Five switching devices you

are likely to spot in most of

the low voltage switchgear

Low voltage switching devices

This technical article will try to shed some light on switching devices usually installed
in low voltage switchgear – circuit breakers, contactors, disconnectors, load-break
switches, switch disconnectors and fuses. There are many variations of these
devices, but the core function is the same – to protect, disconnect, or isolate.

Five switching
devices you are likely to spot in a low voltage switchgear

Low voltage switchgear is designed for switching and protection of electrical

equipment. The selection of switching devices is based on the specific switching
task, e.g. isolation, load switching, short-circuit current breaking, motor switching,
protection against overcurrent and personnel hazard.

Depending on the type, switching devices can be used for single or multiple
switching tasks. Switching tasks can also be conducted by a combination of several
switchgear units.

IEC 60947-1 contains the general stipulations for all types of low voltage
switching devices. Further general stipulations for electromechanical control circuit
devices and switching elements can be found in IEC 60947-5-1. The standards set
down ratings for all devices, and defined test values are assigned to these.

Devices for up to 690 V, for example, have a test level of 1890 V for the rated
insulation voltage. The rated impulse withstand voltage U imp (stated on the switch or
noted in the manufacturer’s documentation) for service in power distribution is as a
rule 6 kV (IEC 60947-1, Table H1).

Figure 1 shows the applications of various switching devices.

Figure 1 – Examples of
applications for low voltage switching devices
Where:

1. Circuit-breaker,
2. Fuse,
3. Disconnector,
4. Load-break switch,
5. Fused switch-disconnector,
6. Motor starter (motor protection switch),
7. Contactor,
8. Overload relay,
9. Switch-disconnector with fuses,
10. Residual current-operated circuit-breaker (RCCB),
11. Miniature circuit-breaker,
12. Residual current-operated circuit-breaker with overcurrent hipping (RCBO),
13. Residual current-operated miniature circuit-breaker (RCD)
When constructing low voltage installations  it must be ensured that no higher
voltages than the rated insulation voltages of the devices can occur .

Table of contents:
1. Circuit breakers
2. Contactors
3. Motor starters
4. Disconnectors, load-break switches and switch disconnectors
5. Fuses

1. Circuit breakers
Circuit-breakers are defined in IEC 60947-2. Circuit-breakers most be capable of
making, conducting and switching off currents under operational conditions.
Furthermore, they must trip in accordance with defined current/time characteristics
under overload and short-circuit conditions.

Circuit-breakers are used in applications with a low switching frequency. Circuit-

breakers without overcurrent releases are known as  switch-disconnectors.

The basic classification criteria for low voltage circuit-breakers are the design
(compact or open) and the quenching principle (non-current limiting or current
limiting).

Compact circuit-breakers consist of an insulating material enclosure which

surrounds the components of the breaker. Such circuit-breakers are constructed for
rated currents of up to approx. 3200 A. The rated short-time current le, is up to 35
kA. Open circuit-breakers are predominantly constructed with a metal surround and
are generally larger than compact circuit-breakers.

They are available for rated currents of up to 6300 A. The rated short-time current l c,
is up to 100 kA.

Non-current limiting circuit-breakers quench the switching arc at the natural

alternating current zero. The conductors are designed with a thermal capability
allowing them to conduct the full short-circuit current.

All system components downstream are also subjected thermally and dynamically to

the unlimited peak short-circuit current.

Figure 2 – ABB’s
compact circuit breakers type EMAX 2 AND TMAX XT with ekip trip units
Current limiting circuit-breakers limit the short-circuit current  before the peak of the
first half-wave is reached. Limitation of the peak value significantly reduces the
dynamic and thermal stresses on the connected system.

Figure 3 shows a diagram of the development of the unlimited (prospective) short-

circuit current and the short-circuit current limited by the switching device. Limitation
of the short-circuit current is achieved  by extremely rapid contact separation and
a sudden prolongation of the breaking arc.

Figure 3 – Limitation of
the prospective short-circuit current
Current limiting circuit-breakers  are particularly suitable for short-circuit protection
of switchgear with a relatively low switching capacity (back-up protection).

