Arc and Ground Fault Circuit Interrupters

Protection in Residential Applications

Lanson Relyea
Product Manager - AFCI/GFCI

© 2008 Eaton Corporation. All rights reserved.

 Evolution Of Circuit Protection

Knife Residential Thermal Mag Thermal Mag Branch Feeder Combination

Switch Fuses Breaker + GFCI AFCI AFCI

• The Electrical industry is continuing to make steps

to improve electrical safety
• Electrical Safety Requires Industry Advancements
In Product & Installation Practices

2
2
Thermal Magnetic Breakers

• In the 1930’s Westinghouse

introduced the “No-Fuze
Load Center” featuring circuit
breakers.
• The basic design and
concept of the thermal
magnetic breaker has not
changed since its initial
release
• Thermal magnetic breakers
protect the homes wiring from
damage due to overcurrent or
short circuit

3
3
UL 489
Molded Case Circuit Breakers

• Calibration
• 135% - Trip within 1 hr for
ratings less than 50A
• 200%
• 2 min – 0-30A
• 4 min – 31-50A
• Endurance (below 100A)
• 6,000 operations w/ current
• 4,000 operations w/o current
• Overload
• Must break 600 percent of
its rated current

4
4
5
5
 Overcurrent Protection

• Overcurrent protection is
provided by bi-metal

• The bi-metal is made of two

metals which expand at
different rates when heated.

• An overcurrent event causes

heating in the bimetal which
bends and allows the trip
mechanism to release

Bi-metal

6
6
 Short Circuit Protection

• Short Circuit protection is

provided by a magnetic
mechanism
• Per Ampere’s law, the
strength of a magnetic field
formed around an electrical
current proportional to the
amount of current
• When a short circuit event
occurs, a large amount of
current flows creating a
strong magnetic field. The Magnetic
Armature
armature is pulled down by
the magnetic field, releasing
the tripping mechanism

7
7
UL 943 / UL 1053
Ground Fault Circuit Interrupters /
Ground-Fault Sensing and Relaying Equipment

UL 943
• Leakage < 6 mA
• Trip time ~15 mS
• Temperature Cycle Testing
• Room Temp, -35ºC, Room
Temp, 60ºC, Room Temp
• Humidity Condition
• 60hrs – 92% Humidity / 85ºF
• Surge Testing
UL 1053
• Leakage within 10% of level
defined by manufacturer
• Humidity Condition
• 60hrs – 92% Humidity / 85ºF
• Surge Testing

8
8
Ground Fault Circuit Interrupters

• GFCI monitor the difference in the current

returning to the breaker versus the current
leaving the breaker

 4.993A
5.000A

X
OK
5.000A 

9
9
 Arcing Faults
• Unintentional Arcing
Condition
• Temperatures In
Excess Of 10,000
degrees Fahrenheit
• Not persistent
enough to heat the
bimetal in Thermal
Magnetic Breakers

10
10
 History of Arc Fault Detection
2001 2002 2003 2004 2005 2008 2011 2014
Product Development

Prototypes for 42 Aircraft AFCI Combination Type AFCI 600/1000VC AFCI

VDC Powernet for 120 VAC, 400 Hz Series Arc Faults
120VAC, 60 Hz
Automotive (not mandated) in PV Systems
High and Low Current
Arc Detection

Branch-Feeder AFCI
120VAC 60 Hz
Combination Type
High Current Arc Aircraft AFCI Receptacle AFCI
Detection 28 VDC 120VAC, 60 Hz
(not mandated)

2008 NEC Requires

2014 NEC:
Combination AFCI
− Expansion of AFCI
Code Development

All Dwelling Areas in

to 120V Kitchen
2005 NEC Requires Residences
2002 NEC Requires Circuits in
Branch Feeder for Combination AFCI Residences
Begining Jan 1, 2008 2011 NEC:
Bedroom Outlets − Allows for use of
− Requires Series Arc
Receptacle AFCI in
Fault Detection on
New Construction w/
PV Systems
Restrictions
− Allows for use of
Receptacle AFCI in
Renovation 11
11
 Types Of Arcing Faults
Series Arcing
L1
Parallel Arcing (Line-Neutral) Load
N
Parallel Arcing (Line-Gnd)
Gnd Equipment Grounding Conductor

