6. Breakers and Fuses
Overall, Circuit Breakers
Provide Better Protection
than Fuses
for Low Voltage
Circuit Protection
…and here’s why.
7. Breakers and Fuses
The Issues
… Technical
Short circuit capacity.
Motor circuit
protectors.
Single-phase
protection.
High/low level
fault protection.
Equipment protection.
Coordination.
Downtime.
Current limiting
fuse characteristics.
- Fuse let-through chart.
- Up-Over-Down Method.
Series ratings.
8. Breakers and Fuses
Short Circuit Calculations
Unlimited Fault Current
2,500 kVA, Z=5.75%
12,470V∆
Calculated Fault 52,296A
480Y/277V
Isc =
kVA
VxZ
=
2,500 x 1,000 x 100
480 x 3 x 5.75
= 52,296A
9. Breakers and Fuses
Secondary Short Circuit Capacity of
Typical Power Transformers
208 Volts, 3-Phase
240 Volts, 3-Phase
480 Volts, 3-Phase
Transformer
Rating 3-Phase
kVA and
Maximum
Short Circuit
kVA Available
Short Circuit Current rms
Symmetrical Amps
Impedance
Percent
from Primary
System
Combined Transformer and Motor
300
5%
Unlimited
18400
17300
8600
500
5%
Unlimited
30600
28900
14400
750
5.75%
Unlimited
40400
38600
19300
1000
5.75%
Unlimited
53900
51400
25700
1500
5.75%
Unlimited
80800
77200
38600
2000
5.75%
Unlimited
51400
2500
5.75%
Unlimited
64300
10. Breakers and Fuses
Effects of Impedance
Fault Current in Thousands of Amperes (Sym.)
1500 kVA Transformer/5.75% Impedance/480 Volts
UTILITY KVA
500,000
60
4 - 750 MCM
2 - 500 MCM
250 MCM
#1/0 AWG
#4 AWG
50
40
30
20
10
0
0
2
5
10
20
50
100
200
500 1000 2000
Distance in Feet from Transformer to Breaker Location
5000
11. Breakers and Fuses
Short Circuit Calculations
Unlimited Fault Current
12,470V∆
2,500 kVA, Z = 5.75%
Calculated Fault
64,328
Note:
Obtain specific impedance
values for each system.
Do not assume the values
shown here will be typical.
12 Feet, 3,200A Copper Feeder Busway
480Y/277V
3,200A
52,296
3,200A Bus
200A
60 Feet
(3) 1-Conductor
#4/0 Copper
THW Insulation
Steel Conduit
Bus Plug
200A
150A
10,968
29,560
Calculated at 100% Motor Contributions
Main
Control
Panel
100 Feet
(3) 1-Conductor
#2 Copper
THW Insulation
Steel Conduit
12. Breakers and Fuses
Line-to-Line-to-Line Fault
Bolted Fault Arcing Fault
Systems must be designed
for worst case conditions.
However, the majority of faults
will be arcing type.
14. Breakers and Fuses
Frequency of Faults
TYPE OF FAULTS INCIDENCE %
FAULT MAGNITUDE
Three-phase bolted ? Approaches fault available
Single-phase bolted 5% 30-60% of fault available
Line-to-line arcing 15% Low to medium (less than 30%)
Line-to-ground arcing
80%
Very low to low (less than 10%)
16. Breakers and Fuses
Motor Circuit Protectors (HMCP)
Typical Motor
Capability Curve
Locked
Rotor Time
Time
Starting Curve
Current
17. Breakers and Fuses
Single-Phase Protection
Single-phasing on three-phase loads cannot
occur with circuit breakers as all three poles
open on a single-phase fault.
Single-phasing on motor loads when a single
fuse blows can cause heating and eventual
damage to motor windings.
To eliminate single-phasing when using
fuses is both costly and inefficient.
Low level arcing faults can continue to be fed
through the load.
18. Breakers and Fuses
Single-Phasing Condition
Protective Device
Starter
A
B
C
“Normal Condition”
10A
10A
Motor
CLEARING TIME
FOR A LOW LEVEL FAULT
A
B
C
10A x 180%
18A
Fault
0
10A x 180%
18A
Motor
Phase
10A
A
B
C
Dual Element Fuse
A
0
Fault
Motor Circuit Protector (MCP)
0
0
Motor
Phase
A
B
C
Clears after multiple cycles.
