SCHNEIDER ELECTRIC

Electrical Installation Guide 2018

CHAPTER H
LV Switchgear: Functions & Selection
COMPREHENSIVE STUDY GUIDE

IEC 60947 Series | IEC 60898 | IEC 60364-4-43

Prepared for study & technical reference

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 SECTION 1 — LV SWITCHGEAR: OVERVIEW &
FUNCTIONS

1.1 What is Switchgear?

Definition
Switchgear = collective term for ALL devices used to protect, isolate, and control
electrical installations and circuits in compliance with IEC 60364 series.

Three MAIN functions of switchgear:

1. ELECTRICAL PROTECTION — against overcurrents, insulation faults, etc.
2. ISOLATION — safe separation of a circuit from the live system
3. CONTROL (switching) — functional, emergency, and maintenance switching

1.2 Three Core Functions — Deep Dive

Function 1 — Electrical Protection

Prevents dangerous or destructive consequences of abnormal currents. Two categories:

Protection target Against what Device used

Persons & animals Electric shock from insulation fault CB with ADS, RCD

Equipment (cables, Overload — excessive current in Overcurrent relay, thermal trip

motors) healthy circuit

Equipment (cables, Short-circuit — complete insulation OCPD: CB or fuse

switchgear) failure (phase-phase, phase-PE)

Motors specifically Long start, stalled rotor, single- Motor protection relay, thermal
phasing, overheating overload relay

Function 2 — Isolation
Isolation = disconnecting a circuit from the rest of the ENERGIZED system so personnel can work
safely. Key requirements:

• ALL live conductors must open (all-pole isolation)

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 • Device must be lockable in open position (padlock) to prevent accidental re-closure
• Must comply with a recognized national or international standard
• Open state must be clearly indicated — either VISUAL (visible open contacts) or MECHANICAL
(indicator solidly welded to shaft)

Isolation requirement Limit / specification

Leakage current — new device ≤ 0.5 mA per phase (contacts open)

Leakage current — end of useful life ≤ 6.0 mA per phase (contacts open)

Impulse withstand voltage — 230/400V (Cat III) 4 kV peak

Impulse withstand voltage — 230/400V (Cat IV) 6 kV peak

Mechanical indicator Must be IMPOSSIBLE to show open if contacts

are welded closed

⚠ Isolation requires ALL live conductors to open — including neutral in certain cases.
Caution: in TN-C, the PEN conductor must NEVER be isolated (it carries protective earth
function).

Function 3 — Switchgear Control

Control type Purpose Where required

Functional Normal energizing/de-energizing of At origin of any installation; at each

switching circuits or equipment in service outgoing circuit; at each distribution
level

Emergency De-energize a live circuit that is, or Must be clearly marked,

switching could become, dangerous RED/YELLOW color, readily
accessible near the hazard

Emergency stop Halt a dangerous movement Must remain activated until deliberately
(machine) reset (key required in unmanned
areas)

Switching for Stop machine so maintenance can At supply to each machine — use
mechanical proceed safely; prevent inadvertent functional switch + safety lock +
maintenance restart warning notice

⚠ Emergency switching/stop devices must be RED on YELLOW background, clearly

identifiable, and NOT lockable in the open position (must remain accessible for re-
energizing by authorized person).

1.3 Additional Functions of Switchgear

• Over-voltage protection — surge arresters (SPDs)
• Under-voltage protection — undervoltage releases associated with contactors or remotely
controlled CBs

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 SECTION 2 — ELEMENTARY SWITCHING DEVICES

2.1 Complete Device Comparison

Device Standard Can break Can break Protection? Isolation? Auto trip?
load? S/C?

Disconnector IEC 60947-3 NO (dead NO (withstand NO YES (if NO

(isolator) system only) only) lockable)

Load-break switch IEC 60947-3 YES (normal Making only NO If marked NO

load) (fault-make)

Contactor IEC 60947-4 YES (high NO (upstream NO (overload via NO NO

frequency) fuse/CB relay) (manual
needed) coil)

Discontactor IEC 60947-4 YES NO Overload only NO YES

(contactor + thermal (overload)
relay)

Fuse IEC 60269 NO YES (within Overload + S/C NO YES (one-

rating) shot)

Circuit breaker (CB) IEC 60947-2 / YES YES (Icu/Icn Overload + S/C YES (if YES
60898 rated) marked) (resettable)

