Switch Fuse Unit (SFU)

It is a combination of switch and fuse. SFU can make, carry, and break the circuit along with
providing over current protection to the installation; while fuse can only provide over current
protection. It is used for low and medium voltages.

Miniature Circuit Breaker (MCB)

It is an automatically operated electrical switch used to protect low voltage electrical circuits
from damage caused by excess current from an overload or short circuit. MCBs are typically
rated up to a current up to 125 A, do not have adjustable trip characteristics, and can be thermal
or thermal-magnetic in operation.

The MCB has many advantages compared to a fuse:

1. It automatically switches off the electrical circuit during the abnormal conditions of the
network (both overload and fault conditions). The MCB is much more reliable in the
detection of such conditions, is it is more sensitive to change in current.
2. As the switch operating knob comes at its off position during tripping, the faulty zone of
the electrical circuit can easily be identified. But in case of a fuse, the fuse wire should be
checked by opening fuse grip or cutout from fuse base, for confirming the blow of fuse
wire. Thus is it much detect if an MCB has been operated compared to a fuse.
3. Quick restoration of supply cannot be possible in case of fuse, as fuses have to be
rewirable or replaced for restoring the supply. But in the case of an MCB, quick
restoration is possible by (literally) flipping a switch.
4. The handling of an MCB is more electrically safe than a fuse.
5. MCBs can be controlled remotely, whereas fuses cannot.

There is two arrangement of operation of a miniature circuit breaker. One due to the thermal
effect of over current and other due to electromagnetic effect of over current. The thermal
operation of the miniature circuit breaker is achieved with a bimetallic strip whenever continuous
overcurrent flows through MCB, the bimetallic strip is heated and deflects by bending. This
deflection of the bimetallic strip releases a mechanical latch. As this mechanical latch is attached
to the operating mechanism, it causes to open the miniature circuit breaker contacts. But during
short circuit conditions, the sudden rising of current causes electromechanical displacement of
plunger associated with tripping coil or solenoid of MCB. The plunger strikes the trip lever
causing the immediate release of the latch mechanism consequently open the circuit breaker
contacts.

If the circuit is overloaded for a long time, the bimetallic strip becomes overheated and
deformed. This deformation of bimetallic strip causes, displacement of latch point. The moving
contact of the MCB is so arranged by means of spring pressure, with this latch point, that a little
displacement of latch causes, release of spring and makes the moving contact to move for
opening the MCB.

The current coil or trip coil is placed in such a manner that during short circuit fault the MMF of
that coil causes its plunger to hit the same latch point and make the latch to be displaced. Hence
the MCB will open in the same manner.

Again when the operating lever of the miniature circuit breaker is operated by hand, that
means when we make the MCB at off position manually, the same latch point is displaced as a
result moving contact separated from fixed contact in the same manner.

Regardless of the operating mechanism – e.g. due to the deformation of the bimetallic strip, or
due to the increased MMF of the trip coil, or due to manual operation – the same latch point is
displaced and same deformed spring is released. This is ultimately responsible for the movement
of the moving contact. When the moving contact separated from fixed contact, there may be a
high chance of arc. This arc then goes up through the arc runner and enters into arc splitters and
is finally quenched. When we switch on an MCB, we actually reset the displaced operating latch
to its previous on position and make the MCB ready for another switch off or trip operation.
Earth Leakage Circuit Breaker (ELCB)

An Earth-leakage circuit breaker (ELCB) is a safety device used in electrical installations (both
residential and commercial) with high Earth impedance to prevent electric shocks. It detects
small stray voltages on the metal enclosures of electrical equipment, and interrupts the circuit if a
dangerous voltage is detected. ELCBs help detect current leaks and insulation failures in the
electrical circuits that would cause electrical shocks to anyone coming into contact with the
circuit.

There are two types of earth leakage circuit breakers—a voltage ELCB and a current ELCB.

Voltage Earth Leakage Circuit Breaker

The working principle of voltage ELCB is quite simple. One terminal of the relay coil is
connected to the metal body of the equipment to be protected against earth leakage and other
terminal is connected to the earth directly. If any insulation failure occurs or live phase wire
touches the metal body, of the equipment, there must be a voltage difference appears across the
terminal of the coil connected to the equipment body and earth. This voltage difference produces
a current to flow the relay coil.

