Overcurrent Protection

An overcurrent is a condition that exists in an electrical circuit when the normal load current is
exceeded. An overcurrent condition can be caused by a short circuit or overload situation.

Short Circuits
With a short circuit situation, the current takes a shortcut around the normal path of current flow.
Although a partial short can increase the current level, it may or may not cause damage depending
on the ratings of the circuit components. However, with a dead short, the resistance of the load
will be completely removed from the normal current path.
If the source has enough stored energy when a dead short occurs, circuit components can be
damaged or explode. Switches can melt or vaporize, conductors can overheat, and the insulation
can burn off. It can also damage the power source.
Fires that result in a loss of property and life can occur due to the temperatures generated by a
partial or dead short. With so much at stake, all circuits must be protected against short circuit
situations.

Overloads
An overcurrent condition can also be caused by an overload situation. For example, consider a
situation where too many loads are connected to a given power source. Even with each of these
individual loads drawing their normal current, the overall current can exceed the rated value of the
source.
If an overload only lasts for a brief time, the temperature rise is minimal and has little or no effect
on the equipment or conductors. Sustained overloads, however, are destructive and must be
prevented.
Unlike short circuits, overloads do not cause a sudden arc and the system might survive an overload
situation even if we do not remove it from the system immediately. Though, over an extended
period of time, overloads may cause a fire by overheating the equipment and conductors.

An overcurrent protection device (OCPD) is a piece of electrical equipment used to protect

service, feeder, and branch circuits and equipment from excess current by interrupting the flow of
current.

Overcurrent protection simply means a fuse, breaker, or fusible link is used to protect the
equipment, a circuit in the equipment, or the equipment’s wiring. These terms are often used
interchangeably because they have some similarities. Breakers or fuses are normally used to
protect the whole unit from excessive current, but they can be sized to protect one component in
the unit. This provides overcurrent protection for the unit and offers optional protection for
components like the transformer or circuit board.
A fuse is a short piece of wire or thin strip which melts when excessive current flows through it
for sufficient time. It is inserted in series with the circuit to be protected. Under normal operating
conditions, the fuse element it at a temperature below its melting point. Therefore, it carries the
normal load current without overheating. However, when a short circuit or overload occurs, the
current through the fuse element increases beyond its rated capacity. This raises the temperature
and the fuse element melts (or blows out), disconnecting the circuit protected by it. In this way, a
fuse protects the machines and equipment from damage due to excessive currents. It is worthwhile
to note that a fuse performs both detection and interruption functions.
A circuit breaker is an equipment which can open or close a circuit under all conditions viz. no
load, full load and fault conditions. It is so designed that it can be operated manually (or by remote
control) under normal conditions and automatically under fault conditions.
For the latter operation, a relay circuit is used with a circuit breaker.
The circuit breaker essentially consists of moving and fixed contacts enclosed in strong metal tank
and immersed in oil, known as transformer oil.
Under normal operating conditions, the contacts remain closed and the circuit breaker carries the
full-load current continuously. In this condition, the e.m.f. in the secondary winding of current
transformer (C.T.) is insufficient to operate the trip coil of the breaker but the contacts can be
opened (and hence the circuit can be opened) by manual or remote control. When a fault occurs,
the resulting overcurrent in the C.T. primary winding increases the secondary e.m.f. This energises
the trip coil of the breaker and moving contacts are pulled down, thus opening the contacts and
hence the circuit.

Introduction to Miniature Circuit Breakers (MCBs)

All fuses should be replaced with MCBs (Miniature Circuit Breakers) for enhanced safety and
control once they have fulfilled their purpose. Unlike a fuse, an MCB operates as an automatic
switch that opens in the event of excessive current flowing through the circuit. Once the circuit
returns to normal, it can be reclosed without the need for manual replacement.
MCBs are primarily used as alternatives to fuse switches in most circuits. Nowadays, a wide
variety of MCBs with breaking capacities ranging from 10KA to 16KA are used in domestic,
commercial, and industrial applications, serving as reliable means of protection.
Miniature circuit breakers (MCBs) are compact in size and are designed to fit into standardized
electrical panels and distribution boards. They work by detecting abnormal levels of current
flowing through the circuit and automatically interrupting the flow of electricity to prevent damage
to the circuit and connected devices. MCBs can be reset after they trip, unlike fuses which must
be replaced. They are an important component of electrical safety systems in residential,
commercial, and industrial buildings.