CB + RCD (RCBO) IEC 60947-2 / YES YES Overload + S/C YES YES
61009 + Earth fault

Impulse (bistable) IEC 60669 Lighting NO NO NO NO

relay circuits only

2.2 Individual Devices — Detailed Study

Disconnector / Isolator

Key facts about disconnectors

Purpose: ISOLATION ONLY — must be operated with NO VOLTAGE on either side (dead
system device)
Cannot make or break current under load — no ratings for these operations
CAN withstand short-circuit currents — rated short-time withstand (typically 1 second)
Can withstand operational overcurrents (e.g. motor starting) — standardized mechanical
endurance
Upstream switch/CB interlocking is frequently used to ensure dead-system operation

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 Q: Can a disconnector be used to de-energize a motor under normal running conditions?
A: NO. A disconnector has no rated current-breaking capability. It must only be operated with
no voltage on either side (or at least no current flowing). To safely isolate a running motor, first
de-energize using the contactor or circuit breaker, then open the disconnector.

Load-Break Switch

Key facts about load-break switches

Non-automatic two-position device (ON/OFF) — can be manual or electrically operated
Designed to make and break loaded circuits under NORMAL conditions
Provides NO protection — does not trip on overload or short-circuit
Has a FAULT-MAKE rating: can close successfully against a short-circuit (electrodynamic
forces OK)
Upstream OCPDs are relied upon to CLEAR faults — the switch only closes into them

Utilization categories (making/breaking capabilities):

AC-20: No-load switching only
AC-21: Resistive loads — making & breaking: 1.5 × In
AC-22: Mixed resistive + inductive loads — making: 3 × In, cos φ = 0.65
AC-23: Motor loads (highly inductive) — making: 10 × In, cos φ = 0.35 (>100A) or 0.45
(≤100A)

Contactor

Key facts about contactors

Solenoid-operated — held closed by energized coil (spring-return on de-energization)
Designed for FREQUENT operation: very high number of close/open cycles
Remote control: coil energized by control circuit (push-button, PLC, BMS, etc.)
Has rated making AND breaking performance according to utilization category
Does NOT provide short-circuit protection — must be used with upstream fuse or CB

Example: 150A AC3 contactor must have minimum breaking capacity of:
AC3 category: 8 × In = 8 × 150 = 1200 A breaking current

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 AC3 = cage motor starting/stopping (most common motor contactor category)
AC1 = non-inductive/slightly inductive loads
AC4 = plugging, inching of cage motors (most onerous duty)

Q: What is the difference between a contactor and a discontactor?

A: A contactor alone provides no overload protection. A discontactor is a contactor with an
integrated thermal-type overload relay, providing protection against sustained overload.
However, a discontactor STILL does not protect against short-circuits — an upstream fuse or
CB is always required for short-circuit protection.

Fuses — Detailed Study

Fuse type Code Application Overload S/C

protection? protection?

General purpose (full gG General LV circuits, YES — full YES — up to

range) cables range from Inf rated Icu
to max

Motor circuit (full gM Motor circuit cables (not YES for cables YES — dual
range) motor overload) only rated In/Ich

Motor circuit (partial) aM Motor circuits with NO — partial YES

separate overload relay range only (≥
4×In)

Industrial low voltage gI Industrial (not domestic) YES YES — NOT for
type gI domestic/similar

Fuse Zones — gG Class (Critical Values to Memorize)

Rated current In Non-fusing current Fusing current I2 Conventional time

Inf

In ≤ 4 A 1.5 × In (will NOT blow 2.1 × In (WILL blow 1 hour

at this) within time)

4 < In ≤ 16 A 1.5 × In 2.1 × In 1 hour

16 < In ≤ 63 A 1.25 × In (changed) 1.6 × In 1 hour

63 < In ≤ 160 A 1.25 × In 1.6 × In 2 hours

160 < In ≤ 400 A 1.25 × In 1.6 × In 3 hours

In > 400 A 1.25 × In 1.6 × In 4 hours

⚠ For In ≤ 16A, gG fuses have 1.5× Inf and must blow at 2.1× In within 1 hour — this is

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relatively lenient. A CB by comparison must NOT trip at 1.05×In for 1 hour. Fuses require
larger cables to avoid long-term thermal damage.

