01 - Circuit Protection and Control Devices

UNIVERSITI KUALA LUMPIR
Malaysian Institute of Aviation Technology
SUBJECT :
ELECTRICAL FUNDAMENTAL 2
(AKD10203/AAB10403)
Subject Code AKD10203/AAB10403

Revision : Original
Issue No : 02 Date : 15/01/07
TOPIC 1 :
CIRCUIT PROTECTION
AND CONTROL
DEVICES

Revision : Original
Issue No : 02 Date : 15/01/07
CIRCUIT PROTECTION DEVICES
 Developed to protect personnel and electrical circuits

from currents and voltages outside their normal
operating range.
 used to stop current flow by opening the circuit.
 must always be connected in series with the circuit.
 when open, indicate problem exist in the circuit.
 should isolate the faulty circuit from the other unaffected
circuit.
 problems should be corrected before restoring the circuit
current.

Revision : Original
Issue No : 02 Date : 15/01/07

In a simple electric circuit, it must
have :
a. Source – battery or generator
b. Switch – to interrupt the circuit
c. Fuse or circuit breaker – to protect
the wire / circuit
d. Load – which consume power
e. Conductor / wire – to carry power
form the source to the load
‘Closed Circuit’ means the electrical load will operate correctly. The
circuit current is 2 ampere.

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Issue No : 02 Date : 15/01/07

‘Open Circuit’ means, when a switch
is closed and the lamp will not light
up. This is due to :
a. Switch faulty (defect)
b. Fuse is blown
c. Wire or conductor is broken
d. Lamp is blown
‘Open Circuit’ mean the load will not operate or malfunction, thus no current
flow.
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‘Short Circuit’ means the current
flow bypass the load and this will
cause the circuit current wire
increase thus burnt the wire.
To protect this wire, the fuse will
blown and the circuit becomes
‘open circuit’.
That is the function of a fuse or
circuit breaker as a protection
devices.
Ex : Resistance of a conductor is 0.1

ohms. Therefore the circuit current will be
12V / 0.1 ohm = 120A

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 Circuit conditions requiring protection devices.
 Direct short or Short circuit – a path of current that
bypass the load to directly flow to the return side of
the circuit
 Caused excessive current flow and heat.
 Excessive current – caused by the decrease in
resistance or total circuit impedance.
 Examples: Change in Ohmic value; Capacitor’s
dielectric leakage; Partial short of Inductor’s winding.
 Excessive heat – generated by higher current or
temperature.
 Examples: Overheat of the motor or generator due to
bearing failure; Rise in temperature around an electrical
or electronic circuit due to failure of a cooling system.

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 Two types circuit protection
device:
1. Fuse:-
 Made of low melting point alloy.
 Made of lead; lead and tin; tin and
bismuth.
 When current flow becomes excessive,
the metal alloy melts and open the
circuit.
 Not resettable and when blown must
be replaced with new one.
 Rated according to the maximum
continuous amperage they can carry.
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Issue No : 02 Date : 15/01/07

a. Fast blow fuse for general
purpose use.
 Has narrow link of metal strip
encased in a tubular glass.
b. Slow blow fuse is used in power

surge area.
 Larger fusible link held under
tension by a small spring.
 Accept a momentary surge of
current.
 A short delay before the metal link
melts.
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Issue No : 02 Date : 15/01/07

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For certification of a normal, utility, acrobatic or
commuter category aircraft.
 CFR 14 Part 23 Requirement -
 1 spare fuse of each rating; or
 50% of each rating whichever is greater.
 CFR 14 Part 91 Requirement – Aircraft flying at night:

 must carry a spare set which may consists of a complete
replacement set of fuses; or
 A quantity of 3 replacement fuse for each kind.
 All spare fuses must be accessible to the pilot in flight.
Note: CFR = Code of Federal Regulation.