What is a Miniature Circuit Breaker (MCB)?

An MCB, or Miniature Circuit Breaker, is an electromechanical device enclosed in molded
insulating material. Its main function is to automatically open the connected circuit when the
flowing current exceeds its set value. It can also be manually operated to switch the connected
circuit ON and OFF, similar to a standard switch, if necessary.
A miniature circuit breaker (MCB) operates using electromagnetism to automatically break the
circuit in case of short circuit or overload faults. It can also be manually operated by a person to
switch the connected circuit on or off.
Following is the generic symbol used for circuit breakers.
CBs are time-delay tripping devices in which the magnitude of overcurrent controls the operating
time. This implies that they operate when overloads persist long enough to pose a danger to the
protected circuit.
As a result, MCBs do not respond to transient loads, such as switch surges and motor starting
currents. Generally, they are designed to operate in less than 2.5 milliseconds during short-
circuit faults and in the range of 2 seconds to 2 minutes in the case of overloads, depending on the
current level.
The typical external appearance of an MCB is shown in the figure. MCBs are manufactured in
various pole versions, including single, double, triple, and four-pole structures, each with different
fault current levels.
Most commonly, MCBs are interconnected to create two and three-pole versions, ensuring that a
fault in one line breaks the complete circuit, providing complete circuit isolation. This feature is
particularly helpful in the case of single phasing in three-phase motor protection.
These devices are rated at 220V for DC supply and 240/415V for AC supply (single and three-
phase) with different short circuit current capacities. Typically, single-phase devices have a load
current range of up to 100A. Some MCBs have the facility to adjust their tripping current capacity,
while others are fixed for specific load currents and short circuit ratings.
MCBs serve multiple functions, such as local control switches, isolating switches against faults,
and overload protection devices for installations or specific equipment and appliances.
Construction of MCB
An MCB is encased in molded insulating material, providing a mechanically strong and insulated
housing.
The switching system consists of a fixed and a moving contact to which incoming and outgoing
wires are connected. The metal or current-carrying parts are made of electrolytic copper or silver
alloy, depending on the rating of the circuit breaker.

The above fig shows the following parts and components inside an MCB (cross-sectional view)
1. Operator (ON-OFF)
2. Operating Mechanism
3. Space for Identification mark
4. Thermal Terminal (Incoming Supply)
5. Thermal Bimetallic Protection
6. Arc Chamber
7. Electromagnetic Protection (Solenoid or Magnetic Coil)
8. Fixed Contacts
9. Moving Contacts
10. Lower Terminal (Outgoing Load)
11. DIN Rail Holder

