Power Transformer Protection and Types of Faults

Table of Contents
 Power Transformer Faults
o Oil & Winding Insulation Faults
o Core Faults
o Windings Faults
o Overload Faults
o Overheating Faults
 Power Transformer Protection
o Built-On Protection
o Differential Protection
o Over-Current Protection
o Restricted Earth Fault Protection
o Overload Protection
o Lightning Protection
o Transformers Fire Protection System
Today, we will discuss about different types of transformer protection and faults in
details.
Transformers are vital equipment in transmission and distribution network and so
the protection against internal and external faults is a very important factor in the
design of those networks.
Transformers faults may occur:
 In the dielectric (insulating) materials, namely in the oil.
 In the windings.
 In the core (less frequent).

Oil & Winding Insulation Faults

Transformer oils are designed to provide electrical insulation under high electrical fields;
any significant reduction in the dielectric strength may indicate that the oil is no longer
capable of performing this vital function.
Some of the things that can result in a reduction in dielectric strength include polar
contaminants, such as water, oil degradation by products and cellulose paper
breakdown.Transformer faults may occur in the oil due to gas formation, ageing,
contamination with air and lack of level and pressure.
In the event of a minor fault like damage to core bolt insulation, local overheating, etc.,
the arcingcauses slow generation of gas in the oil All faults in transformer core and
windings result in the localized heating and breakdown of oil.When the fault is of very
minor type such as hot joint, gas is released slowly and rises towards conservator.
A major fault where severe arcing takes place causes rapid release of large
volume of gas and oil vapor.
This violent evolution of gas and oil vapor does not have time to escape
and instead builds up pressure and bodily displaces the oil, causing surge of oil
to the conservator.
Faults may also occur in the windings insulation material, as a consequence of
oil failure, ageing, overheating and insulation breakdown.
Core Faults
If any portion of the core insulation becomes defective or the laminated structure
of the core is bridged by any conducting material which can permit sufficient
eddy current to flow, it will cause serious overheating.
The insulated core bolts are used for tightening the core. If the insulation of these
bolts fails and provides easy path for stray current, this will lead to overheating.
Mechanical impacts during handling and transportation may apply to the
transformer an equivalent force above 3g (where g is the gravidity acceleration; g
= 9.81 m/s2.), which can cause distortion of the core.
Windings Faults
Common windings faults are:
 Faults between primary and secondary windings (short circuit) of the same phase.
 Short-circuit between the turns of the winding.
These faults usually are a result of dielectric failure, both between windings and
between the turns of the same winding, due to ageing of insulation material,
which may increase due to overloads.
It also must be considered that the windings are subject to both radial and axial
forces related to the current and flux interactions. Radial forces in the inner
winding (normally the LV winding) are in compression while the outer
winding (normally the HV winding) forces are in tension.
Design of the windings and bracing must consider the magnitude of these
forces and provide adequate strength to withstand them without significant
mechanical deformation which could result in a dielectric failure.
Also mechanical impacts during handling and transportation may apply to the
transformer an equivalent force above 3g, which can cause distortion and/or
displacement of the windingsand decrease of the insulation of the windings.
Overload Faults
The loading of transformer is decided by permissible temperature rise of windings
and oil. Permissible oil temperature is 65 °C and hot spot temperature of the
winding is 80 °C at rated load.
As the load of the transformer does not remain steady and varies according to load
curve, the loading of transformer becomes an important operating problem.
The rated output of a power transformer is mentioned on its name
plate with reference to specified temperature rise under specified test conditions.
The output which can be obtained from a transformer without causing undue
deterioration of the insulation may be either more or less than the name plate
rating depending upon the operating conditions, such as ambient temperature, initial
loading, cooling provision, life expectancy, etc.
Overheating Faults
Overheating in transformer may be caused by overloads above the permissible
overloads specified by the manufacturers, according to IEC Standards (60354 for oil-
filled transformers and 60905 for dry type transformers), and external faults, such
as short-circuits on installations downstream. Most of these faults may be limited by
proper maintenance of a transformer.
Overheating may cause a breakdown of the insulation of the windings.
Power Transformer Protection
Built-On Protection