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Issue No : 02 Date : 15/01/07
2. CIRCUIT BREAKER
Automatically open the circuit
when excessive current flow.
Work on the principle of heat
(bimetallic) or magnetic field.
Have some mean to show it
opened the circuit.
Can be reset to restore the
circuit after the fault corrected.

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Ex :
- If no short circuit occur,
the contact will remain
close under normal
operating current.
- an electromagnet not
strong enough to pull
(energise) the contact
open
Magnetic Effect
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Close Circuit
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- when short circuit or excessive

current, an electromagnet
strong enough to pull
(energise) the contact open
- the circuit now become open
circuit
- to restore the circuit is by reset
the circuit breaker by reset
button
Magnetic Effect

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Open Circuit
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Circuit Breaker Using Heating Effect (Bimetallic)

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Circuit Breaker Using Bimetallic and Magnetic Effect

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 CIRCUIT BREAKER (cont)
 Type
 Push to reset
Pop out when overload occur.
Cannot manually open the circuit
Cannot be used as a switch.

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Issue No : 02 Date : 15/01/07

 CIRCUIT BREAKER (cont)
Push-pull
Pop out when overload – normally
identified by white band.
Can be manually pulled out to open
the circuit.
As switches for maintenance purpose

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Overhead Circuit Breaker
Right Hand Console Circuit Breaker

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CIRCUIT BREAKER (Cont.)
 Toggle
 Use as control switch and circuit
breaker.
 Toggle up when the circuit is closed.
 Pop partially down (center position)
when overloaded.
 Restore circuit by moving toggle
switch all the way down and then
toggle up

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Issue No : 02 Date : 15/01/07

 Automatic CB
Not permitted for aircraft used.
Function:-
 In the closed position the
conductive snap–acting disc bridges
the terminal contacts.
 At predetermined overloads, the
resistance heated up due to current
passing through the disc and snaps
the disc into reverse position.
 This opens the contacts and breaks
the circuit. After a short cooling time
the disc automatically closes and
re–establishes the circuit.

Revision : Original
Issue No : 02 Date : 15/01/07

 Electronic Circuit Breaker –
 use on large commercial aircraft to control overloaded power
distribution circuits.
 Using inductive pickups called current transformer.
 Control Unit Computer monitor the pickups signals and opens
the circuit breaker if over current condition exist.
 All aircraft CB is trip-free type –
 Breaker contacts remain open as long as fault exists
irregardless of the actuating control position.
 Allowed to cool before reset.
 Location - install as close as possible to the source –
bus bar.

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Issue No : 02 Date : 15/01/07

Symbol for fuse, circuit breaker and its location.

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Issue No : 02 Date : 15/01/07
 DC Circuit Protector Chart WIRE AN CIRCUIT FUSE
 Use as a guide for the selection of GAUGE BREAKER AMP.
circuit breaker and fuse rating to protect COPPER AMP.
copper conductor wire. 22 5 5
 Basis of Chart 20 7.5 5
18 10 10
 Wire bundles in 135°F ambient and
16 15 10
altitudes up to 30, 000 feet.
14 20 15
 Wire bundles of 15 or more wire, with 12 30 20
wires carrying no more than 20% of the 10 40 30
total carrying capacity of the bundle as 8 50 50
given in Spec. MIL-W-5088 (ASG)
6 80 70
 Protectors in 75 to 85 °F ambient. 4 100 70
 Copper wire Spec. MIL-W-5088. 2 125 100
 Circuit breakers to Spec. MIL-C-5809 or 1 150
equivalent. 0 150
 Fuses to Spec. MIL-F-15160 or
equivalent

Revision : Original
Issue No : 02 Date : 15/01/07
CIRCUIT CONTROL DEVICES
 The device that turn a circuit ‘on’ and ‘off’ or

‘open’ and ‘close’.
 Types:
 Switches – can be operated manually with a lever, button or
electronically using transistor or integrated circuit (IC) .
 Solenoids
 Relays } - operated electrically

Revision : Original
Issue No : 02 Date : 15/01/07

 SWITCHES
 Purpose – to interrupt the flow of current to the component
 Rated
 ampere and voltage, stamped on the switch housing / case.
 if missing, use reference manual for part number.
 Toggle Switch
 used on older aircraft
electrical system.
 operated using a lever.
 replaced due the
design that can be
inadvertently operated.