✔ aM fuses have NO conventional non-fusing current — they are for partial range only (≥
4×In). For overloads below 4×In, a separate thermal relay is mandatory with aM fuses.

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 SECTION 3 — COMBINED SWITCHGEAR ELEMENTS

3.1 Common Switchgear Combinations

Combination Functions provided Typical use

Switch + fuse (switch-fuse) Load switching + S/C protection Domestic, ≤100A at 400V 3-
phase; simple distribution

Fuse-switch (fuse forms the Load switching + S/C protection Domestic, ≤100A
switch blade) (same as above, different
construction)

Fuse-disconnector + S/C protection (fuse) + isolation Motor control — requires

discontactor (disconnector) + load switching + interlock so fuse-disconnector
overload protection (discontactor) can't open under load

Fuse-switch-disconnector + S/C protection + switching + Motor control — switch-

discontactor isolation + overload disconnector CAN open under
load unlike disconnector

CB + contactor Full protection (CB) + frequent Remote control distribution,

remote switching (contactor) high switching rate

CB + discontactor Full protection (CB) + frequent Motor circuits with remote

switching + overload protection control
(discontactor relay)

⚠ The fuse-disconnector has NO load-switching capability. It must be interlocked with

the contactor/discontactor so that the fuse-disconnector cannot be opened while current
is flowing. The fuse-SWITCH-disconnector CAN open under load.

3.2 The Circuit Breaker / Disconnector — The Universal Device

Why the CB/disconnector is the most important switchgear item

A circuit breaker with disconnector capability is the ONLY single device that simultaneously
provides:
✔ Isolation (if marked with disconnector symbol ☐|)
✔ Functional switching (ON/OFF control)
✔ Emergency switching
✔ Switching for mechanical maintenance
✔ Overload protection
✔ Short-circuit protection

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 ✔ Earth fault protection (if RCD module added)
✔ Remote control, indication, and measurement (with auxiliary modules)

No other single device covers all these functions.

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 SECTION 4 — CIRCUIT BREAKER: CHARACTERISTICS &
SELECTION

4.1 CB Construction — Four Essential Parts

Part Function

Arc-dividing chamber (arc Quenches and extinguishes the arc drawn when contacts separate;
chute) divides arc into segments to cool it rapidly

Latching mechanism Holds contacts closed during normal operation; releases ('unlatches')
when trip device activates; linked to operating handle

Trip mechanism (tripping Detects abnormal conditions and releases the latch; can be thermal-
device) magnetic or electronic

Terminal space Accommodates the main power circuit conductors; various types
available (fixed, withdrawable, busbar adapters)

4.2 Trip Unit Types

Trip unit type Overload Short-circuit Advantages Disadvanta

detection detection ges

Thermal- Bi-metal strip Electromagn Simple, low cost, no auxiliary Trip level
magnetic — thermal — etic striker power needed changes with
(uncompensat TEMPERATU pin — ambient
ed) RE instantaneou temperature
DEPENDENT s — must
derate at
high
temperature
s

Thermal- Bi-metal strip Electromagn Stable trip level regardless of Slightly more
magnetic + etic striker ambient temperature (within complex
(compensated compensating pin range)
) strip

Electronic Current Current Temperature-stable, precise, Requires

transformers transformer adjustable, auxiliary
on each signal — measurement/communication/diag power; more
phase — adjustable nostics complex;
digital higher cost
processing

4.3 Fundamental CB Ratings — Master Table

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TERM / SYMBOL DEFINITION & KEY VALUES

Ue — Rated voltage Voltage at which CB is designed to operate (e.g. 230V, 400V,

690V). Must match system voltage.
Ui — Rated insulation Maximum voltage CB insulation can withstand. Rule: Ue ≤ Ui
voltage always.
Uimp — Rated impulse Peak impulse voltage CB can withstand without failure. For
withstand overvoltage coordination with SPDs.
In — Rated current Maximum current carrying capacity at reference temperature
(usually 40°C). CB will not trip continuously at this level.
Irth / Ir — Overload trip Adjustable trip current for overload relay. Must satisfy: IB < Irth ≤ In
setting AND Irth ≤ 1.45 × Iz. Typically 0.4 to 1.0 × In.
Im — Magnetic trip Short-circuit instantaneous or short-time delay trip threshold. Type
setting B: 3–5×In. Type C: 5–10×In. Type D: 10–20×In.
Icu — Ultimate Maximum rms AC short-circuit current CB can interrupt WITHOUT
breaking capacity damage (one-shot). After this test: CB may not be reusable. In kA
rms.
Ics — Service breaking Short-circuit current CB can interrupt AND remain fully functional for
capacity normal service. Usually expressed as % of Icu. Test: O-CO-CO
sequence.
Icm — Making capacity Peak instantaneous current CB can close against. Always higher
than Icu. Icm = k × Icu (k depends on power factor — see table
below).
Icw — Short-time Maximum current Category B CB can carry for specified time (e.g.
withstand 1s) without damage. Enables time-based selectivity. Only Category
B CBs have this.
Frame size rating Highest In setting available for a given CB frame/physical size.
Multiple trip current ranges can fit one frame.

