Switches and breakers

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Dave Pontanal
Joshua Rivera
Christian Azcarraga
Christopher Chen
Rosanna Cruz
Jerome Pili
Circuit Breakers
 An electrical circuit breaker can be operated both manually and automatically to control and
protect the electrical power system. Since modern power systems operate under heavy currents,
special attention should be required to ensure that they can safely interrupt the arc generated
during the circuit breaker’s shutdown.
 Compared to a fuse, which operates only once and requires replacement, a circuit breaker can
be reset manually or automatically to resume regular operation. These are available in a variety
of sizes, from small appliances that protect low-current circuits or individual home appliances.
• Protective relay–circuit breaker combination The protective relay detects and evaluates the fault and determines when the
circuit should be opened. The circuit breaker functions under control of the relay, to open the circuit when required. A closed
circuit breaker has sufficient energy to open its contacts stored in one form or another (generally a charged spring). When a
protective relay signals to open the circuit, the store energy is released causing the circuit breaker to open. Except in special
cases where the protective relays are mounted on the breaker, the connection between the relay and circuit breaker is by hard
wiring.

• Circuit breakers are normally fitted with a number of auxiliary contacts, which are used in a variety of ways in control and
protection circuits (e.g. to energize lamps on a remote panel to indicate whether the breaker is open or closed).
Purpose of circuit breakers (switchgear)
The main purpose of a circuit breaker is to:
 Switch load currents • Make onto a fault
 Break normal and fault currents
 Carry fault current without blowing itself open (or up!) i.e. no distortion due to
magnetic forces under fault conditions.
Parts of a Circuit breaker

 Frame or external casing

 Operating mechanism
 Electrical contacts
 Arc extinguisher
 Trip unit
 Frame or external casing
As the name suggests, the frame protects all the internal components of the circuit
breaker. It also supports the components and provides insulation to contain the arc.
Depending on the current and voltage used, they are further available in three forms: molded,
insulated, and metal.

 Operating Mechanism
All types of circuit breakers use some method to disconnect the power supply. These
typically include spring-loaded switches, solenoid, hydraulic, and pneumatic switches. Its
function is to open or close the contacts of the circuit breaker.

 Electrical contacts
The function of contacts is to pass the current through the circuit breaker when they are closed.
Generally, a circuit breaker has two electrical contacts: a static contact and a temporary contact.
 Arc Extinguisher
This usually extinguishes the arc in the event of a fault. When the contacts are
disconnected, electricity can jump through the gap between the end parts of the contact. This causes
an arc of electricity that can reach very high temperatures. A circuit breaker uses an arc
suppression mechanism (arc extinguisher) to prevent the damage and arc from re-creating
itself.

 Trip Unit
Trip unit helps to detect abnormal current flow in the event of overcurrent and
short circuit. It causes the operating mechanism to open the contacts. An open circuit will not
conduct electricity because the air or other insulator has blocked the current flow in the loop.
Types of Circuit Breakers
 LOW VOLTAGE CIRCUIT BREAKERS
 Miniature Circuit Breaker (MCB)
These types of circuit breakers serve as a substitute for fuses and are used to protect the circuit
from excess current. Miniature circuit breakers are automatic switches that opens when the current flowing
through them exceeds the value for which they are set.
They protect low voltage circuits 240/415V AC with a wide range of current ratings below 125V. This circuit breaker
does not need to be replaced every time. If a fault occurs, it can be reused. These are primarily in household, light-
industrial, and commercial applications.
Advantages of MCB:
 This type of circuit breaker is more liable to
current than a fuse.
 By its use, the faulty area of ​the electric
circuit can be easily identified.
 It can provide a better interface with the
help of a knob as compared to a fuse.
Disadvantages of MCB:
 They are more expensive than fuses.
 The cost of an MCB distribution board is
also costlier.
 Installment and repair are expensive as
compared to fuse.
 Molded Case Circuit Breaker
The molded case circuit breaker is a circuit breaker with a high current rating of up to 2500
amps. These are generally seen where the current rating exceeds the limits of the MCB (Miniature Circuit
Breaker).
This circuit breaker works on a thermal-magnetic tripping mechanism where the thermal
mechanism is used for overloading and magnetic is used for short circuit conditions. It can quickly
dissipate a current of around 10k – 200k amps. They protect equipment like generators, electric feeders,
capacitor banks, motors, etc.
Advantages of MCCB: Disadvantages of MCCB:
 MCCB has an adjustable trip setting.  The cost of MCCB is more as compared to the
MCB-type circuit breaker.
 It can interrupt very large currents.
 This type of circuit breaker requires regular
 It has a movable trip unit.
maintenance.
 It has a very small tripping time thus fast  If a lot of MCCB is used inside the panelboard,
switching during fault current.
it must be cooled.
 It also offers remote ON/OFF feature.
 It has a compact design & takes less
space.
 Earth Leakage Circuit Breaker (ELCB)
ELCB stands for earth leakage circuit breaker. It is a type of circuit breaker that breaks its
circuit upon sensing of leakage current. Leakage current occurs due to insulation failure of the
wiring & it can flow through a person’s body & cause electrical shock. Thus they are used for
protection against electrical shock. They do not offer protection against overloading or short circuit.
Therefore, they must be used in series with an MCB.
 Residual Current Breaker with Overcurrent (RCBO)

