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Review of arcing phenomena in low voltage current

limiting circuit breakers


J.W.McBride and PM.Weaver

Abstract: Low voltage current limiting circuit breakers referred to as miniature circuit breakers
(MCBs) are widely used for electrical fault protection in domestic and light industrial installations.
Modern designs employ current limiting technology where the arc is forced rapidly away from the
contacts through an arc chamber and into a set of splitter plates. The motion of the arc is dependent
on a complex interaction of the anode and cathode root and the arc plasma motion. There is a large
volume of published research work relating to the study of arc phenomena. The paper presents a
selective review of the significant work relevant to the study of arc phenomena in MCBs under short
circuit conditions. Studies of arc column, arc root and arc electrode effects, and the physics of arc
motion as well as developments in the study of arc motion and arc control in MCBs, are reviewed.

1 Introduction First, an overview of the operating principles and techni-


cal requirements for an MCB is presented. This is followed
Miniature circuit breakers (MCBs) are widely used in by a review of the published scientific work relating to the
domestic, commercial and light industrial installations with arc, arcielectrode phenomena, and arc motion studies of
supply voltages in the range 200-500V AC for the protec- relevance to the MCB. Studies relating to the arcing char-
tion of circuits rated up to lOOA from overload and short acteristics in MCBs and specific short circuit arc phenom-
circuit faults (103-104~). ena are then reviewed.
Much development in the physics of switching arc phe- arc
nomena has been concerned with the study of switching
arcs in medium and high voltage circuit breakers. The bulk
of the applied work is of limited relevance to MCBs. Also,
Stack \
given the extreme unpredictability and variety of conditions
and behaviour displayed by the electrical arc, some of the
scientific studies [l, 21, whilst being indispensable back-
ground material, offer little specific information of use in
the area of low voltage switching.
diverging
Despite the emphasis on high voltage work, there has runners
been a steady development in the technology of miniature
devices. Improvements in performance and reductions in
size and cost have been made possible by research and
development work both on an empirical design level as well
as more fundamental research. The published work in this Fig. 1 Typiculminiature circuit hreoker (MCB) urrmg~ment
field has grown steadily since the early 1970s. Much of the Arc moves away from contact region into arc stack
work has been of an empirical nature with arc measurables
studied over limited sets of conditions, which may be diffi- 2 MCB -function and operating principles
cult to extrapolate to the broader operating requirements.
There has been a growing recognition that a more funda- The MCB combines protection against moderate overload
mental understanding of the arc phenomena relevant to arc conditions, where a time delayed response is required, with
motion in MCBs is required to provide research work that very rapid operation in the event of a more serious fault
can embrace the full range of operating conditions of [3, 41. The operating characteristic of interest in this review
interest. is the rapid operation under high current fault conditions
typically up to 16kA. The operation of the MCB is
acheved by means of a sensor to detect the flow of a high
~ ~~~~