High Current Level Arc Low Current Level Arc

“Parallel Arc”
• An Arc Fault That Occurs at 75Amps and higher
• An Arc Fault That Occurs Line-Line or Line-Neutral
“Series Arc”
• An arc fault at low levels down to 5 Amps
• An arc fault at a break or gap in a single conductor
in series with a connected load

12
12
 High Current vs Low Current Arcing
High Current Level Arc Low Current Level Arc
“Parallel Arc” “Series Arc”
• Spikes within the AC Waveform • Current may not rise above handle rating
• Current Spikes above handle rating but… • Arcing evident by high frequency noise being
• Current level of spike are not big enough to generated (pink trace)
trip short circuit mechanism
• Thermal mechanism would not trip in time
to mitigate a fire
2

Breaker
Handle -2

Rating

13
13
 Classifying An Arc Fault
• Operational Arcs - occur in a properly functioning
electrical system
• Switching loads on/off
• Contact closure/opening

• Non-Operational Arcs - potential fire hazards

• Damaged insulation in fixed wiring and appliance
cords
• Loose connections

14
14
Operational Arcs

• Some examples of operational arcs:

15
15
Hazardous Arcs

• Some examples of non-operational arcs:

16
16
Wiring Degradation Drivers
• Temperature
• Humidity
• Mechanical Stress
• Voltage Stress
• Time
• Loose connections
• Stranded Aluminum wiring
• Nails through the wall
• Corrosion
• Do-it-yourselfers
• Rodents

17
17
CPSC Recalls
Shock and Fire Hazards

18
18
CPSC Recalls
Shock and Fire Hazard

19
19
 Life Phases of the Home
There are (3) Major Phases during
the lifespan of a Home…
CONSTRUCTION
• Average of 50-75 Junction
Boxes, switches & Outlets
• Thousands of Feet of Wire
• Electricians work comes before
drywall, cabinets, shelving, and
trim
HOME OWNER MOVES IN
• Home Owners Modify by
adding dimmers, ceiling fans,
more lights
• Pictures get hung more shelves
installed
• Appliances put in place,
extension cords, spa’s
AGING STRUCTURE
• Additions Will Occur
• Rodents May Move In
• Wire Degradation Due To
Humidity, Heat, Vibration
• Weakening Connections Due
To Repetitive Use
• More Loads Being Added
20
20
 Case Study

Location:
Fort Mill, SC
Age of Home:
Home Built in 2005
Background:
An arc fault breaker began
tripping intermittently on a
bedroom lighting circuit when
turning on fan or lights.

21
21
Case Study

• Electrician initially replaced

AFCI but new breaker tripped
as well

• Inspection of the homerun

showed wires were pulled
through a truss connector plate

• Wire was siliconed and taped

to prevent grounding but AFCI
breaker continued to trip
intermittently

• Homeowner requested the

homerun be replaced

22
22
Case Study

• When removing the

homerun, evidence of
an arcing condition
was found on the wire
which was in the wall.

Note the carbonization

on the neutral
indicating arcing

23
23
Codes And Standards

Saving Lives Through Mandating Safety

© 2008 Eaton Corporation. All rights reserved.