4.4 Icm Factor Table (Peak Making vs Icu Breaking)

Icu (rated breaking) cos φ (test p.f.) k factor Icm = k × Icu

≤ 10 kA 0.5 1.7 Icm = 1.7 × Icu

10–20 kA 0.3 2.0 Icm = 2.0 × Icu

20–50 kA 0.25 2.1 Icm = 2.1 × Icu

> 50 kA 0.2 2.2 Icm = 2.2 × Icu

✔ Example: CB with Icu = 100 kA → cos φ = 0.2, k = 2.2 → Icm = 220 kA peak. The CB must
be able to close against 220 kA peak even though it only needs to break 100 kA rms.

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4.5 Ics Test Sequence vs Icu Test Sequence

Rating tested Test sequence CB condition after test Meaning

Icu (ultimate) O – t – CO May be non-functional; Worst case —

dielectric and overload emergency use only;
function verified but CB may verify CB after test
not trip again

Ics (service) O – CO – CO Must be fully functional and CB can be reused after

available for immediate interrupting Ics —
normal service practical operating
condition

⚠ Icu and Ics are often confused. Icu is the MAXIMUM the CB can break — it may be
unusable afterward. Ics is the PRACTICAL service rating. For a reliable installation, Ics at
the point of installation should be ≥ prospective fault current.

4.6 CB Selectivity Categories A and B

Category Definition Icw Trip delay Typical devices

provided? possible?

Category A No deliberate short-time delay NO NO for Molded-case CBs

— trips as fast as possible on instantaneous trip (MCCB), modular
S/C (may have CBs (MCB) — most
selective features common
by other means)

Category B Short-time withstand capability YES — YES — enables Air Circuit Breakers
— can delay tripping to allow manufacturer time-based (ACB), some heavy-
downstream CB to clear first provides Icw selectivity duty MCCBs (e.g.
value and Masterpact)
delay duration

✔ Category B CBs are essential for upstream devices in a selective installation. The Icw tells
you how much current the CB can withstand while waiting for the downstream device to trip.

4.7 Magnetic Trip Types — Selection Guide

Type Trip range Im Use when…

Type B (low 3 to 5 × In Sources with low short-circuit levels (standby

setting) generators, long cable runs, UPS outputs)

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 Type C 5 to 10 × In General purpose protection — most common in
(standard) commercial/industrial

Type D / K 10 to 14 × In (or up to Circuits with high inrush currents: transformers, motors,

(high setting) 20×In for type D capacitors, resistive heating with cold-start
domestic)

Type MA 12 × In Motor circuits in association with contactor and

(12×In) separate overload relay — no overload function needed
from CB

4.8 Temperature Derating

Thermal-magnetic trip units are temperature-sensitive. At high ambient temperature, the bi-metal strip
bends more — the CB will trip at a LOWER current than its rated Irth.

Derating rule and example

CB reference temperature: typically 40°C (for enclosed distribution boards).
At higher temperatures: CB must be derated (trip current set lower).
At lower temperatures: CB can be uprated slightly.

Mutual heating: CBs mounted side-by-side in enclosed enclosures heat each other.
Apply the mutual heating correction factor before selecting the CB.

Example from guide:

Load current = 34 A; installed in closed box with other CBs at 40°C reference
At 40°C, a 40A CB in enclosed conditions → actual carrying capacity = 36.5A
36.5A > 34A ✔ — the 40A CB is acceptable (barely)
If temperature exceeds 40°C, a 50A CB frame would be needed.

Electronic trip units: temperature-stable — they use CTs for detection, not bi-metal strips.
However, the CB enclosure/contacts may still impose temperature limits.