RCBO or residual current breaker with overcurrent is a circuit breaker that is made
from the combination of RCCB & MCB. It offers both the functions of the RCCB & MCB
i.e. the protection against residual current or ground fault current & overcurrent.
Residual Current: It is the imbalance in the current between live & neutral wire due to the
leakage of current to the ground. RCBO offers protection against it to prevent electrical
shock.
Overcurrent: Overcurrent means when the current exceeds its limit. It occurs due to two
reasons: Overloading & short circuit.
Overloading: It occurs due to huge current draw above rated current for a prolonged duration
that can damage the wiring as well as the components.
Short circuit: it occurs when the live & neutral wire comes into direct contact with each
other. There is a huge amount of current flow that can damage electrical equipment.
The RCBO offers protection against both types of fault that is offered individually by RCCB
& MCB.
 Arc Fault Circuit Interrupter (AFCI) Circuit Breaker

AFCI stands for Arc Fault Circuit interrupter; it is another type of low voltage circuit breaker
that offers protection against Arc faults. An arc fault is a high power discharge between two broken conductors.
These arcs can generate enough heat to start fire & cause serious damage to property & life. The AFCI breaks the
circuit upon sensing any arc in the connected circuit.
The arcs are generated due to incorrect or loose joints in cables or damaged cables by nails, twisting,
kinking, etc. Any loose connection in a PowerPoint or old cables may also cause an electrical arc. It can start fire &
disrupt & damage any sensitive electronic equipment.
The arcs generate a non-periodic waveform that is detected by using a sensitive logic circuit. It
discriminates between a normal arc (occur during switching) & an arc fault. As soon as the arc is detected the
circuitry trips the power supply but it cannot prevent the first arc. Although it can prevent the ones that follow &
avoid a potential fire hazard.
 Common Trip (Ganged) Circuit Breakers
A common trip or Ganged circuit breaker is an assembly of two or more than two circuit breakers that
simultaneously break multiple circuits from a fault in only one circuit. The external operating handle of the
individual breakers is tied together. It is usually used in a 3-phase system where a fault in a single phase
must break the power supply to all the phases. It is also used for increasing the current ratings of a CB by
connecting it in parallel.
 HIGH VOLTAGE CIRCUIT BREAKERS
 Oil Circuit Breaker
The type of circuit breaker that uses oil as a dielectric or insulating medium to quench the arc is called oil
circuit breaker. It is one of the oldest types of high voltage circuit breaker & it mainly uses the transformer oil.
The oil used in such circuit breakers has very good insulating properties far better than air. The CB contacts are
submerged in oil which is used to quench the arc once the contacts separate. The heat generated by the arc is dissipated
inside the oil. When CB breaks its current-carrying contacts inside the oil, the distance between the contacts
starts increasing. Initially, there is a very small distance between the contacts but there is also a very high
voltage gradient. Due to this, the oil between the contacts starts ionizing & creates an arc between the
contacts.
The arc generates a lot of heat & vaporizes the oil surrounding it which is mostly decomposed into hydrogen
gas. The hydrogen gas bubbles are rapidly generated surrounding the contact almost ten times the volumes of the oil.
This oil surrounding the gas bubbles put a lot of pressure on it increasing de-ionization of the medium. De-ionization of
the medium increases its dielectric strength that will quench the arc at zero crossing of the current.
Based on the amount of oil being used in OCB (Oil Circuit Breaker), they are classified
into two types
• Bulk Oil Circuit Breaker (BOCB)
• Minimum Oil Circuit Breaker (MOCB)
 Bulk Oil Circuit Breaker (BOCB)
Such type of oil circuit breaker uses the insulating oil to quench the arc as well as insulate the live contacts from the
earthed parts of the CB. Such CB uses oil in bulk.
BOCB has an iron tank that holds the insulating oil inside. The contacts (fixed & moving) are submerged inside the oil.
Upon breaking the contacts, the arc generates heat & produces gas. The pressurized gas displaces the oil inside the
tank where air at the top of the tank is used as a cushion. Therefore, the tank should not be completely filled with oil.
Also, the tank must be strong enough to absorb the pressure released by the gas. There is also a gas vent for releasing
the gas safely outside.
The arc is quenched by utilizing the compressed gas generated by the heat of the arc. Since the contacts are moving,
the distance is also increased between the contacts. it also increases the resistance for the arc. Also, the cooling effect
of the gas also plays its role in quenching the arc once the current goes through zero crossing.
The BOCB is divided into further two types based on the division of arcs to quickly extinguish it.
 Single Break Bulk Oil Circuit Breaker
In single break BOCB, there is only one fixed contact & one moving contact. Upon
fault current, the moving contact pushes backward generating an arc that is extinguished by the
compressed gas inside the oil. As the name suggests, there is only one break between the
contacts.

