also required. 3) Due to high
speed current interruption there is always a chance
of high rate of rise of re-striking voltage and current
chopping. 4) There also a chance of air pressure
leakage from air pipes junctions.
27. 28. As we said earlier that there are mainly two

types of ACB, plain air circuit breaker and air blast

circuit breaker. But the later can be sub divided
further into three different categories. a) Axial Blast
ACB. b) Axial Blast ACB with side moving contact. c)
Cross Blast ACB.
28. 29. In Axial Blast ACB the moving contact is in

contact with fixed contact with the help of a spring

pressure as shown in the figure. There is a nozzle
orifice in the fixed contact which is blocked by tip of
the moving contact at normal closed condition of the
breaker. When fault occurs, the high pressure air is
introduced into the arcing chamber. The air pressure
will counter the spring pressure and deforms the
spring hence the moving contact is withdrawn from
the fixed contact and nozzle hole becomes open. At
the same time the high pressure air starts flowing
along the arc through the fixed contact nozzle
 orifice. This axial flow of air along the arc through
the nozzle orifice will make the arc lengthen and
colder hence arc voltage become much higher than
system voltage that means system voltage is
insufficient to sustain the arc consequently the arc
is quenched.
29. 30. In this type of axial blast air circuit breaker the

moving contact is fitted over a piston supported over

a spring. In order to open the circuit breaker the air
is admitted into the arcing chamber when pressure
reaches to a predetermined value, it presses down
the moving contact; an arc is drawn between the
fixed and moving contacts. The air blast immediately
transfers the arc to the arcing electrode and is
consequently quenched by the axial flow of air.
30. 31. The working principle of Cross Blast Air Circuit

Breaker is quite simple. In this system of air blast

circuit breaker the blast pipe is fixed in
perpendicular to the movement of moving contact in
the arcing chamber and on the opposite side of the
arcing chamber one exhaust chamber is also fitted at
the same alignment of blast pipe, so that the air
comes from blast pipe can straightly enter into
exhaust chamber through the contact gap of the
breaker. The exhaust chamber is spit with arc
splitters. When moving contact is withdrawn from
fixed contact, an arc is established in between the
contact, and at the same time high pressure air
coming from blast pipe will pass through the contact
gap and will forcefully take the arc into exhaust
 chamber where the arc is split with the help of arc
splitters and ultimately arc is quenched
31. 32. References : 1) Electrical Engineering Online

Electrical Engineering Study Site

A low-voltage circuit breaker is one which is suited for

circuits rated at 600 volts or lower. One of the most
commonly used low-voltage air circuit breakers is the
molded case circuit breaker (picture above).
A circuit can be connected or disconnected using a
circuit breaker by manually moving the operating handle
to the ON or OFF position. All breakers, with the
exception of very small ones, have a linkage between
the operating handle and contacts that allows a quick
make (quick break contact action) regardless of how
fast the operating handle is moved . The handle is also
designed so that it cannot be held shut on a short
circuit or overload condition. If the circuit breaker
opens under one of these conditions, the handle will go
to the trip-free position. The trip-free position is midway
between the ON and OFF positions and cannot be re-
shut until the handle is pushed to the OFF position and
reset.
A circuit breaker will automatically trip when the
current through it exceeds a pre-determined value. In
lower current ratings, automatic tripping of the circuit
breaker is accomplished by use of thermal tripping
devices. Thermal trip elements consist of a bimetallic
element that can be calibrated so that the heat from
normal current through it does not cause it to deflect.
An abnormally high current, which could be caused by a
short circuit or overload condition, will cause the
element to deflect and trip the linkage that holds the
circuit breaker shut.

The circuit breaker will then be opened by spring action.

This bimetallic element, which is responsive to the heat
produced by current flowing through it, has an inverse-
time characteristic. If an extremely high current is
developed, the circuit breaker will be tripped very
rapidly.

A cutaway view of the molded case circuit breaker is

shown in Figure 1.
 Figure 1 - Cutaway
view of the molded case circuit breaker

For moderate overload currents, it will operate more

slowly. Molded case breakers with much larger current
ratings also have a magnetic trip element to supplement
the thermal trip element. The magnetic unit utilizes the
magnetic force that surrounds the conductor to operate
the circuit breaker tripping linkage.
When the separable contacts of an air circuit breaker
are opened, an arc develops between the two contacts.
Different manufacturers use many designs and
arrangements of contacts and their surrounding
chambers. The most common design places the moving
contacts inside of an arc chute. The construction of this
arc chute allows the arc formed as the contacts open to
draw out into the arc chute. When the arc is drawn into
the arc chute, it is divided into small segments and
quenched. This action extinguishes the arc rapidly,
which minimizes the chance of a fire and also minimizes
damage to the breaker contacts.

