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Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Lecture



Switching device — a device intended to close or open current in one or more electrical circuits.

1. Classification by design features

In general, all switching devices can be divided into two types:

Contact switching device

A switching device that performs the switching operation by moving its contact parts relative to one another .

Contactless switching device

A switching device that performs the switching operation without moving or destroying its parts (based on semiconductor or gas-discharge devices, magnetic amplifiers, etc.) .

Types of electrical switching devices

The main electrical switching devices are :

  • circuit breaker
  • automatic circuit breaker
  • load switch
  • residual current device
  • disconnector switch (isolator)
  • disconnector
  • changeover switch
  • short-circuiting switch
  • fuse
  • contactor
  • relay
  • starter
  • starting and starting-control rheostats
  • controller

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Example of an electrical circuit diagram containing several switching devices.

Parameters of switching devices

  • Actuating quantity — a physical quantity to which the switching device is designed to respond.
  • Actuating quantity setting — a specified value of the operating or non-operating quantity to which the device is adjusted
  • Time setting — the time-delay value to which the device is adjusted
  • Setting range — the range of setting values to which the device can be adjusted
  • Closing time — the time interval from the moment the closing command is given to the switching device until the specified conditions for current flow in its main circuit are established
  • Own closing time — the time interval from the moment the closing command is given to the contact device until the specified contact touches
  • Own opening time — the time interval from the moment the opening command is given until the contacts of the pole that opens last cease to touch
  • Total circuit-breaking time — the time interval from the moment the opening command is given to the switching device until the current ceases in all poles of the device
  • Time-current characteristic — the dependence of the operating time of the switching device on the current in its main circuit
  • Breaking current — the adopted value of the prospective current in the circuit interrupted by the device at a given instant
  • Making current — the adopted value of the prospective current in the circuit closed by the device at a given instant
  • Through-current withstand capability — the ability of a device, in the corresponding switching position or state, to carry a specified current for a specified time under prescribed conditions and to remain afterward in the prescribed state
  • Mechanical endurance — the ability of a contact device to perform a specified number of operations under specified conditions without current in the circuit of the main and auxiliary contacts, remaining afterward in the prescribed state
  • Electrical endurance — the ability of a contact device to perform a specified number of operations under specified conditions while its contacts switch circuits having specified parameters, remaining afterward in the prescribed state
  • Recovery voltage — The voltage appearing across the contacts of one pole of a switching device in the transient regime immediately after the arc in it has been extinguished.
  • Switching position diagram — A diagram showing the positions of the contacts in the various switching positions of a switching device and the sequence of transition from one switching position to another

1. High-voltage circuit breaker

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Three-phase MKP-110 oil circuit breaker for 110 kV
Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Vacuum circuit breaker for 6 — 10 kV
Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
High-speed DC circuit breaker

High-voltage circuit breaker — a switching device designed for operational closing and opening of individual circuits or electrical equipment in a power system under normal or emergency conditions, with manual, remote or automatic control.

A high-voltage circuit breaker consists of: a contact system with an arc-extinguishing device, current-carrying parts, a housing, an insulating structure and an operating mechanism (for example, an electromagnetic drive, a manual drive).

Parameters

In accordance with GOST R 52565-2006, circuit breakers are characterized by the following parameters:

  • rated voltage Urated (the voltage of the network in which the circuit breaker operates);
  • rated current Irated (the current through the closed circuit breaker at which it can operate for a long time);
  • rated breaking current Io.rated — the highest short-circuit current (rms value) that the circuit breaker is capable of interrupting at a voltage equal to the highest operating voltage under the given transient recovery voltage conditions and the given operating cycle;
  • permissible relative content of the aperiodic component in the breaking current;
  • if the circuit breakers are intended for automatic reclosing (AR), the following cycles must be provided:
Cycle 1: O — tdead — CO — 180 — CO;
Cycle 2: O — 180 — CO — 180 — CO,

where O — opening operation, CO — closing operation followed immediately by opening, 180 — time interval in seconds, tdead — the minimum dead-current pause guaranteed for circuit breakers during AR (the time from arc extinction to the appearance of current at the subsequent closing). For circuit breakers with AR it must be within 0.3…1.2 s, and for circuit breakers with HSAR (high-speed AR) — 0.3 s.

  • through-fault short-circuit withstand capability, characterized by the thermal withstand currents Ith and the limiting through-fault current
  • rated closing current — the short-circuit current that a circuit breaker with an appropriate drive is capable of closing onto without welding of the contacts or other damage, at U-rated and the given cycle.
  • own opening time — the time interval from the moment the opening command is given to the moment the arcing contacts begin to separate.
  • transient recovery voltage parameters at rated breaking current — the rate of rise of recovery voltage, the standardized curve, the amplitude factor and the recovery voltage.

Properties

Medium- and high-voltage circuit breakers (rated voltage 6—220 kilovolts) with a high breaking current (up to 50 kiloamperes) are used at power plants and substations. These breakers are a fairly complex design, operated by electromagnetic, spring, pneumatic, or hydraulic mechanisms. Depending on the medium in which arc quenching takes place, a distinction is made between air-blast circuit breakers, in which the arc is quenched by compressed air; oil circuit breakers, in which the contacts are placed in a tank of oil and the arc is quenched by oil vapor; electromagnetic circuit breakers (generally up to 10 kV), with so-called magnetic blow-out and arc-quenching chambers with narrow slots or grids; SF6 (gas-insulated) circuit breakers, which use the dielectrically strong gas SF6 — «SF6 gas»; and vacuum circuit breakers, in which arc quenching takes place in a vacuum — in the so-called vacuum interrupter (VI). The insulating medium, in addition to quenching the arc, also provides the dielectric strength of the gap between the contacts in the open position, which in turn determines the required contact travel.