Transformers are provided with bullet on (internal protections) for dielectric

failure (formation of gas), temperature, oil pressure, level, winding temperature and on
load tap changer.
According to the construction type of transformers the following protections must be
provided:
Oil-filled transformers with conservator
 Buccholz relay for dielectric failure (2 steps: alarm and trip)
 Oil pressure and level switches (2 steps: alarm and trip)
 Thermostat for oil temperature (2 steps: alarm and trip)
 On-load tap changer protection (2 steps: alarm and trip)
Buccholz relay has multiple methods to detect a failing transformer.
 On a slow accumulation of gas, due perhaps to slight overload, gas produced by
decomposition of insulating oil accumulates in the top of the relay and forces the oil
 level down. A float switch in the relay is used to initiate an alarm signal. Depending on
design, a second float may also serve to detect slow oil leaks.
 If an arc forms, gas accumulation is rapid, and oil flows rapidly into the conservator.
This flow of oil operates a switch attached to a vane located in the path of the moving
oil.
Buchholz relays have a test port to allow the accumulated gas to be withdrawn for
testing. Flammable gas found in the relay indicates some internal fault such
as overheating or arcing, whereas air found in the relay may only indicate low oil
level or a leak.

For transformers equipped with cooling fans and pumps, the temperature devices are
used to automatically start and stop the forced cooling. They are also equipped
to initiate an alarm and a trip for very high transformer temperatures.
Oil-filled sealed transformers
 Gas detection and oil level, pressure and temperature in one single equipment (DGPT
2 – Detection of Gas, Pressure and Temperature) with 2 levels (alarm and trip)
Dry type transformers
 Temperature of windings with 2 levels (alarm and trip) – resistance temperature
detector PT 100 (platinium probe) or PTC (“Positive Temperature Coefficient”), that is
a thermistor (semi conductive material sensitive to temperature).
These protections have a direct action on the tripping coils of the circuit
breakers.
Differential Protection

The ideal way of protecting any piece of power system equipment is to compare the
current entering that piece of equipment, with the current leaving it.
Under normal healthy conditions the two are equal. If the two currents are not equal,
then a fault must exist.
This is done through “differential protection” (ANSI / IEEE / IEC code 87T), which
diagram is shown in Figure 1 and the functioning principle is based in Kirchhoff
current law.
Good to know:

IEC: International Electrotechnical Comission.

ANSI: American National Standards Institute.
IEEE: Institute of Electrical and Electronic Engineers.
 Figure 1 – Differential protection diagram
EHV and HV transformers and autotransformers for volatges above 49.5
kV and MV transformerswith rated power above 3-4 MVA have usually as main
protection a differential protection for winding faults – short-circuits between turns of
a winding or between windings that correspond to phase-to-phase or three-phase type
short-circuits.
If there is no earthing / grounding connection at the transformer location point,
this protection can also be used to protect against earth faults.
If the earth fault current is limited by impedance, it is generally not possible to
set the current threshold to a value less than the limiting current.
This protection is connected to current transformers CT (Current Transformers) at both
side of the transformer (primary and secondary), as it was shown in Figure 1.
The use of transformer differential protection poses some problems that must be taken
into account:
Problem relating to the transformation ratio and the coupling method
The primary and secondary currents have different amplitudes owing to the
transformation ratio and different phases depending on the coupling method (delta-star
transformer makes a phase displacement of 30°). Therefore, the current values
measured must be readjusted so that the signals compared are equal during normal
operation.
This is done using matching auxiliary transformers whose role is to balance the
amplitudes and phases.
When one side of the transformer is star-connected with an earthed neutral, the
matching transformers on this side are delta-connected, so that the residual
currents that would be detected upon occurrence of an earth fault outside the
transformer are cleared.
Figure 16 shows an example of the connection of the differential protection,
using matching auxiliary transformers.