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 SECTION 5 — CIRCUIT BREAKER SELECTION CRITERIA

5.1 Complete Selection Checklist

CB Selection — Step by Step

Step 1: Determine rated voltage Ue — must match system voltage
Step 2: Determine load current IB — calculate from circuit power and voltage
Step 3: Select Irth (overload trip): IB < Irth ≤ In, and Irth ≤ 1.45 × Iz (cable ampacity)
Step 4: Calculate prospective short-circuit current Isc at point of installation
Step 5: Select Icu ≥ Isc (or use cascading/back-up with upstream device)
Step 6: Select Im (magnetic trip type B/C/D/MA) based on circuit load characteristics
Step 7: Check ambient temperature — apply derating if above reference temperature
Step 8: Verify selectivity with upstream and downstream devices
Step 9: Check isolation capability (disconnector symbol ☐|) if required
Step 10: Add auxiliary modules as needed (RCD, auxiliary contacts, remote control, etc.)

5.2 Circuit Breakers in IT Systems — Special Requirement

Double earth fault situation in IT systems

In IT systems, a second fault creates a phase-to-phase fault path through two earth electrodes.
A single CB pole must then clear using PHASE-TO-PHASE voltage across it (400V at 400V
system)
instead of the normal phase-to-neutral voltage (230V).

This means: the CB breaking capacity is MODIFIED (reduced) in IT system double-fault

conditions.

Requirement: CBs used in IT systems must be TESTED according to IEC 60947-2 Annex H
which simulates the double earth fault condition.

CBs not tested to Annex H must display the symbol ⊗ on the nameplate indicating they are

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 NOT suitable for use in IT systems without additional verification.

Q: Why does a double fault in an IT system stress a CB more than in a TN system?

A: In a TN system, a phase-to-earth fault is cleared by one CB pole which sees phase-to-
neutral voltage (230V in a 400V system). In an IT system, a second fault creates a phase-to-
phase short circuit through the two earth paths. A single CB pole must now interrupt across
phase-to-phase voltage (400V). Higher voltage across the same arc gap = harder to extinguish
= CB may fail to interrupt. Hence IT-rated CBs need specific testing.

5.3 Main Incomer and Feeder CB Selection

Single Transformer Supply

The main CB must handle the maximum transformer secondary short-circuit current. If in a consumer's
substation, some standards require a CB with VISIBLE OPEN CONTACTS (withdrawable type).

Multiple Transformers in Parallel

• — must break TOTAL fault current from ALL transformers combined (highest duty)
• — sized according to kVA rating of associated transformer; SMALLER transformer CB
sees HIGHEST current (because more transformers feed into the fault from the other
parallel sources)

⚠ Paradox in parallel transformers: the CB of the SMALLEST transformer must have the
HIGHEST breaking capacity. The smallest transformer contributes least to the fault but
sees the most current from the other transformers feeding through it.

Conditions for successful parallel transformer operation:

1. Same phase shift (vector group) in all units
2. Same voltage ratio primary-to-secondary in all units
3. Similar percentage impedance — so transformers share load in proportion to their kVA ratings

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 SECTION 6 — SELECTIVITY (DISCRIMINATION)

6.1 Principle and Definition

Definition of Selectivity (IEC 60947-2)

Selectivity is achieved when a fault at any point in the installation is cleared by
the protective device IMMEDIATELY UPSTREAM of the fault, while ALL OTHER
protective devices remain in service.

Result: only the faulted circuit is disconnected — all other circuits stay energized.

Types of selectivity:
TOTAL selectivity — upstream CB does not trip for any fault current up to its full Icu
PARTIAL selectivity — upstream CB remains selective only up to a selectivity limit current (Is)
Above Is: both CBs may trip (loss of selectivity)

6.2 Four Methods of Achieving Selectivity

Method Principle How it works Limitation

Current-based Upstream CB has Step the trip current settings Only works for
higher trip threshold (Ir at each level: IrB < IrA, ImB currents below ImB
or Im) < ImA — above ImB, both
CBs may trip
simultaneously

Time-based Upstream CB has Downstream trips instantly; Upstream must

longer time delay upstream waits (S-type, withstand Isc for
Category B with Icw) delay period (requires
Icw) — can mean
long fault duration
upstream

Combined Upstream has TWO Below ImA-delayed: time Requires careful

current + time magnetic thresholds: delay gives selectivity. coordination of two
ImA-delayed and Ii- Above Ii: upstream trips levels
instantaneous instantly (protection limit)

Energy-based Current-limiting CBs — High arc energy at B Requires precise

(arc energy) both open (downstream) trips B; arc coordination of
simultaneously; arc energy at A (upstream) is limiting levels;

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 energy level determines limited — insufficient to trip implemented in
which CB trips A Compact NSX + Acti
9 range

6.3 Logic Selectivity (Zone Sequence Interlocking — ZSI)

How ZSI Works

ZSI uses a PILOT WIRE connecting the trip units of all CBs in a cascade.