Revision : Original
Issue No : 02 Date : 15/01/07
 SWITCHES (cont.)
2. Rocker Switch – replaced
toggle switch for easier
operations, more attractive
and safer installation.
 available with a number of
different contact arrangements.
 named according to the number
of circuits it control and the
number of sets of poles it have.

Revision : Original
Issue No : 02 Date : 15/01/07

 The switches are designed in
different contact arrangements.
1.Single pole, single throw (SPST)
 Has 2 contacts and control only one
circuit – either ‘on’ or ‘off’.
2.Single pole, double throw (SPDT)

 Select 2 conditions for a single
circuit.
 Example: Flap motor switch which
has 2 positions of either to raise or
lower flaps.

Revision : Original
Issue No : 02 Date : 15/01/07

3.Double pole, single throw (DPST)
 control two circuits with only an ‘open’
and ‘close’ position.
 Advantage: both circuits are controlled
together but are fused separately.
4.Double pole, double throw (DPDT)

 Control 2 circuits in 2 conditions.
 May have 2 or 3 positions.
 2 positions – “on” and “off” conditions.
 3 positions – 3 conditions with centre
“off”.

Revision : Original
Issue No : 02 Date : 15/01/07

 Switches (cont.)
3.Momentary Switches
 Held in a particular position
to actuate a circuit.
 Push button switch
4.Rotary or Wafer Switches
 To select several
conditions for a circuit.
 made up of wafers with
contacts arrange radially
around the central shaft
and contact arm.
 may control as many
circuits as are needed.

Revision : Original
Issue No : 02 Date : 15/01/07

5. Precision (Micro) Switches
 Known by its trade name as
MicroswitchesTM.
 Required small movement to
operate by actuating the
plunger to cause the internal
spring to snap the contacts
open or close.
 When used to limit the
movement of a mechanism,
they are typically called Limit
Switch.

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Issue No : 02 Date : 15/01/07

6. Guarded switch
 For critical and emergency
system.

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 Relays and Solenoids
 Used to remotely control components which are
located in places on the aircraft away from the
control device.
A small switch can be used to control a large amount of
current needed to operate high current device.
 Magnetically activated.
 Sometimes referred as contactors by aircraft
manufacturers.

Revision : Original
Issue No : 02 Date : 15/01/07

 Relays
 Categorized by either normally
opened or closed.
 Has a fixed soft-iron core around
which an electromagnetic coil is
wound.
 Depending on the category, the
movable contacts are closed or
opened by the magnetic pull
exerted by the core when the coil is
energized or de-energized.
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Issue No : 02 Date : 15/01/07

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Note :
N.O. – normally open contact
N.C. – normally close contact

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Relays

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 Solenoids
 A movable core that is pulled into
the center of an electromagnetic
coil when the coil is energized.
 Respond quicker and stronger
than relays.
 Typically used for high current
application such as starter
contactors.
 Both relay and solenoid are called

Contactors.
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Issue No : 02 Date : 15/01/07

 Switch Derating
 means that a switch must be rated to sustain more
voltage and current than what the circuit normally
carries continuously.
 due to the switch’s contacts may be subjected to
high voltage spike as switch is turned off or high
current flow through the contacts when the switch is
initially closed.
 Circuits that need to have their switch derated are
lamp, inductive (relay/solenoid), resistive (heater)
and motor.
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Issue No : 02 Date : 15/01/07

