MCB (Miniature Circuit Breaker) –

Construction, Working, Types & Uses

Electrical Technology

17 8 minutes read

What is MCB (Miniature Circuit Breaker), its Construction, Working,
Types & How to select proper MCB for different loads rating?
Table of Contents
 Introduction to Miniature Circuit Breakers (MCBs)
 What is Miniature Circuit Breaker (MCB)?
 Construction of MCB
 Working & Operation of MCB
 Types of Miniature Circuit Breakers (MCB’s)
o Type B MCB
o Type C MCB
o Type D MCB
 How to Select Proper MCB for different loads?
o 1. Nominal rating of the circuit breaker
o 2. kA rating or breaking capacity
o 3. Type of MCB
 Applications of MCB (Miniature Circuit Breaker)

Introduction to Miniature Circuit Breakers (MCBs)

All fuses need to be replaced with MCB for better safety and control when they have
done their job in the past. Unlike a fuse, an MCB operates as automatic switch that
opens in the event of excessive current flowing through the circuit and once the
circuit returns to normal, it can be reclosed without any manual replacement.
MCBs are used primarily as an alternative to the fuse switch in most of the circuits. A
wide variety of MCBs have been in use nowadays with breaking capacity of 10KA to
16 KA, in all areas of domestic, commercial and industrial applications as a reliable

means of protection.
What is Miniature Circuit Breaker (MCB)?

An MCB or miniature circuit breaker is an electromagnetic device that embodies

complete enclosure in a molded insulating material. The main function of an MCB is
to switch the circuit, i.e., to open the circuit (which has been connected to it)
automatically when the current passing through it (MCB) exceeds the value for which
it is set. It can be manually switched ON and OFF as similar to normal switch if

necessary.
MCBs are of time delay tripping devices, to which the magnitude
of overcurrent controls the operating time. This means, these get operated whenever
overload exist long enough to create a danger to the circuit being protected.
Therefore, MCBs doesn’t respond to transient loads such as switches surges
and motor starting currents. Generally, these are designed to operate at less than
2.5 milliseconds during short circuit faults and 2 seconds to 2 minutes in case of
overloads (depending on the level of current).

A typical external appearance of an MCB is shown in figure. MCBs are manufactured

in different pole versions such as single, double, triple and four pole structures with
different fault current levels. Mostly, MCBs are linked to give two and three-pole
versions such that a fault in one line will break the complete circuit and hence
complete circuit isolation are provided. This feature will be helpful in case of single
phasing in three phase motor protection.
These are rated at 220V for DC supply and 240/415 for AC supply (single and three-
phase) with different short circuit current capacity. Typically, single phase devices
have load current range of up to 100 A. Some MCBs have facility to adjust its
tripping current capacity while some devices are fixed for some load current and
short circuit rating.
MCBs are used to perform many functions such as local control switches, isolating
switches against faults and overload protection devices for installations or specific
equipment or appliances.
Construction of MCB
An MCB embodies complete enclosure in a molded insulating material. This provides
mechanically strong and insulated housing. The switching system consists of a fixed
and a moving contact to which incoming and outgoing wires are connected. The
metal or current carrying parts are made up of electrolytic copper or silver alloy
depending on the rating of the circuit breaker.

As the contacts are separated in the event of an overload or short circuit situation, an
electric arc is formed. All modern MCBs are designed to handle arc interruption
process where arc energy extraction and its cooling are provided by metallic arc
splitter plates. These plates are held in a proper position by an insulating material.
Also, arc runner is provided to force the arc that is produced between the  main
contacts.
The operating mechanism consists of both magnetic tripping and thermal tripping
arrangements.
The magnetic tripping arrangement essentially consists of a composite magnetic
system that has a spring loaded dashpot with a magnetic slug in a silicon fluid, and a
normal magnetic trip. A current carrying coil in the trip arrangement moves the slug
against spring towards fixed pole piece. So the magnetic pull is developed on the trip
liver when there is a sufficient magnetic field produced by the coil.
In case of short circuits or heavy overloads, strong magnetic field produced by the
coils (Solenoid) is sufficient to attract the armature of trip liver irrespective of the
position of slug in the dashpot.