Figure –
Transformer differential protection diagram
Nowadays, with electronic and microprocessed protection units, this compensation is
done through software.
Function of the protection is based on the transformation ratio “n” that can be expressed
by the equation:
n = (U1 / U2) = (I2 / I1)
(U1: primary voltage; U2: secondary voltage; I1: primary current; I2: secondary
current).
The above relation is a consequence of the equation of the rated power (S) of the
transformer:
S = √3 x U1 x I1 = √3 x U2 x I2
Problem relating to the transformer inrush current
Transformer switching causes a very high transient current (from 8 to 15 In),
which only flows through the primary winding and lasts several tenths of a second.
It is thus detected by the protection as a differential current and it lasts far longer than
the protection operating time (30 ms). Detection based only on the difference
between the transformer primary and secondary currents would cause
the protection to be activated. Therefore, the protection must be able to distinguish
between a differential current due to a fault and a differential inrush current.
Experience has shown that the inrush current wave contains at
least 20% of second harmonic components (current at a frequency of 100 Hz), while
this percentage is never higher than 5%upon occurrence of an overcurrent due to a fault
inside the transformer.
The protection must therefore simply be locked when the percentage of second
harmonic component in relation to the fundamental harmonic component (current at 50
Hz) is higher than 15%, i.e., “I2 / I1 > 15%”.
Problem relating to the magnetizing current upon occurrence of an overvoltage of
external origin
Magnetizing current, or exciting current, is the current that flows through the primary
winding of a power transformer when no loads are connected to the secondary
winding; this current establishes the magnetic field in the core and furnishes energy
for the no-load power losses in the core. It is responsible for “iron losses”.
The magnetizing current constitutes a difference between the transformer primary
and secondary currents. It is therefore detected as a fault current by the differential
protection even though it is not due to a fault.
In normal operating conditions, this magnetizing current is very low and does not
reach the protection operating threshold.
However, when an overvoltage occurs outside the transformer, the magnetic material
saturates(in general the transformers are dimensioned to be able to operate at
saturation limit for the nominal supply voltage), and the magnetizing current
value greatly increases. The protection operating threshold can therefore be
reached.
Experience has shown that the magnetizing current due to the magnetic saturation has
a high rate of fifth harmonic components (current at a frequency of 250 Hz).
Transformer differential therefore requires fairly complex functions as it must be
able to measure second and fifth harmonic current or, in order to avoid
measuring fifth harmonic currents, it must be able to detect overvoltages of
external origin.
The characteristics of transformer differential protection are related to the
transformer specifications:
 Transformation ratio
 Vector group
 Inrush current
 Permanent magnetizing current

Over-Current Protection
MV transformers with rated power up to 2.5 MVA are usually only protected against
overcurrents using over current relays.
 Three phase or phase-to-phase short circuit, instantaneous (ANSI/IEEE/IEC code 50).
 Three phase or phase-to-phase short circuit, time delayed (ANSI/IEEE/IEC code 51).
 Phase-to-earth short circuit, instantaneous (ANSI/IEEE/IEC code 50N).
 Phase-to-earth short circuit, time delayed (ANSI/IEEE/IEC code 51N).
This set of protections is used on HV and MV transformers with rated power above 3-4
MVA as a “back-up” protection, in addition to the differential protection.
In some installations and networks MV transformers with rated power up to 630
kVA may be protected against overcurrents by fuses associated to switch-
disconnectors, as shown in Figure 2.
In these situations the switch-disconnectors must have a tripping coil to allow the
action of the built-on protections of transformers.
 Figure 2 – Switch-disconnector
associated with fuses
Fuses must have a mechanical latch to indicate the fusion and to provoke three-pole
opening of the switch-disconnector, to avoid the functioning of the installation only with
two phases.
Manufacturers provide tables to choose the rated current of a fuse, taking into account
the rated voltage and power, like the one shown in the Table 1, according to IEC
standards.
Tables vary from manufacturer to manufacturer, according to the standards
used, being recommended to use the table provided by the selected
manufacturer.

Restricted Earth Fault Protection

Restricted earth fault protection (ANSI/IEEE/IEC code 64G/64REF) is used as
a complement or to replace differential protection for windings faults to earth.
An external fault in the star side will result in current flowing in the line current
transformer of the affected phase and at the same time a balancing current flows in
the neutral current transformer, hence the resultant current in the relay is therefore
zero.
So this protection will not be actuated for external earth fault. But during internal
fault the neutral current transformer only carries the unbalance fault
current and operation of the protectiontakes place.
This scheme of restricted earth fault protection is very sensitive for internal earth
fault of electrical power transformer. The protection scheme is comparatively
cheaper than differential protection scheme.
Restricted earth fault protection is provided in electrical power transformer for
sensing internal earth fault of the transformer. In this scheme the CT secondary of
each phase of electrical power transformer are connected together as shown in Figure
3.

Figure 3 – Diagram of restricted earth fault protection

Whenever there is an unbalancing in between three phases of the power transformer,
a resultant unbalance current flow through the close path connected to the
common terminals of the CT secondary.
An unbalance current will also flow through the neutral of power transformer and hence
there will be a secondary current in Neutral CT because of this unbalance neutral
current.
In restricted earth fault scheme the common terminals of phase CT are connected to
the secondary of Neutral CT in such a manner that secondary unbalance
current of phase CT and the secondary current of Neutral CT will oppose each
other.
If these both currents are equal in amplitude there will not be any resultant current
circulate through the said close path. The restricted earth fault protection is
connected in this close path. Hence the relay will not response even there is an
unbalancing in phase current of the power transformer.

