residual current device

Contents Principle of operation Symbols Protection by Residual Current devices Special installations and locations Discrimination Add-on blocks Commercial devices Earth fault relays Torroids Avoidance of unintentional operation Testing of Residual Current Devices Fault finding Maintenance page 103 page 104 page 105

page 106-107

page 108-109 page 110 page 111-112-113-114 page 115-116 page 117 page 118

page 119

page 120 page 121

101

residual current device

Residual Current Devices RCD is a generic term for all types of residual current operated device which by definition is: - A mechanical switching device or association of devices intended to cause the opening of the contacts when the residual current attains a given value under specified conditions. The more common types are...

Residual Current Operated Circuit Breaker (RCCB) A mechanical switching device designed to make, carry and break currents under normal service conditions and to cause the opening of the contacts when the residual current attains a given value under specified conditions. Depending on the age of these devices they will comply with either BS EN 61008 or BS 4293. The British Standard BS 4293 was withdrawn on 1st July 2000 and its moratorium period will end in July 2005, which means manufacturers may continue to produce residual current devices complying with BS 4293 up to 2005 providing the devices are in production before July 2000. In line with the Companys forward thinking and innovative approach to product development, Hager has already introduced residual current devices complying with the Harmonised Standards

Circuit Breaker Incorporating Residual Current Protection. (CBR) A circuit breaker providing overcurrent protection and incorporating residual current protection either integrally or in combination with a residual current unit, which may be factory fitted or fitted in the field. These devices comply with BS EN 60947-2: Circuit Breakers - Annex B.

Socket Outlet Incorporating A Residual Current Device. (SRCD) A socket outlet for fixed installations, which incorporates an integral sensing circuit that will cause the switching contacts in the circuit to open automatically at a predetermined value of residual current. These will comply with BS 7288: 1990.

Residual Current Operated Circuit Breaker With Integral Overcurrent Protection (RCBO) A residual current operated circuit breaker designed to perform the functions of protection against earth fault currents, overloads and short-circuits. These devices comply with BS EN 61009. Appendix G of this Standard also covers RCD add-on blocks for BS EN 60898 circuit breakers

Earth Fault Relay A device incorporating the means of detection of an earth fault current, comparing its value to the earth fault current operating value and giving a signal to an associated switching device to open the protected circuit when the earth fault current exceeds this value. Relays can be directly connected or fed from a separate torroid. There is currently no specific standard for this type of device. It should therefore comply with IEC 755 general requirements for residual current operated protective devices.

102

residual current device principle of operation

Principle of operation Residual current devices monitor the current flowing in a circuit by means of a torroid, which is a small current transformer specially designed to detect earth fault currents. All live conductors will pass through this coil, the currents flowing in the live conductors of a healthy circuit will balance and therefore no current will be induced in the torroid. Live conductors of a circuit include all phase and neutral conductors. When an earth fault is present on a circuit, current will be flowing to earth through an abnormal or unintended path. This earth fault path could be through a person in contact with live parts as shown in Figure 20 as Ic or where insulation has failed through an exposed conductive part shown as Id.
Id

I2

I1

Splitter plates
Id

Ic

Trip relay

Fig 20 Current flowing through torroid in healthy circuit Ires = I1-I2 = 0 Current flowing through torroid in circuit with earth fault Ires = I1-I2=Ic + Id This earth fault current, known as Residual Current (Ires), is seen by the torroid as an imbalance. When the magnitude of this residual current reaches the sensitivity setting In of the device, it will operate to open the contacts.

Torroid

Technology There are two types of technology available in residual current devices, electromagnetic & electronic and both offer very reliable performance. Electromagnetic devices use a very sensitive torroid, which operates the trip relay when it detects very small residual currents. These devices generally require no reference earth lead and are unaffected by temporary loss of supply, as the power to trip the device is derived directly from the fault current. Electronic devices do not need such a sensitive torroid as electronic circuits within the device amplify the signal to operate the trip relay. However, these devices often require a safety earth reference lead to ensure that the device will continue to operate in the event of the supply neutral being lost. The power to trip the device is taken from both the fault current and the mains supply, enabling the overall size of the devices to be reduced. These devices should be disconnected whilst carrying out insulation resistance tests to prevent damage to the device and to avoid incorrect test results. Hager manufacture a range of devices using both technologies. The RCCB range, CBR CB add-on blocks and two module RCBO range are electromagnetic devices, while the single module RCBO range and Earth Fault Relays use electronic technology. The CBR MCCB add-ons are available in both technologies.

