NeeserOvercurrent Protection Basics PDF

4/1/2014
Overcurrent Protective Device (OCPD) Basics

Dan Neeser
Field Application Engineer
Eatons Bussmann Business
Cell: 314-753-2514
email: dan.neeser@cooperindustries.com
2013 Eaton. All rights reserved.
Agenda
Overcurrent Considerations
Overcurrent Protective Basics
Overcurrents
Overloads
Short-circuits & ground faults
Component protection
Arc Flash
Basics Construction, Operation and Ratings (V, A, IR)

Time Current Curves
Let-through Curves
Overcurrent Protective Device Types
Circuit Breakers (MCCB, ICCB, LVPCB, AFCIs, GFCIs)

Fuses (Class L, H, R, J, T, CC)
High Speed Fuses
Supplemental Protectors
Overcurrent Protective Devices Protect From

Overcurrent (NEC Definition)
Any current in excess of the rated current of
equipment or the Ampacity of a conductor. It may
result from overload, short circuit, or ground fault.
FPN: A current in excess of rating may be accommodated by certain
equipment and conductors for a given set of conditions. Therefore, the rules for
overcurrent protection are specific for particular situations.
An Overcurrent Results From

Overload, Short Circuit, or Ground Faults
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Effects Of Overcurrents
Conductor insulation
damage
Fires
Equipment damage
Arc Flash Energy

Overload. (NEC Definition)
Operation of equipment in excess of normal,
full-load rating, or of a conductor in excess of rated
ampacity that, when it persists for a sufficient length
of time, would cause damage or dangerous
overheating. A fault, such as a short circuit or ground
fault, is not an overload.
An Overload Is NOT A
Short Circuit, or Ground Faults
Overload - Example
VS
Source
Load
Load
IOL= VS / RT
Within the normal path
Voltage (V) = 480

Load Resistance (R) = 2 X 12 = 24 ohms
Wire Resistance (R) = 0.01 ohms
Iload = (480) / (0.01 + 24) = 20 Amps

4/1/2014

Short Circuit Current.
Not Defined In NFPA, IEEE or other similar
organization documents
An overcurrent, typically many times larger than
normal operating current
Can be an arcing fault or bolted fault
Can be between phase(s) and/or phase(s) and
ground (ground fault)
A Short Circuit Is An Overcurrent But Not An Overload
Short-Circuit - Example
ISC= VS / RT
VS
Source
Load
R
R
Out of the circuit
Outside the normal path
Voltage (V) = 480

Load Resistance (R) = 12 ohms
Wire Resistance (R) = 0.01 ohms
Iload = (480) / (0.01) = 48,000 Amps
Typical Short-Circuit Currents

Home Receptacle - 200 to 500 amps
Home Service - 2,000 to 10,000 amps
Bussmann Headquarters - 70,000 amps
New York City - 202,000 amps
St. Louis, MO - 210,000
Chicago, IL - 215,000
Dallas, TX - 220,000
Tulsa, Oklahoma - 260,000 amps
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Short-Circuit Currents
Sources of short-Circuits
Utility
Generator
Motors
Decreases due to
impedance
Conductors, bus, etc.
Transformers (size &
impedance)
Must be calculated
10
Eaton Bussmann Short-Circuit Calculator

NEW version
Apple or Android Apps
Web (run from homepage
after entering contact info)
11
OCPD - Voltage & Ampere Rating

Voltage Rating
Circuit Breakers - 120, 120/240, 240, 277, 480,
480/277, 600V.
Fuses - Typically 250 or 600V (Class J & L 600V)
Ampere rating
80% (MCCB-UL 489 and standard fused switch-UL 98)
100% - if CB or fused switch is 100% rated in
enclosure
Few MCCB & Most ICCB - UL489
LVPCB - UL 1066
Bolted pressure switch - UL 977.
12
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OCPD - Interrupting Rating

NEC 110.9: Device interrupting rating MUST
be equal to or greater than the maximum
available fault current.
Chapter 1 Video Clips - Interrupting Rating
13
OCPD Interrupting Rating