Overload Protection
The basic criterion for transformer loading is the temperature of the hottest spot of the solid
insulation (hot-spot). It must not exceed the prescribed value, in order to avoid insulation
faults, since loading capability of power transformers is limited mainly by winding
temperature.
The temperature of solid insulation is the main factor of transformer ageing.
With temperature and time, the cellulose insulation undergoes a depolymerization
process. As the cellulose chain gets shorter, the mechanical properties of paper such
as tensile strength and elasticity degrade. Eventually the paper becomes brittle and
is not capable of withstanding short circuit forces and even normal vibrations that
are part of transformer life. This situation characterizes the end of life of the solid
insulation. Since it is not reversible, it also defines the transformer end of life.
Transformer overloads can occur during contingency conditions that are the product
of one, two, or various system elements being isolated from the power the system. They
can also occur when transformers are already at 80%-90% of their full nameplate
rating and extra capacity is needed, especially during hot summers.
Traditionally, inverse-time overcurrent relays (an inverse-time
curve is characterized by the inverse variation of current with the time, as shown in
Figure 4) for overload protection, but a difficulty is that transformers are usually
outdoors where ambient temperature affects their loadability, and hence
the optimum pickup settings of such relays.
Figure 4 – Inverse-time characteristic curve
However, for liquid-immersed power transformers, the temperature of the winding
hot-spot is the important factor in the long-term life of the transformer.
The insulating oil temperature is dependent on the winding temperature, and is used
to indicate the operating conditions of the transformer. Many numerical transformer
protection relaysavailable today include protection functions that operate on insulating
oil temperatures, calculated loss-of-life due to high oil temperature, and predicted
oil temperatures due to load.
These types of functions are not routinely applied, but modern utility operating
practices try to maximize the utilization of power transformers, which may increase
the occurrence of over-temperature conditions and transformer ageing. Over-
temperature conditions and accelerated aging are adverse system events that must
be identified and protected against.
The most common function provided for thermal protection of power transformers is
the thermal overload (ANSI/IEEE/IEC code 49) function.
The thermal capacity used is calculated according to a mathematical model which takes
into account:
 Current rms values
 Ambient temperature
 Negative sequence current.
The protection gives a trip order when the heat rise E, calculated according to the
measurement of an equivalent current Ieq, is greater than the set point Es.
The protection tripping time is set by the time constant T.
The thermal overload protection function may be used to protect equipment with two
operating rates, for example transformers with two ventilation modes, with or without
forced ventilation (ONAN / ONAF).
Lightning Protection

Lightning protection of power transformers is achieved by surge arresters installed

in the transformer tank, as shown in Figure 5.

Figure 5 – Surge arrester

The most common surge arresters are non-linear metal oxide resistors type
in porcelain or silicone rubber housing, and are fitted in parallel with the object protected
and connected to the earth grid.
Resistance of non-linear resistors is in inverse proportion to the current, that is to
say that the resistance is high for current service values and very low for high
lightning discharge currents.

TRANSFORMER NAMEPLATE (GENERAL REQUIREMENTS).

Following are he minimum information and Data which to be shown on a transformer name
plate.The standards require the following information and data for transformers rated above 500
kVA
(Suppose 1000kVA = 1MVA.
• Name of manufacturer
• Serial number
• year of manufacture
• Number of phases
• kVA or MVA rating
• Frequency
• Voltage ratings.
• Tap voltages.
• Connection diagram.
• Cooling class
• Rated temperature in °C
• Polarity (for Single Phase Transformers)
• Phasor or vector diagram (For Polyphase or Three Phase Transformers)
• % impedance.
• Approximate mass or weight of the transformer
• Type of insulating liquid.
• Conductor material of each winding.
• Oil volume (of each transformer Container/Compartment)
• Instruction for Installation and Operation