The thermal tripping arrangement consists of a bimetallic strip around which a heater
coil is wounded to create heat depending on the flow of current. The heater design
can be either direct where current is passed through bimetal strip which effect part
of electric circuit or indirect where a coil of current carrying conductor is wound
around the bimetallic strip. The deflection of bimetallic strip activates the tripping
mechanism in case of certain overload conditions.
The bimetal strips are made up of two different metals, usually brass and steel.
These metals are riveted and welded along their length. These are so designed such
that they will not heat the strip to the tripping point for normal currents, but if the
current is increased beyond rated value, strip is warmed, bent and trips the latch.
Bimetallic strips are chosen to provide particular time delays under certain overloads.
Working & Operation of MCB
Under normal working conditions, MCB operates as a switch (manual one) to make
the circuit ON or OFF. Under overload or short circuit condition, it automatically
operates or trips so that current interruption takes place in the load circuit. The visual
indication of this trip can be observed by automatic movement of the operating knob
to OFF position. This automatic operation MCB can be obtained in two ways as we
have seen in MCB construction; those are magnetic tripping and thermal tripping.

Under overload condition, the current through the bimetal causes to raise the
temperature of it. The heat generated within the bimetal itself enough to cause
deflection due to thermal expansion of metals. This deflection further releases the
trip latch and hence contacts get separated. In some MCBs, magnetic field
generated by the coil causes develop pull on bimetal such that it deflection activates
the tripping mechanism.

Under short circuit or heavy overload conditions, magnetic tripping arrangement

comes into the picture. Under normal working condition, the slug is held in a position
by light spring because magnetic field generated by the coil is not sufficient to attract
the latch. When a fault current flows, the magnetic field generated by the coil is
sufficient to overcome the spring force holding slug in position. And hence slug
moves and then actuate the tripping mechanism.
A combination of both magnetic and thermal tripping mechanisms are implemented
in most of MCBs. In both magnetic and thermal tripping operations, an arc is formed
when the contacts start separating. This arc is then forced into arc splitter plates via
arc runner. These arc splitter plates are also called arc chutes where arc is formed
into a series of arcs and at the same time energy extracted and cools it. Hence this
arrangement achieves the arc extinction.
Types of Miniature Circuit Breakers (MCB’s)

There are many types of circuit breakers while MCBs are classified into three major
types according to their instantaneous tripping currents. They are
1. Type B MCB
2. Type C MCB
3. Type D MCB
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Type B MCB
This type of MCB will trip instantly at a rate of three to five times its rated current.
These are normally used for resistive or small inductive loads where switching
surges are very small. Therefore, these are suitable for residential or light

commercial installations.
Type C MCB
This type of MCB will trip instantly at a rate of five to ten times its rated current.
These are normally used for high inductive loads where switching surges are high
such as small motors and florescent lighting. In such cases, type C MCBs are
preferred to handle higher value of short circuit currents. Therefore, these are
suitable for highly inductive commercial and industrial installations.

Type D MCB
This type of MCB will trip instantly at a rate of ten to twenty five times its rated
current. These are normally used for very high inductive loads where high inrush
current are very frequent. These are suitable for specific industrial and commercial
applications. The common examples of such applications include x-ray machines,
UPS systems, industrial welding equipment, large winding motors, etc.

The above three types of MCBs provide protection within one tenth of a sec. The
minimum and maximum trip currents of these MCBs are given in a tablular form
below, where Ir is the rated current of the MCB. MCBs can also be classified based
on number of poles such as single pole, double pole, triple pole and four pole MCBs.

 Related Post: Types of Circuit Breakers – Working and Applications

How to Select Proper MCB for different loads?
Choosing a particular MCB for a specific application is a careful task to ensure
reliable protection against overloads and short circuits. If it is not selected according
to the circuit requirements, there will be chances to lead frequent unwanted trippings.
before we going in details, We must know difference between MCB & MCCB, How to
Read MCB Nameplate and difference between ELCB, RCB and RCD Circuit
Breakers
If it is undersized (MCB rating less than the nominal load current), MCB causes
frequent tripping and causes to interrupt the current to the load it is being connected,
because the MCB nominal current less than nominal current value of the load.
Similarly, if it is oversized (MCB rating more than the nominal load current), the load
to it is connected will not be protected efficiently. In such case, the MCB will not trip
even though load is drawing overcurrent’s.
The following are the three factors to be considered for selecting a proper MCB for
specific application.
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1. Nominal rating of the circuit breaker
This is the rated ampere current rating of MCB. This value must be lower than the
current carrying capacity of wiring system and higher than or equal to the maximum
full load current in the wiring system. Generally, this rating should be such that it can
handle 125 percent of continuous load plus rating of non-continuous load. Typically
this can be expressed as
Maximum full load current in the system ≤ Current rating of MCB ≤ Cable
rating
2. kA rating or breaking capacity
This rating refers to the capability of MCB that can trip or interrupt the circuit under
short circuit conditions. It is expressed in Kilo Amps (KA). This rating must not be
less than the prospective short-circuit current. The prospective short-circuit current
the maximum current that exist in the circuit during short-circuit conditions. In
residential installations 6KA MCB is sufficient while 10 KA or above rating MCB is
needed for commercial and light industrial applications.
3. Type of MCB
The type of MCB needed for a specific application decided by operating
characteristics such that various current ratings are required to operate the loads
instantaneously. We have already mentioned various types of MCBs for different
applications above.
Applications of MCB (Miniature Circuit Breaker)
As the main functions and applications has been already described in the above
statements, the very basic uses of MCB is that it is used to protect a circuit (wiring,
connected load and equipment etc) in case of:
 Short Circuit
 Over Current
 Over Load
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Introduction to MCB
The miniature circuit breaker (MCB) plays an important role in
providing overcurrent protection  and a disconnect means in electrical
networks. Recent advancements in circuit breaker technology has increased
breaker performance and protection.