If the voltage difference crosses, a predetermined limit, the current through the relay becomes
sufficient to actuate the relay for tripping the associated circuit breaker to disconnect the power
supply to the equipment. The typicality of this device is, it can detect and protect only that
equipment or installation with which it is attached. It cannot detect any leakage of insulation in
other parts of the system.

Current ELCB or Residual Current Circuit Breaker (RCCB)

Here one CT (Current Transformer) core is energized from both phase wise and neutral wire.
The polarity of the phase winding and neutral winding on the core is so chosen that, in normal
condition mmf of one winding opposes that of another. As it is assumed that, in normal operating
conditions the current goes through the phase wire will be returned via neutral wire if there’s no
leakage in between. As both currents are same, the resultant mmf produced by these two currents
is also zero-ideally.

Molded Case Circuit Breaker (MCB)

It uses air as the dielectric medium to break a circuit. Air has a low dielectric strength as opposed
to other mediums that is why it is used for protection in low voltage circuits. It is an automatic
electrical device. It is a type of circuit breaker that protects the circuit from overloading, short
circuit and current surges. It is an advanced version of miniature circuit breaker MCB since it
operates like one. However, it offers extra features that make it a superior circuit breaker such as
remote closing and adjustable trip settings i.e. its current settings and time settings can be
adjusted according to our needs.

MCCB is used to protect the low voltage distribution system. It is available in rating up to 2500
Amps and 1.1 kV.

Construction of MCCB

An MCCB is made from the following main parts:

1. Arc chute
2. Contacts
3. Operating mechanism
4. Terminal Connector
5. Thermal Trip Unit
6. Magnetic Trip Unit
7. Handle / Trip-free Mechanism
8. Trip Button
Working Principle of MCCB

An MCCB protects a circuit from fault current. It uses thermal and magnetic mechanisms to
break those fault currents. The thermal mechanism is used for overload protection while the
magnetic mechanism is used for short circuit protection

Overload Protection

Overload occurs when the current exceeds a limit for a prolonged duration. MCCB has a thermal
mechanism that contains a bimetallic contact to protect from overload. A bimetallic strip is made
from two different types of metal having different rates of thermal expansion. Upon temperature
change, the strip bends or contracts.

The main current passes through the bimetallic strip. If the current exceeds a certain limit, the
contacts heat up and expand. Due to different expansion rates, the strip bends and trips the
circuit.

In electrical devices, the current can overload for short durations of time, it is normal and should
not be considered as fault current. Therefore, MCCB has a time delay that allows the overload
current for a short duration of time before tripping the circuit.

Short Circuit Protection

MCCB protects against a short circuits using a solenoid that produces electromagnetic force. The
main current flows through the solenoid that attracts and repels a plunger responsible for tripping
the breaker.

If the current remains below the threshold, the solenoid produces a weak magnetic force that
cannot attract the plunger. In short-circuit conditions, very high current flows through the
solenoid that generates a very strong magnetic force. It attracts the plunger that trips the circuit.

Function of MCCB

MCCB as it is an electrical protection device has the following functions

Protection against Overloading

Overloading is the condition when the current exceeds a predetermined limit for a specific
duration of time. The overloading current can damage the equipment, wirings and can create fire
hazards. MCCB offers protection against overloading using a bimetallic strip.

Protection against Short Circuit

A short circuit is a condition when the live wire comes into contact with each other or with a
neutral wire. It can occur due to downed lines or broken or exposed wires or deteriorated
insulation of wires. The current flow due to the short circuit is very large and very destructive.
Short circuit current must be interrupted in the shortest period of time. MCCB can trip short
circuit current up 200k amps in the duration of 0.04 seconds.

A contactor is an electrically-controlled switch used for switching an electrical power circuit. [1]
A contactor is typically controlled by a circuit which has a much lower power level than the
switched circuit, such as a 24-volt coil electromagnet controlling a 230-volt motor switch.

