AIR CIRCUIT BREAKER

(ACB ) SELLECTION AND

DESIGN CALCULATION

Presented by
Prof. Dabhole Y.D.
Assistant Professor SGMCOE Mahagaon
Content
• What is a Circuit Breaker?
o How Does a Circuit Breaker Work?

• Circuit Breaker Size Calculation for Single Phase

Supply
• Circuit Breaker Size Calculation for Three Phase
Supply
• Circuit Breaker Size Calculation for Continuous &
Non-contentious Load
• Good to Know:
• Circuit Breaker Size % and Amps Charts
 What is a Circuit
Breaker?
• A Circuit breaker (CB) is a control and protection 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)
 How Does a Circuit
Breaker Work?
• normal conditions when the circuit current rating is lower than
the circuit breaker rating, the circuit operation is normal
• In case of fault or short circuit when the value of current
exceeds the circuit breaker current, It will automatically trip
• CB current should not be lower nor highest but 125% of
circuit’s current.
 Circuit Breaker Size Calculation
for Single Phase Supply
• To determine the appropriate size of circuit breaker for single
phase supply, it depends on multiple factors like type of load,
cable material and environment temperature etc.

• The general rule of thumb is that circuit breaker size should be

125% of the ampacity of cable and wire or the circuit which
has to be protected by the CB. Let see the following solved
examples:
 Circuit Breaker Size Calculation for
Single Phase Supply
• Example 1:
• Suppose, a 12 gauge wire is used for 20 amperes lighting
circuit having 120V single phase supply. What is the best size
of circuit breaker for that 20 A circuit?
• Solution:
• Circuit Current: 20A
• Circuit Breaker Size: ?
• CB size should be 125% of the circuit current.
• = 125% x 20A
• = 1.25 x 20A
• Circuit Breaker Size = 25A
 Circuit Breaker Size Calculation for
Single Phase Supply
• Example 2:
• What is the appropriate size of circuit breaker for 2000W, single phase 120V
Supply?
• Solution:
• Load: 2000W
• Voltage: 120V (Single Phase)
• Circuit Current:
• According to the ohm’s law,
• I=P/V
• I = 2000W / 120V
• I = 16.66 A.
• Circuit Breaker Size:
• Simply, Multiply 1.2 or 1.25 to the load current.
• 1.2 x 16.66 A
• Circuit Breaker Size = 20 A
Circuit Breaker Size Calculation for Single
Phase Supply
• Example 3:
• What is the suitable size of circuit breaker for 230V, 1840W
load single phase circuit?
• Solution:
• Current = Power / Voltage
• I = 1840W / 230V
• I = 8A
• The minimum rating of circuit breaker should be 8A.
• The recommended size of circuit breaker should be
• = 8A x 1.25
• = 10
 Circuit Breaker Size Calculation
for Three Phase Supply
• To find the breaker size for three phase supply voltage, we
must know the exact kind of load as there are many factors
affecting the load current

• For residential use, we may follow the same formula as above

for single phase with taking the √3 (1.732) due to three phase
power formula.
 Circuit Breaker Size Calculation
for Three Phase Supply
• Example 1: Which size circuit breaker is needed for 6.5kW,
three phase 480V load?
• Solution:
• Power in Three Phase: P = V x I x √3
• Current: P / V x √3
• I = 6.5kW / (480V x 1.732) … (√3 = 1.732)
• I = 6.5kW / 831.36
• I = 7.82A
• The recommended size of circuit breaker is
• 1.25 x 7.82A = 9.77A
• The next closest standard of circuit breaker is 10A.
Circuit Breaker Size Calculation for Three
Phase Supply
• Example 2: Find the appropriate size of CB for 3-Phase 415V,
17kW load?
• Solution:
• Current = Power / (Voltage x √3)
• I = 17000W / (415V x 1.732)
• I = 23.65A
• Recommended Size of Circuit Breaker: 1.25 x 23.65A =
29.5A. The next closest value is 30A.
 Circuit Breaker Size Calculation for
Continuous & Non-contentious Load
• As circuit breakers (CBs) and Overcurrent Protection Devices
(OCPD) are designed for 100% rated current i.e. a 30A circuit
breaker can safely carry the exact 30A current but NEC suggests
80% as a safe current limit as compared to the rated current of CBs

• This is because all loads are not same i.e. some loads are
simultaneous (continuous) while other are non-simultaneous (non-
continuous).

• The 80% of a 30A circuit breaker is 24A. This way, a 30A circuit
can be safely used for 24A circuit.
•
In other words, a load circuit having 24A, the appropriate size of
breaker would be:
• 24A / 0.8 = 30A.
• Example 1: CB Size for 30A Non-contentious Load
• An exact 100% rated for 30A circuit breaker can be used for
30A non-continuous load.
• Example 2: CB Size for 28A Contentious Load
• In case of continuous load, rate of %125 is applicable.
• 1.25 x 28 A = 35A
• Example 3: CB Size for 30A Non-contentious Load & 28A
contentious Load
• = 125% Continuous Load + 100% Non-continuous load
• = (1.25 x 28A ) + (30A)
• = 65 A
 Good to Know:
• An over sized breaker used for protection can damage the water
heater or other connected appliances even leads to the fire due to
overheat.
• An undersized breaker or same rating with load current breaker can
trip and reset the circuit again and again. Use the correct size
breaker.
• A single phase circuit breaker can’t be used for three phase supply
voltage levels.
• A 3-Poles circuit breaker can be used on 3-Phase system using either
2 or 3 poles.
• A 3-Poles circuit breaker can be used on 1-Phase system only and
only if indicated by the markings or instructed by user manual.
• 30A Breaker and 10 gauge wire can be used on 240V AC Supply.
• Breaker cannot be larger than ampacity of wire except for some
loads like more loads.
 Circuit Breaker Size % and Amps
Charts
• The maximum safe current limit is 80% of the rated size of breaker except some
motors
• Keep in mind that the breaker size should not increase the max amperage rating of
cable and wire
The following two charts shows the suitable circuit breaker sizes with

wire gauge and different level of voltages.

Thank You
Any
Questions