3/26/23, 5:46 PM Moulded Case Circuit Breakers Explained - GSES

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Moulded Case Circuit Breakers Explained

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3/26/23, 5:46 PM Moulded Case Circuit Breakers Explained - GSES

Posted on October 11, 2017 by GSES

As installed system capacity continues to increase in the Australian PV market, it is valuable

for system designers and installers to understand the mechanisms behind moulded case
circuit breakers, and the meaning behind their ratings.

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3/26/23, 5:46 PM Moulded Case Circuit Breakers Explained - GSES

A moulded case circuit breaker (MCCB) is a type of electrical protection device that is used to
protect the electrical circuit from excessive current, which can cause overload or short circuit.
With a current rating of up to 2500A, MCCBs can be used for a wide range of voltages and
frequencies with adjustable trip settings. These breakers are used instead of miniature circuit
breakers (MCBs) in large scale PV systems for system isolation and protection purposes.

How the MCCB operates

The MCCB uses a temperature sensitive device (the thermal element) with a current sensitive
electromagnetic device (the magnetic element) to provide the trip mechanism for protection
and isolation purposes. This enables the MCCB to provide:

Overload Protection,
Electrical Fault Protection against short circuit currents, and
Electrical Switch for disconnection.

Overload Protection
Overload protection is provided by the MCCB via the temperature sensitive component. This
component is essentially a bimetallic contact: a contact which consists of two metals that
expand at different rates when exposed to high temperature. During the normal operating
conditions, the bimetallic contact will allow the electric current to flow through the MCCB.
When the current exceeds the trip value, the bimetallic contact will start to heat and bend
away due to the different thermal rate of heat expansion within the contact. Eventually, the
contact will bend to the point of physically pushing the trip bar and unlatching the contacts,
causing the circuit to be interrupted.

The thermal protection of the MCCB will typically have a time delay to allow a short duration
of overcurrent which is commonly seen in some device operations, such as inrush currents

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seen when starting motors. This time delay allows the circuit to continue to operate in these
circumstances without tripping the MCCB.

Electrical Fault Protection against short circuit currents

MCCBs provides an instantaneous response to a short circuit fault, based on the principle of
electromagnetism. The MCCB contains a solenoid coil which generates a small electromagnetic
field when current passes through the MCCB. During normal operation, the electromagnetic
field generated by the solenoid coil is negligible. However, when a short circuit fault occurs in
the circuit, a large current begins to flow through the solenoid and, as a result, a strong
electromagnetic field is established which attracts the trip bar and opens the contacts.

Electrical Switch for disconnection

In addition to tripping mechanisms, MCCBs can also be used as manual disconnection
switches in case of emergency or maintenance operations. An arc can be created when the
contact opens. To combat this, MCCBs have internal arc dissipation mechanisms to quench the
arc.

Deciphering MCCB Characteristics and Ratings

MCCB manufacturers are required to provide the operating characteristics of the MCCB. Some
of the common parameters are explained below:

The maximum current that the MCCB is rated to handle. This

rated frame current defines the upper limit of the adjustable
Rated Frame Current (Inm)
trip current range. This value determines the breaker frame
size.
The rated current value determines when the MCCB trips due to
Rated Current (In): overload protection. This value can be adjusted, to a maximum
of the rated frame current.
This value indicates the maximum voltage which the MCCB can
Rated Insulation Voltage (Ui) resist in lab conditions. The rated voltage of MCCB is typically
lower than this value to provide a safety margin.
This value is the rated voltage for the continuous operation of
Rated Working Voltage (Ue)
MCCB. It is normally the same as or close to the system voltage.
This value is the transient peak voltage the circuit breaker can
Rated Impulse Withstand withstand from switching surges or lightning strikes. This value
Voltage (Uimp) determines the ability of the MCCB to withstand transient over-
voltages. The standard size for impulse testing is 1.2/50µs.

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This is the highest fault current that the MCCB can handle
without being permanently damaged. MCCBs are generally
Operating Short Circuit
reusable after fault interruption operation provided they do not
Breaking Capacity (Ics)
exceed this value. The higher the Ics, the more reliable the
circuit breaker.
This is the highest fault current value that the MCCB can handle.