Figure 4 shows the effects on the peak value to of the let-through current when a

current limiting circuit-breaker is used (curve 2) in comparison with a non-current
limiting circuit-breaker (curve 1), each in relation to the rms value of the rated short-
circuit current.
 Figure 4 – Limitation
of the short-circuit current by a current limiting circuit breaker
At an assumed rms current Irms of 40 kA, the peak level Ip with a non-current
limiting circuit-breaker is 84 kA. The current limiting circuit-breaker however only
permits a peak level of 16.2 kA, which significantly reduces the dynamic stresses on
downstream system components.

Selection of circuit-breakers is first based on the  rated voltage Ue, the rated current
and the rated short-circuit breaking capacity. A distinction is made between two
values for rated short-circuit breaking capacity:

1. The rated service short-circuit current Ics (test sequence 0 — t — CO — t — CO)

and
2. The rated ultimate short-circuit current Icu (test sequence 0 — t — CO),
where:

 CO is a close/open operation, and

 t is the dead time between switching operations (3 min).
The rated service short-circuit current l cs represents the higher load on the
switching device. There are no stipulations in the standards as to which of the two
values is to be used, but for critical applications ( hospitals or congress centres) the
rated service short-circuit current Ics should be used as the design criterion.

The rated short-time current  lcw the utilization category, the ambient temperature and
the installation conditions are then to be taken into account.  The rated short-time
current lcw is a peak value which is stipulated in accordance with Table 1, but which
does not fundamentally provide any new information.
The utilization category classifies the breaker’s design-related characteristics with
regard to selectivity. The distinction is made between:

 Utilization category A (circuit-breakers which are not specially designed for

selectivity, e.g. current limiting circuit-breakers) and
 Utilization category B (circuit-breakers which are specially designed for
selectivity).
Table 1 – Ratio n between short-circuit making and breaking capacity and the
corresponding power factor (for AC voltage circuit-breakers) to IEC 60947-2
Short circuit breaking capacity Icu cosφ Icm=n × Icu
6 kA < Icu ≤ 10 kA 0.5 1.7 × Icu
10 kA < Icu ≤ 20 kA 0.3 2 × Icu
20 kA < Icu ≤ 50 kA 0.25 2.1 × Icu
50 kA ≤ Icu 0.2 2.2 × Icu

A fundamental factor in project planning is  the selection of the protection release ,

which generally may have up to 4 protection functions:

 L – Overload, with settings for trip threshold (current) and inverse time delay.
 S – Selective short-circuit protection, with settings for trip threshold and delay
time with constant energy or definite time characteristic.
 I – Instantaneous short-circuit protection, with setting for trip threshold.
 G – Earth fault protection, with settings for trip and inverse time delay with
constant energy or definite time characteristic.
Circuit-breakers can also be equipped with residual current releases, making it
possible to implement operator protection. Against direct and indirect contact and
protection against fire.

Residual current protection devices are fundamentally distinguished by their design

(add-on electronics unit with integrated instrument transformer or separate
electronics unit (e.g. for door installation) and separate instrument transformer), by
their response current (a.c. fault current, pulsating d.c. fault current, d.c. fault
current) and their delay characteristics (selective or non-selective).

Figure 5 –
Time/current characteristics of protection releases

Go back to Table of Contents ↑

2. Contactors
Electromagnetic contactors are defined in IEC 60947-4-1. They are  mechanical
switching devices with only one position of rest, which are not operated manually
and are capable of connecting, conducting and disconnecting currents in the circuit
under service conditions, including operational overload.

They are especially suitable for high switching frequencies . Contactors are

suitable for switching in accordance with the utilization categories described below.
Protection against short-circuits is to be ensured by upstream protection equipment
(SCPDs).

From a safety point of view, it is important  to provide an additional suitable

switching device as a disconnection system  to isolate individual loads,
especially electrical machines, from the supply network.

Apart from the electromagnetic actuation most often used, there are
also contactors with pneumatic or electropneumatic actuation . For contactors
and control devices on a semiconductor basis, IEC 60947-4-2 covers motor current
circuits, and IEC 60947-4-3 covers non-motor loads with a.c. voltage.