Normal (no fault): each trip unit sends 'low' (no fault signal) on ZSI output.

When a fault occurs downstream of CB-B:

CB-B detects fault → sends 'high' signal UP the pilot wire to CB-A
CB-A receives 'high' input → delays its own trip (moves to time-delay mode)
CB-B trips instantly (no ZSI input telling it to delay)
CB-A resets after a short time if fault is cleared by CB-B

When a fault occurs downstream of CB-A but upstream of CB-B:

CB-A detects fault but receives NO 'high' ZSI input from below
CB-A trips instantly

Key advantage: TOTAL selectivity at ANY current level, even with similar-rated CBs.
No need for high Icw ratings or long time delays at source level.
Compatible with Category B (Masterpact MTZ) and some Category A electronic trip CBs.

✔ ZSI (Zone Sequence Interlocking) solves the main problem of time-based selectivity: it
avoids long time delays at the source. With ZSI, the source CB trips instantly when its
downstream CBs are not reporting a fault on their side.

6.4 Cascading (Back-up Protection)

Cascading principle
A current-limiting CB upstream LIMITS the peak fault current and let-through energy.

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 This allows all downstream CBs and equipment to have LOWER ratings than the actual Isc.
Result: smaller, cheaper downstream components without compromising safety.

Condition: the energy let through by the upstream limiting CB must be LESS than
the energy withstand capability of all downstream components.

Manufacturers provide TESTED cascading tables (e.g. Schneider's NSX250 cascading table).
Do NOT apply cascading outside of the manufacturer's tested and published combinations.

⚠ Cascading is in CONTRADICTION with selectivity. If both CBs open simultaneously in

cascading, selectivity is lost. 'Selectivity enhanced by cascading' (energy-based
selectivity in Compact NSX range) is a special solution that achieves BOTH
simultaneously.

6.5 MV/LV Selectivity in Consumer Substations

Key principle for MV fuse coordination with LV CB

MV fuses protect the transformer. The LV CB protects the LV circuits.

RULE: The LV CB must trip for ALL LV faults BEFORE the MV fuse blows.
The LV CB tripping curve must be ENTIRELY TO THE LEFT of the MV fuse pre-arcing curve.

Two limits on the LV CB short-circuit tripping element:

1. Maximum current setting of magnetic trip: LV CB Isc trip must be set LOW enough
to ensure it trips before the MV fuse pre-arcs
2. Maximum time delay: LV CB must trip fast enough to prevent MV fuse operation

The margin depends on: MV fuse rating, transformer impedance, cable length upstream of LV
CB.

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 SECTION 7 — ULTRA-RAPID CIRCUIT BREAKERS

7.1 When are Ultra-Rapid CBs Needed?

As installed power increases, conventional LV design becomes impossible because fault current levels
exceed the breaking and withstand capabilities of standard LV equipment. Applications include:
• Bus-coupling of parallel transformers or generators
• Onboard merchant vessels and offshore platforms
• Industrial loop networks with high installed power
• Any situation where HV design is impractical

7.2 Two Solutions

Solution Technology Speed Application

Pyrotechnic Explosive charge severs the Microseconds — One-shot — must

interruption device conductor fastest possible be replaced after
operation; used for
extreme fault levels

Ultra-rapid power CB Thomson effect or similar — Much faster than Resettable; limits
(e.g. Masterpact UR) electrodynamic repulsion standard CB current AND
opens contacts at extreme energy; used as tie
speed breaker in bus-
coupling schemes

Ultra-rapid CB as tie breaker

In a system with two transformers and a bus coupler (tie breaker):
Normal operation: two separate busbars, each supplied by one transformer
Bus coupler (Masterpact UR) is NORMALLY OPEN or CLOSED depending on load balancing
needs