Name Plate Rating Of a Transformer

The Data on the Nameplate of transformers contains of kilo-Watts rating, Voltage
Rating,Frequency, Number of Phases, Temperature, Type of Cooling, % Impedance
and Reactance, Name of Manufacture,Year of Manufacture etc.
A Typica Nameplate of a Transformer as follow.
=================================================================
S.No. Description of Data to be given Ra-marks for example
=================================================================
[1] [2] [3]====================
=============================================
1. Manufacturer’s Name: ABB/206788
2. Manufacture’s Serial Number 224106
3. Kind of Transformer Power Transformer
4. 236839Relevent Standard Year I.S/P.S/B.S/ IEC /DIS/JIS NEMA
5. Year of Manufacture 2013
6. Number of Phase 3
7. Rated Power 1000kVA = 1MVA
8. Rated Frequency: 50Hz
9. Rated Voltages: HV 33 kV, LV 11 kV,
10. Rated Currents HV______,LV_______.
11. Vector Group Symbol __________________
12 % Impedance Voltage
( At Raed Current) __________________
13. % Reactance Voltage in % : __________________
14. Types of Cooling ONAM
15 .Total Weight __________Kg
..Mass or insulating Oil __________Kg
..Transportation Weight __________Kg
..Untanking Weight __________Kg
16. Insulating liquid ( if Not Oil) Types: ______________
17. Quantity of Oil ( Liters): __________
18. Details about Tap-Changer __________
19. Rated insulation Level: __________
..Power-Frequency withstand Voltage kV(rms)
20. Other …………………….

Also shown in below image.

Below is a 100kVA (Three-Phase) Transformer nameplate.

 Click image to enlarge.

What is Circuit Breaker (CB) ?

A CB (Circuit breaker) is a device which:

 Control (make or break) a circuit manually or by remote control under normal and fault
conditions.
 Break a circuit automatically under fault conditions (like over current, Short circuit, etc).
 Air Circuit Breaker
 Operates in air (where air-blast as an arc quenching medium) at atmospheric pressure.
 It has completely replaced by oil circuit breaker.
 No chance of oil fire like in oil circuit breaker.
 Rated Current up to 10k A.
 Trip thresholds and delays are adjustable.
 Electronically and microprocessor controlled.
 It is used in large industrial plant for main power distribution.

To know more about ACB, read the article “Air Circuit Breaker (ACB) – Construction,
Operation, Types and Applications.
What is MCB (Miniature Circuit Breaker) ?
 MCB stands for “Miniature Circuit Breaker”.
 Rated current under 100 amps.
 Interrupting rating of under 18,000 amps.
 Trip characteristics may not be adjusted.
 Working principle based on thermal or thermal magnetic operation.
 Suitable for low current circuits (low energy requirement), i.e. home wiring.
 Generally, used where normal current is less than 100 Amps.
To know more about the MCB, check the previous post “MCB (Miniature Circuit

Breaker) – Construction, Working, Types & Applications”.

What is MCCB (Moulded Case Circuit Breaker) ?
 MCBB stands for “Molded Case Circuit Breaker“.
 Rated current in the range of 10-2500 amps.
 Thermal operated for overload and & magnetic operation for instant trip in SC (short
circuit conditions).
 Interrupting rating can be around 10k – 200k amps.
 Trip characteristics is adjustable.
 Suitable for high power rating and high energy i.e. commercial and industrial use.
 Generally, used where normal current is more than 100 Amps.

Main Difference between MCB and MCCB

The main different between MCB and MCCB is the interrupt current rating which is up to
1800 amperes for MCB and 10k – 200k Amperes for MCCB.
 Related Post: Main Difference between Contactor and Starter.
The following table shows the difference and comparison between MCB and MCCB.
Keep in mind that both MCB and MCCB are classified as low voltage circuit breakers
and the operation principle is based on thermo-magnetic for both devices.
 Related Post: Difference Between Relay and Circuit Breaker