A contactor has three components:

 The contacts are the current-carrying part of the contactor. Contact material is chosen for
high electrical conductivity, mechanical strength, and stability under arcing and
oxidation. Commonly used metals include alloys of tungsten, molybdenum, copper etc.
 The electromagnet (or "coil") provides the driving force to close the contacts. The
enclosure is a frame housing the contacts and the electromagnet. Enclosures are made of
insulating materials such as Bakelite, Nylon 6, and thermosetting plastics to protect and
insulate the contacts and to provide some measure of protection against personnel
touching the contacts.
 Magnetic blowouts use blowout coils to lengthen and move the electric arc. These are
especially useful in DC power circuits. AC arcs have periods of low current, during
which the arc can be extinguished with relative ease, but DC arcs have continuous high
current, so blowing them out requires the arc to be stretched further than an AC arc of the
same current.

When current passes through the electromagnet, a magnetic field is produced, which attracts the
moving core of the contactor. The electromagnet coil draws more current initially, until its
inductance increases when the metal core enters the coil. The moving contact is propelled by the
moving core; the force developed by the electromagnet holds the moving and fixed contacts
together. When the contactor coil is de-energized, gravity or a spring returns the electromagnet
core to its initial position and opens the contacts.

For contactors energized with alternating current, a small part of the core is surrounded with a
shading coil, which slightly delays the magnetic flux in the core. The effect is to average out the
alternating pull of the magnetic field and so prevent the core from buzzing at twice line
frequency.

Because arcing and consequent damage occurs just as the contacts are opening or closing,
contactors are designed to open and close very rapidly; there is often an internal tipping point
mechanism to ensure rapid action.

Rapid closing can, however, lead to increase contact bounce which causes additional unwanted
open-close cycles. One solution is to have bifurcated contacts to minimize contact bounce; two
contacts designed to close simultaneously, but bounce at different times so the circuit will not be
briefly disconnected and cause an arc.
Power Factor Improvement

For a particular power supplied, a high power factor reduces the current flowing in a supply
system, which consequently lowers losses (i.e. I2R losses) and hence results in cheaper running
costs. Supply authorities use tariffs which encourage consumers to operate at a reasonably high
power factor. One method of improving the power factor of an inductive load is to connect a
bank of capacitors in parallel with the load.
Capacitors are rated in reactive voltamperes and the effect of the capacitors is to reduce the
reactive power of the system without changing the active power. Most residential and industrial
loads on a power system are inductive, i.e. they operate at a lagging power factor. A simplified
circuit diagram is shown in Figure (a).

Where a capacitor C is connected across an inductive load. Before the capacitor is connected the
circuit current is ILR and is shown lagging voltage V by angle φ1 in the phasor diagram of Figure
(b).

When the capacitor C is connected it takes a current IC which is shown in the phasor diagram
leading voltage V by 90◦. The supply current I in Figure (a) is now the phasor sum of currents
ILR and IC as shown in Figure (b). The circuit phase angle, i.e. the angle between V and I, has
been reduced from φ1 to φ2 and the power factor has been improved from cos φ 1 to cos φ2.
Figure (c) shows the power triangle for an inductive circuit with a lagging power factor of cos
φ1 .

In Figure (d), the angle φ1 has been reduced to φ2, i.e. the power factor has been improved from
cos φ1 to cos φ2 by introducing leading reactive voltamperes (shown as length ab) which is
achieved by connecting capacitance in parallel with the inductive load. The power factor has
been improved by reducing the reactive voltamperes; the active power P has remained
unaffected.

Power factor correction results in the apparent power S decreasing (from 0a to 0b in Figure (d)
and thus the current decreasing, so that the power distribution system is used more efficiently.
Another method of power factor improvement, besides the use of static capacitors, is by using
synchronous motors; such machines can be made to operate at leading power factors.

Electrical Wiring system: A network of wires connecting various accessories for distribution of
electrical energy from the supplier meter board to the numerous electrical energy consuming
devices such as lamps, fans and other domestic appliances through controlling and safety devices
is known as a wiring system.

Methods of Wiring: There are two methods of wiring known as joint box system (or Tee system)
and loop in system.
(i) Joint Box or Tee System: In joint box system the connections to the lamps are made through
joints made in joint box by means of suitable connectors or joint cutouts. In this method though
there is a saving in the quantity of wire or cable required but the same is offset by the extra cost
of joint boxes. The other disadvantage is the number of ‘T’ connection made in wiring system
results in weakness if not properly made. Nowadays the use of this system is limited to
temporary installations only as its cost is low.