Circuit Breakers
Interrupting rating varies - 10, 14, 18, 22, 25, 30,
35, 42, 50, 65, 100, 125, 200 kA. Dependent
upon voltage and manufacturer.
No rejection feature for proper application of
voltage or interrupting rating
Fuses
Minimum interrupting rating of 200,000A (except
for Class H & K - 10,000A) at rated voltage.
Interrupting rating does not vary with voltage.
Many at 300kA.
Unique dimensions or rejection features to prevent
interchangeability
14
OCPD - Current Limitation

A current limiting
fuse will clear a
fault within one half
of a cycle.
Thermal energy is
proportionate to the
square of RMS current
multiplied by the time
(Irms2t)
Mechanical stresses are
proportionate to the
square of peak current
multiplied by the time
(Ip2t)
15
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OCPD - Current Limitation

Conductor protection for fault of 45kA/480V (26kA
with conductor) with non-current-limiting device (1
cycle) vs. current-limiting device (>1/2 cycle)
16
Equipment Protection
NEC 110.10: Equipment short-circuit current ratings must be
adequate for maximum available fault current.
Must Assure Protection
Conductors/Busway
Panelboards/Switchboards
Motor Controllers/MCCs
Switches/Transfer Switches
Industrial Control Panels
HVAC Equipment
Etc.
Current-limiting overcurrent devices can provide increased

short-circuit protection of components and high short-circuit
current ratings for equipment.
17
17
18
18
Arc Flash Energy People Protection

Arc flash Energy Is Dependent On:
Distance from arcing fault
Arcing fault duration or time to clear
Speed of the overcurrent protective device
Arcing fault current magnitude

Available fault current
Current-limitation can reduce
4/1/2014
Arc Flash Testing - Test 4

480V, 22.6kA Short-Circuit Current
640A NCL OCPD: 6 cycle Clearing Time
19
19
Arc Flash Testing - Test 3

480V, 22.6kA Short-Circuit Current
601A CL Fuse: Less Than 1/2 Cycle Clearing Time
20
20
Circuit Breaker Components

Major Components
Molded Case Frame
Operating Mechanism
Contacts
Arc Extinguishers
Trip Units
Tripping Conditions
Overload
Short-Circuit
Ground Fault
Arcing Fault
21
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22

Contact Assemblies
23

Arc Extinguisher
Contacts Separate
Magnetic Field Drives Arc Into
Steel Plates
Arc Is
Confined
Divided
Extinguished
24
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Thermal Protection
Bimetal In Series With Connected Cable
Bimetallic Element Is Heated By The Load Current
Sustained Overload Will Cause Bimetal To Deflect
Deflection Trips The Breaker
25
Magnetic Protection
Electromagnet Winding Is In Series With Load Current
Magnetic
Field
Coil
N
26
Thermal Magnetic
Time Current Characteristic Curve
27
4/1/2014
Different Types And Sizes

Molded Case Circuit Breaker (MCCB)
A circuit breaker that is assembled as an integral unit in a supporting and
enclosing housing of insulating material.
Insulated Case Circuit Breaker (ICCB)

A circuit breaker that is assembled as an integral unit in a supporting and enclosing housing
of insulating material and with a stored energy mechanism.
Low Voltage Power Circuit Breaker (LVPCB)

A mechanical switching device, capable of making, carrying, and breaking currents under
normal circuit conditions and making and carrying for a specified time and breaking currents
under specified abnormal circuit conditions such as those of short circuit. Rated 1000 V ac or
below, or 300 V dc and below, but not including molded-case circuit breakers.
28
Molded Case Circuit Breakers
Miniature G Frame
E Frame
F Frame
J Frame
K Frame
L Frame
M Frame
N Frame
R Frame
15 100A 15 100A
15 125A
10 225A
70 250A
70 400A
70 600A
300 800A
320 1200A
800 2500A
Continuous Ampere Ratings from 15A to 2500A Frame

Interrupting Capabilities of 22KA to 100KA
Found In enclosures, panelboards, switchboards, MCCs and Control
Panels
Industrial AND Residential Applications
29
Insulated Case Circuit Breakers

Typically 800A 6000A
Frame Range
Interrupting Duty 35
150kA
Found In Enclosures,
Switchboards and
Switchgear
30
10
4/1/2014
Low Voltage Power Circuit Breakers
Interrupting Duty from 42kA to 100kA and