SWITCH DERATING FACTOR Nominal Derating
CHART System Type of Load Factor
To determine the proper nominal Voltage (DF)
switch rating so as to obtain
reasonable switch efficiency and 28VDC Lamp 8
service life.
28VDC Inductive (relay-solenoid) 4
– E.g. lamp operated continuously
at 5A in 28V system . The 28VDC Resistive (Heater) 2
nominal capacity of a switch = 5A
X 8 = 40 A ( nominal Rating) 28VDC Motor 3
– Aircraft toggle switch rated at 12V
for 35 A is to be installed in lamp 12VDC Lamp 5
circuit. The continuous current
flow = 35A ÷ 5 = 7A. Therefore, 12VDC Inductive (relay-solenoid) 2
continuous current should not
more than 7A. 12VDC Resistive (Heater) 1
Switch contact – the material is 12VDC Motor 2
carefully selected to avoid failure
DO NOT use AC derated switches in To find nominal rating – continuous current x DF
DC cct, since the amperage capacity To find continuous rating – nominal rating ÷ DF
is different.
Revision : Original
Issue No : 02 Date : 15/01/07

Example
i – Incandscent lamp – draw high current while filament cold; as temperature
increase, resistance also increase and reduced the
current (+ temp coeff)
The switch must rated at 40 ampere for better

efficiency and service life
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Issue No : 02 Date : 15/01/07

If aircraft toggle switch rated at 24V for 35A (nominal) to be installed in lamp
circuit, the continuous current flow = 35A / 8 = 4.375A . Therefore, continuous
current should not more than 4.3 A

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Issue No : 02 Date : 15/01/07
 Switch Installation
 Two position switch – should be mounted with the
upward or forward movement of the switch obtains
the “on” position.
 Component control switch – installed so that the
switch moved in the same direction as the desired
motion of the component.
 Emergency circuit switch – enclosed in a guard
cover which can lifted up before the switch can be
actuated.
 If the switch can be operated inadvertently, the guard cover
may be wired with a lightweight safety wire that can be
broken to gain access to the switch.

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Issue No : 02 Date : 15/01/07
On – Up position
Off – Down position
Landing Gear Control Lever

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Issue No : 02 Date : 15/01/07

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Issue No : 02 Date : 15/01/07
THANK YOU FOR ATTENTION
YOUR NEXT LESSON WILL BE
THREE PHASE SYSTEMS

Revision : Original
Issue No : 02 Date : 15/01/07

01 - Circuit Protection and Control Devices

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UNIVERSITI KUALA LUMPIR

Malaysian Institute of Aviation Technology

Subject Code AKD10203/AAB10403

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

 Developed to protect personnel and electrical circuits

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES

Ex : Resistance of a conductor is 0.1

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES

b. Slow blow fuse is used in power

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

 CFR 14 Part 91 Requirement – Aircraft flying at night:

Subject Code AKD10203/AAB10403

Subject Code AKD10203/AAB10403

- when short circuit or excessive

Subject Code AKD10203/AAB10403

Circuit Breaker Using Heating Effect (Bimetallic)

Subject Code AKD10203/AAB10403

Circuit Breaker Using Bimetallic and Magnetic Effect

Subject Code AKD10203/AAB10403

Subject Code AKD10203/AAB10403

Subject Code AKD10203/AAB10403

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

Overhead Circuit Breaker

Right Hand Console Circuit Breaker

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

CIRCUIT PROTECTION DEVICES

Subject Code AKD10203/AAB10403

Subject Code AKD10203/AAB10403

CIRCUIT CONTROL DEVICES

 The device that turn a circuit ‘on’ and ‘off’ or

Subject Code AKD10203/AAB10403

CIRCUIT CONTROL DEVICES

Subject Code AKD10203/AAB10403

Subject Code AKD10203/AAB10403

CIRCUIT CONTROL DEVICES

2.Single pole, double throw (SPDT)

Subject Code AKD10203/AAB10403

CIRCUIT CONTROL DEVICES

4.Double pole, double throw (DPDT)

Subject Code AKD10203/AAB10403

CIRCUIT CONTROL DEVICES

Subject Code AKD10203/AAB10403