Intelligent Molded Case Circuit Breakers –MCCB

ATOM Switch

Ali Vakili, P.E., LEED® Accredited Professional

District Application Engineer

Eaton Electrical – Pleasanton, CA

Email: AliVakili@eaton.com

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Agenda
• History of MCCB
• Overcurrent and Overloads
• Codes and Standards
• Overcurrent Protective Devices
• Time Current Curves
• Overcurrent Device Construction
• Intelligent Molded Case Breakers
• Solid Sate Breakers
• Closing Remarks

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Types of Overcurrent Protective Devices

• The primary function of an overcurrent protective

device is to protect the conductor from
overheating

3
 Overcurrent Protective Devices - Types
• Circuit Breaker
(NEC Article 100 Definition)
“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.”

“FPN: The automatic opening means can be

integral, direct acting with the circuit breaker, or
remote from the circuit breaker.”

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Different Types And Sizes

• Molded Case Circuit Breaker (MCCB)

“A circuit breaker that is assembled as an integral unit in a supporting and enclosing housing of insulating
material.”

• Insulated Case Circuit Breaker (ICCB)

“A circuit breaker that is assembled as an integral unit in a supporting and enclosing housing of insulating material and with
a stored energy mechanism.”

• Low Voltage Power Circuit Breaker (LVPCB)

“A mechanical switching device, capable of making, carrying, and breaking currents under normal circuit conditions and
making and carrying for a specified time and breaking currents under specified abnormal circuit conditions such as those of
short circuit. Rated 1000 V ac or below, or 300 V dc and below, but not including molded-case circuit breakers.”

Ref: IEEE Std 1015 – 2006 “IEEE Blue Book – Applying Low Voltage Circuit Breakers Used in Industrial and Commercial Power Systems”

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 Insulated Case Circuit Breakers

• Typically 800A –
6000A Frame Range
• Interrupting Duty 35 –
200kA
• Found In Enclosures,
Switchboards and
Switchgear

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 Power Circuit Breakers

• Interrupting Duty from 42kA to 100kA and

Current-Limiting Up To 200kA

• 800A to 6000A Frame

• Found in Enclosures, Switchboards, and Switchgear

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 MCCB Technology Evolution

Intelligent &
Solid sate
Breakers
Global
• Smaller Size
HIC Evolution - Advancements
• World’s 1st 947-2 in short-circuit
HIC MCCBs interruption
• Highest • Higher Current and thermal
industry HIC Density ratings.
Current Limit-R ratings-refined • Communications • Plug-in common
• Current limiting arc interruption. (Optim)
Seltronics • Smallest size
accessories
• World’s first • 1st to introduce • Digital RMS across line.
in Industry
Tri-Pac analog electronic with series ratings. Sensing • 250 Frame
• Combined Standard electronic trip
Classic Family • Integrally fused trip. with digital
high- speed • IEC 157 Std. & • E2 Mining
• 50-600 Amp • 200 kA Rating • 1000 Vac electronic trip
UL 489.
World’s 1st • 5 Frames • 4 Frame Sizes ratings thru interruption higher short • Earth Leakage
with electro- circuit/voltage
Molded • < 30 kA HIC • Built from enhanced arc Devices
Classic Platform interruption magnetic ratings. • Lower Cost
Housing Rating
• First family of repulsion and • highly integrated
Breaker fused bkrs. slot motor. compact design.

1920’s 1940’s 1950’s 1970’s 1980’s 1990’s 2004 2018

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Overcurrents and Overloads

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Overcurrent Protective Devices
Overcurrent (NEC Definition)
“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.”
FPN: A current in excess of rating may be accommodated by certain equipment and
conductors for a given set of conditions. Therefore, the rules for overcurrent protection
are specific for particular situations.

An Overcurrent Results From Overload, Short

Circuit, or Ground Faults

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 Overcurrent Protective Devices Protect From

Overload. (NEC Definition)

“Operation of equipment in excess of normal,
full-load rating, or of a conductor in excess of rated
ampacity that, when it persists for a sufficient
length of time, would cause damage or dangerous
overheating. A fault, such as a short circuit or
ground fault, is not an overload.”