0IEE, 2001
IEE Proceedings online no. 20010185 current - conventionally an electromagnet coil, and an
DO? IO. 1049/ip-smt:20@10185 actuator to control the contact mechanism - typically an
Paper fmt received 17th March and in revised form 31st July 2000 electromagnet plunger. Most modern designs employ the
J.W. McBride is with the School of Engineering Science, University of South- current limiting principle, where the arc voltage works
ampton, Highfield, Southampton, SO17 IBJ, UK against the system voltage to drive the current towards
P.M. Weaver is with PBT Ltd., 1 Astra Centre, Edinburgh Way, Harlow, zero. The result of this is a significant decrease in the peak
Essex, CM2O 2BN, UK current passing through the circuit and reduction in the
ZEE Proc.-Sci. Meci~.Teclziiol., Vol. 148. No. 1, Junirary 2001
total energy admitted to the circuit being protected. Per- current that can flow. At the positive electrode there is an
fomance is dependent on the rapid motion of the arc gen- anode fall region of a similar size to the cathode fall region
erated between opening contacts. Fig. 1 shows a schematic with a voltage drop of 1-12V [l]. Despite extensive
diagram of a typical MCB arrangement. The arc must be research, the processes occurring at the anode and the cath-
forced away from the contacts and into a set of splitter ode are by no means well established. As an indication of
plates called the arc stack. The motion of the arc is depend- the complexity, a review paper written by Guile in 1984 [2]
ent on a complex interaction of the anode and cathode root covers 617 papers written on electrode processes alone. The
and the arc plasma motion. Idealised short circuit current arc current, voltage, contact materials and surrounding
and voltage characteristics are shown in Fig. 2. The con- environment all have an effect on the energy transport
tacts open after the period t& which corresponds with a mechanisms that occur at the electrodes. It is likely that dif-
step in the arc voltage. After contact opening, the arc ferent emission mechanisms coexist in the arc roots.
remains in the contact region for a period t,. The conduc-
tors of the MCB are arranged to create a self-blast mag- 3. I Arc column
netic field which forces the arc along the diverging arc The conductive arc column consists of high temperature
runners (period t,) towards the arc stack. When the arc ionised gases and vapours, known as a plasma [6, 71, with
reaches the arc stack it is split into multiple arcs in series, the bulk of the current carried by the electrons [8]. The arc
resulting in a high total arc voltage Vs required for effective is a region of high luminescence,though in theoretical stud-
current limitation. Fig. 3 shows a typical response from an ies the arc is often regarded as a temperature distribution,
experimental apparatus providing typical values of the arc with the position of the arc deiined as the position of the
voltage, arc current and the duration of the event. temperature maximum [9]. There is evidence that tempera-
tures in the arc chamber are sufficiently high for the gas to
be significantly electrically conductive away from the lumi-
nous region [IO].
The plasma may contain vaporised contact material,
ablated gases from the arc chamber wall and atmospheric
gases. The ionisation of the gas can occur both from ther-
mal dissociation of the hot gas molecules, and impact ioni-
sation from the collisions of accelerated electrons. The
pressure in the arc chamber will be greater than 1 bar.
Under these conditions the arc structure will be typical of a
high pressure arc [I 11 and the arc column will be ‘collision-
dominated’ [12].
*
The conductivity of the arc column is affected mainly by
. .
td
temperature, which is about 6000K in open arcs, but may
Fi .2 Typical arc voltage and arc current clurracteristic wuier coditiota of reach 25000K in high power circuit breakers at current
---
a s%rt circuit event in az M c B
-v
I
maximum [13]. The current density is a dominant factor in
determining the pinch pressure produced by the self mag-
rCod = contact opening delay, 1, = arc immobilitytime, rr = arc running, f,s = arc in netic field of the arc. The pinch pressure drives the convec-
arc stack
tive flow withm the arc and determines the arc radius and
temperature 1141. Belbel and Lauraire 1151 calculated the
average field strength of the arc during the contact opening
400 period in a circuit breaker to be considerably higher than
for a stable arc in air - between 11.9 and 18.7kV/m for a
> 300 range of contact materials. A free burning 20kA arc in air
ai
m has a field strength of about 2.5kVim. The material of the
5 200 conductor affects the field strength, reflecting the fact that
the arc column plasma includes ions from the metal as well
100
as from air. Lee and Slade [13] also report much higher
field strengths in the chamber of MCBs. The thermal and
electrical structures of the arc column are also strongly
0
influenced by the plasma column motion [12].
time, ps I
Fig. 3 Arc voltage and OK current memured iu&r short circuit conditiuar 3.2 Cathode root
The spatial stability of an arc has been observed to be
3 High current arc dependent on the nature of the cathode material. Arcs
drawn on high melting point (refractory) electrodes such as
The high current arc can be described in terms of the arc tungsten, molybdenum and carbon are generally stable