B
C
Clears in less than one cycle.
19. Breakers and Fuses
High/Low Level Fault Protection
Circuit breakers will clear high level
(short circuit) faults safely and effectively.
Circuit breakers in general will clear low level
(overload) faults more effectively than fuses
(e.g., a motor circuit protector will clear a low
current motor fault (X6) in a shorter time than a
fuse). Plus prevent single-phasing.
Circuit breakers can include ground fault
protection. They quickly interrupt dangerous
ground faults before they escalate.
20. Breakers and Fuses
Equipment Protection
IEC 947-4-1 defines two levels of coordination for the motor
starter under short circuit conditions.
TYPE 1 COORDINATION
Under short circuit conditions, the contactor or starter shall cause
no danger to persons or installation and may not be suitable
for further service without repair and replacement of parts.
TYPE 2 COORDINATION
Under short circuit conditions, the contactor or starter shall
cause no danger to persons or installation and shall be suitable
for further use. The risk of contact welding is recognized, in
which case the manufacturer shall indicate the measures to
be taken in regards to equipment maintenance.
21. Breakers and Fuses
Equipment Protection
FACTS
Type 1 coordinated motor branch circuits are capable
of clearing low level faults without damage.
Type 1 may not prevent damage to the motor starter
components in high level faults.
Type 2 does not permit damage to the starter (as noted).
Type 1 or Type 2 does not cover protection of the motor.
Breakers or fuses may be utilized in Type 1 or Type 2.
Type 2 prohibits replacement of parts (except fuses).
Most faults in electrical systems are low level.
Fuses can nuisance trip on startup under Type 2.
22. Breakers and Fuses
Equipment Protection
Reduction in downtime is critical to manufacturing facilities.
CHOICES
Type 1
Must replace heaters.
May need to replace starter.
Type 2 with fuses
Must replace fuses.
Type 2 with breaker
No replacement required.
Type 2 intended to keep production running.
Repair or replacement is recommended.
23. Breakers and Fuses
Why do we have molded case, insulated
case and metal enclosed breakers?
Molded
Case
Circuit
Breakers
Westinghouse Series C
Molded Case Circuit Breakers
70A - 2,500A
Insulated
Case
Circuit
Breakers
Westinghouse SPB Systems
Pow-R Circuit Breakers
200A - 5,000A
Metal
Enclosed
AC Power
Circuit
Breakers
Westinghouse Types DSII/DSLII
Low Voltage AC Power
Circuit Breakers
100A - 5,000A
24. Breakers and Fuses
Time-Current Curve Coordination Study
4.16 kV
MOTOR
A
B C D E
1,000
E
100
Time in Seconds
250 MVA
Phase
Protection
10
A
Ansi 3-Phase
Through Fault
Protection
Curve
(More
Than 10
In Lifetime)
D
250A
1,000
kVA
5.75%
19,600A
C
B
4,160 V ∆
480Y/277 V
1,600A
24,400A
B
1
Transformer
Inrush
.1
1,000A
20,000A
A
175A
Ground
Protection
.01
100 HP-
.5
1
10
100
1,000
10,000
Scale X 100 = Current in Amperes at 480 Volts
M 124A FLC
= Available fault current
including motor contribution.
25. Breakers and Fuses
Electronic Trip Unit
Zone Selective
Interlocking
- Short Time Delay
- Ground Fault
Time Delay
- Instantaneous
Trip Regardless
of Short Time
Delay
- Minimize
Damage
Ground Fault Setting:
1,200A Pickup
0.5 Sec. Time Delay
Zone 1
Breaker 1
Ground Fault Setting:
600A Pickup
0.3 Sec. Time Delay
Zone 2
Breaker 2
Fault 1
Zone 3
Fault 2
LOAD
Zone Interlock Wiring
Ground Fault Setting:
300A Pickup
No Time Delay
26. Breakers and Fuses
Coordination
Fuses coordinate well between each other as
the 2:1 ratio of the current rating is maintained.
Circuit breakers with thermal magnetic trip units will
also coordinate well under the same conditions.
Circuit breakers with adjustable electronic trip
units will coordinate below the 2:1 ratio. Trip unit
settings need to be determined by carrying out
a coordination study.