Classification of high-voltage circuit breakers

By arc-quenching method

  • SF6 (gas-insulated) circuit breakers (tank-type and column-type);
  • Vacuum circuit breakers;
  • Oil circuit breakers (tank-type and minimum-oil);
  • Air-blast circuit breakers;
  • Auto-gas-blast circuit breakers;
  • Electromagnetic circuit breakers;
  • Auto-pneumatic circuit breakers.

By purpose

  • Network (feeder) circuit breakers for voltages of 6 kV and above, used in electrical circuits (other than circuits of electrical machines and electrothermal installations) and designed to carry and switch current under normal circuit operating conditions, as well as to carry current for a specified time and switch it under specified abnormal conditions, such as short-circuit conditions
  • Generator circuit breakers for voltages from 6 to 20 kV, used in circuits of electrical machines (generators, synchronous condensers, high-power motors) and designed to carry and switch current under normal conditions, as well as during starting modes and short circuits. They are generally distinguished by higher rated current values (up to 10,000 A) and breaking current.
  • Circuit breakers for voltages from 6 to 220 kV for electrothermal installations, used in circuits of large electrothermal installations (for example, steel-melting, ore-smelting, and other furnaces) and designed to carry and switch current under normal conditions, as well as in various operating modes and during short circuits.
  • Load-break switches - switches designed for switching at rated current but not rated to interrupt overcurrents. They are used in 3-10 kV networks with an isolated neutral for switching small loads — up to a few megavolt-amperes.
  • Reclosers - remotely controlled, pole-mounted sectionalizing circuit breakers fitted with protection and installed on overhead power line supports
  • Special-purpose circuit breakers.

By type of installation

  • Pedestal-mounted, i.e. having primary insulation to ground of the pedestal type.
  • Suspended, i.e. having primary insulation to ground of the suspended type.
  • Wall-mounted, i.e. mounted on the walls of enclosed switchgear.
  • Withdrawable, i.e. fitted with devices for withdrawing from switchgear cubicles (for maintenance, repair, and to create the so-called "visible break" when working on lines).
  • Built-in, incorporated into packaged switchgear.

By placement category and climatic design

  • five placement categories (indoors and outdoors, under various heating and ventilation conditions);
  • ten climatic versions (U, KhL, UKhL, TV, TS, T, M, OM, V and O) depending on the geographic installation location.

General design and operating principle of air-blast circuit breakers

In air-blast circuit breakers (ABCBs), the energy of compressed air is used both as the driving force that moves the contacts and as the arc-extinguishing medium. The operating principle of the arc-extinguishing device (of the ABCB) is that the arc forming between the contacts is subjected to intensive cooling by a stream of compressed air discharging into the atmosphere. As the current passes through zero, the arc temperature drops and the resistance of the gap increases. At the same time, mechanical disruption of the arc column occurs, and charged particles are carried out of the gap.

Structurally, air-blast circuit breakers are divided into:

  • Breaker with an open isolating gap
  • Breaker with a gas-filled isolating gap
  • Breaker with interrupting chambers in a compressed-air tank

General design and operating principle of SF6 (gas-insulated) circuit breakers

The insulating and arc-quenching medium of these breakers is sulfur hexafluoride SF6 (SF6 gas). The breakers are three-pole devices whose poles either share a single (common) frame and are operated by a single drive mechanism, or each of the three poles has its own frame and is operated by its own drive mechanism (a breaker with independent-pole operation).

The operating principle of these devices is based on extinguishing the electric arc (which arises between the diverging contacts when the current is interrupted) with a flow of SF6 gas.

There are two sources of gas flow generation:

  • an increase in pressure in one of the gas-filled cavities of the arc-extinguishing device, caused by a reduction of its enclosed volume, with the possibility of gas flowing out of it into the zone where the arcing contacts separate arising immediately before they open;
  • an increase in gas pressure in this same cavity due to its expansion under the action of the thermal energy of the electric arc itself.

The first source predominates when interrupting small currents, and the second when interrupting large currents.

Breaker pole

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Three poles of a 400 kV circuit breaker

Live-tank (column) design. The pole is a vertical column consisting of two (or more) insulators, the upper one of which houses the arc-extinguishing device (AED), while the lower one serves as a support for the AED and provides it with the required insulation clearance from the grounded frame. Inside the support insulator is an insulating operating rod connecting the movable contact of the AED to the drive mechanism of the device.

Dead-tank design. The pole is a metal cylindrical tank on which two insulators are mounted, forming the high-voltage bushings of the breaker. In this type of breaker, the AED is located inside a grounded metal enclosure.

Combined design. The pole is a spherical metal enclosure on which porcelain insulators are mounted, forming the high-voltage bushings of the breaker; the arc-extinguishing device is located in one of them, while built-in current transformers are located in the other.

A filter is usually installed in the upper part of the insulator to absorb moisture and the decomposition products of the SF6 gas caused by the electric arc. The filtering element in it is an activated adsorbent — synthetic zeolite NAX.

All modern breakers are also fitted with a safety (pressure-relief) valve — a device with a thin-walled diaphragm that ruptures at the pressure arising from an internal short circuit, but that does not reach the value at which the insulators themselves are tested.

