Siemens Molded Case Circuit Breaker Step 2000 Course

Molded Case Circuit Breakers
STEP 2000
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Table of Contents
Introduction ..............................................................................2 Need for Circuit Protection .......................................................4 Types of Overcurrent Protective Devices..................................8 Circuit Breaker Design ............................................................ 11 Types of Circuit Breakers ........................................................24 Circuit Breaker Ratings ...........................................................29 Time-Current Curves...............................................................31 Selective Coordination ............................................................35 Series-Connected Systems ....................................................37 Catalog Numbers....................................................................40 Residential and Commercial Circuit Breakers .........................42 Sentron Series Circuit Breakers ..........................................50 Sentron Series Digital Circuit Breakers................................57 Internal Accessories ...............................................................68 External Accessories ..............................................................73 Insulated Case Circuit Breakers ..............................................79 ICCB Electronic Trip Unit .........................................................81 Review Answers.....................................................................88 Final Exam ..............................................................................89
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Introduction
Welcome to another course in the STEP 2000 series, Siemens Technical Education Program, designed to prepare our distributors to sell Siemens Energy & Automation products more effectively. This course covers Molded Case Circuit Breakers and related products. Upon completion of Molded Case Circuit Breakers you will be able to: Explain the need for circuit protection Identify various types of overcurrent protective devices Explain the basic electro-mechanical operation of a circuit breaker Identify various types of Siemens circuit breakers Identify circuit protection ratings for various types of Siemens circuit breakers Describe time-current characteristics on a time-current curve Explain the benefits and function of circuit breaker coordination Identify internal and external circuit breaker accessories Explain the difference between molded case circuit breakers and insulated case circuit breakers
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This knowledge will help you better understand customer applications. In addition, you will be better able to describe products to customers and determine important differences between products. You should complete Basics of Electricity before attempting Molded Case Circuit Breakers. An understanding of many of the concepts covered in Basics of Electricity is required for Molded Case Circuit Breakers. If you are an employee of a Siemens Energy & Automation authorized distributor, fill out the final exam tear-out card and mail in the card. We will mail you a certificate of completion if you score a passing grade. Good luck with your efforts.
I-T-E, Sensitrip, EQ, Telemand and Speedfax are registered trademarks of Siemens Energy & Automation, Inc. Sentron and Max-Flex are trademarks of Siemens Energy & Automation, Inc. National Electrical Code and NEC are registered trademarks of the National Fire Protection Association, Quincy, MA 02269. Portions of the National Electrical Code are reprinted with permission from NFPA 70-2002, National Electrical Code Copyright, 2001, National Fire Protection Association, Quincy, MA 02269. This reprinted material is not the complete and official position of the National Fire Protection Association on the referenced subject which is represented by the standard in its entirety. Underwriters Laboratories Inc. is a registered trademark of Underwriters Laboratories Inc., Northbrook, IL 60062. The abbreviation UL shall be understood to mean Underwriters Laboratories Inc. QO is a registered trademark of Square D Company.
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Need for Circuit Protection
Current and Temperature
Current flow in a conductor always generates heat. The greater the current flow, the hotter the conductor. Excess heat is damaging to electrical components. For that reason, conductors have a rated continuous current carrying capacity or ampacity. Overcurrent protection devices, such as circuit breakers, are used to protect conductors from excessive current flow. These protective devices are designed to keep the flow of current in a circuit at a safe level to prevent the circuit conductors from overheating.
Excessive current is referred to as overcurrent. The National Electrical Code (NEC) defines overcurrent as any current in excess of the rated current of equipment or the ampacity of a conductor. It may result from overload, short circuit, or ground fault (Article 100-definitions).
NEC and National Electrical Code are registered trademarks of the National Fire Protection Association.
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Overloads
An overload occurs when too many devices are operated on a single circuit, or a piece of electrical equipment is made to work harder than it is designed for. For example, a motor rated for 10 amps may draw 20, 30, or more amps in an overload condition. In the following illustration, a package has become jammed on a conveyor, causing the motor to work harder and draw more current. Because the motor is drawing more current, it heats up. Damage will occur to the motor in a short time if the problem is not corrected or the circuit is shut down by the overcurrent protector.
Conductor Insulation
Motors, of course, are not the only devices that require circuit protection for an overload condition. Every circuit requires some form of protection against overcurrent. Heat is one of the major causes of insulation failure of any electrical component. High levels of heat can cause the insulation to breakdown and flake off, exposing conductors.
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Short Circuits
When two bare conductors touch, a short circuit occurs. When a short circuit occurs, resistance drops to almost zero. Short circuit current can be thousands of times higher than normal operating current.
Ohms Law demonstrates the relationship of current, voltage, and resistance. For example, a 240 volt motor with 24 of resistance would normally draw 10 amps of current.
When a short circuit develops resistance drops. If resistance drops to 24 milliohms, current will be 10,000 amps.
The heat generated by this current will cause extensive damage to connected equipment and conductors. This dangerous current must be interrupted immediately when a short circuit occurs.
NEC and National Electrical Code are registered trademarks of the National Fire Protection Association. Reprinted with permission from NFPA 70-2002, the National Electrical Code, Copyright 2001, National Fire Protection Association, Quincy, MA 02269.
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Ampacities of Insulated Conductors
Table 310.16 of the NEC provides the maximum current for a given conductor. For example, a #8 American wire gage (AWG) copper conductor with Type THW insulation is rated for 50 amps at 75 C. To avoid overloads and prevent insulation damage, it is necessary to keep the current from exceeding the conductors continuous current rating.
If the raceway contains more than three conductors or the ambient temperature is greater than 30C (86F) the values shown in Table 310.16 must be reduced using derating values provided by NEC (not shown here).
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Types of Overcurrent Protective Devices
Circuit protection would be unnecessary if overloads and short circuits could be eliminated. Unfortunately, overloads and short circuits do occur. To protect a circuit against these currents, a protective device must determine when a fault condition develops and automatically disconnect the electrical equipment from the voltage source. An overcurrent protection device must be able to recognize the difference between overcurrents and short circuits and respond in the proper way. Slight overcurrents can be allowed to continue for some period of time, but as the current magnitude increases, the protection device must open faster. Short circuits must be interrupted instantly. Several devices are available to accomplish this. Fuse A fuse is a one-shot device. The heat produced by overcurrent causes the current carrying element to melt open, disconnecting the load from the source voltage.
Nontime-Delay Fuse
Nontime-delay fuses provide excellent short circuit protection. When an overcurrent occurs, heat builds up rapidly in the fuse. Nontime-delay fuses usually hold 500% of their rating for approximately one-fourth second, after which the currentcarrying element melts. This means that these fuses cannot be used in motor circuits which often have inrush currents greater than 500%.
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Time-Delay Fuses
Time-delay fuses provide overload and short circuit protection. Time-delay fuses usually allow five times the rated current for up to ten seconds to allow motors to start. The National Electrical Code defines a circuit breaker as a device designed to open and close a circuit by nonautomatic means, and to open the circuit automatically on a predetermined overcurrent without damage to itself when properly applied within its rating. Circuit breakers provide a manual means of energizing and de-energizing a circuit. In addition, circuit breakers provide automatic overcurrent protection of a circuit. A circuit breaker allows a circuit to be reactivated quickly after a short circuit or overload is cleared. Unlike fuses which must be replaced when they open, a simple flip of the breakers handle restores the circuit.
Circuit Breaker
Circuit breakers:
SENSE when an overcurrent occurs. MEASURE the amount of overcurrent. ACT by tripping the circuit breaker in a time frame necessary to prevent damage to itself and the associated load cables.
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Circuit Breaker Operation
In the following illustration an AC motor is connected through a circuit breaker to a voltage source. When the circuit breaker is closed, a complete path for current exists between the voltage source and the motor allowing the motor to run. Opening the circuit breaker breaks the path of current flow and the motor stops. The circuit breaker will open automatically during a fault, or can be manually opened. After the fault has been cleared, the breaker can be closed allowing the motor to operate.
Note: Article 240 in the National Electrical Code covers overcurrent protection. You are encouraged to become familiar with this material. Review 1 1. With an increase in current, heat will a. increase b. decrease c. remain the same 2. 3. 4. 5. Two causes of overcurrent are ____________ and ____________ . A ____________ ____________ occurs when two bare conductors touch. An ____________ occurs when electrical equipment is required to work harder than it is rated. The three functions of a circuit breaker are ____________ , ____________ , and ____________ .
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Circuit Breaker Design
The following section presents some basics of circuit breaker design. Variations to these design principles will be presented later in the course. Circuit breakers are constructed in five major components: Frame Frame (Molded Case) Contacts Arc Chute Assembly Operating Mechanism Trip Unit
The frame provides an insulated housing to mount the circuit breaker components. The construction material is usually a thermal set plastic such as glass-polymer. The construction material can be a factor in determining the interruption rating of the circuit breaker. Frame ratings indicate several pieces of important information such as; maximum voltage, ampere rating, interrupting rating, and physical size.
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Straight-Through Contacts
Circuit breakers use contacts to break the circuit and stop the flow of energy. Some conventional circuit breakers use a straight-through contact arrangement. The electrical path through the contacts is a straight line. As discussed in Basics of Electricity, a magnetic field is developed around a currentcarrying conductor. The magnetic fields developed around the contact arms of a straight-through contact arrangement have little or no effect on the contacts arms. During a fault, the contacts are only opened by the mechanical operation of the circuit breaker spring.
As mentioned earlier, current causes heat, which is destructive to electrical equipment. A rise in current causes a corresponding rise in heat. In reality, the thermal energy the circuit will see is proportional to the square of the current multiplied by the 2 time the current flows (I T). This means that the higher the level of current, the shorter the time it takes for heat to damage equipment. In the following illustration, IP represents the peak level the fault current rises before the breaker contacts open.
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Blow-Apart Contacts
Siemens developed a design referred to as blow-apart contacts. With this design, the two contact arms are positioned parallel to each other as shown in the following illustration. As current flows through the contact arms, magnetic fields are set up around each arm. Because the current flow in one arm is opposite in direction to the current flow in the other arm, the two magnetic fields oppose each other. The strength of the magnetic field is directly proportional to the amount of current. During normal current conditions, the magnetic field is not strong enough to force the contacts apart.
When a fault develops, current increases which increases the strength of the magnetic field. The increased strength of the opposing magnetic fields actually helps to open the contacts faster by forcing them apart.
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In comparison, the blow-apart contact design helps to open 2 the contacts faster than the straight-through arrangement. I T is greatly reduced since arc extinguishment in less than 4 milliseconds is common with blow-apart contacts. This means that electrical equipment is exposed to less heat over a shorter period of time. The result is a higher degree of protection.
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Arc Chute Assembly
As the contacts open a live circuit, current continues to flow for a short time by jumping the air space between the contacts in the form of an arc. When the contacts open far enough the arc is extinguished and the current flow stops.
The arc can cause burning on the contacts. In addition, ionized gases form inside the molded case. If the arc isnt extinguished quickly the pressure from the ionized gases could cause the molded case to rupture. An arc chute assembly is used to quench the arc. This assembly is made up of several U shaped steel plates that surround the contacts. As the arc is developed it is drawn into the arc chute where it is divided into smaller arcs, which are extinguished faster.
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Operating Handle
An operating handle is provided to manually open and close the contacts. Molded case circuit breakers (MCCBs) are trip free, meaning that they cant be prevented from tripping by holding or blocking the operating handle in the ON position. There are three positions of the operating handle: ON (contacts closed), OFF (contacts open), and TRIPPED (mechanism in tripped position). The circuit breaker is reset after a trip by moving the handle to the OFF position and then to the ON position.
Operating Mechanism
The operating handle is connected to the moveable contact arm through an operating mechanism. Siemens molded case circuit breakers use an over-center toggle mechanism that is a quickmake and quick-break design. In the following illustration, the operating handle is moved from the OFF to the ON position. In this process a spring begins to apply tension to the mechanism. When the handle is directly over the center the tension in the spring is strong enough to snap the contacts closed. This means that the speed of the contact closing and opening is independent of how fast the handle is operated.
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To open the contacts, the operating handle is moved from the ON to the OFF position. In this process a spring begins to apply tension to the mechanism. When the handle is directly over the center the tension in the spring is strong enough to snap the contacts open. As in closing the circuit breaker contacts, contact opening speed is independent of how fast the handle is operated.
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Trip Unit
The trip unit is the brain of the circuit breaker. It consists of components that will automatically trip the circuit breaker when it senses an overload or short circuit. The tripper bar is moved by a manual PUSH TO TRIP button, a thermal overcurrent sensing element or an electromagnet.
Trip Mechanism
A trip mechanism is held in place by the tripper bar. As long as the tripper bar holds the trip mechanism, the mechanism remains firmly locked in place.
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The operating mechanism is held in ON position by the trip mechanism. When a trip is activated, the trip mechanism releases the operating mechanism, which opens the contacts.
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Manual Trip
MCCBs, heavy duty and above, can be manually tripped by depressing the red PUSH TO TRIP button on the face of the circuit breaker. When the button is pressed the tripper bar rotates up and to the right. This allows the trip mechanism to unlock releasing the operating mechanism. The operating mechanism opens the contacts. The PUSH TO TRIP button also serves as a safety device by not allowing access to the circuit breaker interior in the ON position. If an attempt is made to remove the circuit breaker cover while the contacts are in the closed (ON) position, a spring located under the pushbutton will cause the button to lift up. This action will also trip the breaker.
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Overload Trip
The overload trip unit senses and decides when to act by tripping the circuit breaker. Modern molded case circuit breakers have a lineage traceable to the Cutter Company, which came to be known as the I-T-E Circuit Breaker Company in the late 1800s and early 1900s. The company introduced Inverse Time Element (I-T-E) circuit breakers in the United States. Simply stated, the higher the current, the shorter time it takes for the trip mechanism to activate. Modern thermal-magnetic circuit breakers generally employ a bimetal strip to sense overload conditions. When sufficient overcurrent flows through the circuit breakers current path, heat build up causes the bimetal strip to bend. After bending a predetermined distance the bimetal strip makes contact with the tripper bar activating the trip mechanism.
A bimetal strip is made of two dissimilar metals bonded together. The two metals have different thermal expansion characteristics, so the bimetal bends when heated. As current rises, heat also rises. The hotter the bimetal becomes the more it bends, until the mechanism is released.
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Short Circuit Trip
Short circuit protection is accomplished with an electromagnet. This is referred to as the magnetic or instantaneous element. The electromagnet is connected in series with the overload bimetal strip. During normal current flow, or an overload, the magnetic field created by the electromagnet is not strong enough to attract the armature. When a short circuit current flows in the circuit, the magnetic field caused by the electromagnet attracts the electromagnets armature. The armature hits the tripper bar rotating it up and to the right. This releases the trip mechanism and operating mechanism, opening the contacts. Once the circuit breaker is tripped current no longer flows through the electromagnet and the armature is released.