Fuses cannot do zone selective interlocking.
27. Breakers and Fuses
Coordination
Circuit breaker flexibility.
- Adjustable pickup settings give improved
current coordination.
- Adjustable time delay setting gives improved
time coordination.
- Zone selective interlocking.
• Improving time coordination.
• Reducing damage to equipment.
• Reducing stress on upstream devices.
28. Breakers and Fuses
The Issues
…Technical
…The Advantages of Using Breakers
Downtime
Resettable and reusable devices.
Better coordination.
Closer equipment protection.
Early warning (alarms).
No time lost in searching for
replacement fuses.
Plus ground fault option.
30. Breakers and Fuses
Current Limiting
Available
Short Circuit
Current
I2t = (IRMS)2t
Ip
Peak
Let-Through
Current (Ip)
rms
Let-Through
Current
(Calculated)
IRMS
tmelt
tarc
t
Total
Clearing Time
31. Breakers and Fuses
Hundred Thousands
10
B
Ip = 2.3 x IRMS SYM
5
Current
Limiting
Threshold
100 kA
Available
Fault
Current
600A Fuse
600A
65 kA
600A
35 kA
600A
30 kA
600A
Ten Thousands
10
5
LetThrough
Current
10
Thousands
Maximum Instantaneous Peak Let-Through Amperes
Fuse Let-Through Chart
45 kA
40 kA
32 kA
5
30 kA
1
1
5
Thousands
10
5
Ten Thousands
10
5
10
Hundred Thousands
Available Current in rms Symmetrical Amperes
Fuses Tested at 15% Power Factor
X/R Ratio = 6.6
32. Breakers and Fuses
LetThrough
Fault
Current
Hundred Thousands
B
Ip = 2.3 x IRMS SYM
5
Fuses Tested at
15% Power Factor
X/R Ratio = 6.6
10
Ten Thousands
200A
Fuse
10
200A Fuse
5
Current
Limiting
Threshold
10
Thousands
100 kA
Available
Fault
Current
Maximum Instantaneous Peak Let-Through Amperes
Up-Over-Down Method
5
1
1
10
5
Thousands
5
Ten Thousands
10
5
10
Hundred Thousands
17 kA
100 kA
Available Current in rms Symmetrical Amperes
This method
assumes that
there is no
downstream
fast acting
interrupting
device.
34. Breakers and Fuses
Current Limiting Fuse Characteristics
Stand alone current limiting fuse.
Fuse
Action
Fuse is current limiting and clears
the fault in the first 1/4 cycle.
FAST
SLOW
Fuse
Action
FAST
Current limiting fuse with modern
fast acting circuit breakers.
Breaker begins to open.
Breaker tries to clear the fault.
Dynamic impedance is introduced.
SLOW
The current limiting fuse then
becomes a slow acting device.
35. Breakers and Fuses
The Circuit Breaker Sees the Fault
Before the Fuse
Fuse
Action
FAST
SLOW
…Therefore, the Up-Over-Down
Method DOES NOT WORK
because it’s only a theoretical
calculation.
NEC requires that fuse/breaker
series combinations must be
tested per UL test procedures.
One test is better than
a million calculations.
36. Breakers and Fuses
Fuse manufacturers have
acknowledged that the
Up-Over-Down Method
DOES NOT WORK with
today’s modern high
interrupting circuit breakers.
37. Breakers and Fuses
Three Types of Systems
1. Selectively Coordinated System
2. Fully Rated System
3. Series Rated System
38. Breakers and Fuses
1. Selectively Coordinated System
This system allows or selects the breaker closest to the
overcurrent source to open, thus most closely isolating the problem.
CONTINUITY OF SERVICE
High continuity.
PROTECTION
All breakers fully rated.
COST
Most costly of all three systems.
39. Breakers and Fuses
2. Fully Rated System
In this system, all of the breakers must be fully rated for the
system’s available fault current. This allows for quick selection
of equipment, but allows for less continuity of service in general.
CONTINUITY OF SERVICE
Lower than selectively coordinated system.
Usually higher than series connected system.
PROTECTION
All breakers fully rated.
COST
Lower than selectively coordinated system.
Usually higher than series rated system.