 Double Break Bulk Oil Circuit Breaker

In double break BOCB, there are two fixed contacts & one moving contact. The
fixed contacts are fixated to the tank at both ends connected to the live conductors while
the moving contact can move upward & downward using an insulating rod.
 Advantages
• The oil used for arc quenching has very high dielectric strength
• The oil insulates the live contacts from the earthed parts
• The oil produces hydrogen gas with the heat from the arc which is beneficial for arc quenching.
• The pressure of oil compresses the gas to deionize the medium.
• The gas also helps in cooling the medium.

 Disadvantages
• The oil is inflammable & causes a fire hazard.
• The contacts can get damaged with the arc.
• The carbonization of the oil from the contacts reduces its dielectric strength.
• The contacts & the oil must be checked & maintained regularly.
• The use of huge amount of oil increases its cost
• Their large oil-filled tanks are heavy & take large space.
 Minimum Oil Circuit Breaker (MOCB)
As we know the bulk oil circuit breaker uses a huge amount of oil to quench the arc
which may pose a threat for fire hazard. To reduce such risk, the MOCB uses far less oil than in
BOCB. The oil is only used for arc quenching & not to isolate the live parts from earthed parts.
MOCB has two chambers: the arc chamber & the supporting chamber. The arc chamber
is made from porcelain encased with bakelised paper. It is filled with insulating oil. This
chamber is used for quenching the arc. It contains fixed & moving contacts.
The supporting chamber is made from porcelain mounted on top of a metal chamber.
This chamber is used for isolating the arc chamber as well as support the arc chamber by
mounting it on top of it. this chamber is also filled with oil used only for insulation.
The moving contact moves upwards & downwards with the help of a fixed armed
in the supporting chamber. The moving contact has a fixed piston which is used for forcing the
oil upwards helping to quench the arc.
Under normal conditions, the lower moving contact makes a connection with the upper fixed
contact. Upon fault condition, the arm pulls the moving contact downward & an arc is generated.
This arc is extinguished by the pressurized gas in the oil surrounding it & by pushing the oil from
the support chamber with the help of the piston. As the contact moves downward, a vent
becomes available for the hydrogen gas to exhaust out.
In terms of venting, MOCB is divided into two types.

 Axial Venting MOCB: In axial venting MOCB, the arc chamber vents are designed in such a
way when the moving contacts slide downward to break the circuit. it allows an opening for the
cool oil to move in from the lower vent which sweeps the arc in axial direction through the upper
vent. Axial Venting MOCB: In axial venting MOCB, the arc chamber vents are designed in such
a way when the moving contacts slide downward to break the circuit. it allows an opening for the
cool oil to move in from the lower vent which sweeps the arc in axial direction through the upper
vent.