(ii) Loop-in System: this system is universally used for connections of various lamps or other
appliances in parallel. In this system when a connection is required at a light or switch, the feed
conductor is looped in by bringing it direct to the terminal and then carrying it forward again to
the next point to be fed as shown in fig.-4. The switch and light feeds are carried round the
circuit in a series of loops from one point to another until the last point on the circuit is reached.

The phase or line conductors are looped either in switch board or box and neutrals are looped
either in switch board or from light or fan. Line or phase should never be looped from light or
fan.
Selection or choice of wiring system:
i (i) Safety
ii (ii) Durability
iii (iii) Appearance
iv (iv) Mechanical protection
v (v) Accessibility
vi (vi) Low initial cost
vii (vii) Low maintenance cost

Types of Electrical wiring systems:

(1) Cleat wiring system
(2) TRS wiring system
(3) Lead sheathed wiring system
(4) Wooden batten wiring system
(5) Plastic Casing-capping system
(6) Conduit wiring system
(i) Conduit surface wiring
(ii) Concealed conduit wiring
1. Cleat wiring system: In this system of internal wiring the cables used are either vulcanized
Indian Rubber (VIR) of Polyvinyl chloride (PVC) type. The cables are held by porcelain cleats
about 6 mm above the walls or ceiling. The cleats are made in two halves, one base and the other
cap. The base is grooved to accommodate the cables and the cap is put over it and the whole of it
is then screwed on the wooden plugs (gutties) previously cemented into the wall and ceiling. The
cleats used are of different sizes and different types in order to accommodate cables of various
sizes and different number of cables respectively. The cleats are of three types; one groove, two
grooves and thre grooves to accommodate one, two and three cables respectively.

Advantages:
(i) It is the cheapest system of internal wiring.
(ii) Its installation and dismantlement is easy and quick.
(iii) Material is recoverable after the dismantlement.
(iv) Inspection, alterations and additions can be easily made.
(v) Skilled labour required is little.

Disadvantages:
(i) It is not good looking.
(ii) The wires are exposed to mechanical injury.
(iii) Oil and smoke are injurious to VIR insulation.

2. Casing-Capping wiring system: This is one of the simplest form of electrical wiring system.
This is little bit old/conventional wiring system. Now a days, we often use this wiring system.
PVC insulated cables are placed in plastic casing and covered with cap. The casing is of
rectangular cross section.
The colour of casing channel and cap are normally white or grey. The casing channel and cap are
normally made of plastic. The casing channels and caps are available in market in standard sizes.

Advantages:
(i) It is the cheapest wiring system as compared to concealed wiring system.
(ii) It is strong and long lasting wiring system.
(iii) Replacement and alteration of defective wire is easy.
(iv) It provides protection against mechanical damage.
(v) It is safe from oil, steam, smoke and rain.
(vi) No risk of electric shock due to covered wires and cables in casing and capping.

Disadvantages:
(i) Since it requires better workmanship, the labour cost is high.
(ii) This type of wiring can be used only on surface and cannot be concealed in plaster.
(iii) Internal condensation of moisture may cause damage to the insulation.

3 Conduit wiring system: In this system of wiring steel tubes or PVC pipes known as conduits
are installed on the surface of wall by means of saddles or buried under plaster and VIR or PVC
cables are drawn afterwards by means of GI wire.

Advantages:
(i) It provides protection against mechanical damage.
(ii) It provides complete protection fire due to short circuit.
(iii) The whole system is waterproof.
(iv) Replacement and alteration of defective wiring is easy.
(v) Its life is long.
(vi) It is shocked proof also if earthing is properly done.

Disadvantages:
(i)It is very costly system of wiring.
(ii) Its eraction is not easy and required time.
(iii) Experienced and highly skilled labour is required for carrying out the job.