An Overload Is NOT A
Short Circuit, or Ground Faults

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 Overcurrent Protective Devices Protect From
Short Circuit Current.
• Not Defined In NFPA, IEEE or other similar organization
documents
• An overcurrent, typically many times larger than normal
operating current

• Short-Circuit Current Rating (NEC Definition)

• Short Circuit Current Rating (SCCR) is a rating on components and assemblies
representing the maximum level of short-circuit current that a component or
assembly can withstand. This rating is used to determine compliance with NEC
110.10. “SCCR” labeling is required on all panels and assemblies.

A Short Circuit Is An Overcurrent But Not An Overload

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Example – Overload

R R R
Source

Load Load
VS
R R
R R R

IOL= VS / RT
Within the normal path
Example – Short Circuit

Iload = VS / RT
RT = RL +R1 + R2 + R3 + R4 + R5 + R6 + R7 + R8
R R R R
1 2 3 4
Source

Load
VS
RL
R R R R
8 7 6 5

Voltage (V) = 480

Load Resistance (R) = 24 ohms
Wire Resistance (R) = 0.01 ohms = 8*0.01 = 0.08Ohms
Iload = (480) / (0.08 + 24) = 19.93 Amps
Class Example – Short Circuit

Iload = VS / RT
RT = R1 + R2 + R7 + R8
R R R R
1 2 3 4
Source

Load
VS
RL
R R R R
8 7 6 5

Voltage (V) = 480

Load Resistance (R) = 24 ohms
Wire Resistance (R) = 0.01 ohms = 4*0.01 = 0.04Ohms
Iload = (480) / (0.04) = 12,000 Amps
 Effects Of Overcurrents – Ground Fault

• People and Equipment Protection

Levels

Ground Faults Are Overcurrents

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 Effects Of Overcurrents

• Conductor
insulation damage
• Equipment
damage
• Fires
• Arc Flash Energy

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The Overcurrent Protective Device Works
To Prevent The Hazardous Consequences
Of Dangerous Overcurrents

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Codes and Standards

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Codes And Standards

• NFPA – National Fire Protection Association

• NFPA 70: “National Electrical Code”
• NFPA 70E: “Standard for Electrical Safety In the Workplace”
• NFPA 99: “Health Care Facilities”
• NFPA 70B: “Recommended Practice

View For Free @ www.nfpa.org

(www.nfpa.org/70)

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Codes And Standards
• UL – Underwriter’s Laboratories
• UL 489: “Molded-Case Circuit Breakers, Molded-
Case Switches and Circuit-Breaker Enclosures”
• UL 1087: “Molded Case Switches”
• UL 1699: “Arc-Fault Circuit Interrupters”
• UL 943: “Ground-Fault Circuit Interrupters”
• UL 1077: “Supplementary Protectors for Use In
Electrical Equipment”
• UL 1053: “Ground-Fault Sensing & Relaying
Equipment”

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Codes And Standards

• NEMA – National Electrical

Manufacturers Association
• AB 1: “Molded-Case Circuit Breakers,
Molded Case Switches, and Circuit-Breaker
Enclosures” (Now = UL 489)
• AB 3: “Molded-Case Circuit Breakers and
Their Application”
• AB 4: “Guidelines for Inspection and
Preventive Maintenance of Molded-Case
Circuit Breakers Used in Commercial and
Industrial Applications”

Free Downloads @ www.nema.org

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Overcurrent Protective Devices

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Time Current Curves (TCC)
Trip Curve Describes 1000

Device Operation
100

• Designed To Trip On

Time (Seconds)
10
Overcurrents
1.0
• Designed To Protect
The Conductor From 0.1

Thermal Damage 0.01

0.005

• Device Needs Time & 0.5 20 200

Current (Amps)
1000

Current To Trip
Understanding How An Overcurrent Protective Device
Operates Is Important

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Time Current Characteristic (TCC) Curves
The Trip Curve 1000

• A Trip Curve Is Plotted 100

Maximum

Time (Seconds)
Time Vs. Current 10
Clearing

A Breaker Trips
• The Curve Tells The Trip 1.0 At Some Time

Times For Various Between These Bands

0.1 Minimum
Levels Of Current Clearing

0.01
• Minimum and Maximum 0.005
0.5 20 200 1000
Clearing Times Current (Amps)

Understanding How An Overcurrent Protective Device

Operates Is Important

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 Circuit Breaker Components
• Major Components
• Molded Case Frame