As the contacts separate during an overload or short circuit situation, an electric arc is formed. All
modern MCBs are designed to handle arc interruption processes, where arc energy extraction and
cooling are provided by metallic arc splitter plates.
These plates are held in position by an insulating material. Additionally, an arc runner is provided
to guide the arc produced between the main contacts.
The operating mechanism incorporates both magnetic tripping and thermal tripping arrangements.
The magnetic tripping arrangement essentially comprises a composite magnetic system with a
spring-loaded dashpot containing a magnetic slug in a silicon fluid, along with a normal magnetic
trip. A current-carrying coil in the trip arrangement moves the slug against the spring towards a
fixed pole piece. The magnetic pull is developed on the trip lever when a sufficient magnetic field
is produced by the coil.
In the case of short circuits or heavy overloads, the strong magnetic field produced by the coils
(solenoid) is sufficient to attract the armature of the trip lever, irrespective of the position of the
slug in the dashpot.
The thermal tripping arrangement consists of a bimetallic strip around which a heater coil is wound
to generate heat depending on the flow of current.
The heater design can be either direct, where current passes through a bimetal strip affecting part
of the electric circuit, or indirect, where a coil of a current-carrying conductor is wound around the
bimetallic strip. The deflection of the bimetallic strip activates the tripping mechanism in the case
of certain overload conditions.
The bimetal strips are made up of two different metals, usually brass and steel. These metals are
riveted and welded along their length. They are designed in such a way that they will not heat the
strip to the tripping point for normal currents. However, if the current exceeds the rated value, the
strip is warmed, bent, and trips the latch. Bimetallic strips are chosen to provide specific time
delays under certain overloads.
Working and Operation of MCBs
Under normal working conditions, an MCB operates as a manual switch to turn the circuit ON or
OFF. In the event of an overload or short circuit, it automatically trips to interrupt the current flow
in the load circuit.
The visual indication of this trip can be observed by the automatic movement of the operating knob
to the OFF position. This automatic operation in an MCB can be achieved in two ways, as we have
seen in MCB construction: magnetic tripping and thermal tripping.
Under overload conditions, the current passing through the bimetal causes its temperature to rise.
The heat generated within the bimetal itself is sufficient to cause deflection due to the thermal
expansion of metals. This deflection further releases the trip latch, leading to the separation of
contacts.
In some MCBs, the magnetic field generated by the coil causes it to exert pull on the bimetals,
resulting in deflection that activates the tripping mechanism.

Under short circuit or heavy overload conditions, the magnetic tripping arrangement comes into
play. During normal working conditions, the slug is held in position by a light spring because the
magnetic field generated by the coil is not sufficient to attract the latch.
When a fault current flows, the magnetic field generated by the coil becomes strong enough to
overcome the spring force holding the slug in position. Consequently, the slug moves and actuates
the tripping mechanism.
Most miniature circuit breakers implement a combination of both magnetic and thermal tripping
mechanisms. In both magnetic and thermal tripping operations, an arc is formed when the contacts
start separating. This arc is then directed into arc splitter plates via an arc runner.
These arc splitter plates, also called arc chutes, transform the arc into a series of arcs while
simultaneously extracting and cooling its energy. This arrangement ensures effective arc
extinction.
Types of Miniature Circuit Breakers (MCBs)

There are many types of circuit breakers while MCBs are classified into the following major
types according to their instantaneous tripping currents. They are as follows:
Type A MCB
Type A MCBs, characterized by their tripping curve, are designed to provide protection against
low-level overcurrents, making them suitable for circuits with a high capacitive load, such as those
powering fluorescent lighting.
With a tripping current range of 2-3 times their rated current, Type A MCBs respond to overcurrent
conditions at a relatively low threshold. This sensitivity is particularly advantageous in
applications where electronic devices and sensitive equipment are prevalent
Type B MCB
Type “B” MCB will trip instantly at a rate of three to five times its rated current. These are
normally used for resistive or small inductive loads where switching surges are very small.
Therefore, these are suitable for residential or light commercial installations.

Type C MCB
Type “C” MCB will trip instantly at a rate of five to ten times its rated current. These are normally
used for high inductive loads where switching surges are high such as small electric motors and
fluorescent lighting.

In such cases, type C MCBs are preferred to handle higher values of short circuit currents.
Therefore, these are suitable for highly inductive commercial and industrial installations.
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Type D MCB
Type “D” miniature circuit breaker will trip instantly at a rate of ten to twenty five times its rated
current. These are normally used for very high inductive loads where high inrush current is very
frequent.
These are suitable for specific industrial and commercial applications. The common examples of
such applications include x-ray machines, UPS systems, industrial welding equipment, large
winding motors, etc.