Arc-extinguishing device

The arc-quenching device is designed to ensure rapid quenching of the electric arc that forms between the breaker's contacts when they open. Developing a rational and reliable design for an arc-quenching device presents considerable difficulties, since the processes occurring during arc quenching are extremely complex, insufficiently studied, and governed by many factors that cannot always be foreseen in advance. Therefore, the final design of an arc-quenching device can be considered complete only after it has been experimentally verified.

Modern circuit breakers are equipped with a self-blast (auto-puffer) type arc-quenching device, which demonstrates its calculated advantages when interrupting large currents.

The arc-quenching device (AQD) contains fixed and moving contact systems, each of which has main contacts and arcing contacts fitted with elements made of arc-resistant material. The main contact of the fixed system and the arcing contact of the moving system are of the socket type, while the main contact of the moving system and the arcing contact of the fixed system are of the pin type.

In addition to the main and arcing contacts, the moving system contains a fixed current-carrying sleeve connected to the AQD's current terminal; a piston device that creates elevated pressure in the sub-piston chamber during interruption; and two PTFE nozzles (large and small) that direct gas flows from the high-pressure zone to the zone where the arcing contacts separate. The large nozzle also prevents radial displacement of the moving system's contacts relative to those of the fixed system, since it never leaves the guide bushing of the main fixed contact.

The main contact of the moving system is a stepped copper sleeve, the narrow part of which is shaped to fit into the socket-type main contact of the fixed system, while the wide part has two grooves in which current-collecting (closed wire) coil springs are located, remaining constantly in contact with the fixed current-carrying sleeve that surrounds them.

Gas system

The gas system of the apparatus includes:

  • self-contained sealing valves (SSVs) and column filling valves;
  • a manifold that, during operation of the apparatus, connects the gas cavities of the columns to each other and to the SF6 density indicator;
  • the density indicator itself, a pointer-type electrical-contact pressure gauge with a temperature-compensation device that refers the readings to the pressure value at a temperature of 20ºC;
  • connecting tubes with nipples and seals.

The SF6 density indicator (density sensor) has three pairs of contacts: one, which closes when the SF6 density drops significantly due to leakage, is intended to give a signal (for example, a light signal) that the columns need to be refilled; the other two, which open when the SF6 density falls to an impermissible level, are intended to block control of the breaker or to automatically trip the apparatus while simultaneously blocking closing (as determined by the substation design).

Operating mechanism

Breaker operating mechanisms provide control of the breaker — closing, holding in the closed position, and opening. The mechanism shaft is connected to the breaker shaft by a system of levers and links. The breaker's operating mechanism must ensure the necessary reliability and speed of operation, and, with electrical control, the lowest possible power consumption.

Two types of operating mechanisms are used in SF6 circuit breakers:

Spring-operated mechanism:

  • the energy accumulator is a set of helical cylindrical springs
  • the control element is a kinematic system of levers, cams, and shafts.

Spring-hydraulic operating mechanism:

  • the energy accumulator is a set of disc (Belleville) springs
  • the control element is a hydraulic system.

Requirements for circuit breakers

The circuit breaker is the most critical apparatus in a high-voltage system; during faults it must always ensure reliable operation. If a breaker fails, the fault develops further, leading to severe damage and large material losses associated with loss of power supply and the shutdown of large enterprises.

In this regard, the main requirement for circuit breakers is an especially high reliability of operation under all possible operating conditions. Interruption of any load by a breaker must not be accompanied by overvoltages that are dangerous to the insulation of the installation's components. Since a short-circuit condition is the most severe for the system, the breaker must ensure that the circuit is interrupted in the shortest possible time.

General requirements for the design and characteristics of circuit breakers are established by the standards:

  • GOST R 52565-2006 «Alternating-current circuit breakers for voltages from 3 to 750 kV. General specifications.»
  • GOST 12450-82 «High-voltage alternating-current circuit breakers. Switching off unloaded lines».
  • GOST 8024-84 «Permissible heating temperatures of current-carrying parts, contact connections, and contacts of apparatus and electrical devices for alternating current at voltages above 1000 V.»
  • GOST 1516.3-96 «Alternating-current electrical equipment for voltages from 1 to 750 kV. Requirements for the dielectric strength of insulation».

Taking a breaker out of service for inspection and repair involves considerable difficulty, since it is necessary either to switch to a different switchgear configuration or simply to disconnect consumers. For this reason, a breaker must be capable of the greatest possible number of short-circuit interruptions without inspection and repair. Modern circuit breakers can interrupt up to 15 short circuits at full breaking capacity without inspection.

Low-voltage switches

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Designation of a switch on an electrical diagram: Designation of switches and outlets on drawings

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Types of household switches

Progress does not stand still even where switches are concerned; they are made ever more convenient, attractive, and functional, and are adapted for use in different situations. Hence the variety of types:

  • - plain switches;
  • - two-way (through) switches;
  • - intermediate (cross) switches;
  • - illuminated switches;
  • - remotely controlled switches;
  • - pilot (indicator) switches;
  • - dimmer switches;
  • - timer switches;
  • - motion-sensor switches;
  • - occupancy-sensor switches.
  • master switch

Another classification divides them into types according to the operating principle of the switching mechanism.

  1. 1. Rotary switch, inside which there is a rotating contact mechanism. Changing the position of the rotary toggle closes and opens the contacts.
  2. 2. Push-button switch, which, when the button is pressed, alternately opens or closes the contacts.
  3. 3. Changeover switch has three pairs of contacts and a blade inside it. This switch does not break the circuit; here the blade flips over onto the two other contacts. That is, what occurs is not switching off, but switching over.