• Operating Mechanism
• Arc Extinguishing And Contacts

• Trip Units

• Tripping Conditions
• Overload

• Short-Circuit
• Ground Fault

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Thermal Protection
• Bimetal In Series With Connected Cable
• Bimetallic Element Is Heated By The Load Current
• Sustained Overload Will Cause Bimetal To Deflect
• Deflection Trips The Breaker

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Thermal Magnetic
Time Current Characteristic Curve

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Labels and Ratings

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Overcurrent Device Ratings

• Amp Rating
• Interrupting Rating
• Withstand Rating

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Circuit Breaker Labels

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The Electronic Era

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Electronic Trip Units
• 1973 Saw The
Introduction of
The Seltronic™
Circuit Breaker
• The First
Electronic
Circuit Breaker
On The Market

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Integration With The Breaker

Trip Unit

Circuit Board
Flux
Transfer
Shunt
Trip
Current Transformer

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 Time-Current Characteristic
Depicts the time required for an
1000
Long Time
Pickup
overcurrent protective device to open
Long Time
automatically
Delay
100 • Three Regions
Time In Seconds

10
Short Time
Pickup
• Long-time: Opening in minutes

Short Time Delay • Short-time: Opening in seconds or

1.0 (I2t)
tenths of seconds.

0.1 Instantaneous • Instantaneous: Opening with no

Pickup
intentional delay - milliseconds
0.01
0.005
0.5 1 10 100
Multiples of Rated Current

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 Communications

• Remote Data Collection

• Energy / Voltage / Current
• Cause Of Trip And Other Alarm Information
• Control HTTP
WEB
HTTP
URL
WEB
Internet
URL
Internet

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Zone Selective Interlocking

• Communication Between Breakers

Isc

• Reduces Trip Time When Possible

• Helps With Arc Flash Energy Reduction
Case 1:
• Both Breakers See Fault
• Upstream Breaker Waits As Designed

Case 2:
• Only Upstream Breaker Sees
Fault
• No Input From
Downstream Breaker
• Trip As Fast As Possible

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 Arc Flash Reduction Switch
• ALWAYS WORK
DE-ENERGIZED
• Manually or
Automatically enables
analog instantaneous
pickup
• Protects all downstream
equipment / personnel
• Limits energy available
during maintenance

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Electromechanical Intelligent Breakers

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 Product Attributes!

• Globally rated breakers— UL,

CSA, CCC & IEC
• 1, 2, 3 & 4 pole frames
• Smaller number of frames (15A –
2500A)
• Up to 100kAIC/480V &
65kAIC/600V
• Field installable thermal-magnetic
& electronic trip units
• Through-cover accessories and
improvements galore
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Intelligent Breaker Features
• Software Configurations
• Breaker Health
• Arc flash Mitigation
• Enhanced Ground Fault
• Metering Accuracy
• Programmable Relays
• Communications
• Testing and Commissioning

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 Software Protection Manager
BEFORE: Set points manually, hand held test kits with different
connections by platform, manual transcribing for test reports, temporary
meters for troubleshooting and attempting to capture events

AFTER: USB-equipped trip units and PC-based software to configure, test,

and troubleshoot trip units in the field

• Set point Configuration: Allows direct-to-trip unit or offline set up,

including duplication of settings between units

• Control Mode: Capture waveforms, reset TU, or set date/time

• Test Mode: Run secondary injection & create test reports

• Real Time Data: Provides information regarding all status and

metered data direction from the trip unit Waveform Capture Test Report

• Event Summaries: Stores up to 200 events, detailed information

on most recent (10) trip and (10) alarm events, and time
adjustments to the real time clock

• Reports: Allows printing of real time data & events from trip unit

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 Introducing Breaker Health
BEFORE: Operational condition and wear of breaker
is unknown, no warning that breaker is near end of life

AFTER: Breaker Health algorithm provides real-time

evaluation of breaker condition by tracking and
analyzing diagnostic details including:
Breaker operations
Short circuit fault levels
Operational time
Internal temperature
Overloads
• Communicates breaker status at 25% Health to
prompt for breaker maintenance or inspection
• Also optional to configure a programmable relay