 Radial Venting MOCB: While in radial venting MOCB, the vents are designed radially along the
arc chamber. Therefore, the arc is swept radiallythrough the multiple vents.The radial venting
has low pressure thus the oil has low dielectric strength. Therefore, radial venting MOCB is used
for high current at low voltages.
 Advantages
• It requires a very less amount of oil.
• Less amount of oil means the risk of fire hazard is low.
• It has low weight.
• It has small size & takes up small space
• It is cheaper than BOCB.
• It has easier maintenance & oil can be easily replaced.
• Best for installation in places where it is not frequently used.

 Disadvantages
• Lesser oil is more affected by the amount of carbonization from the contacts.
• The oil quickly losses its dielectric strength.
• It requires more frequent maintenance.
 Oil less Circuit Breaker
Such type of high voltage circuit breaker does not use oil as arc quenching
medium. There are different types of arc quenching mediums that can be
used instead of oil. Following are the type oil-less CBs using various arc
quenching medium;
• Air Circuit Breaker
• Air Blast Circuit Breaker
• SF6 Circuit Breaker
• Carbon Dioxide Circuit Breaker
• Vacuum Circuit Breaker
 Air Circuit Breaker (ACB)
Air circuit breaker or ACB is a type of HV oil-less circuit breaker that uses air as its arc extinguishing
medium. It is used for short circuit & overcurrent protection up to 15KV & 800 to 10K Amps. It is
preferable than oil circuit breaker due to the absence of inflammable oil & the risk of fire hazards.
As we know, the objective of a circuit breaker is to safely extinguish the arc & prevention of arc re-
striking. In order to extinguish the arc, we have to increase the arc voltage (minimum voltage
required to maintain the arc). ACB uses the air as a medium to extinguish the arc. Unlike the other
mediums, the air can be used in various ways to extinguish the arc by using various methods such
as cooling the arc, increasing the arc length, splitting the arc & air blasting, etc.
 Air Chute Air Break Circuit Breaker
The air chute air break circuit breaker has two types of contacts i.e. main contacts & arcing contacts.
The main contacts are made from silver-plated copper to reduce its resistance. The arcing contacts
are made from a copper alloy that has very high heat resistance to absorb the damage from arcing.
Under normal operation, both contacts are closed. The main contacts conduct current due to their
low resistance. When the main contacts open, the current diverts through the arcing contacts.
Afterward, the arcing contacts are open where the arc is established & extinguished. The arcing
contacts are easily replaceable in case of wear & tear.
 Sulphur Hexafluoride (SF6) Circuit Breaker
Sulphur Hexafluoride or shortly known as SF6 is a non-flammable & insulating gas that
has very high electronegativity. It has a high tendency to absorb electrons.
When the arc is struck between the contacts, the medium is ionized due to free electrons.
The SF6 absorbs the free electrons & form negative ions that are far heavier than free electrons. Due to their
heavyweight, they are immobile & reduces the mobility of charges. This enhances the dielectric strength of
the medium where the arc is quenched.
The SF6 has far more superior insulating & arc quenching capabilities than air almost
100 times better. The SF6 is very expensive & a greenhouse gas. SF6 itself is not toxic but its product gases
are toxic & Its emission is dangerous for the environment. Therefore, a close circuit gas system is designed
for such breaker where the SF6 gas is reutilized after each operation. The system also monitors its pressure
which is directly proportional to its dielectric strength
 Vacuum Circuit Breaker (VCB)
A Vacuum Circuit Breaker or VCB is a type of circuit breaker that uses the vacuum as
the arc quenching medium. The vacuum has very high dielectric strength & arc quenching properties far
more superior than any other medium. It can quickly recover its dielectric strength. Due to its high
dielectric strength, VCB requires a very small gap between its contacts to prevent restriking. The
pressure of the vacuum used in VCB is in the range of 10^-7 to 10^-5 torr (1 torr = 1mm of Hg). It is
suitable for switching medium-voltage ranging from 22kV to 66 kV.