Molded case circuit breakers come in a wide range of

sizes and current ratings. There are six frame sizes
available: 100, 225, 400, 600, 800, and 2,000 amps. The
size, contact rating, and current interrupting ratings are
the same for all circuit breakers of a given frame size.
The continuous current rating of a breaker is governed
by the trip element rating. The range of voltage
available is from 120 to 600 volts, and interrupting
capacity ranges as high as 100,000 amps.

Much larger air circuit breakers are used in large

commercial and industrial distribution systems. These
circuit breakers are available in much higher continuous
current and interrupting ratings than the molded case
circuit breaker. Breakers of this type have current
ratings as high as 4,000 amps, and interrupting ratings
as high as 150,000 amps.

Most large air circuit breakers use a closing device,

known as a stored energy mechanism, for fast,
positive closing action. Energy is stored by compressing
large powerful coil springs that are attached to the
contact assembly of a circuit breaker. Once these
springs are compressed, the latch may be operated to
release the springs, and spring pressure will shut the
circuit breaker.

Circuit breaker closing springs may be compressed

manually or by means of a small electric motor. This
type of circuit breaker can be classified as either a
manually- or electrically-operated circuit breaker. When
a large air circuit breaker is closed, the operating
mechanism is latched. As the circuit breaker is closed, a
set of tripping springs, or coils, are compressed, and the
circuit breaker may then be tripped by means of a trip
latch. The trip latch mechanism may be operated either
manually or remotely by means of a solenoid trip coil.

As previously stated, circuit breakers may be operated

either manually or electrically. Electrically-operated
circuit breakers are used when circuit breakers are to
be operated at frequent intervals or when remote
operation is required.

Manually operated circuit breaker

The manually-operated circuit breaker closing springs

are normally compressed by a hand crank just prior to
operation of the breaker. Figure 6 shows a large air
circuit breaker which is classified as a manually-
operated stored energy circuit breaker. The closing
springs are compressed by pulling downward on the
large operating handle on the front of the breaker.
Closing this circuit breaker is accomplished manually by
depressing the small closing lever.

Tripping this circuit breaker is done by means of the

tripping lever, located at the bottom front of the breaker.
 Thermal-Magnetic Trip Unit
In addition to providing a means to open and close its
contacts manually, a circuit breaker must automatically
open its contacts when an overcurrent condition is
sensed.

The trip unit is the part of the circuit breaker that

determines when the contacts will open automatically.

In a thermal-magnetic circuit breaker, the trip unit

includes elements designed to sense the heat resulting
from an overload condition and the high current
resulting from a short circuit. In addition, some thermal
magnetic circuit breakers incorporate a PUSH TO TRIP
button.

Trip Mechanism

The trip unit includes a trip mechanism that is held in

place by the tripper bar. As long as the tripper bar holds
the trip mechanism, the mechanism remains firmly
locked in place.
 Trip Unit with Trip Mechanism

The operating mechanism is held in the ON position by

the trip mechanism. When a trip is activated, the trip
mechanism releases the operating mechanism, which
opens the contacts.

Note: the drawings in this section show an AC power

source; however, a DC source could also be used.

The operating mechanism is held in the

ON position by the trip mechanism.
Manual Trip

Some molded case circuit breakers, especially larger

breakers, can be manually tripped by pressing the
PUSH TO TRIP button on the face of the circuit
breaker. When the button is pressed the tripper bar
rotates up and to the right. This allows the trip
mechanism to unlock releasing the operating
mechanism.

The operating mechanism opens the contacts.

The PUSH TO TRIP button also serves as a safety

device by preventing access to the circuit breaker
interior in the ON position. If an attempt is made to
remove the circuit breaker cover while the contacts are
in the closed (ON) position, a spring located under the
pushbutton causes the button to lift up and the breaker
to trip.

Manual trip mechanism

Overload Trip

Thermal-magnetic circuit breakers employ a bi-metalic

strip to sense overload conditions. When sufficient
overcurrent flows through the circuit breakers current
path, heat build up causes the bi-metalic strip to bend.
After bending a predetermined distance, the bi-metalic
strip makes contact with the tripper bar activating the
trip mechanism.

Thermal-magnetic circuit breakers

employ a bi-metalic strip to sense overload conditions.

Circuit breaker contacts

A bi-metalic strip is made of two dissimilar metals
bonded together. The two metals have different thermal
expansion characteristics, so the bi-metalic strip bends
when heated. As current rises, heat also rises.

The hotter the bi-metalic becomes the more it bends.

After the source of heat is removed, as when the circuit
breaker contacts open, the bi-metalic strip cools and
returns to its original condition. This allows a circuit
breaker to be manually reset once the overload
condition has been corrected.
Short Circuit Trip

As previously described, current flow through a circuit

breakers blow-apart contacts creates opposing
magnetic fields. Under normal operating conditions,
these opposing forces are not sufficient to separate the
contacts. When a short circuit occurs, however, these
opposing forces increase significantly.