Master switch

Under the term "Master switch" one usually means a switch that, when pressed, turns off all lighting groups as well as all outlet groups connected to it

Globally, there are two types of master switches:

  • A master switch that only sends a signal to turn off the corresponding loads. Pressing it again does not turn them back on.
  • A master switch that controls a contactor, to which the required lighting and outlet groups are connected. When it is turned off, the contactor interrupts the power supply, and when turned on, it restores it.

The first option is the correct one; it can be implemented using traditional wiring with minor modifications, while the second option conceals drawbacks that are not obvious at first glance.

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

A proper master switch based on QUID

QUID makes it possible to correctly implement the central shutdown scenario even in traditional systems

The central shutdown scenario is convenient for turning off all lighting; it is triggered by a doorbell-type switch with backlighting. Such an illuminated switch is appropriately placed at the head of the bed, near the front door, and in other places where central shutdown of all or selected lighting or outlet groups may be needed.

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Wiring diagram for a controlled outlet in a "Master switch" system

To connect a controlled outlet that will participate in the central shutdown scenario, but will not be centrally turned on and will only be turned on from a local switch, the following circuit can be used (using a relay and doorbell buttons)

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Contactor-based master switch

This type of central shutdown is quite popular among those who want additional convenience for minimal money

At first glance, this type of switch can save time and electricity, as well as provide additional safety. We disagree with this, and we will now explain why.

Operating principle of a contactor-based master switch

An ordinary switch is connected to the control terminals of a contactor, to which, in turn, all lighting groups and controlled outlets are connected. When the master switch is on, the contactor passes current through itself, powering all connected devices. When the switch is turned off, the contactor interrupts the power supply.

If you turn on all the lights in the house from local switches, then using the master key you will turn off all the lights and then turn them on simultaneously, which entails certain drawbacks.

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Example of a contactor-based master switch in operation

Suppose you live in a two-story house, during the construction of which the crew grouped all the lighting groups, as well as some outlet groups, together and connected them through a contactor located in the panel,

You are about to leave the house, but you don't remember whether the lights are off in all the rooms, and moreover you suspect that the iron was left on in the laundry room, but you're not worried, because with one press of the key you turn everything off and calmly leave the house.

After a while, someone from your family arrives, earlier than you.

To use the lights and outlets, they need to turn on the master switch. After that, all the lights in the apartment come on, and the iron is energized again.

But the person who arrived doesn't know this...

It turns out that a contactor-based master switch only creates an illusion of convenience, but in reality causes nothing but problems.

On top of that, the power supplies used for both light fixtures and LED strips have high inrush currents — from 30 to 60 A — and there can be dozens of them, so on a cold start the current surge can reach a thousand or even several thousand amperes. A 2.5 mm² wire is rated for a current of 25 A. Yes, the peak values last only fractions of a second, but they have a negative effect on the equipment and can trigger tripping of the protective circuit breaker and other problems.

The inability to use local switches once the main disconnect has de-energized the system makes it pointless to use such a scenario when someone remains in the house or apartment.

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Disadvantages of a contactor-based master switch

  • All loads switch on simultaneously
  • No real savings in time or resources for light control
  • High inrush currents that reduce the reliability and safety of the electrical network
  • If accidentally switched off — for example, if guests mix it up, or a child plays a prank — everything turns off and the master switch must be reactivated
  • The "central off" scenario cannot be used as a night mode
  • It is impossible to control curtain drives

Location of the master switch

QUID master switches for controlling lighting and curtains can be located at the entrance/exit of the house or apartment, as well as in the bedroom or study — in general, in places where the function of switching off all lighting loads, as well as centralized curtain control, might be needed.

It is worth noting that such a switch should be positioned so as to rule out accidental pressing while someone is in the house. It should be visually distinct from the other switches — whether by color or by a pictogram. It could even be a key-operated switch of this kind.

As for the placement of a contactor-based master switch, everything said above applies to it as well, only with stricter requirements regarding unauthorized or accidental access. In essence, in this case such a main element plays the role of the knife switch, which it, in fact, duplicates

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Master switch in a smart home

When using "Smart Home" control systems, any switch can be assigned as the master switch, since this is exactly the "turn everything off" scenario, and it works correctly, although it already requires skills in setup and connection.

instead of a master button, one can of course use a common knife switch, circuit breaker, or load switch, each with its own advantages and disadvantages

2. Automatic circuit breaker

An automatic circuit breaker is a contact switching device (mechanical or electronic) capable of making, carrying, and breaking currents under normal circuit conditions, as well as making, carrying for a specified (rated) time, and automatically breaking currents under specified abnormal circuit conditions, such as short-circuit currents.

History of the invention of automatic circuit breakers

The line protection automatic breaker was invented by the American scientist Charles Grafton Page in 1836. The first design of an automatic circuit breaker was described by Edison in 1879, while his commercial power supply system used fuses. The design of modern automatic circuit breakers was patented by the Swiss company Brown, Boveri & Cie in 1924.

Role of automatic circuit breakers in the electrical circuit

A circuit breaker is designed to protect an electrical circuit from overload and short-circuit currents. Its main difference from a fuse link is the possibility of repeated use and the stability of the set threshold (trip) value.