MCB – Miniature circuit breaker construction (on photo: ABBs MCB NA C16, 16A, 10kA, 3-pole-
neutral)

A breaker is a device designed to isolate a circuit during an

overcurrent event without the use of a fusible element. A breaker is a
resettable protective device that protects against two types of
overcurrent situations:

1. Overload and
2. Short Circuit.

MCB Construction Details

MCB – Miniature circuit breaker

construction details

Thermal / Magnetic trip units

Current Limiting Breakers use an electromechanical (Thermal /Magnetic)
trip unit to open the breaker contacts during a overcurrent event. The
thermal trip unit is temperature sensitive and the magnetic trip unit is current
sensitive.

Both units act independently and mechanically with the breaker’s trip

mechanism to open the breaker’s contacts.
Current Flow

MCB – Current flow during operation (All

highlighted components are energized during operation)

Overload protection
The thermal trip unit protects against a continuous overload. The thermal unit
is comprised of a bimetal element located behind the circuit breaker trip bar
and is part of the breaker’s current carrying path.

When there is an overload, the increased current flow heats the

bimetal causing it to bend. As the bimetal bends it pulls the trip bar
which opens the breaker’s contacts. The time required for the bimetal to
bend and trip the breaker varies inversely with the current. Because of this,
the tripping time becomes quicker as current increases in magnitude.
Overload protection is applicable to any installation, conductor,
or component which can be subjected to low-magnitude but longtime over-
currents.

Low-magnitude, long-time over-currents can be  dangerous  because they

reduce the life of the electrical installation, conductor, and components and if left

unchecked could result in fire.

 MCB Overload protection

Magnetic trip units (short circuit protection)

The Magnetic trip unit protects against a short circuit. The magnetic trip
unit is comprised of an electromagnet and an armature.

MCB Magnetic trip units

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Components of a magnetic trip unit

When there is a short circuit, a high magnitude of current passes through
the coils creating a magnetic field that attracts the movable armature towards
the fixed armature. The hammer trip is pushed against the movable contact
and the contacts are opened.

The opening of the breakers contacts during a short circuit is complete

in 0.5 milli-seconds.

MCB Components of a magnetic trip

unit

Arc runners / Arc chutes

The arc runner and arc chute limit and dissipate the arc energy during the
interruption of an overload or short circuit event.

During an overload or short circuit event, the contacts of the

breaker separate and an electrical arc is formed between the contacts
through air. The arc is moved into the arch chute by “running” the arc
down the interior of the breaker along the arc runner. When the arc
reaches the arc chute it is broken into small segmented arcs. The segmented
arcs split the overall energy level into segments less than 25V.

Each 25V segment does not have a high enough energy level to maintain an
arc and all energy is naturally dissipated.
 MCB Arc runners / Arc chutes

Breaker curves
Thermal Trip Unit (region one)
The first sloping region of the breaker curve is a graphical representation of
the tripping characteristics of the thermal trip unit.

This portion of the curve is sloped due to the nature of the thermal trip unit.
The trip unit bends to trip the breaker’s trip bar in conjunction with a rise in
amperage (temperature) over time. As the current on the circuit increases,
the temperature rises, the faster the thermal element will trip.

Example using the curve below:

If you had a 10A breaker and the circuit was producing 30 amps of current,
the breaker would trip between 2 seconds and 1 minute. In this example you
would find the circuit current on the bottom of the graph (Multiples of rated
current). The first line is 10 amps (10 amp breaker x a multiple of one), the
second line is 20 amps (10 amp breaker x multiple of 2), and the third line is
30 amps (10amp breaker x multiple of 3). Next you would trace the vertical
30A line up until it intersects the red portion of the breaker thermal curve.