The current that flows through the contacts also flows

through a conductor that passes close to the circuit
breakers trip unit. At fault current levels, the magnetic
field surrounding this conductor provides sufficient
force to unlatch the trip unit and trip the breaker.

Short Circuit Trip

The combined actions of magnetic fields forcing

contacts apart while simultaneously tripping the circuit
breaker result in rapid interruption of the fault current.
In addition, because the magnetic forces are
proportional to the current, the greater the fault current,
the shorter the time it takes to interrupt the current.

SOURCE: SIE
 Air Circuit Breakers : Charging method
Manual charging type
The closing coil is charged by manual charging handle. For
closing, first charge the spring by using the charging handle, and
then press the close button(I, ON) for closing, the open button(O,
OFF) for opening
When closing spring is completely charged, charge indicator
indicate "Charge"
It is mechanically locked not to press the close button(I, ON) and
open button(O, OFF) simultaneously
Contact condition of the main circuit is shown on the(O, OFF), (I,
ON) indicator.

Motor charging type

The closing spring is charged by a motor ON charging method or
OFF charging method is available selectively.
-OFF charging method : When the breaker is opened, the closing
spring is charged automatically. It can change to ON charging method
by removing b(Ab) contact like beside circuit diagram
 -ON charging method : The closing spring is charged automatically
when the breaker is closed.It can change to OFF charging method by
using b(Ab) contact. There is a contact to indicate the charging
completion(TS+, TS-). Since the contact signal of charging completion
switch is connected to the external terminal, It is easy to construct a
circuit(ex.Automatic closing circuit) by using that contact
Manual charging is also available
With the breaker closed(I, ON), only manual charging is
possible(motor charging cannot be performed)
With the open button(O, OFF) pressed, closing cannot be
performed(electrical and mechanical lock)
When OFF Lock device is in use, closing cannot be worked.
(electrical and mechanical lock)
Opening should follow at least one second after completion of
charging
Pumping prevent circuit is included with the closing coil(electrical
lock)
Please note that pumping prevent circuit can be reset when the
voltage of input signal drops
Voltage Reset voltage
AC Rated voltage 85% under
DC Rated voltage 85% under
Motor charging circuit

Note
*1
Since charging completion contact (TS+, TS-) terminal is for
contact output power should not be allowed.
*2
Charging completion contact capacity is equal to that high of
capacity of auxiliary contact in page 27.
Motor ratings
Inrush
Rated current Steady Power Charging
voltage peak current(A) consumption(W) time(sec)
value(A)
AC/DC 110 7 3.5 385
50/60Hz 220 7 3.5 770
125 7 3.5 437 5 Under
DC 24 30 11 264
48 30 5.5 264
Note
*
The range of operating voltage : 85-110%
 The Basics of Circuit Breaker Maintenance
Jul 1, 2012By James R. White, Shermco Industries,
Inc. | Electrical Construction and Maintenance

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What is in this article?:

The Basics of Circuit Breaker Maintenance

Arc Extinguishers

Understanding circuit breaker maintenance and the basic

components and operation of MCCBs, ICCBs, LVPCBs, MVACBs,
& MVVCBs

Circuit breakers are used in nearly all electrical systems from

residential dwellings to electric utility facilities. We rely on them to
protect our systems from damaging overcurrents and short circuits.
Understanding circuit breaker construction and operation is key to
realizing their limitations and proper usage. This article covers basic
components and operation of popular types of circuit breakers,
including molded-case (MCCB), insulated-case (ICCB), low-voltage
power (LVPCB), medium-voltage air-magnetic (MVACB), and
medium-voltage vacuum (MVVCB) circuit breakers.
 Key Components
MCCBs contain five components a frame, operating mechanism,
interrupting structure, trip unit, and terminal connections. These
components are shown in Fig. 1.

1. Frame houses and supports the components and also

provides insulation to contain the arc.

2. Operating Mechanism opens and closes the contacts.

3. InterruptingStructure includes the arc chutes and all

current-carrying parts except the trip unit. Arc chutes are designed to
interrupt the arc quickly, usually 1.5 to two cycles for MCCBs and
ICCBs.

4. Trip Unit senses abnormal current flow and causes the

operating mechanism to open the contacts. MCCB trip units are
usually of the thermal-magnetic type.