Classification of circuit breakers

GOST

GOST 9098-78 establishes the following classification of circuit breakers:

  1. By the type of current of the main circuit: DC; AC; DC and AC.
    The rated currents of the main circuits of breakers intended for operation at an ambient air temperature of +40 °C must comply with GOST 6827. The rated currents for the main circuits of a breaker are selected from the series: 6.3; 10; 16; 20; 25; 32; 40; 63; 100; 160; 250; 400; 630; 1000; 1600; 2500; 2000; 4000; 6300 A. Breakers may additionally be produced for rated main circuit currents of: 1500; 3000; 3200 A.
    The rated currents of the maximum current releases of breakers intended for operation at an ambient air temperature of +40 °C must comply with GOST 6827.
    The following rated currents of maximum current releases are permitted: 15; 45; 120; 150; 300; 320; 600; 1200; 1500; 2000; 3000; 3200 A.
  2. By design: air circuit breaker (ACB) from 800 A to 6300 A, molded-case circuit breaker (MCCB) from 10 A to 2500 A, modular circuit breakers (MCB) from 0.5 A to 125 A.
  3. By number of poles of the main circuit: single-pole; two-pole; three-pole; four-pole.
  4. By the presence of current limiting: current-limiting; non-current-limiting.
  5. By type of release: with a maximum current release; with a shunt (independent) release; with an undervoltage or zero-voltage release.
  6. By the time-delay characteristic of the maximum current releases: without time delay; with time delay independent of current; with time delay inversely dependent on current; with a combination of the above characteristics.
  7. By the presence of free contacts («auxiliary contacts») for secondary circuits: with contacts; without contacts.
  8. By the method of connecting external conductors: rear connection; front connection; combined connection (upper terminals with rear connection and lower terminals with front connection, or vice versa); universal connection (front and rear).
  9. By type of installation: drawout with plug-in contacts; fixed.
  10. By type of trip design: selective, non-selective.
  11. By type of drive: manual; motor-driven; spring-operated.
  12. By the presence and degree of protection of the breaker against environmental effects and against contact with live parts of the breaker and its moving parts located inside the enclosure (in accordance with the requirements of GOST 14255).

Selective circuit breaker

In the standards of the USSR and Russia, selective circuit breakers are circuit breakers with a time delay (0.25—0.6 sec.) on instantaneous trip (see the article «Instantaneous trip») . Such breakers, combined with breakers having instantaneous trip at the lower stage, make it possible to build selective tripping in the event of a short circuit.

Selective circuit breakers (Selective Main Circuit Breaker) in accordance with the German standard DIN VDE 0641-21 also have a selectivity function, but implement it in a different way.

Design of a circuit breaker

Circuit breakers can be single-pole, two-pole, three-pole, or four-pole, and have the following structural components: a main contact system, an arc-extinguishing system, a trip mechanism drive, a release (trip unit, trip units), and auxiliary contacts (optional).

The contact system can be three-stage (with main, intermediate, and arcing contacts), two-stage (with main and arcing contacts), or single-stage (when using metal-ceramic materials).

The arc-extinguishing system can consist of chambers with narrow slots or chambers with arc-quenching grids. Combined arc-extinguishing devices — slotted chambers together with an arc-quenching grid — are used to extinguish the arc at high currents.

For each design of circuit breaker there is a limiting short-circuit current which is guaranteed not to cause the breaker to fail. Exceeding this current can cause the contacts to burn or weld together. For example, for popular series of domestic breakers with a trip current of 6-50 A, the limiting current is usually 1000—10,000 A.

Circuit breakers are manufactured with manual and motor drives, in fixed or drawout designs.

The drive of a circuit breaker serves for closing and automatic tripping, and can be manual direct-action or remote (electromagnetic, pneumatic, and the like).

Circuit breakers have direct-action relays called trip units.

Releases

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Electromagnetic release of a General Electric G61 modular circuit breaker
Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Bimetallic strip of a General Electric G61 modular circuit breaker
Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Trip unit connection diagrams

Releases (trip units) are electromagnetic, electronic, microprocessor-based, or thermal-bimetallic elements that serve to trip the circuit breaker via the free-tripping mechanism in the event of a short circuit, overload, or loss of voltage in the primary circuit (directly: electromagnetic and thermal-bimetallic elements; or indirectly through a separate independent electromagnetic release: electronic and microprocessor-based ones).

The free-tripping mechanism consists of levers, latches, rocker arms, and tripping springs, and is designed for instantaneous tripping of the circuit breaker (regardless of the position of the closing control: it is impossible to hold the circuit breaker in the closed position when the release operates), as well as to prevent re-closing of the circuit breaker onto a short circuit while a closing command continues to be present.

Electromagnetic release (instantaneous trip)

The instantaneous release is a solenoid (7), whose moving core can also actuate the tripping mechanism. The current flowing through the breaker passes through the solenoid winding and causes the core to be drawn in when a set current threshold is exceeded. Unlike a thermal release, the instantaneous release operates very quickly (fractions of a second), but at a significantly greater current overshoot: 2÷10 times the rated value, depending on the type (circuit breakers are divided into types (classes) A, B, C, and D depending on the sensitivity of the instantaneous release). In circuit breakers for large currents, starting in the 1970s electronic releases began to be used (for example, domestic circuit breakers of the «Elektron» series, some types of breakers of the A-37 and VA series), and more recently, microprocessor-based releases (microprocessor-based protection units) .