If you follow the horizontal lines, on both sides of the red curve, to
the left you will see that the breaker can trip as fast as 2 seconds and
no slower than 1 minute.

Magnetic Trip Unit (region two)

This region of the breaker curve is the instantaneous trip unit. MCB –
miniture circuit breaker ’s instantaneous trip unit interrupts a short circuit in
2.3 to 2.5 milliseconds. Because of this the curve has no slope and is
graphically represented as a vertical straight line.

Example using the curve above:

If you had a 10 amp breaker the magnetic trip element would interrupt a
short circuit between 10 and 30 amps (10 amp breaker x multiple of 2 and 3)
in 2.3 to 2.5 milliseconds.

Breaker Contacts (region three)

This region of the curve is the time required for the contacts of the breaker to
begin to separate. The contacts will open in less than .5 milliseconds and is
graphically represented by the bottom vertical portion of the curve.

MCB – Miniature curcuit breaker

curves

Reference:  ABB – Application guide | Miniature circuit breakers

Thermal Overload Relay Working Principle
Hi friends, in this article, I am talking about thermal overload relay
working principle and its function in a DOL starter. I hope you will
find this article informative and helpful.
 
A thermal overload relay works on the heat produced by the
excessive overload current. The heat produced by the overload current
is utilized to trip the motor circuit. These are mostly used for
protection of low-voltage squirrel cage induction motors or DC
motors of lower output rating.
 

 
The function of a thermal overload relay, used in motor starter
circuits is to prevent the motor from drawing excessive current which
is harmful to motor insulation.
 
It is connected either directly to motor lines or indirectly
through current transformers. It de-energies the starter and stops the
motor when excessive current is drawn.
 
Thermal Overload Relay Working
Principle
 
Whenever the motor is overloaded, it will draw more current from the
line and will be heated up gradually. The overload relay is intended to
protect the motor against sustained overloads.

The overload relay is installed on motor control circuit to make a

contact in the trip circuit or mechanically operate the trip bar thus
shutting down the motor in the event of excessive load.
 
It consists bimetallic strips. The heat produced by the overload current
is utilized to heat the bimetallic strips.
 
Under normal operating condition the strip remains straight but under the action of
fault current the strip is heated and bent and the relay contacts get separated which
de-energizes the motor control circuit.
 
The force required to bend the bimetallic strips can be adjusted by an
adjuster. In other words, it can be adjusted to operate at different
overload currents.
 
The thermal overload relay does not provide short circuit protection  as it takes
sufficient time to open the contacts. Therefore, this type of relay is
used in conjunction with fuses to provide overload and short circuit
protection to the circuit.
 
These relays have inverse time characteristics i.e. the tripping time
becomes less as the over load and hence current increases. These are
rated in trip class. The trip class specifies the period of time it will take
to operate in an overload condition. The most common classes are 5,
10, 20 & 30. Class 30, 20, 10 and 5 overload relays will trip within 30,
20, 10 and 5 seconds respectively at 600% of motor full load amps.
 

Function of Overload Relay in DOL Starter

 

 
The circuit diagram for a DOL starter for a three-phase induction motor is
shown in Figure. The starter essentially consists of a set of ‘start’ and ‘stop’
push buttons with associated contacts, overload and under voltage
protective devices.
 
The start push button (S1, usually green colored) is a momentary contact
switch that is held normally open by a spring. The stop push button (S 2,
usually red colored) is a momentary contact switch that is held normally
closed by a spring. The operation is as follows.
 
When the start push-button S1 is pressed, the operating coil ‘C’ ( or the
main contactor) get energized through the overload contact ‘D’ (normally
closed). This closes the three main contacts ‘M’ that connect the motor to
the supply. At the same time, the auxiliary contact ‘A’ is also closed.
 
When the auxiliary contact is closed, a new circuit is established through
the stop push button, auxiliary contact and operating coil ‘C’.  Since the
operating circuit is now maintained by auxiliary contact, the motor keeps on
running even after releasing the start push button.
 
If the supply fails or line voltage drops below a certain value, the main
contacts and the auxiliary contact are opened. Upon return of the supply,
the contactor cannot close until the start button is pressed again.
 
When the motor is overloaded, it draws current more than its normal
operating current. This overload current heats the bimetallic strip of the
thermal overload relay.
 
Now due to this heat, bimetallic strip starts bending. After some time, it
bends sufficiently and motor control circuit opens at point ‘D’ (the point is
shown in Figure). It disconnects the operating coil from the supply. As a
result, the motor stops.