 2005 vs. 2008 NEC
Article 210.12 - AFCIs
2005 NEC
“Dwelling Unit Bedrooms. All 120-volt, single phase,
15- and 20-ampere branch circuits supplying outlets
installed in dwelling unit bedrooms shall be protected
by a listed arc-fault circuit interrupter, combination type
installed to provide protection of the branch circuit”

2008 NEC
“Dwelling Units. All 120-volt, single-phase, 15- and 20-
ampere branch circuits supplying outlets installed in
dwelling unit

family rooms, dining rooms, living rooms,

parlors, libraries, dens,
bedrooms, sun rooms, rec. rooms,
closets, hallways,

or similar rooms or areas shall be protected by a listed

arc fault circuit interrupter, combination-type, installed to
provide protection of the branch circuit”

25
25
National Electrical Code
Article 210.12
Introduction of Branch Feeder AFCI to the National Electrical Code.
Protection of branch circuits supplying bedroom receptacle outlets as of
January 1, 2002.

Listed Branch Feeder AFCI protection of branch circuits supplying

bedroom outlets.

Branch circuits supplying outlets installed in dwelling unit bedrooms

shall be protected by a listed arc-fault circuit interrupter, combination
type, installed to provide protection of the branch circuit

Branch feeder AFCI’s permitted to be used until January 1, 2008.

Location of the of AFCI is permitted to be within 6’ of the origin of the

branch circuit via a metal raceway or a cable with a metallic sheath.
Combination-Type AFCI required on Bedroom, Family Rooms, Living
Rooms, Parlors, Libraries, Dens, Sun Rooms, Recreation Rooms, or
Similar Rooms.
It shall be permitted to install a combination AFCI at the first outlet.
RMC, IMC or EMT or steel armored cable, Type AC, meeting the
requirements of 250.118, using metal outlet or junction boxes must be
installed between the origin of the Branch Feeder and the first outlet.

26
26
 2011 NEC – AFCI Requirements
(These requirements use AFCI
receptacles when renovating or
replacing a circuit that would
otherwise require AFCI per the
NEC. Outlets protected by an
upstream AFCI are not required
to have AFCI functionality)
210.12
• No expanded use of AFCI
• No removal of conduit requirement
Required use in Renovate:
210.12 (B) Branch Circuit Extensions or Modifications -
Dwelling Units. In any of the areas specified in 210.12(A),
where branch circuit wiring is modified, replaced or extended,
the branch circuit shall be protected by:
1. A listed combination AFCI located at the origin of the
branch circuit; or
2. A listed outlet branch circuit AFCI located at the first
receptacle outlet of the existing branch circuit.”
406.3(D) Receptacle Replacement Requirements
(4) Arc-Fault Circuit-Interrupters. Listed combination arc-fault
circuit interrupter receptacles shall be provided where
replacements are made at receptacle outlets that are required
to be so protected elsewhere in this code.
Exception: Unless the receptacle is protected 27
by an upstream
27
AFCI.
 2014 NEC – AFCI Requirements
Impact Assessment
• Kitchens now require AFCI protection
• Laundry areas now require AFCI protection
• Dormitories now require AFCI protection
• The OBC AFCI is permitted with restrictions
210.12 Arc-Fault Circuit-Interrupter Protection. Arc-fault circuit-interrupter protection
shall be provided as required in 210.12(A) and (B). The arc-fault circuit interrupter shall be
installed in a readily accessible location.” [P2-116] [C2-37]

(A) Dwelling Units. All 120-volt, single phase, 15- and 20-ampere branch circuits
supplying outlets or devices installed in dwelling unit kitchens, family rooms, dining rooms,
living rooms, parlors, libraries, dens, bedrooms, sunrooms, recreation rooms, closets,
hallways, laundry areas, or similar rooms or areas shall be protected by any of the means
described in (1) through (6) [P2-85] [P2-82a] [P2-80] [C2-52]

(1) A listed combination type arc-fault circuit interrupter, installed to provide protection
of the entire branch circuit.
28
28
 2014 NEC – AFCI Requirements
Receptacle Requirements
(2) A listed branch/feeder type AFCI installed at the origin of the branch circuit in
combination with a listed outlet branch circuit type arc-fault circuit interrupter installed at
the first outlet box on the branch circuit. The first outlet box in the branch circuit shall be
marked to indicate that it is the first outlet of the circuit. [C2-59]