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Review 2 1. 2. Circuit breakers use ____________ to break the circuit and stop the flow of energy. Siemens developed ____________ - ____________ contacts that greatly reduce the amount of time it takes for breaker contacts to open when a fault occurs. The ____________ ____________ assembly reduces contact damage by dividing the arc into smaller segments which can be extinguished faster. Siemens circuit breakers use an ____________ ____________ toggle mechanism that is a quick-make and quick-break design. A ____________ strip uses two dissimilar metals bonded together. An ____________ is used to sense a short circuit.
3.
4.
5. 6.
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Types of Circuit Breakers
Instantaneous Magnetic Trip-Only Circuit Breakers
Instantaneous magnetic-trip-only circuit breakers do not provide overload protection and are used on motor circuits where overload protection is provided by a motor starter. The current level at which an instantaneous trip circuit breaker trips is adjustable. The name comes from the electromagnet used to sense short circuit current. The purpose of overload protection is to prevent the motor from operating beyond its full-load capability. In the schematic illustrated below, a motor is supplied through a 3-pole circuit breaker, motor starter contacts and separately supplied overload contacts. Heat generated from excessive current will cause the overload contacts to open, removing power from the motor.
Thermal-Magnetic Circuit Breakers
Thermal-magnetic circuit breakers have both overload and instantaneous trip features. When an overload condition exists, the excess current will generate heat, which is detected in the circuit breaker. After a short period of time, dependent on the rating of the breaker and amount of overload, the breaker will trip, disconnecting the load from the voltage source. If a short circuit occurs, the breaker responds instantaneously to the fault current and disconnects the circuit.
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Interchangeable Trip Circuit Breakers
The user does not have access to the trip unit on some circuit breakers. This means the trip unit cannot be changed with another. Interchangeable trip is actually a design feature that is available on some thermal-magnetic and some solid state breakers. The advantage of a breaker with an interchangeable trip unit is the user can change the continuous current rating of the breaker without replacing the breaker. This is done by replacing the trip unit with one of a different rating.
Note: Care must be exercised when considering interchangeable trip circuit breakers. A circuit breaker may be UL (Underwriters Laboratories, Inc.) Listed for a specific interchangeable trip unit only. Circuit breaker frames are usually designed to prevent the installation of an improper trip unit size or type. Molded Case Switch Siemens molded case circuit breakers are available as a molded case switch. Molded case switches employ the same operating mechanism as the thermal magnetic and magnetic only units. A preset instantaneous function is factory installed to allow the switch to trip and protect itself at a high fault current, but the switch provides no thermal overload protection.
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Current Limiting Circuit Breakers
Many electrical distribution systems can deliver large short circuit currents to electrical equipment. This high current can cause extensive damage. Current limiting circuit breakers will reduce the current flowing in the faulted circuit to substantially less magnitude. This helps protect expensive equipment. One way to accomplish current limiting is with an additional set of contacts that feature two moveable arms. These are referred to as dual-pivot contacts, which separate even more quickly than the single-pivot contacts. The dual-pivot contacts are connected in series with the single-pivot contacts. As with the single-pivot design, current flows in opposite directions through the contact arms, creating a magnetic repulsion. As current increases, the magnetic repulsion force increases.
In an overload condition where current may only be one to six times normal current, the contacts remain closed until the breaker trips. In a short circuit condition fault current is extremely high, both sets of contact arms may open simultaneously, generating high impedance arcs. The contact gap of the dual-pivot contacts increases more rapidly, therefore generating arc impedance more rapidly. Once the arcs are extinguished, the dual-pivot contacts close on their own due to spring tension. The single-pivot contacts are held open by the breaker mechanism, which will have tripped during the fault and must be manually reset.
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The frame on current limiting circuit breakers of this design is extended to allow room for the dual-pivot set of contacts. Siemens current limiting breakers are easily identified by a red label and can handle fault currents of up to 200,000 amps.
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Solid State Circuit Breakers
Solid state circuit breakers function similarly to thermalmagnetic breakers. The basic breaker mechanism is still mechanical. The tripping unit is solid state. Siemens Sentron Series solid state breakers are referred to as Sensitrip circuit breakers. As with the thermal-magnetic tripping unit, the Sensitrip circuit breaker tripping unit performs the following three functions: Senses magnitude of current flow Determines when current becomes excessive Determines when to send a trip signal to the breaker mechanism
Sensitrip circuit breakers use a microprocessor to execute numerous functions programmed in the unit. These units have a greater degree of accuracy and repeatability. Adjustments on the trip unit allow the user to select numerical values the microprocessor will use in performing protective functions. Current sensors mounted in the trip unit monitor the value of load current. The value of current is reduced to a low level and converted to a digital voltage, which is used by the microprocessor. The microprocessor continuously compares the line current with the value set by the user. When current exceeds a preset value for the selected time, the trip unit sends a signal to a magnetic latch. The magnetic latch opens the breakers contacts, disconnecting the protected circuit from the power source.
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Circuit Breaker Ratings
Ampere Rating
Every circuit breaker has a specific ampere rating. The ampere rating is the maximum continuous current a circuit breaker can carry without exceeding its rating. The main purpose of circuit breakers is to protect the conductor and equipment. As mentioned earlier, conductors are rated by how much current they can carry on a continuous basis, known as ampacity. As a general rule, the circuit breaker ampere rating should match the conductor ampacity. For example, if the conductor is rated for 20 amps, the circuit breaker should be rated for 20 amps. Siemens I-T-E breakers are rated on the basis of using 60 C or 75 C conductors. This means that even if a conductor with a higher temperature rating were used, the ampacity of the conductor must be figured on its 60 C or 75 C rating. There are some specific circumstances when the ampere rating is permitted to be greater than the current carrying capacity of the circuit. For example, motor and welder circuits can exceed conductor ampacity to allow for inrush currents and duty cycles within limits established by NEC. Generally the ampere rating of a circuit breaker is selected at 125% of the continuous load current. This usually corresponds to the conductor ampacity which is also selected at 125% of continuous load current. For example, a 125 amp circuit breaker would be selected for a load of 100 amps.
Voltage Rating
Circuit breakers are also rated according to the maximum voltage they can handle. The voltage rating of the circuit breaker must be at least equal to the circuit voltage. The voltage rating of a circuit breaker can be higher than the circuit voltage, but never lower. For example, a 480 VAC circuit breaker could be used on a 240 VAC circuit. A 240 VAC circuit breaker could not be used on a 480 VAC circuit. The voltage rating is a function of the circuit breakers ability to suppress the internal arc that occurs when the circuit breakers contacts open.
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Circuit Interrupting Ratings
Circuit breakers are also rated according to the level of fault current they can interrupt. When applying a circuit breaker, one must be selected which can sustain the largest potential short circuit current which can occur in the selected application. Siemens circuit breakers have interrupting ratings from 10,000 to 200,000 amps. To find the interrupting rating of a specific circuit breaker refer to the Speedfax catalog.
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Time-Current Curves
Time-current curves, similar to the one shown on the following page, are used to show how fast a breaker will trip at any magnitude of current. The following illustration shows how a time-current curve works. The figures along the bottom (horizontal axis) represent current in amperes. The figures along the left side (vertical axis) represent time in seconds.
To determine how long a breaker will take to trip at a given current, find the level of current on the bottom of the graph. Draw a vertical line to the point where it intersects the curve. Then draw a horizontal line to the left side of the graph and find the time to trip. For example, in this illustration a circuit breaker will trip when current remains at 6 amps for .6 seconds. It can be seen that the higher the current, the shorter the time the circuit breaker will remain closed. It can be seen from the timecurrent curve on the following page that actual time-current curves are drawn on log-log paper, and the horizontal line is in multiples of the breakers continuous current rating. From the information box in the upper right hand corner, note that the time-current curve illustrated on the following page defines the operation of a CFD6 circuit breaker. For this example a 200 ampere trip unit is selected.