MCB and MCCB Selection

Now the question is that for a situation, where standard current carrying capacity
needed is 100A with breaking capacity of 15KA, what should be used? An MCB or
MCCB? We assume cost is not very different.
Both are in moulded case and having almost similar features especially when we are
comparing with fixed thermal setting option of MCCB and they are classified as low
voltage circuit breakers. For magnetic setting, we can select MCB as per curve and
MCCB will have either fixed setting or can be adjusted.
 Related Post: Difference between Circuit Breaker and Isolator / Disconnector
So what is the criteria to make a selection of MCB or MCCB? Space can be a point of
consideration as MCBs are more compact but it doesn’t make a big point as bigger size
of MCCB brings many advantages too like better fault clearing mechanism. keep in
mind that both MCB & MCCB are low voltage circuit breakers and created to respond to
IEC 947 standards (We are going to discuss these standards below)
Actually there is difference in standards they follows. An MCB is supposed to function in
accordance to IEC 60898-1 (Unless mentioned otherwise) and so is tested accordingly.
While an MCCB is tested in accordance with IEC60947-2. So to understand the
difference between MCB and MCCB we need to get a brief idea of these two standards.
 Related Post: Main Difference Between Electrical and Electronic Engineering?
Difference between IEC 60898-1 and IEC 60947-2
IEC60898-1
It defines behavior of circuit breaker having rated operational voltage not exceeding
than 440V (between Phases), Rated current not exceeding than 125A (We have range
0.5A-125A) and rated short circuit capacity not exceeding than 25KA ( Usually it is
10KAin MCB). This is designed for unskilled user (or say uninstructed user) and for
devices not being maintained consequently. Also pollution degree covered is zero
pollution to maximum pollution (degree 2). These are the circuit breakers we find in
residential homes, shops, school & offices electrical distribution switchboards.
 Related Post: What is the Difference Between Neutral, Ground and Earth?
IEC60947-2
This standard applies to circuit-breakers, the main contacts of which are intended to be
connected to circuits, the rated voltage of which does not exceed 1000 V a.c. or 1500 V
d.c.; it also contains additional requirements for integrally fused circuit-breakers. It
covers very high range of standard current carrying capacity (We have range of 6A-
6300A) and meant for skilled user. The device is also supposed to be maintained
properly. Also pollution degree is to be 3 or more. These circuit breakers are industrial
applications and protect the power distribution of up to 1000 volts AC. and 1500 volts
DC. (For MCBs, MCCBs & ACBs)
So it is clear that these items are different in their fundamentals. An MCB designed for
indoor, pollution-free conditions and would not be suitable for harsh, outdoor
applications that require pollution degree 3.
Typically, IEC 60898-1 certified Circuit Breakers meet minimally required performance
to proof proper protection of household installations: Pollution degree 2, impulse voltage
4kV, isolation voltage is the same as nominal voltage 440V. That is the reason why
usually we meet limited number of technical information printed on Circuit Breakers.
It is not necessary that Circuit breakers certified with IEC 60898-1 can’t be certified with
IEC 60947-2, but for sure any manufacturer need to obtain certification. Rating of same
MCB can be different for different standards, so, it is highly recommended to check the
data properly printed on it.
 Related Post: Staircase Wiring Circuit Diagram – How to Control a Lamp from 2 Places by 2-
Way Switches?
So, the application and needs will decide that which device is to be used or selected.
Comparison Between IEC 69896-1 & IEC 60947-2
MCB Characteristic IEC 60898-1 IEC 60947-2

Rated Current: In 6 – 125A 0.5 – 160A

SC Breaking Capacity <25kA <50kA

Rated Voltage: Ue 400V 440V, 500V, 690V

Impulse Voltage: Uimp 4kV 6kV – 8kV

Pollution Degree 2 3

Curves B,C,D B,C,D,K,Z,MA

Application Current AC AC or DC

Electrical Auxiliaries No Monitoring Control

How to select MCB or MCCB at Different Circuit Levels?

well. As we have cleared everything in the above sections as well as, the MCB
nameplate rating data also give an appropriate information, but the choice of MCB or
MCCB is based on certain factors and conditions like;
 ICS as a % from ICU. (See Difference between ICS & ICU in term of Circuit Breakers)
 Maximum Operating Voltage
 Insulation voltage
 Mechanical operation ( endurance and durability)
 Breaking Capacity for each Operating Voltage
Below are types of MCBs which shows the magnetic fault protection. Also, to prevent
the accidental overloading of the cable at no fault, there is a thermal device in MCB to
eliminate the chances of unwanted tripping operation of MCB. For short circuit
protection in home appliances, the current rating is about to 6kA while for heavy and
industrial operation, it is above the 10kA.
MCB Type Min Tripping Current (Ir) Max Tripping Current (Ir) Operating Time

Type B 3 5 0.04 – 13 Sec

Type C 5 10 0.04 – 5 Sec

Type D 10 20 0.04 – 3 Sec

by the way, it depends on your needs and requirement for what you want to install.
Many other different factors affect the situation, So you will have to read the next article
below as we have added some simple calculation and formulas for MCB installation &
selection for Electrical Wiring.
Applications Standards to be Followed

