SPECIAL PURPOSE CIRCUlT BREAKERS

George D. Gregory EdLarsen

3700 s i street sw 2300 Northwood Drive
Cedar Rapids, IA 52406 Salisbury, MD 21801
Members: PlOlS Worki i Croup ofthe IEEE Low-Voltageprdecbon'

Subcommittee Absbrvrct -
The PlOlS Working Group of the IEEE Low-
Voltage protection Subcommitteeisfiniisbingaaapplication
wide for low-voltage circuit brepLers. when tk p~pnwrrl
process has been completed, the guide Win be published in a
WWIEEE"Color Book" called the IEEEBlue Book. Tbis
paperp~~Chapter7oftheguidetitled,"SpecialPurpose
CircuiiBrPkcr&" Chapter 7 ptoviecS an overview of tk
descriptions, applications, ratings, code comidemtiolrg test-
i n g ~ ~ b , d s e t t i a g s o f h - ~ c i r c u i t b r e P k e r s
othertbrurthecon~~thamal-~lladdcdeas
e circuit breakccs wbih are tbe industrystandrvd for indus-
trial and commercial applications, "he&? chwa breakers
provide a range of Sdutbns for specirle applications of
overcurrent prdectioa.
7.1 Intmducbo'0
Themost widely wedcircuitbreakers areconventionalthennal-
magneticcircuitbreakers.Thesegeneralprvposecircuitbreakers Instantane.€)wtrip only circuit baealrers (motor circuit protec-
a r e t h e i n d u s l r y ~Thermal-magneticcircuitbreakersuse tors) provide &justable shortcircuit protection but no overload
bimetals and elecmmagnea- assembliesto~botll~
protection. They are magnetic triponlycimitbrealrers, with no
andmagneticovemrrent~tionTheircharacteristicinverse. thermalelements, and thexefm, p v i & no thermal protection.
time tripping (due to thebimetal) andan instantaneousaipping
characteristic (due to the ekaanagneac- portiOnofthecircuit Sinceexternalo~protectionmustbeusedwith~circuit
breaker) rn ideally suited for many applicaaons varying from breakeas,theycannotbeusedforttranchcircuitputection.These
residential loads to heavy industrial loads. A thmd @ping circuitbreakersare~yimarilyasComcomponentsinmotacircuits
action isonewhichemploysabimetal which bends with heat mtil incombinatiorrwithmsmtersstxhasin~m~cen~
itreleases themechanismwhichallowsthecircuitbreakertotrip. orindi~ualcombinationmatorstarters. Theyarealsousedin
Thermal hipping provides inverse time response, i.e., as the welding equipment fa shorwircuit protection only. Several
overloadincreaseS,theheatingandtripphgtimeSareredwed.A manufixtmm have add-on current-limibg attachments that, if
magnetictrippingactian is one whichemploysasolenoidmagnet added to the end ofthe instan- trip circuit hK!akef* will
whichattractsan~totripthecircuitbmaker.Magneticorip
s~~~ynlisetheshortc~uitwithstandcurrentratingofthe
response is instantaneous,with no trip &lay.
combinationstarter.
Therearealsoelectmnk tripcircuit breakers which use trans-
Adiscussionofratin~andtesting~the,~tan~strip
formers and sensors which measure and time cmxt levek and
canparethemtopredeterminedval~.whenthepedetermined circuitbreakertoitsintende!dapplication. settingsoftripadjust-
cucrent and timelevelshavebeenreached,the elecaonic trip unit men& are discussed along with applications requirements for
sends a signal to an internal solenoid w h i i trips the circuit
protection of motor circuits under the Natitml Electrical code.
breaker. Thetripunit canbeprogmmmedtope&rmamultiitude
OffunctionS. 7 3 Mining Circuit Breakers
Specialp~selow-voltagecircuitbreakersarevariationsof
Mining circuit brealrers are specifically designed for mining
thethemal~corelechunktripcircuitbreakemwithfunc-
tions, ratings, testing and setting adjustments modified to meet appliations and pennit the user to Comply with the Federal
q-tsoftheirspecialapp-. Low-voltageovercurrent Registerformkingstandards Theronnalapeaionofself-
pmtection devicesarede~as~rangingfromzerotloo0 ~lledminingequi~tsub~itsaairingcabletoeJrtreme
volts AC ms.Most low-vdtage systemsare600 vdts AC IS OT
k'Ihisguidecovexsbothmol&d - case~t~andknv - andfkquentflexing,twistingandcrushing. Asadt,ekmical
voltage power circuit breabers. faultsintrailingcablesoccurmuchmorefrequentlythanwiriagin
0-7803-06?4-1~$03@Em.W 1311
standard stationary installations. Additionally, the presence
of loose coal dust and other combustible materials makes the
occurrence of such faults very hazardous. For these reasons,
adequate trailing cable protection is extremely important.