(3) A listed supplemental arc protection circuit breaker installed at the origin of the
branch circuit in combination with a listed outlet branch circuit type arc-fault circuit
interrupter installed at the first outlet box on the branch circuit where all of the following
conditions are met:
(a) The branch circuit wiring shall be continuous from the branch circuit overcurrent device
to the outlet branch circuit arc-fault circuit interrupter.
(b) The maximum length of the branch circuit wiring from the branch circuit overcurrent
device to the first outlet shall not exceed 15.2 m (50 ft) for a 14 AWG or 21.3 m (70 ft)
for a 12 AWG conductor.
(c) The first outlet box in the branch circuit shall be marked to indicate that it is the first
outlet of the circuit. [C2-59]

29
29
 2014 NEC – AFCI Requirements
Receptacle Requirements
(4) A listed outlet branch circuit type arc-fault circuit interrupter installed at the first
outlet on the branch circuit in combination with a listed branch circuit overcurrent
protective device where all of the following conditions are met:
(a) The branch circuit wiring shall be continuous from the branch circuit overcurrent device
to the outlet branch circuit arc-fault circuit interrupter.
(b) The maximum length of the branch circuit wiring from the branch circuit overcurrent
device to the first outlet shall not exceed 15.2 m (50 ft) for a 14 AWG or 21.3 m (70 ft) for
a 12 AWG conductor.
(c) The first outlet box in the branch circuit shall be marked to indicate that it is the first
outlet of the circuit. [C2-59]
(d) The combination of the branch circuit overcurrent device and outlet branch circuit AFCI
is identified as meeting the requirements for a "System Combination" type AFCI and is listed
as such.

(5) If RMC, IMC, EMT, Type MC, or steel armored Type AC cables meeting the
requirements of 250.118, metal wireways, metal auxiliary gutters and metal outlet and
junction boxes are installed for the portion of the branch circuit between the branch-circuit
overcurrent device and the first outlet, it shall be permitted to install a listed outlet branch-
circuit type AFCI at the first outlet to provide protection for the remaining30portion of the 30
 2014 NEC – AFCI Requirements
Receptacle Requirements
(6) Where a listed metal or nonmetallic conduit or tubing or Type MC Cable is encased
in not less than 50mm (2 in.) of concrete for the portion of the branch circuit between the
branch circuit overcurrent device and the first outlet, it shall be permitted to install a listed
outlet branch circuit type AFCI at the first outlet to provide protection for the remaining
portion of the branch circuit. [C2-46] [P2-103]

31
31
Introducing AFCI

32
32
 Introducing AFCI
Operating Handle Push To Test Button

Instantaneous Trip Element

Long Delay Trip Element
( Armature )
( Bimetal )

Latch Piece

Load Terminal
Mechanism Spring

Moving Contact Member

Load Neutral Terminal

Arc Fault Sensing Circuitry

Stationary Contact Member

Panel Neutral Wire

33
33
 Installation
• Basic Installation Notes
• Circuit Breaker Pigtail Termination To Neutral Bar
• Load Hot (black) AND Neutral (white) Landed To
The Circuit Breaker
• Press The Test Button
• Plug A Load Into The Circuit To Ensure No
Shared Neutral Mistakes

Grounded
• Common Mistakes Neutral

• Landing Load Neutral (white) on the Neutral

Bus & Not The Breaker
• Shared or Grounded Neutral
• Not Pressing The Test Button After Installation
34
34
What Causes the Breaker to Trip?

