CIRCUIT BREAKERS

A circuit breaker is a device that is used to completely disconnect a circuit when any abnormal condition exists. The circuit breaker can be designed to actuate under any undesirable condition

INTRODUCTION
The purpose of a circuit breaker is to break the circuit and stop the current flow when the current exceeds a predetermined value without causing damage to the circuit or the circuit breaker. Circuit breakers are commonly used in place of fuses and sometimes eliminate the need for a switch. A circuit breaker differs from a fuse in that it "trips" to break the circuit and may be reset, while a fuse melts and must be replaced. Air circuit breakers (ACBs) are breakers where the interruption of the breaker contacts takes place in an air environment. Oil circuit breakers (OCBs) use oil to quench the arc when the breaker contacts open

A low-voltage circuit breaker is one which is suited for circuits rated at 600 volts or lower. One of the most commonly used low-voltage air circuit breakers is the molded case circuit breaker (Figure 1).

Figure 1 Molded Case Circuit Breaker

A cutaway view of the molded case circuit breaker is shown in Figure 2

Figure 2 Cutaway View of Molded Case Circuit Breaker

A circuit can be connected or disconnected using a circuit breaker by manually moving the operating handle to the ON or OFF position. All breakers, with the exception of very small ones, have a linkage between the operating handle and contacts that allows a quick make (quick break contact action) regardless of how fast the operating handle is moved. The handle is also designed so that it cannot be held shut on a short circuit or overload condition. If the circuit breaker opens under one of these conditions, the handle will go to the trip-free position. The trip-free position is midway between the ON and OFF positions and cannot be re-shut until the handle is pushed to the OFF position and reset.
A circuit breaker will automatically trip when the current through it exceeds a pre-determined value. In lower current ratings, automatic tripping of the circuit breaker is accomplished by use of thermal tripping devices. Thermal trip elements consist of a bimetallic element that can be calibrated so that the heat from normal current through it does not cause it to deflect. An abnormally high current, which could be caused by a short circuit or overload condition, will cause the element to deflect and trip the linkage that holds the circuit breaker shut. The circuit breaker will then be opened by spring action. This bimetallic element, which is responsive to the heat produced by current flowing through it, has an inverse-time characteristic. If an extremely high current is developed, the circuit breaker will be tripped very rapidly.
For moderate overload currents, it will operate more slowly. Molded case breakers with much larger current ratings also have a magnetic trip element to supplement the thermal trip element. The magnetic unit utilizes the magnetic force that surrounds the conductor to operate the circuit breaker tripping linkage.
When the separable contacts of an air circuit breaker are opened, an arc develops between the two contacts. Different manufacturers use many designs and arrangements of contacts and their surrounding chambers. The most common design places the moving contacts inside of an arc chute. The construction of this arc chute allows the arc formed as the contacts open to draw out into the arc chute. When the arc is drawn into the arc chute, it is divided into small segments and quenched. This action extinguishes the arc rapidly, which minimizes the chance of a fire and also minimizes damage to the breaker contacts.
Molded case circuit breakers come in a wide range of sizes and current ratings. There are six frame sizes available: 100, 225, 400, 600, 800, and 2,000 amps. The size, contact rating, and current interrupting ratings are the same for all circuit breakers of a given frame size. The continuous current rating of a breaker is governed by the trip element rating. The range of voltage available is from 120 to 600 volts, and interrupting capacity ranges as high as 100,000 amps.
Much larger air circuit breakers are used in large commercial and industrial distribution systems. These circuit breakers are available in much higher continuous current and interrupting ratings than the molded case circuit breaker. Breakers of this type have current ratings as high as 4,000 amps, and interrupting ratings as high as 150,000 amps.
Most large air circuit breakers use a closing device, known as a "stored energy mechanism," for fast, positive closing action. Energy is stored by compressing large powerful coil springs that are attached to the contact assembly of a circuit breaker. Once these springs are compressed, the latch may be operated to release the springs, and spring pressure will shut the circuit breaker. Circuit breaker closing springs may be compressed manually or by means of a small electric motor. This type of circuit breaker can be classified as either a manually- or electrically-operated circuit breaker.
When a large air circuit breaker is closed, the operating mechanism is latched. As the circuit breaker is closed, a set of tripping springs, or coils, are compressed, and the circuit breaker may then be tripped by means of a trip latch. The trip latch mechanism may be operated either manually or remotely by means of a solenoid trip coil.
As previously stated, circuit breakers may be operated either manually or electrically. Electrically-operated circuit breakers are used when circuit breakers are to be operated at frequent intervals or when remote operation is required. When the electrically-operated stored energy circuit breaker is tripped, the spring is recharged by the spring charging motor so that the breaker is ready for the next closing operation. The manually-operated circuit breaker closing springs are normally compressed by a hand crank just prior to operation of the breaker. Figure 3 shows a large air circuit breaker which is classified as a manually-operated stored energy circuit breaker. The closing springs are compressed by pulling downward on the large operating handle on the front of the breaker. Closing this circuit breaker is accomplished manually by depressing the small closing lever. Tripping this circuit breaker is done by means of the tripping lever, located at the bottom front of the breaker