40. Breakers and Fuses
3. Series Rated System
This is a system of series connected breakers which have
been tested in combination and shown to effectively protect the
system. Downstream breakers are not fully rated for the system’s
available fault current but the upstream breaker, which is tested
in combination, protects the downstream breaker by operating
before damage occurs.
CONTINUITY OF SERVICE
Continuity of service may suffer.
PROTECTION
Downstream breakers not fully rated.
COST
Usually the least costly system.
41. Breakers and Fuses
Series Ratings
Fuses
Circuit Breakers
100 kA
100 kA
100 kA
100 kA
100 kA
100 kA
100 kA
100 kA
100 kA
65 kA
14 kA
14 kA
14 kA
14 kA
14 kA
14 kA
14 kA
14 kA
FULLY RATED
SERIES RATING
Series ratings can
not be done with fusesthere’s no advantage.
Circuit breakers are
tested as a component and
tested in an assembly.
42. Breakers and Fuses
The Issues
… Practical
Safety.
Monitoring and
communications.
Testability.
Accessorization.
Size.
Economics.
Cost.
43. Breakers and Fuses
The Issues
…Practical
…The Advantages of Using Breakers
Safety
Breakers are dead front devices.
Fused switches have exposed live parts.
Terminal shields and end covers available.
Fuses can be easily replaced with
devices that are improper and have
different characteristics.
Handle mechanism allows resettability
of breaker without needing access.
44. Breakers and Fuses
The Issues
…Practical
…The Advantages of Using Breakers
Monitoring and
Many functions can be integral
Communications
to electronic trip units.
- Earth leakage/ground fault.
- Monitoring functions.
- Metering.
- Energy.
- Power factor.
- Communications.
45. Breakers and Fuses
The Issues
…Practical
…The Advantages of Using Breakers
Testability
Electronic trip units are field testable.
Fuses are not field testable.
Push to test in the field.
Verify each unit off the assembly line.
46. Breakers and Fuses
The Issues
…Practical
…The Advantages of Using Breakers
Accessorization
Accessories are difficult to apply to fuse
switches and are very costly.
Both internal and external circuit breaker
accessories are easy to install and are
cost effective.
Internal.
- Shunt trip.
- Auxiliary contacts.
- Undervoltage release. - Bell alarms.
External.
- Motor operators.
- Interlocks.
- Handle mechanisms. - Cylinder locks.
47. Breakers and Fuses
The Issues
…Practical
…The Advantages of Using Breakers
Size
Smaller devices allow for more room
in an assembly.
Assemblies with fusible devices are larger.
Space saving in control panel.
48. Breakers and Fuses
Practical Issues
Space and Cost Comparisons
PRL 4F Fusible
PRL 4B
Breaker
Wall
Space
1200A
FDP
VERT.
1200A ND
73.5”
400A KD
400A KD
400A KD
400A KD
400A
FDPW
400A
FDPW
400A
FDPW
90”
400A
FDPW
Thru-Feed
Lugs
36”
72”
$1,410 Additional for Fuses
SAVINGS…
59% Wall Space
Equipment Cost
Savings
Installation Time
Cost of Fuses and
Labor for Replacement
Downtime
PLUS Spares
Floor
Space
11.3”
2.83 Sq. Ft.
18”
9 Sq. Ft.
69% Floor Space
49. Breakers and Fuses
The Issues
…Practical
…The Advantages of Using Breakers
Economics
No spares required.
Fuses need to be replaced.
Breakers are more electrically efficient.
(Fuses have a higher wattage dissipation.)
Cost
Less downtime.
Less contractor labor to handle and install.
$ $ saved in floor and wall space.
Saves panel space.
50. Breakers and Fuses
Why Use a Breaker in a Distribution System:
Prevents single-phasing.
Motor protection.
Coordination.
Zone interlocking.
Resettable.
Dead front, no exposed parts.
Space savings.
Prevents downtime.
Accessorization.
Testable.
51. Breakers and Fuses
Why Use a Breaker in a Control Panel:
Prevents single-phasing.
Motor protection.
Ground faults.
Resettable.
Dead front, no exposed parts.
Space savings.
Prevents downtime.
Accessorization.
Testable.
Notes de l'éditeur
Cutler-Hammer/Westinghouse has been a world leader in circuit protective devices since inventing the circuit breaker over seventy years ago.