Circuitbnakersusedtoprotectundergmundcircuitshavetight
tolerances, dust shields and gaskets, non-moistwe absorbing materials, heavy-duty
operating mechanisms, and mmsion resistant nameplates. They must be located in areas
which are accessible for inspection and testing and that have a safe roof.
In the guide,details of ratings, testing and settingsare provided
relative to the applicationof protecting trailing cables in mines.
7.4 Current-limiting Circuit Breakers
Current-limiting circuit breakers are basically conventional
molded-case thermal-magnetic or electronictrip circuit breakers
designed so that high-speed contact separation is achieved under
high-level fault conditions. This high-speed contact Separation
effectively limitspotentiallyhigh-level faultcurrentsandisachieved by
closely spaced parallel contact arms carrying current in o p site
directions. In some cases, the current-limiting contacts are a
second set of contacts in series with the primary contacts.
Current-limiting circuit breakers not only provide high
inter-rupting ratings, but also limit l e t - h g h current and
energy to downstream devices and conductors. The
current-limiting action is sufficient to reduce Ip and Pt let-
through to values that can protect lowerrateddownstream
components including branch and feeder circuit breakem.
A common application of this is using the current-
limiting circuitbreaker as either an integralor remote main
circuit breaker for lighting panelboards on systems with high
available fault currents. This is called a series connected rating.
It is important to note that manufacturers must test to demonstrate
that the downstream device is protected. There is presently no
accurate method of calculating this protection.
Underwriters Laboratories Standard UL 489 defines a current-
limitingcircuitbreakeras: “Acircuitbreakerthatdoesnotemploy a
fusible element and that when operating within its current-limiting range,
limitsthe let-through 12t to a value less than the Pt of a 1/2 cycle wave
of the syrnmemd prospective current.”
Current-limiting circuit breakers can be reset and service re-
stored in the same manner as conventional circuit breakers even
after clearing maximum level fault currents. Of course,whenever
it is suspected that acircuitbreakerhasinterruptedafaultator near
its interrupting rating, a visual or opemtional inspection should be
made to assess differencesfrom a new circuit bmker. If differ-
ences are significant,additional functional testing or
replacement is called for.
1312
Current-limiting circuit breakers are available from 15-600
amperes, rated up to 600 V, and have interrupting ratings up to
200,OOO rms symmetrical amperes. These circuit breakers com-
pletely clear the faulted circuit within the first half cycle.
7.5 Molded-caseSwitches (Circuit Interrupters)
Molded- switches are similar in construction to thermal-magnetic
circuit breakers except that the thermal OverCurrent protection is not
present. The magnetic short-circuit protection may or may not also be
removed. These switches are intended for use as disconnect devices
only. Because of their molded-consauction,theyare more compact
than conventionaldiscannect switches and accept electrical
accessories for added flexibility. They are discussed in this
chapter since construction and testing are similar to that of
circuit breakers of the same frame size.
There are two types of molded-case switches: non-automatic
and automatic. Standard non-automatic molded- switches have no
thermal or magnetic hipping elements. They consist of circuit
breaker contacts,bussing and lugs for the highest ampere
ra~gineachcircuitbreakerframesizeandaremanuallyope~~
only. Although these devices are primarily used in motor branch
circuits,theyneednotbehorsepowerratedbecausenormallytheu
withstand ratings are much greater than the lacked rotor currents
produced on such circuits. Automatic molded- switches
also do not provide overcurrent protection. However,
they do include a preset non-adjustable magnetic trip
element point calibrated to protect the switch
against thedamaging effects of high-levelfault Currents.
M01ded -w~switchesare capable of making and breaking
load currents up to six times theii marked rating. As a result,
these switches can be applied where horsepower ratings are
quired. Molded-case switches meet the requirements of the
National Electrical Code Section 430-109:
‘“Thedisconnecting means shall be a motor circuit
switch rated in horsepower, a circuit breaker, or a
moldedase switch (non-automatic circuit interrupter).”
Molded- switches used as service disconnects must be
marked ”Suitablefor use as service equipment.” Both automatic
andnon-automaticswitchesaretestedforashortcircuitwithstand
rating with an overcurrent protective device in series. The
short-circuit rating is marked on the switch.
Molded- switches have ratings similar to those of safety
switches with ratings from 30 to 1200 amps at 250 or 600volts.
Details of ratings and testing are included in the section.