Figure 6 – Example of 3
pole, 100 amp, non-reversing across the line contactor with 24V DC coil and 1 NO
and 1 NC auxiliary contacts
Contactors are selected by utilization categories, as shown in Table 2. In addition,
the ratings (voltage, current, ambient temperature and control voltage) are to be
considered. Background conditions such as switching frequency, number of poles,
type of coordination, short-circuit level, start-up conditions and contact life are also
to be taken into account.
There are various aids and programs available from manufacturers and in the
Internet for selection of contactors. The contactor must be capable of correct
operation within a range of 85% to 110% of the rated control voltage, with control
current flowing. Important accessories for contactors include for example  clip-on
auxiliary contact blocks and overload relays for fitting to the contactor output
terminals.

The auxiliary contacts of contactors are „positively driven” in accordance with IEC
60947-5-1. NC auxiliary contacts in the contactors are „ mirror contacts“, i.e. they
cannot be closed at the same time as the NO main contacts. The positive driving
and mirror property are essential in the implementation of safety circuits.

Table 2 – Utilization categories for contactors to IEC 60947-4-1

T
able 2 – Utilization categories for contactors to IEC 60947-4-1
Go back to Table of Contents ↑

3. Motor starters
Motor starters based on electromechanical switching devices are also defined in
IEC 60947-4-1. Accordingly, motor starters (Figure 7) are used to start motors,
accelerate them to normal speed, ensure motor operation, disconnect the motor
from the power supply and, by means of suitable protection systems, protect the
motor and the corresponding circuit in the case of overload.

The starter may function as a direct-on-line starter ( DOL), reversing starter (REV),
star-delta starter (YD), heavy starter (HD) or soft starter.

Short-circuit protection, overload protection and in many cases also an isolation

device are required. Circuit breakers are preferred for short-circuit protection .

As motor starters are as a rule used on the power distribution level, the components
most be designed for a rated impulse withstand voltage U imp of 6 kV.

Figure 7 –
Basic structure of a motor starter
The protection requirements play a decisive role in the design of a motor starter
(Figure 8).
 Figu
re 8 – Alternatives for motor control
Overload relays detect overloading of the motor or the failure of a phase, and then
act on the contactor to switch the motor off. There are both thermal and electronic
overload relays, with various tripping classes (e.g. Class 10 or Class 30) for normal
starting or heavy starting of the motor.

For direct online starting the overload relay is set to the  rated service current of
the motor (le), and for star-delta starting to 0.58 × le.

In its simplest version, a motor starter can consist of a single device, namely
a circuit-breaker with thermal / electromechanical releases . A manual motor
starter switch is a circuit-breaker with a special tripping characteristic, as shown in
Figure 8.

Circuit-breaker to IEC 60947-2 and 60947-4-1 with short-circuit and overload

releases for protection of motors:

Figure 9 –
Functions of a manual motor starter
Go back to Table of Contents ↑

4. Disconnectors, load-break switches and

switch disconnectors
The requirements for mechanical switching devices for switching of load currents
and safe isolation of systems or subsystems from the supply network are the subject
of standard IEC 60947-3.

Disconnector
The isolating function of the disconnector in the open position is
characterized by the following features:

1. Increased dielectric strength of the contact gap (demonstrated by a test at

impulse voltage)
2. Low leakage current across the isolating distance Clear indication of the OFF
position of the contacts
3. No inadvertent closing (e.g. by vibration) Facilities for actions to prevent
impermissible reclosing
A disconnector can only open and close a circuit if either a current of negligible
quantity is switched off or on, or if there is no significant voltage difference between
the two contacts of each pole.

Figure 10 – Low voltage switch

disconnectors range
Load-break switch
A load-break switch can, under normal conditions in the circuit, if applicable with
specified overload conditions, make, conduct and break currents and, under
specified abnormal conditions such as a short-circuit, conduct these short-circuit
currents for a specified period.

Switch-disconnector
A switch-disconnector is a load-break switch that meets the requirements specified
for an isolating distance in the open position.

Switch-disconnector with fuses

Unit comprising switch-disconnector and fuses, in which one fuse is connected  in
series with the switch-disconnector  in one or more phases. Fuse switch-
disconnector

Figure 11 – ABB’s motorized

switch disconnector 160-2500A;
A fuse switch-disconnector is a switch-disconnector in which a fuse link or a fuse
holder with fuse link forms the movable contact.