roots and the arc column. The arc roots can be character- with stationary arc roots. When low melting point materi-
ised by hgh electric fields, high thermal gradients and high als (cold cathode) such as copper and silver are used as
current densities relative to the arc column [l]. At the nega- electrodes in the absence of a driving magnetic field the
tive electrode there is a cathode fall region, known as the cathode root is a mobile spot which moves over the surface
cathode root, with a voltage drop of 8-20V, most of which in an irregular fashion. These reported differences have led
is across a distance of about l@3-10-2mm [5].The voltage to the classification of arcs into two main types: refractory
drop depends on the ionisation potential of the gaseous arcs and cold cathode arcs [l, 21.
material in the cathode region, and the contact material. Electrons can gain sufficient energy to escape from the
The cathode current has a minimum value of about 30 mA surface of the conductor through heating (thermionic emis-
at atmospheric pressure but there is no upper limit to the sion). This only occurs sigificantly above lOOOK [16],
, IEE Proc.-Sci. Meas. Techno/., Vol. 148. Nu. I , Jmtrcir.v 2001
i.e. in the boiling point range of the metals typically used in contacts into the arc stack. Despite this, immediately after
the contact system (Ag boiling point 243513). Significant arc ignition under high current conditions, the arc roots
thermionic emission can therefore usually only be sup- may be immobile, or moving at a very low velocity. Sloot
ported on cathodes of refractory materials such as carbon and Bosch [17] proposed that this was due to the arc roots
or tungsten, which have boiling points > 4000K. There are having been formed on contact surfaces already melted by
no theories of a single emission mechanism that satisfacto- thermal effects during initial contact separation. The mol-
rily explain the high current densities estimated at the cath- ten surface will affect the arc root mobility. The arc would
ode root [8]. However, a number of theories of ‘non- be maintained by field emission of electrons in the metal
thermionic’ emission have been proposed, and it is proba- vapour above the molten pool. A region of space charge
ble that these can occur simultaneously at the cathode root from ionised metal vapour is required to maintain the high
on a cold cathode material [l]. It is thought that the domi- electric field, so the arc can only move at the velocity of the
nant emission mechanism then determines the behaviour of temperature front in the conductor. This explains the mol-
the motion of the whole arc [17, 181. ten tracks on arc runners that occur during periods of
reduced arc motion. Around the molten region the oxide
3.3 Anode root layer on the surface of the conductor would be damaged by
In most situations the anode cannot emit positive ions the high temperatures at the arc root, preventing significant
[I, 191 and is considered to be less dominant in determining oxide layer emission [17, 181.
the characteristic of the arc. The anode functions as an If, however, the magnetic force caused the flexible arc
electron acceptor with the current carried almost entirely by column to bend forward it is conceivable that the oxide
electron flow, unlike the cathode where the current may be layer away from the molten root region could become
carried by both electrons and positive ions. As at the cath- charged with positive ions from the discharge. If the oxide
ode, a contraction region and increase in current density layer beyond the molten region is brought to sufficiently
has been observed between the arc column and the positive high emission efficiency a new cathode root site could
electrode. There is also a voltage drop across a very narrow form, with the arc maintained by oxide layer type field
region close to the electrode due to the space charge. Esti- emission. This arc could then move at high velocity, limited
mates of the anode fall voltage vary from 1 or 2V at high only by the charging time of the oxide layer. When the arc
current to 12V at low currents.
moves at high velocity the surface damage to the oxide
3.4 Plasma and vapour jets layer by the heat of the arc root would be minimised, and
Vapour and plasma jets occur when the electrodes get so hence high velocity oxide layer motion could be main-
hot that rapid evaporation occurs and high velocity jets of tained
metal vapour form [13]. The constrictions at the roots of
non-thermionic arcs give rise to high current densities, neg- 4 Arc motion research
ative pressure gradients and strong magnetic fields. These
Consideration is now given to arc movement in devices and
interact to drive plasma jets away from the constriction.
The direction of the plasma jet is approximately normal to in particular under conditions applicable to the low voltage
current limiting circuit breaker (MCB). Initial consideration
the surface at the place where the arc root is attached. If
thls direction does not correspond with the path of the is given to the arc drawn between opening contacts.
shortest distance between the electrodes then the actual arc
path will follow the direction of the jets for a short dis-
tance, and then bridge between the two jets to complete the
current path. As the arc roots wander over a surface, the
direction of the jets can fluctuate violently [20].