Conductor materials used in cables: The function of conductor usually known as core in cable
is to carry electrical current. Copper and aluminium are the materials used as conductors in
power and lighting cables.
Copper: Though silver is the best conductor of heat and electricity but due to its high cost it is
rarely used. The next bets conductor is copper. It is cheaper as compared to silver. The electrical
conductivity of copper is comparatively high. The resistivity of pure copper is 1.786×10−8 Ω−𝑚.
It is mechanically strong, hard, extremely tough, durable and ductile. It is highly resistive to
corrosion, oxidation etc. it can be easily soldered and welded. The specific weight of copper is
8900 kg/𝑚3 at 20𝑜𝐶 or 9.9 𝑔𝑐𝑚3⁄. Its melting point is 1083 oC.
Aluminium: Aluminium is frequently used in place of copper for electric cables used for long
distance power distribution. The electrical conductivity of aluminium is about 60% of copper
(resistivity being 2.87×10−8 Ω−𝑚 at 20 oC) so for same resistance for a given length, the
aluminium required will be 1.61 times that of copper in volume and 1,26 times that of copper in
diameter. The only application of aluminium cables for wiring in the buildings is for the
‘continous busbar’ system of distribution.
Classification of cables: The cables employed for internal wiring of building may be divided
into different groups.
According to:
(i) Conductor used
(ii) Number of cores
(iii) Voltage grading
(iv) Types of insulation used.
(i) According to conductor:
(a) Copper conductor cable
(b) Aluminium conductor cable
(ii) According to number of cores:
(a) Single core cable
(b) Two core cable
(c) Three core cable
(iii) According to voltage Grading:
(a) 250/440 V cable
(b) 650/100 v cable
(iv) According to type of insulation:
(a) Vulcanized Indian rubber (VIR) cable
(b) Polyvinyl chloride (PVC) cable
(c) Lead sheathed cable
(d) Weather proof cable
(e) Flexible cable
(f) Cross linked polyethylene (XLPE) cable
(g) Tough rubber sheathed (TRS) cable

Insulating Materials: the conductor is covered with insulating material so that it may prevent
leakage of current from the conductor i.e. the insulating material should be extremely high
resistive to the flow of electric current through it. The insulating materials used in electric cables
should possess the following properties:
(i) High insulation resistance to avoid the leakage current.
(ii) High dielectric strength to avoid electrical breakdown of the cable.
(iii) High mechanical strength to withstand the mechanical handling of cables.
(iv) Non-hygroscopic
(v) Non-inflammable
(vi) Low cost
(vii) Unaffected by acids and alkalies to avoid any chemical action.

(1) PVC cables: These cables are available in 250/440 v and 650/1100 V and are used in casing-
capping, wooden batten and conduit wiring system. In this type of cable conductor is insulated
with PVC insulation. Since PVC is harder than rubber, PVC cables does not required cotton
tapping and bedding over it for mechanical and moisture protection.

(2) Weather Proof Cable: These cables are used for outdoor wiring and for power supply or
industrial supply. Theses cables are either PVC insulated or VIR insulated conductors. Being
suitably tapped (only in case of VIR cable) braided and then compounded with weather resisting
material. These cable are available in 240/415 V and 650/1100 V. theses cables are not affected
by heat or sun or rain.

(3) Flexible cords and cables: the flexible cords consist wires silk/cotton/plastic covered. Plastic
cover is popular as it is available in different colours. Flexible cords have tinned copper
conductors. Flexibility and strength is obtained by using conductors having number of strands.
These wires or cables are used as connecting wires for such purposes as from ceiling rose to
lamp holder, socket outlet to portable apparatus such as radios, fans, lamps heaters etc. These
must not be used in fixed wiring.

Fuse: Fuse is a current interrupting device which breaks or opens the circuit (in which it is
inserted) by fusing the element when the current in the circuit exceeds a certain value.
Fuse Element or Fuse wire: It is that part of the fuse which actually melts when an excessive
current flows in the circuit and thus isolates the faulty device from the supply circuit.
Principle of Operation: The action of a fuse is based upon the heating effect of the electric
current. In normal operating conditions, when the current flowing through the circuit is within
safe limits, the heat developed in the fuse element carrying this current is readily dissipated into
the surrounding air, therefore, fuse element remains at a temperature below its melting point.
However, when some fault such as short circuit occurs or when the load connected in a circuit
exceeds its capacity, the current exceeds the limiting value, the heat generated due to this
excessive current cannot be dissipated fast enough and the fusible element gets heated, melts and
breaks the circuit.