Current-Limiting Up To 200kA
800A to 6000A Frame
Found in Enclosures, Switchboards, and Switchgear
Draw-out & maintenance capabilities
31
Electronic Trip Units
Trip Unit
Circuit Board
Flux
Transfer
Shunt Trip
Current Transformer
32
Time-Current Characteristic
Long Time
Delay
100
Time In Seconds
Depicts the time required for an

overcurrent protective device to open
automatically
Long Time
Pickup
1000
Three Regions
Short Time
Pickup
10
Long-time: Opening in minutes
Short Time Delay

(I2t)
1.0
Short-time: Opening in seconds or

tenths of seconds.
0.1
Instantaneous Pickup
0.01
0.5
10
Instantaneous: Opening with no

intentional delay - milliseconds
100
Multiples of Rated Current
33
11
4/1/2014
Communications
Remote Data Collection
Energy / Voltage / Current
Cause Of Trip And Other Alarm Information
Control
HTTP
WEB
URL
Internet
34
Zone Selective Interlocking

Communication Between Breakers
Reduces Trip Time When Possible
Isc
Helps With Arc Flash Energy Reduction
Case 1:
Both Breakers See Fault
Upstream Breaker Waits As Designed
Case 2:
Only Upstream Breaker Sees Fault
No Input From Downstream
Breaker
Trip As Fast As Possible
35
Arc Flash Reduction Switch

ALWAYS WORK
DE-ENERGIZED
Manually or Automatically
enables analog
instantaneous pickup
Protects all downstream
equipment / personnel
Limits energy available
during maintenance
36
12
4/1/2014
Arc Flash Reduction Switch

Clearing times are much
faster than ZSI
Clearing times are faster
than standard INST
Ref: Incident energy calculated using IEEE STD 1584TM-2002 method for a 480 Vac system, working distance of 24 inches,
37
Grounding type = solid grounded
and Equipment type = Switchgear.
Arc Detection / Fire Prevention
Technology Has Progressed To Enable Enhancement

Of The Residential MCCB
Residential And Commercial Applications
38
Arc Detection / Fire Prevention

Push To Trip Test Button
Arc Fault Sensing Circuitry
Operating Handle
Load Terminal
Latch Piece
Panel Neutral Wire

Mechanism Spring
Moving Contact Member
Load Neutral Terminal
Electromagnet
Instantaneous Trip Element

( Armature )
Stationary Contact Member
Long Delay Trip Element
( Bimetal )
39
13
4/1/2014
Dual Element Time Delay Fuses

Dual Element Time-Delay
MODERN CL FUSES
Designed to be sized close to load and accommodate
motor and transformer inrush which could not be
accomplished by single-element non-time-delay or fastacting fuses.
Overload (time delay) Element
Short Circuit (current limitation) Element
Shortcircuit element
Overload Element
40
Dual Element Time Delay Fuse - Overload

Before

Under sustained overload condition,
spring operated trigger assembly
separates the connector from the
short-circuit element, opening the
circuit.
After
41
Dual Element Time Delay Fuses Short Circuit

Under a short-circuit
condition, restricted
portions of the short-circuit
element melt (vaporize)
and arc to burn back the
resulting gaps until the
arcs are suppressed by
the arc quenching material
and increased arc
resistance.
42
14
4/1/2014
Fuse Classes
High Speed Fuses

Permitted to provide short-circuit, ground-fault
protection for motor branch circuits utilizing
power electronic drives
43
Fuse Class Dimensions
44
44
Time Current Characteristic (TCC) Curves

The Trip Curve
Average
1000
A Trip Curve Is Plotted Time Vs.