The need for molded case circuit breakers was created in 1918 when numerous applications for electrical motors resulted in a demand for a device that would ensure safe operation and, at the same time, protect electrical circuits. During this period, individual motors were used for the first time in industrial plants to operate machine tools, and in private homes to operate appliances. Plant electricians were constantly changing fuses blown during motor startups because of the lack of properly designed fuses for motor circuit protection.
Inspectors were also concerned about fire hazards. Fuses were being replaced by fuses with too high of an ampere rating. Plug fuses were being bridged by pennies and cartridge fuses were being replaced with copper bars. Inspection authorities became involved and attempted to find a solution to the problem.
Meetings with switch manufacturers were initiated in an effort to find a solution. Switch manufacturers were asked to develop a switching device that would interrupt a circuit under prolonged overload conditions. The device would have to be safe, reliableand tamperproof. It should also be resettable so as to be reusable after an interruption without replacing any parts.
During this period of research and development, Westinghouse produced the DE-ION arc extinguisher for use in large oil circuit breakers. Although too large in its initial form to be practical for small circuit breakers, the arc extinguisher was eventually modified into a usable size. The first compact, workable circuit breaker was developed in 1923 when the modified arc extinguisher was coupled with a thermal tripping mechanism. It was not until four years later (1927), however, that Westinghouse research engineers found the ideal combination of materials and design that permitted circuit breakers to interrupt fault currents of 5,000 amps at 120 volts AC or DC. One year later (1928), Westinghouse placed the first circuit breaker on the market. Its acceptance was instantaneous.
Circuit breakers are usually selected by knowing the systems voltage, total load, and available fault current.
Fuse manufacturers typically talk of 200,000 and 100,000 amp faults. Are these real world values?
This 2,500 kVA transformers would typically be the largest size in most plants. The fault available is only 52,296 AIC, assuming unlimited utility fault is available. Typically faults available are 500 MVA which would further reduce this value to 48,128.
Salesperson’s Warning Note: If double ended substation, tie breaker closed and mains in parallel. 105,000 may exist for a duration.
This chart shows secondary short circuit capacity of typical power transformers assuming unlimited utility fault available, 100% motor contribution and no wire impedance.
Where greater than 100,000 AIC exists, Cutler Hammer manufactures circuit breakers up to 200,000 AIC for these unusual circumstances (because 2,500 kVA can deliver 64,300). But in reality, the fuse manufacturers talk about 200 K that does not exist very often. Plus you have to consider the switch or equipment you are putting the fuse in, even if rated for 200,000.
Point out why we have 65 K breakers.
Here we are showing the available fault current of a typical transformer found in an industrial plant. This 1,500 kVA transformer can deliver 38,600 amps of fault current. The size of the conductor and the distance away from the transformer adds impedance to the system to further reduce the available fault current.
Example: A 100 feet of (2) 500 MCM cables causes the available fault current to drop below 31,000 amps. Also note 100 feet of #4 wire causes the fault current to drop below 10,000 amps. This is what you may see at a control panel.
This is a one line showing the affects of impedance of the fault available through the power distribution system.
Points
A) Is the main bus fault available off the transfomer secondary.
B) Is feeder fault with 100% motor contribution (motors act like generators contributing to the fault current during the fault).
C) Cable fault with 60 feet downstream of a feeder.
D) Typical fault available in a 100 amp control panel.
Note: If the typical 1,500 kVA transformer was used in place of the 2,500 kVA, worst case, the currents would be as follows:
A) 31,400
B) 38,600
C) 17,750
D) 6,600
It is important to realize that the short circuit available currents are calculated assuming a worst case three-phase bolted faultas shown in the left hand corner of the overhead. All short circuit protective devices should be selected such that they can safely interrupt this fault level. Rarely if ever do actual faults approach this level. Most faults are arcing faults, caused by an accidental contact of tools with live conductors or by insulation failure inside a wire or motor.
The magnitude of an arcing fault is significantly reduced due to added impedance introduced by the arcing fault.
Although the magnitude of the arcing fault can be much lower, these faults can be the most dangerous due to the energy released at the point of the arc and the concern of what path the current flows.
Where do most faults occur with a distribution system?