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 Standardizing ARMS Functionality
BEFORE: ARMS differed in functionality between breakers MCCB Power Breaker
trip units
AFTER: Maintain industry-leading solution with added
consistency amongst frames and enhanced functions:
• OFF/Remote-ON switch and blue LED trip unit, self-
powered with current above ~20%
• Remote switch wiring and remote indication capability
via programmable relay
• Remote switching via communications Typical ARMS Wiring Adjustable Levels

• Adjustable ARMS levels via screen or PC Based

Software

White Paper published to provide

thought leadership on 240.87
approved methods for arc energy
reduction, advantages and
disadvantages
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 Added ZSI Testing and Indication
BEFORE: No way to verify Zone Selective
Interlock activation or test functionality
AFTER: Comprehensive system test
capabilities and advanced ZSI functionality
• ON / OFF capability
• On screen visual indication, and remotely
by programmable relay
• Indication appears during testing and in
service (TU Reset removes signal mark)
• Can be used to detect integrity of wiring
connections between devices
• TCCs will be noted w/ ZSI response time
• Common between MCCB and ACB

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 Enhanced GF Protection & Coordination
BEFORE: Ground fault protection Expanded GF Settings
limited up to 300ms flat response and
no ability to turn off (must swap
breaker/TU)
AFTER: Expanded protection of
ground fault increases coordination
capabilities and provides ability to turn
protection off

• ON/OFF feature simplifies system testing

• GF switch combines functionality of LSIG, LSIA, & OFF
• Expanded GF delays
o Flat and I2t profiles in all GF units
o Flat: 100ms to 1 sec / I2t: 0.67ms to 300 ms

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 Metering Accuracy
Metering Accuracy
Metering Parameters
Trip Units meet ANSI c12.1 Current metering Real-time voltage Summary menu PC software interface allows
delivering 1.0 Accuracy Class • Graph current as a metering highlights metered for more information in the
percent of Ir • A, B, C phases values display
energy readings* • View current across • Two types: • Average current (A) • I, V, P, Temp
A, B, C phases • Line-to-Neutral • Line-Line voltage (V) • Energy
• Neutral Current • Line-to-Line • 3 phase power (kW) • Power Demand
• Ground current • Net energy (kWh) • Peak Power Demand
• Frequency (Hz) • Max/Min Current
• V Min/Max Line to Line
• V Min/Max Line to Neutral
• One Cycle Current

* from 20% to 120% of the breaker ampacity

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Introducing Programmable Relays
BEFORE: Single, pre-programmed relay provided with ARMS, GFA, or High Load Alarm
AFTER: Multiple relays that can be programmed for breaker and trip unit visibility

Programmable Relay Features

• Breaker status (ON, OFF, TRIP)

Indications • Trip events: any trip, Long Delay, Short Delay, Instantaneous,
Short Circuit, Ground Fault, Neutral, or Maintenance Mode

• High load, overload, ground, ground pre-alarm

Alarms • High temperature, thermal memory
• Breaker health

Communications • Open/Close breaker pulsed, Output 1, Output

• ARMS indication
Safety
• ZSI signal received, ZSI signal sent, ZSI Active

Trip Unit Status • Low battery, internal faults, set point error, comms error

• Available on MPCB
Motor Protection • Phase loss, phase unbalance
• Under voltage, over voltage

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 Versatile Communications Options
BEFORE: Modbus RTU or proprietary communications were only
options for MCCB. Had to sacrifice space, technology or expense

AFTER: Multiple options in MCCB from 15A to 2500A and compatible

with ACB electronics; imbedded option in breaker with a possibility of
dual communications from a single device
• Modbus RTU: Imbedded in trip unit; standard offering
• CAM Communications: Breaker includes communications
capability; protocol determined by CAM module connected; 1 CAM
per Breaker ECAM PCAM
ECAM
• Modbus TCP and http …and ultimately… SNTP (time sync),
BACnet, ProfiNet, IEC 61850, SMTP (email protocol)

PCAM
• Profibus DP

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 PC Software Breaker Testing
BEFORE:
Functional Test – Simulated Injection
• PC Software sends message to the TU test driver code through USB
• Protection routines respond per the settings to trip the breaker

AFTER:

Functional Test – Secondary Injection

• Separate code in the trip unit creates a signal which is injected in
parallel with the output of the Ct’s mimicking the sensor’s output
• Protection routines respond per the settings to trip the breaker
• Unique offering to intelligent breakers and the ‘best’ test method
offered via a test kit

Current Sensor Test

• Separate code in the trip unit creates a signal which is directed
through the CT’s to verify continuity
• Unique offering to intelligent breakers and when coupled with
Secondary Injection offers complete testing of the functionality of an
eT/U

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Accessories
• UVRs/Shunt trips
• Aux/Alarm switches
• Rotary handles
• Plug in blocks and withdrawable cassettes

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 Accessories – Aux and Alarm Switches
Features and Options
• Same switch used for both Aux and Alarm positions
• Snap-in design for a secure fit
• Wire channels available for lead termination
• Available in NO, NC, and OC options
• Termination options include pigtail (3.0m or 0.75m),
screw terminal, and NEW push-in-clamp

Dedicated right pocket, snap-in accessories

• Removable secondary cover for easy install
• Shared styles between different Frames

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 Accessories – Shunt Trips and UVRs
Features and Options
• New design with reduced power consumption
• Styles available in all standard voltages
• Snap-in design for a secure fit
• Wire channels available for lead termination
• Termination options include pigtail (3.0m or 0.75m),
screw terminal, and NEW push-in-clamp

Dedicated left pocket, snap-in accessories

• Removable secondary cover for easy install
• Available on all the Frames

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 Accessories – Rotary Handle Mechanisms
Features and Options
• Standard design (Black & Grey)
• Emergency design (Red & Yellow)
• Standard handle locks
• Optional mechanism padlock
• Optional door interlock
• Optional cylinder key lock (IEC)

Close-coupled and Variable Depth Handles

• Easy installation with hardware NFPA79 compliant handle for
• Available on all intelligent breakers frames variable depth assemblies

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Product Configurator QR Code

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 Asset Management
Serialized QR codes will enable an enhanced ownership experience
for Market by providing a portal to product support resources,
improved transactional efficiency, product tracking, authenticity
verification, warranty claims processing, and more.

Scanning the QR code brings user content specific to that product

through Asset Management (AM) App on iOS and Android

Delivered AM Content
• Product authentication
• Access to technical content
• Warranty registration
• Animated or video instructions
Near Term AM Content
• Downloadable test reports

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Wrap-up
• Customer Value Props
• Better than Before

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 Intelligent Breakers Delivers!
Delivering Power Distribution Solutions that Deliver Business Outcomes

UPTIME /
SAFETY ENERGY SAVINGS SPEED
RELIABILITY

• Breaker Health • Breaker Health • 1% Energy and • Product Selector

• ARMS • Enhanced Comms Power Metering • ZSI Testing
• ZSI Indication • Ground Fault • Programmable • PXPM testing and
• Product Traceability Alarm Relays configuration
• Cause of trip • ZSI • Thru-cover
indication accessories
• PXPM analytics

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Intelligent Breakers Delivers!
Better than Before
• Easily installed accessories with commonality
• Replaceable trip unit
• Modular comms & relays
• Manufacturing test report availability
• Improved product traceability
• ZSI with On/Off, testable, indication
• Common MCCB & ACB ARMS design
• USB port / secondary injection testing

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 Emergence of solid state
overcurrent protective devices

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61
 Power Electronic Breakers
Emerging technology enabling significant benefits

• Ultra Fast switching – improving

Legacy safety and elimination of arc.
Mechanical breaker • Efficient direct current (DC)
moving parts switching
• Enable complete remote
management and control
• Integrated Revenue-grade metering
• Simplified load shedding (no motor
operator)

Control IGBTs Power

• Software defined device (MCP,
& gate supply
drive Breaker, Contactor, Starter, etc.)
Future • Functionality dictated by software for
Power Electronic Breaker future functionality expansion
no moving parts

MOVs Diode bridge Snubber

capacitor
Circuit Breaker technology comparison
Power electronic breaker vs Traditional breaker
Mechanical Power Electronic
Breaker Breaker

Breaker Costs + - Up to 10-20X today

Speed of Interruption - +
Power Efficiency / Losses + -
Remote Management - +
Remote Actuation (open / close) - +
Direct Current Interruption - +
Software Defined Solution - +
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Thank You

Questions?

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