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Overload Protection Component
The top part of the time-current curve shows the performance of the overload trip component of the circuit breaker. Timecurrent curves are shown as bands, and the actual performance of any one breaker can fall anywhere within the band. Using the example CFD6 breaker and 200 ampere trip unit, the time the breaker will trip for any given overload can easily be determined using the same procedure as previously discussed. For example, the breaker will trip between 25 seconds and 175 seconds at 600 amps with a 40C ambient temperature, which is 3 times the trip unit rating. This is illustrated by the time-current curve on the following page. The bottom part of the time-current curve shows the performance of the instantaneous trip component (short circuit) of the circuit breaker. The maximum clearing time (time it takes for breakers to completely open) decreases as current increases. This is because of the blow-apart contact design which utilizes the magnetic field built-up around the contacts. As current increases the magnetic field strength increases, which aids in opening the contacts. This circuit breaker has an adjustable instantaneous trip point from 900 A to 2000 A, which is 4.5 to 10 times the 200 A trip unit rating. If the trip point adjustment is set to minimum (900 A), and a fault current of 900 amps or greater occurs, the breaker will trip within 1 cycle (16.8 ms). If the trip point setting is set to maximum (2000 A), and a fault current of 900 amps occurs, the breaker will trip between approximately 12 and 55 seconds. A greater fault current will cause the breaker to trip faster.
Instantaneous Trip Component
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Selective Coordination
Selective coordination is the application of circuit protective devices in series such that under overload or fault conditions, only the upstream device nearest the fault will open. The rest of the devices remain closed, leaving other circuits unaffected. In the following example a short circuit has occurred in the circuit fed by branch circuit breaker C Power is interrupted to . equipment supplied by circuit breaker C only. All other circuits remain unaffected.
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Circuit Breaker Coordination
Time current curves are useful for coordinating circuit breakers. If the trip curves of main breaker Afeeder breaker B and , , branch breaker C are placed on the same graph, there should be no overlapping, indicating the breakers are coordinated. The three circuit breakers in the following example have been coordinated so that for any given fault value, the tripping time of each breaker is greater than the downstream breakers. In the following illustration circuit breaker C is set to trip if a 400 amp fault current remains for .04 seconds. Circuit breaker B will trip if the fault remains for .15 seconds, and circuit breaker A if the fault remains for .8 seconds. If a 400 amp fault occurs downstream from circuit breaker C it will trip first and clear , the fault. Circuit breakers A and B will not trip.
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Series-Connected Systems
When selecting circuit breakers it is extremely important to know both the maximum continuous amperes and available fault current. This is true for any circuit breaker that is selected for any application. NEC article 110-9 states: Equipment intended to interrupt current at fault levels shall have an interrupting rating sufficient for the nominal circuit voltage and the current which is available at the line terminals of the equipment. Equipment intended to interrupt current at other than fault levels shall have an interrupting rating at nominal circuit voltage sufficient for the current that must be interrupted. There are two ways to meet this requirement. The first method is to select circuit breakers with individual ratings equal to or greater than the available fault current. This means that, in the case of a building with 65,000 amperes of fault current available at the service entrance, every circuit breaker must be rated at 65,000 amperes interrupting capacity (AIC).
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The second method is to select circuit breakers with a series combination rating equal to or greater than the available fault current at the service entrance. The series-rated concept is that the main upstream breaker must have an interrupting rating equal to or greater than the available fault current of the system, but subsequent downstream breakers connected in series can be rated at lower values. For example, a building with 65,000 amperes of available fault current might only need the breaker at the service entrance to be rated at 65,000 AIC. Additional downstream breakers can be rated at lower values. The series combination must be tested and listed by UL.
Siemens series-rated breakers are listed under Integrated Equipment Short Circuit Ratings in the Siemens Speedfax catalog, and in the UL Recognized Components Directory (yellow books) Volume 1. Your Siemens sales engineer can provide more information on Siemens series-rated circuit breakers.
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Review 3 1. ____________ magnetic-trip-only circuit breakers protect against short circuits, but provide no overload protection. ____________ magnetic circuit breakers have both overload and instantaneous trip features. Siemens current limiting circuit breakers can interrupt up to ____________ amps. The maximum continuous current a circuit breaker can carry is known as its ____________ rating. The upper part of a time-current curve represents the ____________ ____________ component, while the lower part of a time-current curve represents the instantaneous trip component. Circuit breaker ____________ will allow the circuit breaker supplying a circuit that faults to trip, but all upstream circuit breakers will remain unaffected.
2. 3. 4. 5.
6.
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Catalog Numbers
To help identify each type of circuit breaker, a catalog number is assigned. The catalog number provides a description of the circuit breaker. There are five parts to the standard I-T-E molded case circuit breaker catalog number. The following figure illustrates a typical catalog number.
Part 1
Part 1 signifies the circuit breakers frame type. There are four basic frame types available: normal duty, heavy duty, extra heavy duty, and fuseless current limiting. Most normal duty breakers are rated up to 240 VAC and have a maximum interrupting capacity of 10,000 or 22,000 amps. Heavy duty breakers have a stronger case. They are rated up to 600 VAC and have interrupting capacities up to 65,000 amps. This is the Sentron Series. There are eight basic Sentron Series frames: ED, FD, JD, LD, MD, ND, PD and RD. Extra heavy duty frames are rated up to 600 VAC and have interrupting capacities up to 100,000 amps. An extra heavy duty circuit breaker will have an H in the frame type designation. For example, a normal duty circuit breaker might be identified as QP The same circuit . breaker in an extra heavy duty frame will be identified as HQP . This is also true for the Sentron Series. For example, a heavy duty Sentron circuit breaker might be identified as FD6. The same Sentron circuit breaker in an extra heavy duty frame will be identified as HFD6. The same method is used to identify current limiting frames. For example, a current limiting circuit breaker in the ED6 frame will be identified as CED6.
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Part 2
Part 2 indicates the number of poles on the circuit breaker. Sentron Series circuit breakers can be provided with 1, 2, or 3 poles. The number of poles reflects the number of ungrounded phases that are connected. For example, a 1-pole breaker might be used on a simple lighting circuit, and a 3-pole breaker might be used on a 3-phase AC motor.
Part 3
Part 3 identifies the style of breaker. B M F T W S = = = = = = 40 C calibrated complete breaker 50 C calibrated complete breaker Breaker frame only Trip unit calibrated for 40 C Trip unit calibrated for 50 C Molded case switch
Part 4 Part 5
Part 4 shows the circuit breakers continuous current rating. In the example shown on the previous page it is 125 amps. Part 5 indicates a special circuit breaker identifier, such as automatic switches.
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Residential and Commercial Circuit Breakers
Siemens has several circuit breakers that are used in residential, commercial and light industrial applications. These circuit breakers are normally plug-in or bolt-on types that mount in load centers or panelboards. Other types are also available, for example, circuit breakers that mount on a DIN rail. There are several variations of circuit breakers, and this section will attempt to explain the most popular of them. The specific ratings for each circuit breaker can be found in the Speedfax catalog.
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EQ Frame Circuit Breakers QP Circuit Breakers
EQ frame circuit breakers, which includes QP BL, and BQ type , circuit breakers, are UL Listed for use with EQ load centers. One type of circuit breaker that belongs to the EQ family is the QP plug-in breaker. Depending on the specific QP type circuit breaker, the following ratings are available: Interrupting rating Continuous ampere rating Volts Number of poles 10,000, 22,000, or 65,000 amps 15-125 amps 120/240 VAC or 240 VAC 1, 2, or 3
For example, referring to the circuit breaker section of the Speedfax catalog, it can be seen that a 1-pole, 15 amp QP breaker, rated for an interrupting capacity of 10,000 amps at 120/240 VAC is a Q115. A 20 amp breaker is a Q120.
The following illustration shows a QP 1-pole breaker installed in an interior from an EQ load center.