Residential Buildings IEC 60898-1

Commercial Buildings IEC 60898-1 or IEC 60947-2

Industries IEC 60947-2

Anyhow, You will have to read the next article about the proper selection of MCB or
MCCB according to your needs.
Difference between ICS & ICU in term of Circuit Breakers.
ICS = Service Braking Capacity (means, Circuit breaker can remove the fault, but it may
not be usable afterwards.)
ICU = Ultimate Braking Capacity (means, Circuit breaker can remove the fault and remain
usable)
Characteristic of MCB and FUSE
 Both MCB and Fuse rated in Amperes which is known as Nominal Current or Rated Current.
 Keep in mind that an MCB or Fuse with rated current of 50A will not trip when current of
more than 50A is flowing through it.
 The reason is that MCB and Fuse with same rated current has different properties.
 For a 63A MCB and 60A Fuse where it should trip in 0.2 sec, MCB will trip at 260A and fuse
will trip at 600A. It shows Fuse delay is very high as compared to MCB.
 Sometimes, fuse blow itself without a reason. It may be due to the previous overloads for
specific time which has not been noticed.
 In case of Fuse, if the rated current is 60A, it will carry up to 80A for an hour or two. This is
the same like modern PVC cables hold 50% overload for an hour.
 A previous post can be read for more details under the title of “Main Difference between
Fuse and MCB“
What is ELCB (Earth Leakage Circuit Breaker)
ELCB stands for “Earth Leakage Circuit Breaker” and it is used for protecting a
person from electric shock and injury. The needs of these devices arise because of the
number increasing in injuries as well as deaths because of electric shock. This device is
invented almost 50 years ago, but nowadays ELCB is not suitable because of its some
disadvantages hence another device RCB (Residual circuit breaker) or RCD (Residual
Current Devices) whose functionality is same with more advantages, but theory of
operation is entirely different from ELCB. some of ELCB characteristic are as follow:

 As name suggest, its operated on earth leakage current.

 Line (Phase or Live), Neutral (N) and Earth Wire connected to the load points through ELCB.

ELCB Construction:
It is international standard that each electronics device enclosure should be earthed. So, there
would be no chance of electrocutions. For proper operation of ELCB, its need to bury a metallic
rod deep in the soil and ELCB is connected between the wire coming from the rod to the wire
attached to the external metallic body of the Electrical device or you can say that ELCB is
connected to the Earth wire.

ELCB Operation:
When the live wire (accidentally) touches the metallic body of the connected device or
appliance, then there is potential generated between the earthed rod and the metallic
enclosure of that device. The circuitry (inside the ELCB) senses the potential difference
and when this potential difference reached at 50volt then ELCB cuts off the main supply
from the connected device. This way it ensures the safety of the human beings.
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Methods)
To know the operation time of ELCB, lets see the following example.
The safest limit of current which human body (depends on multiple factors) can
withstand is 30mA sec. Suppose the human body resistance (hands to feet) is 500Ω
and he touches to the live wire having voltage of 230V AC to the ground. The current
flowing through body to the ground will be:
I = 220V/100Ω = 440mA
Now, The ELCB must be opertaed in
30mA sec / 440A = 0.068m sec.
However, it is not used widely nowadays because of its some major disadvantages
mentioned in the next section.
 Electrical Shock Hazards & Effects on
Human Body

Disadvantages of ELCB:
 Without proper earth connection, ELCB will not work. If the wire attached to the earthed rode
is loose or broken, then ELCB would not able to sense the potential hazardous voltage on
the metallic body of the electrical/electronic device.
 ELCB is attached between earthed wire and metallic body of the electrical appliances. But
there are many other parallel paths for the currents to flow from the connected device body
to earth without going through earthed wire. E.g. there are many metallic pipes in the house,
which can provide a parallel path for the current to flow towards the earth. In this way,
sometime ELCB is not able to detect the hazardous voltage on the metallic body of the
device, which may cause serious injury.
 If someone gets in touch with live phase wire, ELCB will not Trip because in this case, there
will be no current flow in the earth wire. In fact, current is flowing from the live wire to earth
through the person’s body.
 When a live wire comes in contact with neutral wire, short circuit will occur, hence, ELCB will
not trip because there will be no current in the earth wire.
 There are many cases in which, there is a current flow in the earth wire, but the situation is
not hazardous in such cases, but it gives false trip e.g. lightening strike, current starts flowing
in the earth wire and ELCB trips.
To overcome with the above disadvantages of ELCB, another Device named Residual
Current Breaker (RCB) is invented to use for earth leakage protection.
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What is RCD , RCB or RCCB ?
Residual Current Device (RCD) is also known as Residual Current Breaker (RCB)

or Residual Current Circuit Breaker (RCCB).