Thermal Release

It is a bimetallic strip (5) that is heated by the current flowing through it. When the current exceeds the permissible value, the bimetallic strip bends and activates the tripping mechanism. The tripping time depends on the current (the time-current characteristic) and can range from seconds to an hour. The minimum current at which the thermal release must trip is 1.45 times the setting current of the thermal release. The trip current is adjusted during manufacture using an adjusting screw (6). Unlike a fuse, a circuit breaker is ready for reuse once the strip has cooled down. The role of the thermal release can be performed by an electromagnetic (instantaneous) release equipped with a hydraulic time-delay mechanism. Such circuit breakers are notable for their fire safety, since they have no heated element (bimetallic strip).

A bimetallic strip is a band made of two metal strips with different coefficients of thermal expansion. In a circuit breaker it acts as the thermal release. The two strips are not fused together and are usually joined at one end by soldering or welding. The other ends are fixed in place. The bimetallic strip is connected in the circuit in series with the load. As it is heated by the electric current, the strip bends toward the metal with the lower coefficient of linear expansion. In the event of an overload, the bending of the strip causes the circuit breaker to trip .

Tripping of Circuit Breakers

Tripping can occur without a time delay or with a delay. Based on their own (inherent) trip time ts, o (the interval from the moment the monitored parameter exceeds its set value to the moment the contacts begin to separate), a distinction is made between normal breakers (ts, o = 0.02-1 s), time-delayed (selective) breakers, and high-speed breakers (ts, o < 0.005 s).

Normal and selective circuit breakers do not have a current-limiting action. High-speed breakers, like fuses, do have a current-limiting action, since they interrupt the circuit before the current in it reaches the value Ip.

Selective circuit breakers make it possible to implement selective protection of networks by installing circuit breakers with different time delays: the shortest at the load end, increasing in steps toward the power source.

Characteristics of Circuit Breakers

Instantaneous Trip (Interruption) Current

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Trip diagram of modular circuit breakers from various manufacturers (the region of instantaneous trip currents is shaded)

According to GOST R 50345-2010 (clause 5.3.5), household AC circuit breakers are divided into the following types (classes) by instantaneous trip current:

  • type B: from over 3·In up to and including 5·In (where In — is the rated current) (used to protect lighting circuits or lines of considerable length)
  • type C: from over 5·In up to and including 10·In (used to protect outlet groups or lines with loads that have increased starting currents)
  • type D: from over 10·In up to and including 20·In (used to protect transformers or lines with loads that have large starting currents)

Industrial circuit breakers can be of the following types:

  • type L: over 8·In
  • type Z: over 4·In
  • type K: over 12·In

European manufacturers' classifications may differ somewhat. In particular, there is an additional type A (over 2·In up to 3·In).

ABB has circuit breakers with curves K (8 — 14·In) and Z (2 — 4·In), which comply with IEC 60947-2.

Testing of Circuit Breakers

The characteristics of breakers are checked in the course of type tests (durability of markings; reliability of screws, current-carrying parts and connections; reliability of terminals for external conductors; protection against electric shock; electrical insulation arrangements; temperature rise (28-day test); interruption characteristic; mechanical and electrical (switching) endurance; short circuit; resistance to mechanical shocks and impacts; heat resistance; resistance to abnormal heat and fire; corrosion resistance).

Design Variants of Circuit Breakers

​​Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Circuit breaker in a plug-fuse-style enclosure

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

3-pole protective circuit breaker for direct mounting

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Circuit breakers used in the USA

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Circuit breakers of Soviet manufacture

Modular Circuit Breaker

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Internal construction of a modular circuit breaker
1
2
2
3
4
5
6
7
8
9

A circuit breaker rated for small currents nowadays most often has a modular design intended for mounting on a DIN rail. The internal construction of a modular circuit breaker is shown in the figure on the right. Switching on and off is done with the lever (1); the wires are connected to the screw terminals (2). The latch (9) secures the breaker's housing on the DIN rail and, if necessary, allows it to be easily removed (to do this, the latch must be pulled back by inserting a flat screwdriver into the latch's loop). Circuit switching is performed by the movable (3) and fixed (4) contacts. The movable contact is spring-loaded; the spring provides the contact pressure force in the on state and ensures their rapid opening when the tripping mechanism's pawl is released via one of two releases: thermal (5) or electromagnetic (7). An electric arc may occur while the contacts are opening, so the contacts have a special shape and are located next to the arc-quenching grid (8).

3. Voltage Monitoring Relay

A voltage monitoring relay is a device that prevents the occurrence of overvoltage or undervoltage, protecting the devices on that network. The operating principle of this device is to prevent overload of electrical appliances.

4. Load Switch

A load-break switch — a high-voltage (or low-voltage) switching device which, in terms of permissible switching currents, occupies an intermediate position between a disconnector (switching under load is prohibited (as an exception, switching on the no-load current of transformers and lines is permitted — see Disconnector for details)) and a circuit breaker (oil, vacuum, air, electromagnetic, SF6) that is capable of interrupting, without damage, both rated load currents and overcurrents under fault conditions. A load-break switch permits switching of the rated current, but is not designed to break currents during a short circuit. Interruption of overcurrents in such switches is carried out by special fuses.

Drive of the Load-Break Switch

The drive of load-break switches can be a manual type with direct closing and opening from a pre-tensioned spring. Sometimes an electric drive for closing is used (for example in the VVNR «Volna») as well as a solenoid for remote opening.