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QP breakers can be used in single family homes where the available fault current does not normally exceed 10,000 amps. In some instances where fault current exceeds 10,000 amps, a QPH might be selected. In apartments, condominiums, and commercial buildings the available fault current is normally greater than 10,000 amps. Series-rated circuit breakers can be used. For example, a QPH feeder disconnect, with an interrupting capacity of 22,000 amps might be placed in front of a QP branch with an interrupting capacity of 10,000 amps. There are restrictions when using series-rated breakers. Refer to the Speedfax catalog for acceptable series-rated combinations.
BL an BQ Breakers
BL and BQ bolt-on breakers also belong to the EQ family. These breakers bolt directly to the power bus on panelboards in commercial and industrial applications, or the tab on the BQ can also be used to accept wire connectors.
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Depending on the specific BL type circuit breaker, the following ratings are available: Interrupting rating Continuous ampere rating Volts Number of poles 10,000, 22,000, or 65,000 amps 15-125 amps 120/240 VAC or 240 VAC 1, 2, or 3
For example, referring to the circuit breaker section of the Speedfax catalog, it can be seen that a 1-pole, 15 amp BLH breaker, rated for an interrupting capacity of 22,000 amps at 120/240 VAC is a B115H. A 20 amp breaker is a B120H.
Another bolt-on circuit breaker belonging to the EQ family is the BQ breaker. A BQ 2-pole breaker is illustrated below.
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Depending on the specific BQ type circuit breaker, the following ratings are available: Interrupting rating Continuous ampere rating Volts Number of poles 10,000, 22,000, or 65,000 amps 15-125 amps 120/240 VAC or 240 VAC 1, 2, or 3
For example, referring to the circuit breaker section of the Speedfax catalog, it can be seen that a 2-pole, 20 amp BQ breaker, rated for an interrupting capacity of 10,000 amps at 120/240 VAC is a BQ2B020.
BQD Tpe Circuit Breakers
BQD type circuit breakers (not shown) are panel-mount-only for light industrial loads or 277 VAC lighting. Depending on the specific BQD type circuit breaker, the following ratings are available: Interrupting rating Continuous ampere rating Volts Number of poles 14,000 or 65,000 amps 15-100 amps 277 or 277/480 VAC 1, 2, or 3
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CQD Circuit Breaker
The CQD type circuit breaker is similar to the BQD, but mounts on a DIN rail. The one and two pole devices have a high intensity discharge (HID) rating for high pressure lighting. Depending on the specific CQD type circuit breaker, the following ratings are available: Interrupting rating Continuous ampere rating Volts Number of poles 14,000 or 65,000 amps 15-100 amps 120, 240, 277 or 277/480 VAC 1, 2, or 3
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QJ Circuit Breakers
QJ type circuit breakers can be used as main circuit breakers in EQ 3-phase load centers. They are also used as branch circuit breakers in commercial panelboards and switchboards. Depending on the specific QJ type circuit breaker, the following ratings are available: Interrupting rating Continuous ampere rating Volts Number of poles 10,000, 22,000, or 42,000 amps 60-225 amps 240 VAC 2 or 3
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QD Circuit Breakers
The QD type circuit breakers are UL Classified for certain Square D Company load centers in place of Square D QO circuit breakers. A panelboard compatibility list is packaged with each Siemens QD circuit breaker. Siemens QD circuit breakers are to be used only in those Square D panelboards shown on the compatibility list. Depending on the specific QD type circuit breaker, the following ratings are available: Interrupting rating Continuous ampere rating Volts Number of poles 10,000 amps 15-60 amps 120/240 VAC 1 or 2
Review 4 1. 2. 3. 4. Part one (1) of the catalog number identifies the circuit breakers ___________ type. An extra heavy duty FD6 type circuit breaker will be identified as ____________ . The continuous ampere range of the QP type circuit breakers is from ____________ to ____________ amps. The Siemens type ____________ circuit breaker can be used as a replacement for a Square D QO circuit breaker in certain Square D load centers. The ____________ type circuit breaker mounts on a DIN rail.
5.
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Sentron Series Circuit Breakers
Siemens Sentron Series circuit breakers are available in nine frame sizes: ED, FD, JD, LD, LMD, MD, ND, PD, and RD. Sentron Series circuit breakers have a wide range of uses in commercial and industrial applications, such as: combination motor starters, control centers, and distribution and power circuits in panelboards and switchboards, machine tools, resistance welder control panels, service entrance protection and main distribution feeder circuits in switchboards.
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Ampere Rating
Sentron Series breakers are available with ampere ratings from 125 to 2000 amps. Each frame is divided into specific ampere ratings. For example, in the following table it can be seen that the ED frame has a maximum continuous current range of 15 to 125 amps. When selecting a circuit breaker, refer to the Siemens Speedfax catalog for specific product ratings.
Voltage Rating
Breakers are rated according to the maximum voltage they can handle. Sentron breakers are available with the voltage ratings shown below. It should be noted that breakers may be applied on systems with lower voltages than their maximum voltage rating, but never on systems above their maximum voltage ratings.
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Interrupting Rating
The interrupting rating refers to the level of fault current that a breaker can safely interrupt. Sentron breakers are available with interrupting ratings from 10,000 to 200,000 amps. A color coded label system is used to identify the maximum interrupting rating.
The easiest way to determine the interrupting rating of a specific circuit breaker is with the interrupting selector in the Speedfax catalog. For example, if a customer required a 100 amp Sentron Series circuit breaker capable of interrupting 10,000 amps at 240 VAC, the ED2 could be selected. However, if the customer required a 100 amp Sentron circuit breaker capable of interrupting 200,000 amps at 480 VAC, either the CED6 or the CFD6 could be selected. Another column, not shown here, references a page number where more detail can be found concerning the selected circuit breaker.
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ED Frame Sentron Circuit Breaker
The ED frame circuit breaker is the smallest and least expensive circuit breaker in the Sentron Series family. Its frame ampere rating is 125 amps. ED frame circuit breakers are used in individual enclosures, switchboards, panelboards and load centers. ED frame circuit breakers are available as a molded case switch, instantaneous magnetic trip circuit breaker (motor circuit protection), or thermal magnetic circuit breaker which provides complete overload and short circuit protection. The trip circuit is non-interchangeable. Fixed instantaneous trip values are shown in the following chart:
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Other Sentron Series Circuit Breakers
The other Sentron Series circuit breakers (FD, JD, LD, LMD, MD, ND, PD, and RD) range in frame size from 250 to 2000 amperes.
Some Sentron Series circuit breakers, like the JXD6 are UL listed for reverse feed applications. This means that power can be applied to the load side of the circuit breaker. Depending on the specific circuit breaker, Sentron Series circuit breakers are available as a molded case switch, instantaneous magnetic trip circuit breaker (motor circuit protection), or thermal magnetic circuit breaker which provides complete overload and short circuit protection.
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Some circuit breakers, like the FD6 breaker have interchangeable trip units. Other circuit breakers, like the JXD6 have non-interchangeable trip units. The instantaneous trip values are externally adjustable. For example, a CFD6 circuit breaker with a 200 ampere trip unit was used during the timecurrent curve discussion. It can be seen from the following table that the trip unit can be adjusted in eight steps from 900 to 2000 amps.
Selecting a Sentron Series Circuit Breaker
Selecting a circuit breaker requires the use of the Siemens Speedfax catalog. Suppose a customer requested a Sentron Series interchangeable trip, 2-pole circuit breaker with a continuous ampere rating of 300 amps, capable of interrupting an available fault current of 35,000 amps at 600 volts. The first place to look would be the Interrupting Selector of the Speedfax catalog. It can be seen from the following example that there are four possible choices: HJD6, HJXD6, HLD6, and HLXD6.
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The next step would be to go to the Discount Schedule. The JD frame is a 400 ampere frame and the LD frame is a 600 ampere frame. If the customer does not need the larger frame, the JD frame will be a good choice. The right catalog number is HJD62B300.
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Sentron Series Digital Circuit Breakers
The Sentron Series circuit breakers are also available in a digital circuit breaker version, referred to as Sensitrip III. Sensitrip III circuit breakers utilize a microcomputer which makes it possible to customize overcurrent protection which is matched exactly to the loads of an electrical system.
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True RMS Sensing
Some solid state circuit breakers react to peak currents of a sine wave. This method accurately measures the heating effect of the current on sine waves that are perfectly sinusodial. Frequently, however, sine waves are distorted due to harmonics on the line. When this happens, peak current measurement does not adequately evaluate the true heating effect of the current.
Sensitrip III digital circuit breakers use true RMS sensing to detect what is really happening with current. RMS (root-meansquare) current is the effective value of AC current. Sensitrip III RMS sensing capabilities take multiple, instantaneous samples of the actual current waveshape for a more accurate picture of its true heating value.