Current
The Curve Tells The Trip Times

For Various Levels Of Current
Minimum melt, average melt

total clear
Fast acting fuses faster in

overload region than time-delay
fuses. Similar in short-circuit
region.
Melt
100
Time (Seconds)
Total
Clear
10
A Fuse Opens
Overload
At Some Time
1.0
Between These Bands

Minimum
0.1
Melt
Current Limiting
Threshold
Short Circuit
0.01
20
200
Current (Amps)
Understanding How An Overcurrent Protective Device

Operates Is Important
1000
0.5
45
15
4/1/2014
Fuse Class Current Limitation

All manufacturers must comply with maximum letthrough values (Peak/I2t) for each fuse class
(at fault currents of 50, 100, 200, 300kA)
46
Current Limiting Effect Charts

Manufacturer (fuse or circuit breaker)
published data provides actual Ip and Irms letthrough
47
Class L
Large
Class L Low-Peak
KRP-C-(AMP)SP
600V, 601A 6000A, 300kA
Characteristics
Time Delay
Current limiting
Applications
Mains and feeders in electrical distribution
equipment
Large motors
48
16
4/1/2014
Class T
Tiny
Fast-acting
300V AC or 600V AC
Up to 1200A
Amperage case sizes include:
200kA Interrupting rating

Current limiting
Rejection feature class or size rejecting
Best space saving design of any power
fuse
30, 60, 100, 200, 400, 600, 800, 1200
Applications:
Heating and lighting circuits
Single phase lighting circuits (277V)
Residential and multi-metering
49
Class H
Hazardous
Class H One-Time
NON-(AMP)/NOS-(AMP)
250V/600V, 1/8A-600A
60A or Less 50kA, above 60A - 10kA
Characteristics
Non-Time Delay
Non-current-limiting & non-rejecting
Recommend REPLACE with RK5/RK1
Applications
General purpose
HVAC, light commercial
50
Class RK5
Rejection
Class RK5 Fusetron
FRN-R-(AMP) / FRS-R-(AMP)
250V/600V, 1/10A 600A, 200kA
Characteristics
Dual Element Time Delay
Good current limitation
Optional Open Fuse Indication
Applications
Feeders and branch circuits in electrical
distribution and OEM equipment
Time delay good for across the line start motor
applications and transformer primaries
51
17
4/1/2014
Class RK1
Rejection
Class RK1 Low-Peak
LPN-RK-(AMP)SP/LPS-RK-(AMP)SP
250V/600V, 1/10A 600A, 300kA
Characteristics
Better current limitation
(better Type2 and Arc Flash protection)
Less time delay than RK5
Optional open fuse indication
Applications
Feeders and branch circuits
Primarily Building Systems
Electrical Safety Upgrade
52
Class J
Junior
Class J Low-Peak
LPJ-(AMP)SP
600V, 1A 600A, 300kA
Characteristics
Better time delay than CC
Less time delay than RK1/RK5
Very current limiting

Smaller than RK1/RK5
Open fuse indication Optional
Applications
Feeder and branch circuits
OEM & Building Systems
Type 2 Protection
53
Class J
Junior
Class J DFJ High Speed Fuse
DFJ-(AMP)
600V, 1A 600A, 200kA
450Vdc, 100kA
Characteristics
High speed performance: extremely current limiting
(similar to high speed fuses)
Applications
Drive branch circuits
Heater circuits with solid state relays (SSRs)
Protect power electronics and provide branch circuit
protection
Fit HSF performance into standard, off the shelf,
switches, holders and blocks
54
18
4/1/2014
Class CF
CUBE FUSE
Class CF - TCF(amp), TCF(amp)RN or FCF(amp)RN
TCF - 600Vac/300Vdc, 1-100A, 300kA/100kA

FCF - 600Vac/dc, 1-100A 200kA/50kA
Characteristics
DE Time Delay or Fast Acting

Class J Performance
Very Current Limiting
Small physical Size
Finger safe IP20
Optional Indicating version time-delay only
Applications
General purpose; e.g. motor circuits (Type 2 Protection,

transformers, heaters, feeders and branch circuit protection
WCF_RN CUBEFuse for 690Vac wind turbine systems
(UL 248 Recognized) .
55
Class CC
Control Circuit or Charlie Chaplin (little hat)
Class CC - General Features
600V, up to 30A
Very Current Limiting
Space Saving Design - 13/32 X 1
Grooved ferrule provides rejection feature from

supplementary fuses with same dimensions
(midget fuses) when Class CC fuseholders are
used
Offer 3 different fuse types
Time delay (for motor circuit: LP-CC)
Time delay (for control transformer primary: FNQ-R)
Non-time delay (Non-inductive loads: KTK-R)
56
Class G Fuses
Growing
Time-delay
600V AC, up to 20A
480V AC, 25-60A
Amperage case sizes include:

Current limiting
Rejecting feature
Length of fuse varies with the amperage
Applications:
15, 20, 30, 60
Small Motors
Small Transformers
General applications with inrush current
57
19
4/1/2014
Edison-Base Fuses and Fuseholders

NEC 240.51(B) permits the use of plug fuses
of the Edison-base type to be used only for
replacements in existing installations where
there is no evidence of overfusing
NEC 240.53(A) Classifies Type S fuses as:
Not over 125V
0-15A, 16-20A, and 21-30A
NEC 240.53(B)
Type S fuses cannot be interchangeable with a
lower ampere classification
Type S fuses are required to be designed for use in
only a Type S fuseholder or an Edison-based
fuseholder with a Type S adapter inserted.
58
Circuit Breaker versus Fuse

Circuit Breakers
Fuses
Size & Flexibility (IR)

Resettability (OL)
Shunt/Common Trip
Integral Ground Fault
Protection (multi-level)
Adjustable Trip Settings
Advanced Protection &
Monitoring Features
Arc Flash (above 800A and
lower fault currents)
Switching Operations and
Drawout Capability for
Maintenance
Reliability limited
maintenance
Ease of application (V&IR),
rejection features
Current-limitation
Component Protection (motor
circuits, high SCCR and
protection of solid-state
equipment)
Arc Flash Protection (typically
800A and less and higher fault
currents)
Ease of Selective Coordination
(use of fuse ampacity ratios)
59
Questions And Comments

Thank You
20

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4/1/2014

Overcurrent Protective Device (OCPD) Basics

2013 Eaton. All rights reserved.

Overcurrent Protective Basics

Basics Construction, Operation and Ratings (V, A, IR)

Overcurrent Protective Device Types

Circuit Breakers (MCCB, ICCB, LVPCB, AFCIs, GFCIs)

2013 Eaton. All rights reserved.

Overcurrent Protective Devices Protect From

An Overcurrent Results From

2013 Eaton. All rights reserved.

Overcurrent Protective Devices Protect From

Within the normal path

Voltage (V) = 480

Iload = (480) / (0.01 + 24) = 20 Amps

Overcurrent Protective Devices Protect From

Out of the circuit

Outside the normal path

Voltage (V) = 480

2013 Eaton. All rights reserved.

Typical Short-Circuit Currents

Eaton Bussmann Short-Circuit Calculator

2013 Eaton. All rights reserved.

OCPD - Voltage & Ampere Rating

OCPD - Interrupting Rating

2013 Eaton. All rights reserved.

OCPD Interrupting Rating

OCPD - Current Limitation

OCPD - Current Limitation

2013 Eaton. All rights reserved.

Current-limiting overcurrent devices can provide increased

Arc Flash Energy People Protection

Arcing fault current magnitude

2013 Eaton. All rights reserved.

Arc Flash Testing - Test 4

2013 Eaton. All rights reserved.

Arc Flash Testing - Test 3

2013 Eaton. All rights reserved.

Circuit Breaker Components

Circuit Breaker Components

2013 Eaton. All rights reserved.

Circuit Breaker Components

2013 Eaton. All rights reserved.

Circuit Breaker Components

2013 Eaton. All rights reserved.

2013 Eaton. All rights reserved.

2013 Eaton. All rights reserved.

2013 Eaton. All rights reserved.

Different Types And Sizes

Insulated Case Circuit Breaker (ICCB)

Low Voltage Power Circuit Breaker (LVPCB)

2013 Eaton. All rights reserved.

Molded Case Circuit Breakers

Continuous Ampere Ratings from 15A to 2500A Frame

2013 Eaton. All rights reserved.

Insulated Case Circuit Breakers

2013 Eaton. All rights reserved.

Low Voltage Power Circuit Breakers

Interrupting Duty from 42kA to 100kA and

Electronic Trip Units

2013 Eaton. All rights reserved.

Depicts the time required for an