If the fault current exceeds this value, the MCCB will be unable
to trip. In this event, another protection mechanism with a
higher breaking capacity must operate. This indicates the
Ultimate Short Circuit
operation reliability of the MCCB.
Breaking Capacity (Icu)

It is important to note that if the fault current exceeds Ics but

does not exceed Icu, the MCCB can still remove the fault, but
may be damaged and require replacement.

This is the maximum number of times the MCCB can be

Mechanical Life
operated manually before it fails.
This is the maximum number of times the MCCB can trip before
Electrical Life
it fails.

Sizing the MCCB

MCCBs in an electrical circuit should be sized according to the circuit’s expected operating
current and possible fault currents. The three main criteria while selecting MCCBs are:

The rated working voltage (Ue) of the MCCB should be similar to the system voltage.
The trip value of the MCCB should be adjusted according to the current drawn by the load.
The breaking capacity of the MCCB must be higher than the theoretical possible fault
currents.

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Types of MCCB
Type of Operating Operating Surge Installation
Application Suitability
MCCB Current Time Current Location
Trips
between 3 Domestic
and 5 applications Resistive
0.04-13 Sub feeder of
Type B times (lighting and load Low
seconds Distribution board
rated resistive application
current elements)
(In)
Trips
between 5
At
and 10 Commercial or Inductive
0.04-5 incoming/outgoing
Type C times industrial load Moderate
seconds of Distribution
rated applications applications
Board
current
(In)
Inductive –
Trips
capacitive
between
load
10 and 20 Commercial or At incoming of
0.04-3 applications
Type D times industrial High Distribution
seconds (Pumps,
rated applications Board/Panels
motor, large
current
winding
(In)
motors etc.)
Trips
between8 Inductive
and 12 and motor At incoming of
0.04-5 Industrial
Type K times loads with High Distribution
seconds applications
rated high inrush Board/Panels
current currents.
(In)
Highly sensitive
Trips to short circuit
between 2 and are used
and 3 for protection At sub feeder of
0.04-5 Medical
Type Z times of highly Very low Distribution board
seconds instruments
rated sensitive for IT equipment.
current devices such as
(In) semiconductor
devices

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Figure 1: Trip curve of type B, C, and D MCCBs

MCCB Maintenance
MCCBs are subjected to high currents; therefore maintenance of MCCBs is critical for reliable
operation. Some of the maintenance procedures are discussed below:

1. Visual Inspection
During the visual inspection of a MCCB, it is important to look out for deformed contacts or
cracks in casing or insulation. Any burn marks on contact or casing should be treated with
caution.

2. Lubrication
Some MCCBs require adequate lubrication to ensure the smooth operation of the manual
disconnection switch and internal moving parts.

3. Cleaning
The dirt deposits on MCCBs can deteriorate the MCCB components. If the dirt includes any
conducting material it may create a path for current and cause an internal fault.
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4. Testing
There are three main tests that are carried out as a part of maintenance procedure of a MCCB.

Insulation Resistance Test:

The tests for a MCCB should be conducted by disconnecting the MCCB and testing the
insulation between the phases and across the supply and load terminals. If the measured
insulation resistance is lower than the manufacturer’s recommended insulation resistance
value then the MCCB will not be able to provide adequate protection.

Contact Resistance:
This test is conducted by testing the resistance of the electrical contacts. The measured value
is compared to the value specified by the manufacturer. Under normal operating conditions,
contact resistance is very low since MCCBs must allow operating current through with
minimum losses.

Tripping Test:
This test is conducted by testing the response of the MCCB under simulated overcurrent and
fault conditions. Thermal protection of the MCCB is tested by running a large current through
the MCCB (300% of rated value). If the breaker fails to trip, it is an indication of failure of
thermal protection. The test for magnetic protection is conducted by running short pulses of
very high current. Under normal conditions, magnetic protection is instant. This test should be
conducted at the very end as high currents increase the temperature of contacts and
insulation, and this may alter the results of other two tests.

Conclusion
The correct selection of MCCBs for the required application is key to providing adequate
protection in sites with high power equipment. It is also important to carry out maintenance
actions at regular intervals and each time after trip mechanisms have been activated to
ensure the safety of the site is maintained.

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