5. Terminal Connections provides a suitable connection

from the breaker to the conductor. Molded-case circuit breakers
typically bolt directly to the bus.
Most manufacturers MCCBs have similar components and similar
appearance.
ICCBs have the same basic construction as MCCBs, but use solid-state
and digital trip units (as opposed to thermal-magnetic trip units) and
have much higher interrupting ratings. ICCBs are often draw-out type,
as opposed to bolt-in, although they can be either.
 LVPCBs (Photo 1 at right) are also known as air-frame and draw-out
circuit breakers. There are five major assemblies on a typical LVPCB:
1.
1. Disconnects or Stabs
Main disconnects connect the circuit breaker to the
main bus.
Secondary disconnects connect the circuit breaker to
the control circuits.
Ground disconnect connects the circuit breaker to the
ground bus.
2. Contacts
Arcing transfers the arc to the arc runners in the arc
chute.
Main carry the main load current.
Auxiliary make and break the control circuits.
3. Arc Extinguishers or Arc Chutes interrupt and contain
the arc.

4. Operating Mechanism opens and closes the contacts.

5. Overcurrent Trip Device modern circuit breakers have

digital trip units, although older units could be air dashpot or oil
dashpot types. Typical functions are long-time delay (LTD), short-time
delay (STD), instantaneous (INST), and ground fault (GF).

Medium-voltage circuit breakers have the same basic components as

their lower voltage counterparts, but use protective relays that are
separately mounted in the switchgear. MVVCBs use a vacuum bottle
instead of contact assemblies and arc chutes found on MVACBs.Photo
2 (right) shows a typical MVACB, while Photo 3 shows an MVVCB.
Main Disconnects (stabs)
The main disconnects connect the circuit breaker to the bus. LVPCBs
typically use either vertical or horizontal rows of straight, spring-
loaded fingers to make contact with the bus bar, although on larger
frame sizes they may have round or tulip-style disconnects. Photo
4 shows the backboard assembly of an LVPCB with primary,
secondary, and ground disconnects clearly visible.
Most medium-voltage metal-clad circuit breakers will use tulip-style
disconnects (Photo 5) and have some type of spring around them to
ensure good contact with the bus. Medium-voltage, draw-out circuit
breakers have the primary disconnects in the switchgear guarded by a
shutter mechanism installed in the switchgear cubicle. As the circuit
breaker is removed (racked out), the shutter closes. When the circuit
breaker is racked into the connected position, the shutter opens,
allowing the primary disconnects to make.
Secondary Disconnects (stabs)
The secondary disconnects bring power from the control circuits into
the circuit breaker.Photo 4 shows an LVPCB and its secondary
disconnects. The typical arrangement for this breaker is to connect and
disconnect these stabs as the breaker is racked in and out of its
cubicle. Photo 6 shows the typical arrangement for an MVACB, which
often has to be manually connected.
Ground Disconnect (contact shoe)
The frame of the circuit breaker must be connected to the ground bus
so that a short circuit or fault will be taken to ground immediately and
allow the protective devices to operate as quickly as possible. The
ground disconnect connects the frame of the circuit breaker to the
ground bus (Photo 7 at right). The ground disconnect is the first
connection made when racking a breaker in and is the last connection
broken when racking it out. This ensures that the frame of the breaker
is grounded whenever there is a possibility of the frame being
energized.
Arcing Contacts
Arcing contacts are designed to prevent the main contacts from being
damaged and can be made of alloys of silver, cadmium, tungsten, and
zinc. The tungsten, cadmium, and zinc make the arcing contacts
harder, so when the contacts open and close they will not deteriorate
as quickly. When the circuit breaker opens, the main contacts part first
and then the arcing contacts part, drawing the arc across them. When
the circuit breaker closes, the arcing contacts make first, again drawing
the arc across them. This prevents the main contacts from carrying the
arc and preserves them.
The contact surfaces are shaped so that they have a rubbing motion,
referred to as wipe. Wipe helps clean the contact surface, and is
caused by one of the contact surfaces being contoured and the other
surface being flat. When the contacts close, the contoured surface will
have a wiping motion against the flat surfaced contact. Arcing contacts
will usually have an arcing horn on the very top of the contact
structure. The arcing horn aids in transferring the arc from the arcing
contact to the arc runner in the arc chute.
Main Contacts
The main contacts are constructed of a softer alloy using less tungsten
or zinc and more silver. They carry the load current, so they must have
a lower resistance to current flow. The mains are larger, which also
decreases their resistance.
Auxiliary Contacts

Auxiliary contacts control electrical functions within the circuit

breaker, such as turning the spring-charging motor on and off at the
appropriate times. On LVPCBs, auxiliary contacts are mounted on the
frame of the breaker (Photo 8 at right). Medium-voltage metal-clad
switchgear will typically have the auxiliary contacts mounted in the
switchgear, rather than the breaker frame. Auxiliary contacts are
mechanically driven from the operating mechanism and are used for
control and indicating circuits. They are connected to the operating
mechanism by a linkage and operate at the same time the main
contacts do.

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