On a fault on one busbar:

Masterpact UR opens ULTRA-RAPIDLY (before fault current reaches peak)
Limits energy delivered to the faulted busbar
Prevents the fault from propagating to the healthy busbar
Protects all downstream equipment from the full prospective fault current

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 SECTION 8 — KEY TERMS & VALUES TO MEMORIZE

TERM / SYMBOL DEFINITION & KEY VALUES

gG fuse Full range general purpose fuse. Protects against BOTH overload
and short-circuit. Non-fusing at 1.25–1.5×In; fusing at 1.6–2.1×In
within conventional time.
aM fuse Partial range motor fuse. Protects against short-circuit ONLY (≥
4×In). A separate thermal overload relay is ALWAYS required. aM
fuses cannot protect against overloads.
gM fuse Full range motor fuse. Dual rated: In (fuseholder continuous current)
and Ich (time-current characteristic — same as gG fuse of
equivalent rating). Smaller than equivalent gG.
Icu Ultimate breaking capacity (kA rms). Maximum current CB can
interrupt — may not function afterwards. Test: O-t-CO.
Ics Service breaking capacity. CB remains fully functional after
interrupting this current. Test: O-CO-CO. Often expressed as % of
Icu (25%, 50%, 75%, or 100%).
Icm Rated making capacity (kA peak). Highest instantaneous current CB
can close against. Icm = k × Icu where k = 1.7 to 2.2 depending on
power factor.
Icw Short-time withstand current. Only for Category B CBs. Maximum
current CB can carry for specified time (1s typically) without
damage. Enables time-based selectivity.
Ir / Irth Overload trip current setting. Adjustable: 0.4 to 1.0 × In. Must
satisfy: IB < Ir ≤ In AND Ir ≤ 1.45 × Iz.
Im Magnetic (instantaneous) trip current. Type B: 3–5×In. Type C: 5–
10×In. Type D: 10–20×In. MA: 12×In (motor, no overload function).
Cat. A CB No deliberate short-time delay. No Icw rating. Standard MCCBs and
MCBs. May achieve selectivity by other means (energy-based, ZSI).
Cat. B CB Short-time delay capability. Icw rating provided. ACBs and some
heavy MCCBs. Enables time-based selectivity.
ZSI Zone Sequence Interlocking (Logic Selectivity). Pilot wire connects
CB trip units. Downstream fault: downstream CB trips instantly;
upstream CB delays. Total selectivity without long time delays.
Cascading Upstream current-limiting CB reduces let-through energy, allowing
downstream CBs to have lower ratings. Manufacturer-tested
combinations required. Contradicts selectivity.
Leakage — new ≤ 0.5 mA per phase with contacts open.
isolator
Leakage — end of life ≤ 6.0 mA per phase with contacts open.
isolator

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AC3 contactor Squirrel cage motor starting/running. Breaking at 8×In. Most
common motor contactor category.

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 SECTION 9 — SELF-TEST QUESTIONS & ANSWERS

Switchgear Functions

Q: What are the three main functions of LV switchgear?

A: 1. Electrical PROTECTION — against overload, short-circuit, and insulation faults (earth
fault). 2. ISOLATION — safe disconnection from the energized system, lockable, with proof of
open state. 3. CONTROL (switching) — functional switching for normal operation, emergency
switching, emergency stop, and switching for mechanical maintenance.

Q: What is the difference between emergency switching and switching for mechanical
maintenance?
A: Emergency switching de-energizes a circuit that IS or COULD BECOME dangerous — it is
immediate and the device must be clearly marked (RED/YELLOW) and accessible. Switching
for mechanical maintenance is planned: it stops a machine so that mechanical work can be
done safely, using a safety lock and warning notice to prevent inadvertent restart. Emergency
switching is reactive (hazard present); maintenance switching is preventive (planned work).

Fuses

Q: What is the difference between gG, gM, and aM fuses? Which provides overload
protection?
A: gG (general purpose): full range — protects against BOTH overload and short-circuit. gM
(motor, full range): dual-rated, full range but primarily for cable protection — overload relay still
needed for motor itself. aM (motor, partial range): NO overload protection (only for ≥ 4×In fault
currents) — a thermal overload relay is MANDATORY alongside aM fuses.