Residual Current Breaker (RCB) works on the assumption that the current going to the
electronics device must come out from the neutral wire, if there is no other way for
current flow. In simple words, RCB measures the current going inside the connected
device and coming out from the device. If both of these current are equal, then there
would no problem with the normal functionality of the device.
This device is also known as Current Operated ELCB which is known as RCCB
nowadays. This device is more sensitive and accurate than ELCB and its functionality
does not (entirely) depend on the earthed rode wire connection like voltage ELCB.
Some of RCCB (RCD or RCB) characteristic are as follow:
 Most widely used RCD is 30mA to 10mA.
 300 to 500mA RCCB are used for fire protection such as in lighting circuits with little chances
of electric shock.
 Line (Phase or Live) and Neutral (N) both wires are connected to the load points through
RCCB (RCD)
 RCD operate and trip when there is an earth fault current in the circuit.
 The same amount of current should flows through Neutral Wire as current flows in Live
(Phase) wire i.e. equal current should flows in both Phase and Neutral Wire.
 If RCD detect unequal current (Phase and Neutral Current should be same as mentioned
above) in phase or neutral wire, it will trip the circuit and disconnect the load points in 30m
sec.
 RCD devices are very effective for electric shock protection.
 In a home where earthing system is connected only to earth rod and not to the main
incoming supply cables, all circuits must be protected by an RCD otherwise, MCB might not
get the specified fault current which is important to trip the MCB from connected circuits.
Related Posts:

 Wiring of the Distribution Board with RCD

 Wiring of the Distribution Board without RCD
Working of RCD or Current Operated RCCB:
The polarity of the phase winding and the neutral winding is opposite in normal condition.
Therefore, EMF generated by the phase wire cancels out by the EMF of the neutral wire. If there
is a difference in the incoming and outgoing currents, then the resultant EMF will not be zero
and can be sensed by the CT of RCB. The signal from the RCB current transformer is fed to the
RCB circuit and it opens the main power contacts.

Advantages of RCD:
 If there is no connection between the ground and the enclosure of the device, and a person
touches the metallic body of that device. In this case, incoming and outgoing current will be
different and RCB will Trip in contrast with ELCB.
 Functionality of RCB (Residual Current Breaker) does not effect by lightning strikes.
 It does not trip falsely.
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Disadvantages of RCD:
 RCD don’t provide protection against Current Overload. But the main MCB will trip the
circuit as RCCD won’t trip in case of a live or neutral faults i.e. short circuit and overload. For
this reason, RCBO (MCB with RCD in a single unit) are used for proper protection.
 It operates only on normal supply wave forms i.e. it will not detect the pulsating DC and
half wave rectified waveform. For these reason, special RCCB are used which is also
operating on rectified pulsating DC voltage.
 Annoyance operation of RCD in case of sudden changes in load current. RCDs are
very sensitive and operate on even a very small amount of faulty current very quickly. In
case of switching of old electrical appliances, there is a small constant current flow through
earth which lead to trip the circuit.
 RCD will not protect against overheating, Live – Neutral Shocks, and Socket outlet
being wired with its Live & Neutral Terminals.
RCBO (Residual Circuit Breaker with Overload)
As we know that RCD won’t provide protection against Overload, hence an MCB and
RCD are presented in a single unit known as RCBO (Residual Circuit Breaker with
Overload). The operating principles are same as above but it provide more and reliable
operation with overload protection in single box.
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Installation
Difference between ELCB and RCCB
Characteristic ELCB RCCB (Also known as RCD or RCB)

Abbreviation Earth Leakage Circuit Breaker Residual Current Circuit Breaker

Voltage Operated Device (Old Name, Current Operated Device (New Name,
Operation
Old Technology). New Technology).

Only detects earth faults that flow back It will detect any earth fault. That’s why
Fault Detection
through the main earth wire. they are using now instead of ELCB.

Connected to Phase, Neutral as well as It is only connected to Phase and

Connection
Earth Wire. Neutral Wire.

Installation Needs an earth connection itself. No need of earth connection.

 AC = used for Alternating Current  AC = Used for Alternating Current

Types
 A = Used for Square-wave  A = Used for Square-wave
 B = Used to DC  B = Used to DC

Nuisance Tripping Less High

Cost Costly Less Cost

Not recommended. Replace it with Almost all wiring systems use RCCD
Applications
RCCD. nowadays.

Keep in mind that both ELCB and RCCB are used for the same purpose but wiring
connection is different i.e. in RCCB, only phase and neutral wire should be connected
through it whereas in ELCB, main earth wire is connected through it.