3.5 Arc movement


It has been widely noted that the arc roots influence arc
motion and can create a ‘surface drag’ [21]. Sloot and
Bosch [17] identified that a solid conductor model of arc
motion was only applicable when the arc was moving at
high velocity, when the electrode effects did not dominate,
Jones and Fang [12] concluded that for arcs less than
50” long moving at less than 5 O d s electrode effects
/ ’area defined as contact
region
needed to be considered. Guile [2] concluded that at cur- Fig.4 Details ofregions in vicinity ofMCB contacts where delays ir? arc root
rents in excess of lOOA the increases in magnetic fields near motion can occur
A - fixed contact ignition site, B - moving contact ignition site, C - edge of fixed
the surface of the conductors were not negligible. In this contact, D corner in fixed contact arc runner, E - moving contact tip, F - moving
contact arc runner
regime the arc motion may be governed by the magneti-
cally driven movement of the cathode emission site and the
formation of vapour jets due to magnetic constriction of 4. I Arc contact time
the plasma. It has been demonstrated both experimentally [151 and
The magnetic field acts on the charged particles in the theoretically [12] that short arc contact times are critical for
plasma of the arc column. At pressures around atmos- obtaining optimum current limiting performance in an
pheric the electromagnetic force is transmitted to the gas as MCB and minimising contact erosion. Fig. 4 identifies
a whole through multiple collisions of the charged particles regions (A-F) in the vicinity of the switchmg contacts that
with the other particles in the plasma. This deflects the arc can lead to delays in arc motion. The term ‘arc immobility’
column like a flexible current carrying conductor [22]. has been used in the literature to describe a number of
In an MCB the conductors are arranged in such a man- different effects, and some care in the definition of terms is
ner that the current produces a magnetic field transverse to required. The following definitions are used in this paper:
the arc. The resultant force directs the arc away from the arc immobility - both roots of the arc are immobile; arc
Mens Teclinof , Vof 148 No I January 2001
1EE Piu6 -21 3
contact time - the total period during which the arc is in the htion. Recent advances have employed optical fibre arrays,
contact region, between D and F in Fig. 4. It ends when coupled with modern light detection and digital recording
both arc roots have moved away from the contacts on to circuitry to obtain image resolutions of 1 million pictures
the arc runners. It is this period that most researchers refer per second [28, 291, i.e. 1000 images of the arc per ms over
to as ‘arc immobility’; initial arc root immobility - occurs at the period of interest. Images of the arc are reconstructed
the ignition site where the arc is drawn between the open- by computational processing of the optical data. Typical
ing contacts, A and B, in Fig. 4; m c root commutation examples are shown in Fig. 5, where the motion of the arc
deluy - any period of delay caused by an arc root commu- through the chamber of an MCB is illustrated.
tating from one surface to another, for example between E The optical data can be analysed to provide comprehen-
and F; further arc root immobility - arc root immobility sive data on the movement of the arc [30]. By selective
that occurs away from the initial ignition site, for example analysis of regions of the image, the movement of the arc
at corner D. roots can be identified [32, 34-36] as shown in Fig. 6. In
‘Switching arc effects’ is a term that applies to the specific this case the moving contact time was defined as the time
arcing conditions caused by an arc ignited between opening difference between the start of the arc and the point where
contacts. This is characterised [23] by conduction through the root passes 10 mm displacement. This corresponds to
asperities on the contact surface, which form a molten the root moving off the moving contact. The fixed contact
metal bridge as the contacts separate. The metal vaporises time was defined as the period between the ignition of the
and ionises to form a drawn arc. Alternatively, for experi- arc and the start of the root motion. These parameters can
mental studies the arc can be ignited by high voltage break- be clearly identified and easily measured in the arc root dis-
down of the airgap 124271or by rupture of a fusewire. The placement plots shown in Fig. 6.
‘immobility times’ reported from this type of investigation
40 > , 600
are not equivalent to the times obtained from opening con- :a :b
tacts.

time, ps
Fig.6 Anode root (AR) c u d catlwde root (CR) trajectories ~Uzcisimultune-
ow urc voltuge meusurenznts for a short circuit urc in U miniature circuit
breuker
y = 0 position corresponds to arc ignition site on contacts as shown in Fig. 5
Points marked U and 6 correspond to the iniagcs shown in Fig. 5
ti
a
The availability of such comprehensive optical data per-
mitted new direct measurements of arc root dynamics [34].
It is now possible to measure both anode and cathode arc
root contact times on fixed and moving contacts 130, 341.
The insights gained [35, 361 have clarified the definition and
measurement of the arc contact time (see Section 4.1), lead-
ing to improved assessment of the effects of design varia-
bles on circuit breaker performance. This makes possible a
more direct approach to circuit breaker design optimisa-
tion, leading to improved performance 1331.