Being able to monitor true RMS current precisely is becoming more important in todays electrical distribution systems because of the increasing number of power electronic devices being used that can distort the waveform of the current. The microcomputer in Sensitrip III breakers samples the AC current waveform many times a second, converting each value into a digital representation. The microcomputer then uses the samples to calculate the true RMS value of the load current. This capability allows Sensitrip III breakers to perform faster, more efficiently and with repeatable accuracy.
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Maximum Continuous Ampere Rating
Sensitrip III breakers are available in 400 through 1600 amp, 600 VAC and below, frames. A color label system is used to identify the interrupting category of the circuit breaker. Blue = standard interrupting rating Black = high interrupting rating Red = current limiting Frames are grouped according to maximum current. For example, it can be seen from the following table that a 1200 ampere frame Sensitrip III is available with 800, 1000, or 1200 maximum continuous amperes. Maximum continuous amperes is also referred to as nominal ampere rating (In).
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Adjustable Functions
Curve shaping allows adjustment of individual circuit breakers for proper coordination between upstream and downstream devices. The basic adjustable functions are shown in the following illustration.
The time-current curve on the preceding page reflects one possible setup for a 1200 ampere Sensitrip III circuit breaker with a nominal (maximum continuous ampere) rating of 1000 amps. This time-current curve will be the basis for discussing adjustable features of the Sensitrip III circuit breakers. Continuous Amps (Ir) Continuous Amps (Ir) varies the level of current the circuit breaker will carry without tripping. Ir is a percentage of the circuit breakers nominal rating (In). Continuous amps can be adjusted from 20 to 100 percent of the circuit breakers nominal rating. For example, a 1000 amp Sensitrip IIl breaker can be changed from 1000 amps to 800 amps by adjusting the breaker continuous amps setting to 80%.
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Long-Time Delay
Long-time delay causes the breaker to wait a certain amount of time to allow temporary inrush currents, such as those encountered when starting a motor, to pass without tripping. The adjustment is from 2.2 to 27 seconds at six times the continuous amps (Ir) setting. As shown below, the long-time 2 delay effects the position of an I T slope. This means that lower levels of current will allow the breaker to remain online for longer periods of time.
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Short-Time Pickup
Short-time pickup is used for selective tripping. The short-time pickup function determines the amount of current the breaker will carry for a short period of time, allowing downstream protective devices to clear short-circuits without tripping the upstream device. Short-time pickup is adjustable from 1.5 to 10 times the trip unit ampere setting (Ir). For example, a 1000 ampere frame can be adjusted to trip anywhere from 1500 to 10,000 amps. The switch also has an OFF position to eliminate short-time pickup and short-time delay.
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Short-Time Delay
Short-time delay, used in conjunction with short-time pickup, controls the time involved in postponing a short-time pickup 2 trip. There are two modes: fixed time, or I T ramp. Fixed 2 time is adjustable from .05 to .5 seconds. The I T ramp mode is adjustable from .18 seconds to .45 seconds, providing a short inverse time ramp. This allows better coordination with downstream thermal-magnetic circuit breakers and fuses. A fixed instantaneous trip point of 10,000 amps trips the breaker automatically and overrides any pre-programmed instructions.
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Instantaneous Pickup
Instantaneous pickup is used to trip the circuit breaker with no intentional delay at any current between 2 and 40 times the breakers continuous ampere setting (Ir). In this example instantaneous pickup has been set to 10 times the continuous amp setting, or 10,000 amps (10 x 1000) with a continuous amp setting of 1000 amps. In this case a higher setting would still trip at 10,000 amps due to a fixed instantaneous override of 10,000 amps which automatically trips the breaker regardless of the instantaneous pickup setting. If the continuous amp setting had been 300 amps, setting the instantaneous pickup at 10 would make the instantaneous setting equal to 3000 amps, well below the fixed instantaneous override.
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Ground Fault Pickup
Ground fault pickup controls the amount of ground fault current that will cause the breaker to interrupt the circuit. The adjustment can be set from 20 to 70% of the maximum breaker rating. In compliance with NEC 230-95 (A), no trip point setting exceeds 1200 amps. The ground fault pickup is divided into three sections; .1s, .2s, and .4s. This feature adds a time delay of .1, .2, or .4 seconds to the breakers trip when a ground fault occurs.
The ground fault pickup time delay feature is useful for circuit breaker coordination. In the following illustration, upstream breaker A has been set to .2s and downstream breakers B and C have been set to .1s. A ground fault occurring in the circuit supplied by B will trip the B breaker without disturbing A or C .
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Review 5 1. 2. 3. Sentron Series breakers are available in frame sizes from 125 to ____________ amps. A ____________ color label is used to identify a current limiting Sentron Series breaker. True ____________ sensing is an advantage of the Sentron Sensitrip III circuit breakers over thermal-magnetic breakers. Setting the continuous amps setting of a Sensitrip III 1200 amp breaker to 50% changes the breakers continuous current trip point to ____________ amps. Long-time delay on a Sensitrip III is adjustable from ____________ to ____________ seconds. If a 1000 amp Sensitrip III breakers continuous amps is set to 100% and instantaneous pickup is set to 8 , the breaker will trip instantaneously (without intentional delay) at ____________ amps.
4.
5. 6.
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Internal Accessories
An accessory is an addition that adds to the performance of a circuit breaker or adapts the circuit breaker for specific application requirements. Various accessories are available for Siemens molded case circuit breakers. Internal accessories are used to modify a breakers performance. The four internal accessories are shunt trip, undervoltage trip, auxiliary switches, and bell alarm. ED Frame Accessories Mounting of internal accessories is handled differently for ED frame circuit breakers than for the other Sentron Series type circuit breakers. ED frame circuit breaker internal accessories are mounted on the side of the circuit breaker as shown in the following illustration.
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Other Sentron Series Accessories
To mount internal accessories in all other Sentron Series circuit breakers, the cover is removed and the accessories installed as shown in the following illustrations.
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Shunt Trip
It is sometimes necessary to trip a breaker from a remote location. For example, if someone were to get caught in a piece of machinery, anyone can push a panic button tripping the breaker. One or all critical circuit breakers may be tripped at the push of a button from a distant control point by use of a shunt trip device. The shunt trip device consists of a coil in series with a limit switch. When the circuit breaker contacts are closed the limit switch is closed. Depressing a customersupplied pushbutton energizes the shunt trip coil, causing the breakers mechanical latch to disengage the trip mechanism and opening the circuit breakers contacts. When the circuit breakers contacts open the limit switch also opens, removing power from the shunt trip coil. As with any trip the breaker must be reset manually.
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Undervoltage Trip
The undervoltage trip device is designed to automatically trip the circuit breaker when the supply voltage drops to a low value (35-70% of nominal line voltage). The device also prevents the circuit breaker from being reclosed until the supply voltage returns to at least 85% of its normal level.
Auxiliary Switch
An auxiliary switch consists of one set of normally open and one set of normally closed contacts. Contact A is open when the circuit breaker is in the Off or Tripped conditions. Contact B is closed when the circuit breaker is in the Off or Tripped conditions. This accessory is used to indicate whether a circuit breaker is on or off from a remote location. For example, in the following illustration an indicator light is connected to a customers power supply through contact A . When the circuit breaker is switched on, the light illuminates, indicating the circuit breakers contacts are closed and the breaker is supplying power to the load. When the circuit breaker is switched off, contact A opens, turning the indicator light off.
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Bell Alarm Switch
The bell alarm switch differs from the auxiliary switch in that it only functions when the circuit breaker trips. Opening and closing the circuit breaker by means of the operating handle does not affect the position of the alarm contacts. The A contact closes when the circuit breaker trips. The B contact opens when the circuit breaker trips. A horn or indicator light can be used to indicate the circuit breaker has tripped.
Accessory Combinations
The maximum number of internal accessory combinations available for each breaker type is shown in the Speedfax catalog.
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External Accessories