Most faults occur at the end of the distribution system where it is easier and more likely to get accidental contact with live parts. Other areas in the system typically are much more isolated from personal contact.
This is the percent of incidence.
Magnitude shows percentage of available fault you could expect to see.
A lot of the line-to-line arcing faults start out as line-to-ground and when they are not caught quickly, they can cascade into a more severe fault.
Of these common fault incidences, the contact of a tool inside a control cabinet with exposed live parts such as older design starters, fuses and bus bars.
Another likely area of faults occurring is in motors.
All industry, in one way or another, depends upon electrical motors to perform critical functions.
Most faults on a motor circuit are generally caused by an insulation breakdown within the motor windings. The initial fault current is low in relationship to the system capacity with these types of faults. This low level fault causes an arcing condition that, if not arrested could cascade like a chain reaction. As the fault cascades, it broadens the physical area of the fault, shorting out more and more of the motor windings.
Prior to 1969, fusible devices and thermal magnetic breakers were the most common form of motor branch circuit protection. Both of these devices provided somewhat acceptable results. However, evidence reported by trade journals indicated that the level of protection was not totally effective.
In 1969, available data indicated that approximately 19%* of all fires recorded in the United States were the result of motor failures.
* Source IAEI News
The HMCP Motor Circuit Protector was developed to meet customer needs for improved motor short circuit protection.
To achieve the required performance, the HMCP was designed with three closely calibrated current sensors and an adjustable trip mechanism into the high performance Series C Circuit Breaker. The current sensors allowed the HMCP to clear faults in excess of its trip rating in one cycle or less with a high degree of repeatability. The adjustable trip mechanism provided the flexibility to place the trip setting just above the motor inrush, clearing low level faults quickly while ignoring motor starting currents. By utilizing the basic Series C design, the HMCP also offered high interrupting ratings in combination with motor starters, dead front construction, resettability after a trip, a wide variety of accessories and a reliable disconnect in a compact size.
Since the introduction of the MCP (motor circuit protector) by Westinghouse in 1970, and its increased use as a motor branch circuit protective device, the incidence of fires, as a result of motor failures, has declined dramatically. In 1983, the incidence of fires of electrical origin in the United States and Canada combined, as a result of motor failures, was down to approximately 3%.*
* Source IAEI News
Another advantage these HMCPs provide is protection from single-phasing after a fault.
Most single-phase conditions are caused by a blown fuse resulting from a single-phase fault.
Explain example.
Fault happens on load side of disconnect. One fuse blows.
The motor single-phases and overloads causing the current to increase (180%) in the remaining phase. It now takes some time for the remaining fuses to blow. Typically overload relays do not react to this condition. An HMCP trips all phases at the same time eliminating the single-phase condition.
In review:
Breakers will clear high level faults effectively and safely.
Breakers in general clear low level more effectively and these are what most commonly happen in an electrical system.
1)Those contacts in the starter can weld and just need to bepried apart with a screwdriver. It may have deteriorated the life of that starter and needs replacement at the nextavailable opportunity.
2)You may not get your motor running with the fuse protectionyou would need.
3)Your heaters took a hard hit, it could change their resistance value.
The answer is coordination.
The differentiating factor of these breakers is a term called withstand. Withstand is the ability for the breaker to delay its tripping under a fault condition.
Molded Case Circuit Breakers are designed for use at the end of the distribution system. They need to trip rapidly therefore they have a lower withstand capability. (They usually have a withstand of 18 cycles at 10 times their rating.)
Power Breakers are intended for use upstream in a distribution system where they must wait for a downstream device to interrupt the fault. This keeps from taking the whole plant down.
Metal enclosed can have withstands at 60 cycles for their interrupting rating.
Insulated Case can have withstands of 30 cycles.
Note: The equipment upstream is braced and the bus bars are designed to be able to handle this fault for this period of time.
In the coordinated system, we want the device curves on the left to trip first. This makes sure that the closest device to the fault handles it.
Note: Oftentimes you need the ability to adjust the curves around transformers inrush points or have the ability to coordinate with a fuse.
Explain how Zone Selective Interlocking works (see SA-11581C, page 8).
Coordinates short time and ground fault - advantage instantaneous trip without time delay on short time or ground fault.
1)Coordination reduces stress on upstream devices andequipment.