Figure 3 Large Air Circuit Breaker

High-Voltage Circuit Breakers
High-voltage circuit breakers (including breakers rated at intermediate voltage) are used for service on circuits with voltage ratings higher than 600 volts. Standard voltage ratings for these circuit breakers are from 4,160 to 765,000 volts and three-phase interrupting ratings of 50,000 to 50,000,000 kVA.
In the early stages of electrical system development, the major portion of high-voltage circuit breakers were oil circuit breakers. However, magnetic and compressed-air type air circuit breakers have been developed and are in use today.
The magnetic air circuit breaker is rated up to 750,000 kVA at 13,800 volts. This type of circuit breaker interrupts in air between two separable contacts with the aid of magnetic blowout coils. As the current-carrying contacts separate during a fault condition, the arc is drawn out horizontally and transferred to a set of arcing contacts. Simultaneously, the blowout coil provides a magnetic field to draw the arc upward into the arc chutes. The arc, aided by the blowout coil magnetic field and thermal effects, accelerates upward into the arc chute, where it is elongated and divided into many small segments.
The construction of this type of circuit breaker is similar to that of a large air circuit breaker used for low-voltage applications, except that they are all electrically operated.
Compressed-air circuit breakers, or air-blast circuit breakers, depend on a stream of compressed air directed toward the separable contacts of the breaker to interrupt the arc formed when the breaker is opened. Air-blast circuit breakers have recently been developed for use in extra high-voltage applications with standard ratings up to 765,000 volts.
Oil circuit breakers (OCBs) are circuit breakers that have their contacts immersed in oil. Current interruption takes place in oil which cools the arc developed and thereby quenches the arc. The poles of small oil circuit breakers can be placed in one oil tank; however, the large high-voltage circuit breakers have each pole in a separate oil tank. The oil tanks in oil circuit breakers are normally sealed. The electrical connections between the contacts and external circuits are made through porcelain bushings.

Circuit Breaker Control
As we have discussed, circuit breakers may be remotely operated. In order to operate the breakers from a remote location, there must be an electrical control circuit incorporated. Figure 4 shows a simple control circuit for a remotely-operated breaker.
Control power is supplied by an AC source and then rectified to DC. The major components of a simple control circuit are: the rectifier unit, the closing relay, the closing coil, the tripping coil, the auxiliary contacts, and the circuit breaker control switch.

Figure 4 Simple Circuit Breaker Control Circuit - Breaker Open

To close the remotely-operated circuit breaker, turn the circuit breaker control switch to the close position. This provides a complete path through the closing relay (CR) and energizes the closing relay. The closing relay shuts an auxiliary contact, which energizes the closing coil (CC), which, in turn, shuts the circuit breaker, as shown in Figure 5. The breaker latches in the closed position. Once the breaker is shut, the "b" contact associated with the closing relay opens, de-energizing the closing relay and, thereby, the closing coil. When the breaker closes, the "a" contact also closes, which enables the trip circuit for manual or automatic trips of the breaker. The circuit breaker control switch may now be released and will automatically return to the neutral position.
To open the circuit breaker, turn the circuit breaker control switch to the trip position. This action energizes the trip coil (TC), which acts directly on the circuit breaker to release the latching mechanism that holds the circuit breaker closed.
When the latching mechanism is released, the circuit breaker will open, opening the "a" contact for the tripping coil and de-energizing the tripping coil. Also, when the circuit breaker opens, the "b" contact will close, thereby setting up the circuit breaker to be remotely closed using the closing relay, when desired. The circuit breaker control switch may now be released

Figure 5 Simple Circuit Breaker Control Circuit - Breaker Closed

As you can see from Figure 4 or 5, the circuit breaker control circuit can be designed so that any one of a number of protective features may be incorporated. The three most commonly-used automatic trip features for a circuit breaker are overcurrent (as discussed previously), underfrequency, and undervoltage. If any one of the conditions exists while the circuit breaker is closed, it will close its associated contact and energize the tripping coil, which, in turn, will trip the circuit breaker


SUMMARY
The important information covered in this chapter is summarized below
Circuit Breaker Summary
·    The purpose of a circuit breaker is to provide a means for connecting and disconnecting circuits of relatively high capacities without causing damage to hem.
·    The three most commonly-used automatic trip features for a circuit breaker are overcurrent, underfrequency, and undervoltage.