4.2 Influence of contacts on arc contact time


Much early work concentrated on the critical contact gap
required for the end of arc contact immobility. However,
Rieder [24] surmised that this also depends on the arc cur-
b rent and magnetic flux density in the arc chamber. The
Fig. 5 Arc Uiiages in arc clunder of a circuit breuker opening velocity and contact opening delay also have an
U Arc just moving from contact region
b Arc moving along arc ninners effect. While the arc is immobile, changes occur to the sur-
Anode is on diverging runner. Image times correspond to points marked in Fig. 6 faces of the contacts and conductors, which can further
Circles correspond to optical fibre positions
prolong the arc root immobility. Rieder [25] arranged the
current feed symmetrically from either side of the contact
Optical methods of investigating arc motion have position so that the magnetic forces on the arc due to the
recently been improved with the advent of solid state high magnetic field of the fault current were eliminated. An
speed imaging using optical fibre arrays to monitor the arc external magnetic field was applied after a delay to allow
motion [28-331. Traditional methods using high-speed time for changes in the surface conditions. Using the same
photography do not have sufficient time resolution for a method, Poeffel [27] measured the arc position using an
detailed study of arc motion, as the event period of concem optoelectronic device on long flat parallel copper elec-
here is 1-5ms, as shown in Fig. 3. Solid state imaging using trodes. The main observations were that in a magnetic field
CCD arrays is also not able to offer the required time reso- of B > I O x 10-2 T the arc moved, but under some condi-
4 I E E Proc.-Sci. Meus. Techno/., Vol. 148, No. I , January 2001
tions at low velocity (< lads), causing damage to the con- there was a critical wall separation, dependent on both the
tacts. Periods of low velocity arc motion were termed contact material, wall material and current. Wall separation
‘reduced arc motion’. This is in broad agreement to the below this critical value prevented arc motion. Gassing
work of Sloot and Bosch [l?, who proposed that when the walls were more likely to impede arc motion under unfa-
arc is ignited the cathode spot is often acting on a molten vourable conditions than nongassing ones.
area, which does not provide the conditions for high veloc- Lindmayer and Paulke [43] used a one dimensional fibre
ity arc movement. optic array to measure the light signals in a simplified arc
The cathode and anode roots have been shown experi- chamber for arcs up to 4kA. The technique showed that
mentally to exhibit quite different mobility characteristics the front of the arc moved away from the contact region
[37]. Although the dynamics of the cathode root is thought before the rear of the arc. At low currents low sidewall sep-
to dominate the arc motion [8], the anode root can also aration increased arc contact times, but as the current
affect arc mobility in some situations [35, 361. increased the sidewalls had less effect.
A general investigation of the effects of the contact open- Steps, changes in geometry, venting and contact velocity
ing speed and contact material on the arc contact time all affect both anode and cathode motion [35, 361. This cre-
(referred to as ‘arc immobility time’) was carried out by ates a complicated interdependency requiring a structured
Belbel and Lauraire in 1985 [15]. The time referred to here approach to the investigations. A full Taguchi analysis of
as ‘immobility time’ is the sum oft, and t, in Fig. 1. Belbel effects of arc chamber parameters has been conducted [MI.
and Lauraire showed a requirement for a high opening This concluded that the venting of the arc chamber had a
velocity (1Oms-’), but more recent studies [35, 361 on arc major influence on the arc motion or commutation from
root motion using optical fibre arrays to provide a more the moving contact on to the fixed arc runner, between E
detailed analysis show that t h s may not be necessary. and F in Fig. 4.
Belbel and Lauraire found that increasing the current
increased the arc contact times. Arc contact times were 4.4 Arc root commutation
generally lower on copper contact materials than on silver Arc commutation is the transfer of the arc roots from one
or silver cadmium oxide contact materials. At contact surface to another accompanied by a change of materials
opening velocities below 6ms-* wider sidewall separation or surface geometry. Experimental studies [37] show that