External accessories make circuit breakers suitable for specific applications. A variety of external accessories are available. Read Connecting Studs Rear connecting studs are used for switchboard mounting of circuit breakers. Rear connecting studs are available in various lengths of either bus or cable connections.
Rocker Arm Assembly
The rocker arm assembly is used to mechanically interlock two adjacent circuit breakers of the same frame configuration. Both circuit breakers can be open at the same time, but this allows only one breaker to be closed at any time.
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Max-Flex
The I-T-E Max-Flex flange-mount handle operator is a flexible cable control device used for remote switching of a circuit breaker within an enclosure. The flexible cable is connected directly to the breaker switch handle at one end and a factory installed switch at the other end. The remote handle operator located on the enclosure is used to perform mechanical open/ close switching operations. The cable comes in standard 3 or 4 foot lengths, however, lengths up to 20 feet can be ordered. When using a standard circuit breaker handle extension, it is necessary to exactly align the breaker with the extension. With the Max-Flex handle operator this exact alignment isnt necessary.
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Telemand Electric Motor Operator
The I-T-E Telemand electric motor operator is designed to open, close and reset a circuit breaker by remote control. It is mounted on the face of the circuit breaker so that it can engage the breakers operating handle. The built-in motor is connected to remote pushbuttons. Pressing the ON pushbutton causes the electric motor to move the circuit breaker to the ON position. Pressing the OFF pushbutton causes the electric motor to move the circuit breaker to the OFF position. To reset the circuit breaker from the tripped position, press the OFF pushbutton to move the handle to the OFF position. Then press the ON pushbutton to the close the breaker contacts.
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Plug-In Assemblies
Plug-in mounting assemblies provide means for a quick change out of circuit breakers and molded case switches without disturbing the power connections.
Terminal Connectors
Various terminal connectors are available to permit easy front connection of either copper or aluminum insulated conductors to the terminal of a circuit breaker or molded case switch. Terminal connectors are designed and tested to accommodate the conductors or requirements outlined within the related UL standards.
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Handle Blocking Device
A handle blocking device is a non-lockable device that may be added to a circuit breaker to secure the handle in either the ON or OFF position. The device slides into slots provided on the circuit breaker. This device prevents accidental operation of the handle. The device will not prevent the circuit breaker from tripping when blocked in the ON position. The following illustration shows the handle blocked in the ON position.
Handle Padlocking Device
The handle padlocking device is used to padlock the circuit breaker in the ON or OFF position. The device mounts over the handle and a customer supplied padlock is used to lock the handle. The breaker will still trip if locked in the ON position.
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Ground Fault Sensor
An external ground fault sensor is available for the ED frame circuit breakers. The relay functions to de-energize a circuit within an established period of time when the current to ground exceeds a predetermined value. This is done by detecting a 5 mA 1 mA or 30 mA 6mA current difference between two or more load conductors passing through the sensor.
Review 6 1. A ____________ - ____________ option is used when it is necessary to trip a breaker from a remote location, but cannot be used to reset the breaker. An ____________ ____________ device is used to automatically trip a circuit breaker when the supply voltage drops. The advantage of the Max-Flex flange-mount handle operator versus a handle extender is that ____________ ____________ isnt necessary. A ____________ ____________ is used to prevent two adjacent circuit breakers from being ON at the same time. ____________ - ____________ mounting assemblies provide a means for a quick change out of circuit breakers without disturbing the power connections.
2.
3.
4.
5.
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Insulated Case Circuit Breakers
The discussion to this point has been on molded case circuit breakers. Another type of circuit breaker is the low voltage air circuit breaker. Instead of having a molded case, the operating mechanism of a low voltage air circuit breaker is assembled on a metal frame for use in switchboards and switchgear. The components of a low voltage air breaker are larger and heavier for severe duty applications. Unlike molded case circuit breakers, low voltage air breakers have high short time withstand capabilities (breakers ability to ride through a short circuit event). Molded case circuit breakers, on the other hand, have high interrupting ratings. A circuit breaker was needed that could supply high short time withstand and high interrupting ratings. Insulated Case circuit breakers (ICCBs) were designed to fill that need.
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Ampere Ratings
There are six frames: 800, 1200, 2000, 3200, 4000, and 5000 amps. Interchangeable rating plugs and a continuous current adjustment are provided with each trip unit. ICCBs can be applied in applications from 100 to 5000 amps through 600 VAC. The frame ampere rating is determined by the current sensors in the breaker.
Interrupting Ratings
ICCBs use color coded labels to clearly identify the interrupting class of each breaker. A removable rating plug installed on the trip unit allows a user to select a current rating from 50 to 100 percent of the current sensor value. The following chart reflects the RMS ampere interrupting rating of Siemens insulated case circuit breakers.
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ICCB Electronic Trip Unit
The electronic trip unit uses a microprocessor to execute the numerous functions programmed in the unit. The adjustments on the trip unit allow the user to select what values are to be used by the microprocessor in performing its protective function.
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Interchangeable Rating Plugs
The trip unit is designed to use field interchangeable rating plugs. Rating plugs allow the effective ampere rating of the circuit breaker to be modified within a range of 50-100 percent of the breakers frame ampere rating.
The interchangeable rating plug is located at the top of the electronic trip unit.
Principle of Operation
Current is derived from current sensors (transformers) mounted in the breaker. The current signals from the transformers are converted to digital values in the trip unit. The electronic trip unit monitors current levels at an equivalent sampling rate of 353 samples per cycle per phase. It then decides when the circuit breaker should be tripped due to an overcurrent condition. A magnetic latch in the circuit breaker causes the breaker to trip when it receives a trip command from the electronic trip unit.
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Continuous Amps and Long-Time Delay
The continuous ampere adjustment sets the current level at which the breaker will continuously operate without tripping. For example, if a rating plug is 2000 amps and the continuous ampere adjustment is set to 50%, the breaker will continuously operate at current levels up to 1000 amps. The long-time delay adjustment is used to set the tripping delay of the circuit breaker based on the magnitude of the overcurrent condition (6 times Ir). For example, if the rating plug is 2000 amps and long-time delay is set to 10 seconds, a fault current of 12,000 amps (6 x 2000) will cause the breaker to trip after 10 2 seconds. Long time is an inverse I T ramp function. This means the higher the current, the shorter the time the circuit breaker will remain ON .
Short-Time Pickup and Short-Time Delay
The short-time pickup adjustment is used to set the level of high current the breaker will carry for a short period of time without tripping. This adjustment is set in multiples of the value of the rating plug (Ir). Together with short-time delay, this adjustment allows downstream breakers time to clear short circuit faults without tripping upstream breakers. Short-time delay is used to set the time interval the breaker will wait before responding to the current value selected by short-time 2 pickup. There are two modes of operation: fixed and I T. The 2 I T delay has the characteristic of being inversely proportional to the square of the magnitude of the current. This means higher overcurrent conditions have shorter delays.
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Instantaneous Pickup and Instantaneous Override
The instantaneous pickup adjustment is used to set the current level at which the breaker will trip without an intentional time delay. Non-delayed tripping as a result of severe overcurrent minimizes potential damage to electrical systems and equipment. This adjustment is set in multiples of Ir.
An instantaneous override function is provided on all trip units. It is nominally set at the short-time rating of the respective breaker frame size. This allows the breaker to ride through high fault currents up to its short-time capability, however, it is selfprotecting above these values.
Ground Fault Pickup and Ground Fault Delay
The ground fault pickup adjustment is used to set the level of ground current at which circuit interruption will be initiated. Together with ground fault delay, this adjustment allows selective tripping between main and feeder or other downstream breakers. The available ground fault pickup settings are given in the following table. In compliance with NEC 230-95 (A), no trip point setting exceeds 1200 amps.
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The ground fault delay adjustment is used to set the time interval (in seconds) the breaker will wait before responding once the ground fault pickup level has been reached. There 2 are two modes of operation: inverse time (I T) and fixed delay. Above 50 percent of the frame rating the inverse time delay reverts to a fixed delay of the same value.