7.6 Integrally-fused Circuit Breakers
Integrally-fusedcircuitbreakersareusedinsystemswithhigh
available fault currents. They are available in both molded-case
and powercircuit breaker constructions. They provide
high interrupting capability through the use of
specially designed
current-limiting fuseswhich are assembled into the housing of the
circuitbreaker or,in the case of high ampere power
circuitbreaker frames, in a separate fuse truck. The fuses in these
devices are designed to blow, and need replacement, only after a high-
level fault. The circuit breaker portion is inteflocked so that when any
fuse opens, the circuit breaker will automatically trip, opening all
poles of the circuit breaker, and eliminating the possibility of
singlephasingcausedbytheopeningofoneofthefusesAddition.-ally,
many circuit H e r s are equipped with a mechanical inter-lock which prohibits the
circuit breaker from closing with a missing or blown fuse.
In the molded- circuit breaker construction, the fuses are
generally located within an added housing and separated hthe
sealed trip unit of the circuit breaker for easy access. In
power circuit breaker construction, the fuses are mounted on the
rear of the circuit breaker frame or in a separately mounted fuse
truck. Both mounting methods provide easy access to the fuses.
Whenapp~edonhighshort-circuitcurrentcapacitysystems,the
effectsof the let-through characteristicsof the fused circuitbreak-ers
on downstream equipment must be considered. The presence of the
current-limitingfuse as part of the fiwd circuitbreaker does not
necessarily imply that the downstream equipment can ad-equately
withstand these effects. Manufacturers must test to
assuterhatinallcombinationsthedownstreamdeviceispr~ted. There is no
accurate method of calculating this protection.
Fused circuit breakers do not have any current-limiting effect until the
current associated with the fault exceeds the threshold current of
the fuse. The fused circuitbreaker performs as any other circuit breaker
in the overload and low short-circuitrange. How-ever, as the shortxircuit
current begins to a p v h the capacity of the circuit breaker, the fuse clears
the fault preventing circuit breaker damage. The fuse clears the
fault within the 1st half cycle and greatly reduces the Ip and Pt let-
boughs. Because the fuse
hasnooverlaadelemntandoperatesonhighfaultsonlyitiscalled
a current-limiting fuse or limiter.
Where downseeam protection of smaller circuit breakers is
required, smaller cmnt-limiting fuses can be used to protect
these circuit breakers. Using fused circuit breakers to protect standad
circuit breakers downstream is sound design, provided the
manufacturer’s cooTdination data is applied carefully and it is
understood that reduced size limiters may be necessary and may result in
less than ideal coordination within the fused circuit breaker and
therefore more frequent blowing of the limiter fuses. In no case should
combinations of trip devicesand fuses which are not approved by the
manufacturer be installed. Where fuses of different manufacture are
being considered for the same system, the characteristia and peak let-
through current of a given fuse rating may vary substantiallybetween
manufacturers. Electrical
distributorswhostockordinarycurrent-limiting fusesrarely
stock these current-limiting fuses. It is wise tokeep at
least one set of spare limiters of each size used.
Details of testing are provided in the section including a discussion
of coordinationbehveen the circuit breaker and fuse.
CONCLUSION
The five categories presented in Chapter 7 were care.My
chosen as those categories most used. They are
also rreated as defmite categoriesby codes,
standards and regulating authorities.
Chapter7hasbeenWrittenandreViewedcarefullybymembers
of the P1015 Working Group.
References
[1 I UL 489 Standardfor Safety Molded-Case Circuit Breakers
andcircuit-BreakerEncloswes,EighthEdition. Northbrook,
IL., Underwriters LaboratoriesInc., 1991.
121American National Standard Test Proceduresfor Low-Volt-
age AC Power Circuit Breakers Used in Enclosures. ANSI
C37.50-1989.
[31 UL 508 Standard for Safety Industrial Control Equipment.
Northbrook, IL., Underwriters LaboratoriesInc., 1991.
[4] UL 845 Standard for Sdety Motor Control Centers,
Northbrook, IL., Underwriters Laboratories Inc., 1991.
[5] National Electrical Code 1990. Quincy, MA, National Fire
Protection Association, 1989.
[6] Title 30 - Mineral Resources, “Chapter 1 - Mine Safety
and
Health Administration.” Code of Federal Regulations.
[7] Molded Case Circuit Breakers and Molded Case Switches,
NEMA Standards Publication No.AB 1,1986.
[8] UL Recognized Component Directory. Northbrook, E.,
Underwriters LaboratoriesInc.
[9] UL 1087 Standard for Safety Molded-Case Switches.
Northbrook, IL., Underwriters Laboratories Inc.,1986.
[ 101 An American National StandardlIEEE Standard for
Low-Voltage AC Power Circuit Breakers Used in Enclosures.
ANSVIEEE C37.13-1990.
111 American National Standard Preferred Ratings, Related
Requirements, ana‘ Application Recommendationsfor Lav-
Voltage Power circuit Breakers and AC Power
Circuit Pro-tectors. ANSI C37.16-1989.
123 American Natwnal Standard for Trip Devices for AC and
General Purpose DC Low-VoltagePower Circuit Breakers.
ANSI C37.17-1979(R1988).