led to lower arc contact times, whilst at 6ms-’ the sidewall under comparable conditions the arc commutes faster
separation appeared to have little affect on the arc contact across an obstacle on the anode root than on the cathode,
time. although there are some exceptions. It was also noted that
In an earlier investigation Lindmayer [38] also used the the cathode root crosses steps by moving continuously
arc voltage to measure the arc contact time (referred to as along the surface. When it reaches the edge or gap, the root
‘arc staying time’), in conjunction with high-speed cine pic- climbs downwards along the vertical edge. When the cath-
tures. Even after a few fractions of a millisecond parts of ode root crosses a wide gap, the root again moves down
the plasma column had reached the arc stack, even though the vertical face, until the column touches the opposite cor-
the arc roots remained on the contacts. The arc then either ner of the gap. Narrow gaps, however, can be crossed with-
jumped straight into the arc stack or moved on to the arc out the root climbing down into the gap. The anode root
runner and then into the arc stack. Lindmayer also found jumps gaps and steps without the anode root climbing
that copper contacts gave the lowest arc contact times, fol- down the vertical face. Arc commutation across steps and
lowed by silver, nickel, cadmium, silver nickel alloys and gaps can be facilitated by increasing the magnetic flux den-
silver cadmium oxides. Silver graphite produced the longest sity of the driving field, decreasing the height of the step,
arc contact times. The times were higher than those choice of suitable step geometry, increasing the width of the
recorded by Belbel and Lauraire [15]. Lindmayer also contact gap, and reducing the gap depth in case of a cath-
recorded that a higher magnetic blast field could reduce arc ode gap. The venting condition of the arc chamber has a
contact times. Despite the poor immobility characteristics, major influence on the commutation of anode and cathode
silver graphite is widely used for its anti-weld characteristic from the moving contact on to a futed arc runner [35, 361.
[39, 401.
Later Behrens [41] used a single optical sensor that trig- 4.5 Arc running
gered when the front of the arc grew to reach a point 22 During arc running the arc roots have been shown to move
mm from the contacts, a period that he called the ‘growing differently along plain electrode surfaces [45, 461. The cath-
time’. This is approximately equivalent to the arc contact ode root moved in a continuous motion, whilst the anode
time measured from the arc voltage. Again the conclusion moved in discrete steps. The cathode roots tend to run
was that, increasing contact velocity, and the use of iron along the edges and stay on corners of an electrode, whdst
behind the contact pieces to increase the magnetic flux den- the anode root is not attracted to the edges.
sity, resulted in lower arc contact times. In a recent study It is uncertain whether the running velocity of the arc is
[35, 361, high opening velocity of the moving contact was dominated by a balance of the electromagnetic and aerody-
also shown to facilitate arc movement, but contact velocity namic forces on the arc column or by the behaviour of the
could be reduced by optimal design of the arc chamber, arc roots. Experimental data have shown that the surface
allowing for the application of new types of actuator. condition can affect the arc running velocity and it has
been suggested that the ‘surface drag’ at the arc roots is
4.3 Arc chamber geometry and material probably related to the electron emission characteristics of
The arc chamber wall material is usually either a nongas- the cathode surface. Although most authors share the opin-
sing ceramic or an ablative polymer. The material chosen ion that the phenomena at the cathode root dominate the
can have a significant effect on the mobility of the arc. The arc mobility, there have been some observations that cer-
depth of the arc chamber and sidewall separation is also tain aspects of arc mobility depend on the anode rather
critical. than the cathode material.
Rieder [42] concluded that, for Cu contacts, although no The gas in the arc chamber is air mixed with metal
significant influence of the wall material was observed, vapours from the hot contacts, and also can include
IEE Proc -Scr MeaJ Tethnol, Vol 148, No I Janunry 2001 5
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IEE Proc.-Sci. Meus. Technol., Vol. 148, No. I , Januury 2001

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