Trip Status
The query button switch and trip status indicator lights provide the user a means for determining what type of fault caused the trip unit to trip the circuit breaker. Fault indicators are provided for: O.L. S.T. S.C. G.F . Overload or Long-Time Fault Short-Time Fault Short Circuit or Instantaneous Fault Ground Fault
When a fault occurs the fault information is stored in the trip unit. When the Query button is pushed the appropriate fault indicator will light.
Integral Test
The integral test function enables the user to exercise the trip unit electronics, magnetic latch and breaker mechanism. The purpose of the test function is to provide the user with an easy means to conduct a go/no go type test before bringing the circuit breaker on-line.
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Optional Display Module
The optional display module provides the features for allowing the user to locally monitor the phase currents. The display module plugs into the front of the trip unit. The load monitor alarm feature provides a local alarm display and an output signal for an external alarm when the average of the phase currents exceeds the alarm set point. The current demand feature provides two ampere demand factors. The present demand setting displays the present ampere demand calculated on 15 minute intervals. The maximum demand setting displays the maximum ampere demand since last reset. To reset the maximum demand memory, the operator should simultaneously press the Phase and G.F buttons on the integral test function. .
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Ground Fault Monitor
The ground fault monitor allows the user to monitor ground fault current. The ground fault delays are divided into three time delay bands: 0.1, 0.3, and 0.5 seconds. There are three ground fault pickup levels available. LO equals 20% of the frame rating. HI equals the frame rating or 1200 A, whichever is less. MED equals the average of LO and HI . The ground fault monitor displays the ground fault current in amps. When the ground fault current reaches a level 12% below the selected pickup setting the display will start to flash. When ground fault current reaches the selected setting the display will flash OL The ground fault monitor can be utilized with a display . relay module or a remote indicator panel to provide a set of contacts for ground fault alarm. When used in conjunction with either of these devices and a shunt trip, the ground fault monitor can be used as ground fault sensing and relaying equipment per UL -1053.
Ground Fault Monitor
.1S MED LO MAX
HI
LO
.3S MED HI LO
HI Amps
MED .5S
Review 7 1. 2. 3. 4. A red label ICCB at 480 VAC has an interrupting rating of ____________ kA. A 600 amp rating plug is available in the ___________ and ___________ amp breaker frame sizes. The trip unit monitors current levels at an equivalent sampling rate of ____________ samples per second. Setting the continuous amp setting of a 1000 amp rating plug to 75% makes the ICCB a ____________ amp breaker. In compliance with NEC 230-95, the maximum ground fault trip point setting of an ICCB is ____________ amps.
5.
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Review Answers
Review 1 Review 2 Review 3 Review 4 Review 5 Review 6 Review 7
1) a; 2) overloads, short circuits; 3) short circuit; 4) overload; 5) sense, measure, act. 1) contacts; 2) blow-apart; 3) arc chute; 4) over-center; 5) bimetal; 6) electromagnet. 1) instantaneous; 2) thermal; 3) 200,000; 4) ampere; 5) overload protection; 6) coordination. 1) frame; 2) HFD6; 3) 15 to 125; 4) QD; 5) CQD. 1) 2000; 2) red; 3) RMS; 4) 600; 5) 2.2 to 27; 6) 8000. 1) shunt trip; 2) undervoltage trip; 3) exact alignment; 4) mechanical interlock; 5) plug-in. 1) 150; 2) 800, 1200; 3) 353; 4) 750; 5) 1200.
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Final Exam
The final exam is intended to be a learning tool. The book may be used during the exam. A tear-out answer sheet is provided. After completing the test, mail the answer sheet in for grading. A grade of 70% or better is passing. Upon successful completion of the test a certificate will be issued. Questions 1. With an increase of current, temperature will a. decrease c. remain the same 2. b. d. increase increase and decrease
The amount of current a conductor can carry on a continuous basis is known as a. ampacity c. peak current b. d. instantaneous current AWG
3.
Overcurrent protection is covered by NEC article a. 110 c. 240 b. d. 430 384
4.
A contact design which uses magnetic fields developed around the contacts to help force them apart during an overcurrent condition is known as a. straight-through c. dual-pivot b. d. single-pivot blow-apart
5.
The operating mechanism in Siemens molded case circuit breakers is a/an ______ design. a. over-center c. center-off b. d. normally open normally closed
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6.
The brain of the circuit breaker is the a. arc chute c. trip unit b. d. frame operating mechanism
7 .
The type of circuit breaker that provides both overload and short circuit protection is a/an _______circuit breaker. a. b. c. d. instantaneous magnetic-trip-only interchangeable trip molded case switch thermal-magnetic
8.
Siemens Sentron Series circuit breakers use a ______ label to identify a high interrupting category circuit breaker. a. black c. blue b. d. red yellow
9.
The upper-most portion of a time-current curve for a Sensitrip III circuit breaker shows the ______ performance of a circuit breaker. a. b. c. d. short circuit protection instantaneous trip continuous current current interrupting
10. The application of circuit protective devices in series, such that under overload or fault conditions, only the upstream device nearest the fault will open is known as a. series-rating c. instantaneous trip 11. b. d. selective coordination current limiting
The maximum continuous ampere rating available for the BQ circuit breaker is a. 15 amps c. 50 amps b. d. 100 amps 125 amps
12. The QP circuit breaker is a/an _____ circuit breaker a. bolt-on c. plug-in b. d. Sentron Series insulated case
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13. The type of circuit breaker that mounts on a DIN rail is a. BQD c. CQD b. d. BL BQC
14. The maximum continuous ampere range of an ND circuit breaker is a. 15-125 amps c. 800-1200 amps 15. True RMS sensing a. b. c. d. measures peak currents only provides more accurate picture of true heating samples current every 1/2 second measures peak voltages only b. d. 200-400 amps 1800-2000 amps
16. Which of the following adjustments is not available on a Sensitrip III circuit breaker? a. continuous amps c. long-time delay 17 . b. d. instantaneous delay short-time delay
An accessory used to indicate a circuit breaker has tripped is a a. bell alarm switch c. auxiliary switch b. d. undervoltage trip shunt trip
18. A device used to allow only one of two adjacent circuit breakers to be closed at any time is a a. b. c. d. mechanical interlock Max-Flex handle operator Telemand electric motor operator handle blocking device
19. Insulated case circuit breakers provide _______ interrupting ratings and _______ short-time withstand. a. high , poor c. low, poor b. d. low, excellent high, excellent
20. In compliance with NEC 230-95, no ground fault trip point setting can exceed ____ amps. a. 1200 c. 100,000 b. d. 10,000 200,000 91
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quickSTEP Online Courses
quickSTEP online courses are available at http://www.sea.siemens.com/step. The quickSTEP training site is divided into three sections: Courses, Downloads, and a Glossary. Online courses include reviews, a final exam, the ability to print a certificate of completion, and the opportunity to register in the Sales & Distributor training database to maintain a record of your accomplishments. From this site the complete text of all STEP 2000 courses can be downloaded in PDF format. These files contain the most recent changes and updates to the STEP 2000 courses. A unique feature of the quickSTEP site is our pictorial glossary. The pictorial glossary can be accessed from anywhere within a quickSTEP course. This enables the student to look up an unfamiliar word without leaving the current work area.
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Siemens Molded Case Circuit Breaker Step 2000 Course

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What are the main types of overcurrent protective devices discussed in the document?

What are the main types of overcurrent protective devices discussed in the document?

What are the main components of a circuit breaker?

What are the main components of a circuit breaker?

Molded Case Circuit Breakers

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Need for Circuit Protection

Current and Temperature

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Ampacities of Insulated Conductors

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Types of Overcurrent Protective Devices

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Circuit Breaker Operation

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Circuit Breaker Design

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Arc Chute Assembly

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Short Circuit Trip

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Types of Circuit Breakers

Instantaneous Magnetic Trip-Only Circuit Breakers

Thermal-Magnetic Circuit Breakers

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Interchangeable Trip Circuit Breakers

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Current Limiting Circuit Breakers

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Solid State Circuit Breakers

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Circuit Breaker Ratings

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Circuit Interrupting Ratings

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Overload Protection Component

Instantaneous Trip Component

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