Types of Load-Break Switches

By the method of arc extinguishing, load-break switches are divided into:

  • Auto-gas — the most common type of load-break switch in Russia and the CIS;
  • Vacuum — the most promising type of load-break switch;
  • SF6
  • Air
  • Electromagnetic

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Vacuum load-break switch

Low-Voltage Household Load-Break Switch

This is a device that allows a circuit under load to be quickly closed or opened. A load-break switch is not the same as a circuit breaker, since it has no automatic tripping system. However, load-break switches have reinforced contacts whose service life far exceeds that of the contacts of ordinary breakers. This is necessary in order to be able to safely de-energize a line that is under load. If a load is switched off with an ordinary circuit breaker, the arc that forms when the circuit is broken can eventually cause the contacts to weld together. Therefore, ordinary breakers cannot be used for switching a load on and off. They are needed to protect the wiring in the event of an abnormal situation arising in the power supply circuit they protect.

Some models of load-break switches also have double contact break, which guarantees complete de-energization of the disconnected line.

In order to be able to visually confirm that the contacts of the mini knife switch have opened, some models have a special viewing window. Through it you can see the state (closed or open) of the switch's contacts.

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

They come in 1, 2, 3 and 4-pole versions. The choice depends on whether your network is single-phase or three-phase and whether the neutral needs to be broken by the switch. Such load-break switches are mounted on a standard DIN rail. This is very convenient, since they can be installed in any distribution panel.

By current rating, mini knife switches are classified in the same way as circuit breakers. That is, 16, 20, 25, 32, 40, 63, 80, 100, 125A.

Applications of Load-Break Switches

Load-break switches are installed in switchgear and substations of 6-10 kV and allow switching of up to several MVA, depending on the design and rated current.

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Auto-gas load-break switch

Advantages of the Load-Break Switch

  • Simplicity of manufacture and operation;
  • Significantly lower cost compared to other circuit breakers — several times lower (especially for auto-gas types);
  • Ability to switch off and on rated load currents;
  • Availability of inexpensive overcurrent protection in the form of fuses, usually filled with quartz sand (type PK, PKT);
  • Presence of a visible break between the contacts, which rules out the need to install an additional disconnector (a visible break is necessary for the safety of work on the outgoing line).

Disadvantages of the Load-Break Switch

  • Switching of rated powers only;
  • Short service life (for gas-blast type load-break switches);

Additional Elements of the Load-Break Switch

As additional elements, a load-break switch may be fitted with manually operated earthing blades (in which case mechanical mutual interlocking of the earthing blades and the load-break switch's power contacts is usually provided), a remote tripping solenoid, and signal contacts indicating the position of the switch contacts and fuse operation.

5. Residual Current Device, RCD, RCBO

Not to be confused with a circuit breaker.

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
An RCD with a rated residual operating current IΔn of 0.03 A

Residual current device (RCD) , (English: residual current device, RCD) - a mechanical switching device intended to make, carry and break electric currents under normal operating conditions and to open the contacts when the residual current reaches a specified value under specified conditions. Used as an RCD are a circuit breaker controlled by residual current without built-in overcurrent protection (RCCB) and a circuit breaker controlled by residual current with built-in overcurrent protection (RCBO).

Difference between an RCCB and an RCBO: an RCCB trips on a leakage current that must not exceed 30 mA for personal protection and 0.5 A for fire protection; an RCBO protects not only against leakage, it also provides reliable protection against overloads and short circuits in the mains network

Purpose of the Residual Current Device

RCDs with a rated residual operating current not exceeding 30 mA are intended for additional protection of persons against electric shock. Used as part of «automatic disconnection of supply» protection .

In AC systems, additional protection by means of an RCD must be provided for:

  • socket outlets and power outlets with a rated current up to 32 A;
  • mobile equipment with a rated current up to 32 A used outdoors.

The RCD disconnects the protected circuit:

  • upon direct contact of a person or animal with live electrical equipment;
  • upon failure of the basic insulation and contact of live parts with an exposed conductive part.

Requirements for the installation and use of RCDs are given in the IEC 60364 series of standards for building electrical installations.

Operating Principle of the Residual Current Device

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Diagram explaining the operating principle of an RCD
Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
An RCD disassembled

The main component of an RCD is a differential (residual current) transformer, designed to detect the residual current. If the residual current exceeds or equals the rated residual operating current, the electrical circuit will be opened.

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices
Internal construction of an RCD connected in-line with the wires

The photograph shows the internal construction of one type of RCD. This RCD is designed to be installed in-line with the wire. The line and neutral conductors from the power source are connected to terminals (1), and the RCD's main circuit is connected to terminals (2).

When the button (3) is pressed, the contacts (4) (as well as another contact hidden behind assembly (5)) close, and the RCD allows current to flow. The solenoid (5) holds the contacts in the closed position after the button is released.

The secondary winding (6), to which the residual-current release is connected. Under normal conditions the current in the line conductor equals the current in the neutral conductor, but these currents are opposite in direction. Thus, the currents cancel each other out and no EMF is induced in the coil of the differential (toroidal) transformer.

A ground fault current disrupts the balance in the differential transformer: a larger current flows through the line conductor than through the neutral conductor (part of the current flows through the person's body, i.e. bypassing the transformer). The residual current in the primary winding of the differential transformer causes an EMF to appear in the secondary winding. This EMF is immediately detected by the sensing device (7), which cuts off power to the solenoid (5). The de-energized solenoid no longer holds the contacts (4) closed, and they open under the force of the spring.

The device is designed so that tripping occurs within a fraction of a second, which greatly reduces the severity of the consequences of electric shock.

The test button (8) makes it possible to check that the device is working by passing a small current through the orange test wire (9). The test wire passes through the core of the differential transformer, so the current in the test wire is equivalent to an imbalance of the current-carrying conductors, i.e. the RCD should trip when the test button is pressed. If the RCD does not trip, it is faulty and must be replaced.