Q: For a 100A gG fuse, what is the conventional non-fusing current and fusing current,
and how long does the test run?
A: 100A is in the 63–160A range. Non-fusing current = 1.25 × 100 = 125A (fuse will NOT blow
at this current). Fusing (melting) current = 1.6 × 100 = 160A (fuse WILL blow within 2 hours at
this current). Conventional time = 2 hours.

Circuit Breaker Characteristics

Q: What is the difference between Icu and Ics?

A: Icu (ultimate breaking capacity) is the maximum fault current the CB can interrupt — after

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 this test (O-t-CO sequence), the CB may not be reusable but must at least maintain dielectric
integrity and overload function. Ics (service breaking capacity) is the current the CB can
interrupt and remain fully functional, ready for immediate service (O-CO-CO sequence). Ics ≤
Icu. The installation should ideally have Ics ≥ prospective fault current.

Q: A CB has Icu = 50 kA. What is its Icm?

A: For Icu = 50 kA: cos φ = 0.25, k = 2.1. Icm = 2.1 × 50 = 105 kA peak. This is the highest
instantaneous current the CB can successfully close against.

Q: A thermal-magnetic CB rated 40A at 40°C is installed in a closed distribution box with

other CBs at 50°C ambient. Is it adequate for a 34A load?
A: At 50°C in an enclosed box with mutual heating, the 40A CB carries approximately 36.5A
(from derating table). Since 36.5A > 34A, the 40A CB is adequate. However, the margin is
small — if temperature rises further or mutual heating is worse than assumed, a 50A CB should
be selected for safety.

Selectivity

Q: What is the difference between total and partial selectivity?

A: Total selectivity: the upstream CB does not trip for ANY fault current up to the breaking
capacity of the downstream CB. Partial selectivity: the upstream CB remains selective (does not
trip) only up to a selectivity limit current Is. For fault currents above Is, both CBs may trip
simultaneously, losing selectivity.

Q: Why is time-based selectivity alone insufficient for ACBs at the top of a multi-level
distribution system?
A: Time-based selectivity requires the upstream (source-level) CB to delay its trip to allow
downstream CBs to clear faults first. The longer the delay, the longer the full fault current flows
through the upstream bus bars and transformers, causing thermal and electrodynamic stress.
Long time delays require high Icw ratings at every level. ZSI (Logic Selectivity) solves this by
allowing the upstream CB to trip instantly when it is the device closest to the fault, avoiding the
time-delay overhead while still being selective.

Q: What is 'cascading' and what is the condition for its use?

A: Cascading (back-up protection) allows downstream CBs to have a breaking capacity lower
than the prospective fault current at their location, because an upstream current-limiting CB
limits the peak and energy of any fault current that passes through it. Condition: the let-through
energy of the upstream CB must be LESS than the thermal and electrodynamic withstand of all
downstream components. Only manufacturer-tested combinations from published cascading
tables should be used — never extrapolate.

Q: In an IT system, why must CBs be specifically tested per IEC 60947-2 Annex H?

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A: In an IT system, a second earth fault creates a phase-to-phase fault path. A single CB pole
must interrupt under phase-to-phase voltage (e.g. 400V) instead of phase-to-neutral voltage
(230V). Higher voltage across the arc gap makes it harder to extinguish the arc. Standard CBs
tested at phase-to-neutral voltage may fail to interrupt under these conditions. Annex H tests
simulate the double-fault condition to verify adequate performance. CBs not tested to Annex H
must display the ⊗ symbol indicating they are not verified for IT system use.

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 QUICK REFERENCE CARD — CHAPTER H

Switchgear Capability Matrix

Device Isolate Func. Emrg. Ovld. S/C Prot. Earth

Switch Switch Prot. Prot.

Disconnector YES ✔ NO NO NO NO NO
(withstand)

Load-break switch If marked YES ✔ YES ✔ NO NO (fault- NO

make)

Contactor NO YES ✔ YES ✔ NO NO NO

(remote)

Discontactor NO YES ✔ YES ✔ YES NO NO

(relay)

Fuse NO NO NO Partial YES ✔ NO

(gG/gM)

Circuit breaker YES ✔ YES ✔ YES ✔ YES ✔ YES ✔ NO

CB + RCD (RCBO) YES ✔ YES ✔ YES ✔ YES ✔ YES ✔ YES ✔

Schneider Electric — Electrical Installation Guide 2018 — Chapter H

Study guide prepared for technical reference and examination preparation.

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