1. Detection of an Arcing Condition

2. Overloaded Circuit
• Too many appliances on one circuit
3. Grounded Neutrals
• Wiring error
4. Overvoltage
• Lightning storm or surge from the utility
5. Electrical Interference from a device
6. Pushing the “TEST” Button

35
35
36
36
 FCC Regulations
Conducted Emissions
§ 15.107 Conducted limits.
(a) Except for Class A digital devices, for equipment that is designed to be connected to the public utility
(AC) power line, the radio frequency voltage that is conducted back onto the AC power line on any
frequency or frequencies within the band 150 kHz to 30 MHz shall not exceed the limits in the following
table, as measured using a 50 μH/50 ohms line impedance stabilization network (LISN). Compliance with
the provisions of this paragraph shall be based on the measurement of the radio frequency voltage between
each power line and ground at the power terminal. The lower limit applies at the band edges.

Eaton’s Options
1) Contact the Manufacturer
2) Enter a Complaint with FCC / UL
3) Make a Better Product!

37
37
Case Study
Manmade vs Hazardous Arcs

Common electronic
stepdown transformer
(low voltage lighting)

Beyond FCC limits for

conducted emissions

dB scale: 20 dB = 10X

SPEED
650
LIMIT MPH!

65

38
38
 Case Study
Manmade vs Hazardous Arcs
High Frequency Noise Arc Signature
Electronic Transformer Series Arc Test per UL 1699
(low voltage lighting)

39
39
 Troubleshooting
Basic Troubleshooting Techniques
1. Is the breaker functioning properly?
• Disconnect the load wire and the neutral, leave the pigtail connected
• Turning the breaker on.
• Press the Test Button.
2. Check For Grounded Neutrals
3. Is there a load creating the issue?
• Disconnect All Loads From The Receptacles . . . Including Surge Strips
4. Narrow down the wiring issue
• Break The Circuit Into Smaller Chunks – disconnect wire at every junction
• Add sections back until the issue is found

 



40
40
Trip Codes We Capture…
(Eaton Only)

1) High Frequency – Series arcing condition or

interference from a device
2) Ground Fault – Ground leakage sensed by breaker
3) Parallel – Parallel arcing condition
4) Short Delay – A large amount of current is flowing
through the breaker (in excess of 15X the handle
rating)
5) Overvoltage – Overvoltage Condition (>150V)
6) Test Button / Self Test Failure

41
41
5A Threshold

“It only trips when I have a light on

and the fan and…”
• 5A minimum threshold per UL 1699
• Not enough energy in < 5A arc to create a fire
• Use a high wattage load
on the same circuit to
determine the device
causing the issue

42
42
Solutions
Universal Solutions
• Surge Device
• Filters noise via capacitor to ground
• Must be installed on the device or
between the device and the breaker.
• Ferrite Beads
• Can become saturated if too much
noise is present

Eaton Solutions
• Next Generation
• Reduced unwanted tripping through
software changes creating tolerance
for non-compliant devices

43
43
 Case Study
Surge on a Vacuum
High Frequency Noise Reduced Interference with
Conducted by a 12A Vacuum Surge Device

44
44
Next Generation BR (1”)
Compact Footprint

Feature
Compact as a Standard

Benefit
Better access to
conductors and neutral
bars in wireway

45
45
Next Generation BR (1”) and CH (3/4”)
Updated Electronics

Feature
Redesigned Electronic
Hardware and Software
Benefit
Highly resistant to
unwanted tripping due to
non-compliant devices

46
46
Next Generation BR (1”) and CH (3/4”)
Diagnostic LED

Feature
Diagnostic LED Signals
up to 7 Trip Codes
Benefit
Immediate feedback to
diagnose and resolve
tripping
• Standard Feature in CH
• Optional Feature in BR

47
47
 A Word On Handheld Testers…
UL Says…
• The Button Rules
AFCI / Tester Compatibility
• Not every tester will not trip every breaker
• Eaton Handheld tester is approved for
use with Eaton Breakers
So…What is the Value?
• Is receptacle on AFCI/GFCI?
• Confirm wiring
• Visual for Home owner

48
48
Thank You

TOGETHER WE CAN MAKE A DIFFERENCE

© 2008 Eaton Corporation. All rights reserved.

50
50