2)Set up system as though there was no zone selectiveinterlocking.
3)Positive coordination without time delays.
4)No interlock on Instantaneous trip.
We can do this even with molded case circuit breakers.
Review.
Ground fault at motor can take main down and all other feeders. (Depends on level of fault and the main.)
Ground fault on the panel will take only that machine down.
Circuit breakers can do internal or external ground fault sensing.
They will catch the ground fault before it cascades into a fault of more magnitude. (Helps with equipment and personal safety.)
In Europe, they call this earth leakage protection. It is very common in their panels and making it into the USA.
Fuse switches are not recommended for ground fault. For a fused switch to be used as ground fault device, it must be rated to handle the available fault levels while opening.
Most switches except bolted pressure switches are not rated for this application.
Current limiting is defined by UL as a device that limits the total I2t let-through less than the I2t of a 1/2 cycle, when operating inside its current limiting range.
Fuse manufacturers talk a lot about current limiting and peaklet-through.
Fuses work very well at high level faults when there is a lot of energy with the ability to melt the links.
As the fault goes down, they become less current limiting as shown by the overhead.
Note: Current limiting breakers are also available and most of our breakers limit the current.
Salesperson’s Notes: Short circuit devices are tested with power factors that you typically do not recognize as being standard in a plant. The reason is the fault acts in an assymetrical configuration as opposed to the one a plant talks about in normal operation.
Many peope still subscribe to the Up-Over-Down Method that was once promoted by fuse manufacturers.
They assumed a 100 kA fuse protected a 17 kA breaker by using the let-through curve of the fuse.
All assumptions they made were on theory, not testing.
Lab conditions do not always exist in the field.
Why new circuit breakers open so much faster than old designs.
The contacts are designed utilizing a pivoted reverse loop and causes the current to flow in opposite directions in parallel paths, creating a blow-apart effect. This natural blow-apart action combined with the pivoted contact design dramatically increases the overall blow-apart action which quickly draws a high impedance arc and effectively limits the let-through current. Because of this current limiting action, a fault never reaches its peak value of current.
Salesperson’s Note: Right hand rule.
The Up-Over-Down Method does not account for the dynamic impedance introduced by today’s circuit breakers.
NEC-240-83 requires that all series rated combinations be tested and labeled.
It is because of the requirements of tested combination, that we do not publish let-through current curves.
We feel all combinations should be tested.
When people use the Up-Over-Down Method, what they are trying to achieve is what we call a series rated system. In addition to a series rated system, there are selectively coordinated and fully rated systems. Let’s discuss the difference.
Most expensive - used for continuity/critical loads.
Uses higher withstand rated breakers (power breakers) in order to coordinate trip curves for system - allows downstream breaker to clear fault first.
All breakers and fuses are rated for the available fault current.
Typically using molded case circuit breakers that are all rated for the full available fault.
Coordination can be lost above the withstand of the upstream breaker. (Roughly 10 times the rating of the source,i.e., 400 amp breaker 4,000 amp withstand for 18 cycles.)
Less continuity since upstream breaker may trip before downstream breaker can clear downstream fault.
If we rate anything series rated, we have tested it in these conditions.
This circuit board was tested as a series.
We reviewed the technical issues, let’s discuss the practical reasons.
There is no evidence to show fuses are safer than breakers as the fuse manufacturers lead you to believe.
More people are injured by accidental contact with live parts as commonly found in fused equipment.
Breakers are designed with dead front covers and terminal shields are available to keep you completely isolated from live parts.
Handle mechanisms allow you to reset without opening the operator door. With fuses, you must go in and replace the fuses, exposing yourself.
Earth leakage is driven by the European market typically30 milliamps.
With deregulation, you need to understand where you are using energy.
Breaker performance can be verified through nondestructive testing.
Every breaker is tested off the assembly line.
All fuse testing is destructive (except resistance tests). You never really know where it will actually trip.
Salesperson’s Note: NEMA AB-4 1991 Field Testing of Breakers.
Self explanatory.
Fuse manufacturers do 70% of their business in replacement fuses.
Fuse manufacturers would love to keep selling you replacement fuses.
Over the life of the equipment, it will cost you a lot in replacement fuses.
In startup and testing at an OEM, it will cost more in replacement of fuses instead of resetting the breaker.