Limitations of the Residual Current Device

The RCD will not trip if a person comes under voltage but no ground fault current arises, for example when simultaneously touching both the line and neutral conductors of the protected circuit. It is impossible to provide protection against such contact, since there is no way to distinguish current flowing through a person's body from the normal flow of current in the load. In such cases only mechanical protective measures are effective (insulation, non-conductive enclosures, etc.), as well as switching off the electrical installation before servicing it.

An RCD whose operation depends on the mains voltage needs a power supply, which it draws from the protected circuit. This makes it potentially dangerous when a break occurs in the neutral conductor upstream of the RCD while the line conductor remains live. In this case the RCD will be unable to disconnect the circuit, since the voltage in the protected circuit is insufficient for it to operate. An RCD whose operation does not depend on the mains voltage is free of this drawback.

History of the Residual Current Device

The first patent (German patent No. 552678 of 08.04.28) for an RCD was obtained in 1928 by the German company RWE (Rheinisch — Westfälisches Elektrizitätswerk AG). The first working prototype of the protective device was produced by the same company in 1937. A small differential transformer was used as the sensor, and a polarized relay with a sensitivity of 0.01 amperes and a response time of 0.1 s served as the actuating element.

The sensitivity of the prototype device was 80 mA – further increases in sensitivity were held back by the lack of materials with the required magnetic properties. In 1958, Dr. Biegelmeier of Austria proposed a new circuit design for the RCD. Such RCDs are now marked with the letter G. In this design, false tripping caused by lightning discharges was eliminated and the sensitivity was increased to 30 mA.

The boundary curves of alternating current and the physiological effect of current on the human body were established through tests in 1940—1950 at the University of California, Berkeley by the American scientist Charles Dalziel. During the tests, volunteers were exposed to electric current with a known voltage and current magnitude.

In the early 1970s, most RCDs were produced in circuit-breaker-type enclosures. Starting in the early 1980s, in the USA most residential RCDs were already built into outlets.

In the USSR, the first experiments in RCD design began in 1964. The first production RCD for equipping three-phase electrified tools was manufactured in 1966 by the Vyborg «Elektroinstrument» plant, based on a design by VNIISMI. The first residential RCD in the USSR was developed in 1974, but was not put into series production. Series production of residential RCDs began in 1988 in significant quantities (up to 200 thousand units per year). A typical RCD of that time was an extension cord with a socket on the cord. From 1982, all educational electrical equipment supplied to schools was mandatorily fitted with an RCD, which received the name «school type». Production volume reached up to 60 thousand units per year. For the needs of industry and agriculture, protective devices IE-9801, IE-9813, UZOSh 10.2 (still in production), and RUD-0.5 were manufactured.

Nowadays, RCDs intended for DIN-rail mounting in a distribution board are predominantly used, while built-in RCDs have not yet become widespread.

Classification of Residual Current Devices

By method of control

  • RCDs without an auxiliary power source
  • RCDs with an auxiliary power source:
    • performing automatic tripping upon failure of the auxiliary source, with or without time delay:
      • performing automatic reclosing when the auxiliary source is restored
      • not performing automatic reclosing when the auxiliary source is restored
    • not performing automatic tripping upon failure of the auxiliary source:
      • capable of tripping when a hazardous situation arises after failure of the auxiliary source
      • not capable of tripping when a hazardous situation arises after failure of the auxiliary source

By type of installation

  • fixed, installed with fixed wiring
  • portable, installed with flexible cords and extension leads

By number of poles

  • two-pole;
  • four-pole.

By ability to adjust the tripping residual current

  • non-adjustable;
  • adjustable:
    • with discrete adjustment;
    • with continuous adjustment.

By resistance to impulse voltage

  • allowing the possibility of tripping under impulse voltage;
  • resistant to impulse voltage.

By operating conditions in the presence of a DC component

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Type AC RCD: an RCD whose tripping is ensured by a differential sinusoidal alternating current, whether suddenly applied or slowly rising .

Type A RCD: an RCD whose tripping is ensured both by sinusoidal alternating and by pulsating direct differential current, whether suddenly applied or slowly rising .

Type B RCD: an RCD that guarantees tripping like a type A device and additionally trips:

  • at differential sinusoidal alternating current with a frequency of up to 1000 Hz;
  • at differential sinusoidal alternating current superimposed on a smoothed direct current;
  • for differential pulsating direct current superimposed on a smooth direct current;
  • for differential pulsating rectified current from two or more phases;
  • for differential smooth direct current, applied suddenly or rising gradually, regardless of polarity[10].

RCD Type F: an RCD that guarantees tripping as a Type A device in accordance with the requirements of IEC 61008-1 and IEC 61009-1, and additionally trips:

  • for composite differential current applied suddenly or rising gradually between a phase and neutral, or between phases and a grounded mid-point conductor;
  • for differential pulsating direct current superimposed on a smooth direct current[10].

By presence of a time delay (in the presence of a differential current)

  • RCD without time delay — general-purpose type;
  • RCD with time delay — type S, to ensure selectivity.

For a simple test of different types of RCBOs, the so-called battery test can be used

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

Types of Switching Devices: Voltage Monitoring Relays, Load Break Switches, Residual Current Devices

See also

  • [[b9111]]
  • [[b8443]]
  • relay
  • transient processes
  • dielectric (air) breakdown

See also

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