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Type G MCB
Type “G” MCBs are capable of providing protection against both overcurrent and earth fault
current, similar to AFCIs and RCDs. They are typically required in specific areas of residential
and commercial buildings to enhance electrical safety.
According to the NEC, they are required to be installed in bedrooms, living rooms, hallways, and
circuits serving outlets and devices in certain other areas to detect and mitigate the risk of electrical
fires caused by arcs in wiring.
Type H MCB
Type “H” MCBs are similar to Type G MCBs, designed to provide protection against both arc
faults and overcurrents, especially in electrical systems powered by direct current (DC) supply.
Type K MCB
Type “K” MCBs are utilized to offer protection against overcurrents and short circuits in
applications where the likelihood of faults is high, such as instances with high inrush currents in
motors and inductive applications.
Type Z MCB
Type “Z” MCBs are designed for electronic circuits and sensitive equipment. They provide
protection against low-level overcurrents and are suitable for circuits with semiconductor devices.
The above types of MCBs (based on tripping currents and curves) provide protection within one
tenth of a sec. The minimum and maximum trip currents of these MCBs are given in a tabular form
below, where “Ir” is the rated current of the MCB.
MCBs can also be classified based on the number of poles such as single pole, double pole, triple
pole and four pole MCBs.

How to Select a Proper MCB for Different Loads?

Selecting the appropriate MCB for a specific application is a meticulous task essential for ensuring
reliable protection against overloads and short circuits. Failure to choose an MCB in accordance
with the circuit requirements may result in frequent and unwanted tripping.
Before delving into the details, it’s crucial to understand the differences between MCBs, MCCBs,
ELCBs, RCBs, RCDs, or RCCBs circuit breakers, and to learn how to read the data printed on the
MCB nameplate.
If the MCB is undersized (with a rating lower than the nominal load current), it can lead to frequent
tripping, interrupting the current to the connected load, as the MCB’s nominal current is less than
the load’s nominal current.
Conversely, if the MCB is oversized (with a rating higher than the nominal load current), the
connected load may not be efficiently protected. In such cases, the MCB might not trip even when
the load draws excessive current.
Three critical factors must be considered when selecting the proper MCB for a specific application.

1. Nominal Rating of the Circuit Breaker

This is the rated ampere current rating of MCB. This value must be lower than the current carrying
capacity of wiring system and higher than or equal to the maximum full load current in the wiring
system. Generally, this rating should be such that it can handle 125 percent of continuous load plus
rating of non-continuous load. Typically this can be expressed as
Maximum full load current in the system ≤ Current rating of MCB ≤ Cable rating
 2. kA rating or breaking capacity
This rating refers to the capability of MCB that can trip or interrupt the circuit under short circuit
conditions. Its rating is expressed in Kilo Amps (KA). This rating must not be less than the
prospective short-circuit current.
The prospective short-circuit current is the maximum current that exists in the circuit during short-
circuit conditions. In residential installations 6KA MCB is sufficient while 10 KA or above rating
MCB is needed for commercial and light industrial applications.
3. Type of MCB
The type of MCB needed for a specific application is decided by operating characteristics such
that various current ratings are required to operate the loads instantaneously. We have already
mentioned various types of MCBs for different applications above.
Applications of an MCB (Miniature Circuit Breaker)
As the main functions and applications have already been described in the above statements, the
fundamental purpose of an MCB is to protect a circuit (wiring used in residential, commercial, and
industrial electrical panels, connected load, equipment, etc.) in the case of:
1. Overload and Overcurrent Protection: MCBs are primarily used to protect electrical circuits
from overloads. When the current exceeds the rated capacity of the MCB, it trips and interrupts
the flow of electricity, preventing damage to the circuit and appliances.
2. Short Circuit Protection: MCBs also protect against short circuits, which occur when
there is a low-resistance connection between two conductors. The MCB detects the sudden
surge in current and trips to prevent overheating and fire hazards.
3. Ground Fault Protection: Some MCBs are equipped with ground fault protection, which
detects leakage currents to the ground. This is important for safety, as it can prevent electric
shocks and protect against insulation failure.
4. Selective Coordination: MCBs are often used in coordination with other protective
devices, such as fuses or larger circuit breakers, to ensure that the device closest to the fault
opens first, minimizing downtime and damage.
5. Remote Control: Some advanced MCBs (e.g. smart Wi-Fi circuity breaker) come with
remote control capabilities, allowing for easier monitoring and control of electrical circuits
in industrial or commercial settings.