Current Rating: This rating is specified by manufacturer. It is defined as the rms value of the
current which the fuse wire can carry continuously without deterioration, and with temperature
rise within specified limit.

Fusing Current: It is defined as the minimum value of current at which the fuse element or fuse
wire melts.
For a round wire the approximate value of fusing current is given by 𝐼=𝑘 𝑑32⁄
𝑤ℎ𝑒𝑟𝑒 𝑘 𝑖𝑠 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑐𝑎𝑙𝑙𝑒𝑑 𝑡ℎ𝑒 𝑓𝑢𝑠𝑒 constant, depending upon the metal of the fuse element
Fuse Element Materials: The materials used fuse element must be of low melting point, low
ohmic losss, high conductivity (or low resistivity), low cost and free from deterioration.
Experience has shown that the most generally suitable material for the fuse element is a low
melting point material such as tin, lead or zinc.
The materials commonly used for fuse elements are tin, lead, silver, copper, zinc, aluminium and
alloy of lead and tin. An alloy of led and tin (lead 37% and tin 63%) is used for small current
rating fuses( say not beyond 15A). for current exceeding 15 A this alloy is not used as the
diameter of the wire will be larger and after fusing the metal released will be excessive.

Advantages of Fuse:
(a) It is the cheapest form of protection available.
(b) It needs no maintenance.
(c) Its operation iss completely automatic.
(d) It interrupts an enormous short circuit current without noise, flame, gas or smoke.
Disadvantages:
Considerable time is lost in rewiring or replacing a fuse element after operation.

Earthing

Earthing is defined as “the process in which the instantaneous discharge of the electrical
energy takes place by transferring charges directly to the earth through low resistance
wire.” Low resistance earthing wire is chosen to provide the least resistance path for leakage of
fault current. To ensure safety, earthing can be done by connecting the electrical appliance to
earthing systems or electrodes placed near the soil or below the ground level. The electrode or
earthing mat equipped with a flat iron riser is installed under the ground level. It helps to connect
all the non-current-carrying metallic parts of the equipment.

This picture below shows the earthing system incorporated into an electrical system.
When the overload current is passed through the equipment or when the fault occurs in the
system due to the current, the fault current from the equipment flows through the earthing
system. The earth mat conductors aid in raising the voltage value equal to the resistance of the
earth mat multiplied by a ground fault and helps guard the equipment against overload current or
fault current.

In homes, there shall be three types of wires, live, neutral, and earth. Live and neutral carry
electric current from the power station and the earth is connected to the buried metal plate.
Electric appliances like refrigerators, iron boxes, and TV are connected to the earth wire while
operating. Hence, these devices are protected from the surge or faulty electrical supply. Local
earthing is done near the electrical metre of the house.

Types of Earthing

There are three types of earthing, they are:

 Pipe earthing
 Plate earthing
 Strip earthing

Pipe earthing is the best and most efficient way of earthing and is also easily affordable. Pipe
earthing uses 38mm diametre and 2 metres length pipe vertically embedded in the ground to
work as earth electrodes.

In plate earthing, an earthing plate made of copper or G.I. is buried into the ground at a depth
more than 3 metres from the ground level. This earthing plate is embedded in an alternative layer
of coke and salts.

Strip earthing is used in transmission processes. Strip electrodes of cross section not less than
25mm X 1.6mm of copper or 25 mm X 4mm of G.I. or steel are buried in horizontal trenches of
a minimum depth of 0.5m.

Advantages of Earthing

1. Earthing is the safe and the best method of offering safety. We know that the earth’s
potential is zero and is treated as Neutral. Since low equipment is connected to earth
using low resistance wire, balancing is achieved.
2. Metal can be used in electrical installations without looking for its conductivity, proper
earthing ensures that metal does not transfer current.
3. A sudden surge in voltage or overload does not harm the device and person if proper
earthing measures are done.
4. It prevents the risk of fire hazards that could otherwise be caused by the current leakage.