103

residual current device symbols

Symbols. A number of different symbols and values are used to identify devices. It is important to be able to read and understand these values especially when periodically inspecting and testing an installation, as the original design data may not be available. In Rated current of the contacts - Expressed in amperes e.g. 100A. RCCB 2P 16A 25A 40A 63A 80A 100A In Sensitivity or residual operating current - Usually expressed in amperes e.g. 0.03A for 30mA Selective type - Indicates that the device incorporates a tripping time-delay feature Time delay setting - Usually expressed in seconds e.g. 0.3 Operational voltage - This is the supply voltage at which the device is expected to operate, however it should be noted that the devices are current operated and therefore may be able to operate at other voltages. Hager two pole RCCB devices are suitable for both 230Vac and 110Vac. Rated making and breaking capacity expressed in amperes e.g. 1500A Rated conditional short-circuit current 4P 16A 25A 40A 63A 80A 100A Ue 1500A 1500A 1500A 1500A 1500A 1500A 13kA 13kA 13kA 13kA 13kA 13kA 6kA 6kA 6kA 6kA 6kA 6kA 3.5kA 11kA 3.5kA 11kA 3.5kA 11kA 3.5kA 11kA 3.5kA 11kA 3.5kA 11kA 5kA 5kA 5kA 5kA 5kA 5kA 3kA 3kA 3kA 3kA 3kA 3kA 1500A 1500A 1500A 1500A 1500A 1500kA 13kA 13kA 13kA 13kA 13kA 13kA 6kA 6kA 6kA 6kA 6kA 6kA 3.5kA 11kA 3.5kA 11kA 3.5kA 11kA 3.5kA 11kA 3.5kA 11kA 3.5kA 11kA 5kA 5kA 5kA 5kA 5kA 5kA 3kA 3kA 3kA 3kA 3kA 5kA
short circuit current capacity with of the RCCB only 60A

BS 1361 fuses
80A 100A

with BS 88 fuse
60A 80A 100A

It is important to remember that where a residual current device does not incorporate overcurrent protection a fuse or circuit breaker must always be used.

S
t

Table 36 There are situations where these tables are not applicable. An example is when an RCCB is incorporated in a consumer unit complying with BS EN 60439-3 Annex ZA. Annex ZA prescribes the conditional short-circuit test to verify the capability of the assembly to safely withstand a 16kA fault. Hager RCCB devices also feature an earth fault indicator, which indicates whether the device has operated due to a residual current or to remote tripping by an undervoltage release or shunt device. If the device has been operated manually the indicator will not change. AC class These devices detect residual sinusoidal alternating currents, whether these are suddenly applied or rise slowly. However, they may not detect non-linear residual currents which have a dc component, due to power semiconductor switching systems or computer-based equipment connected to the circuit. Devices that will detect both residual sinusoidal alternating currents and residual pulsating direct currents, whether suddenly applied or slowly rising. This type of device is sometimes referred to as dc sensitive but cannot be used on pure dc circuits. This symbol indicates the suitability of the device as a disconnector to perform the function of isolation. The RCCB & RCBO devices are lockable by using an MCB locking kit MZ175 and a suitable padlock. High level filtering - All RCDs manufactured by Hager incorporate a filtering circuit to help eliminate the nuisance tripping that voltage and current transients may cause. These transients may be due to switching of large or non-linear loads, faults on other parts of the installation or disturbances on the supply network.

lm Inc

The Hager RCCB range has a making and breaking capacity (Im) of 1500A, which means it can open, or be closed onto a fault of that magnitude without damage.If the RCCB is coordinated correctly with a fuse or circuit breaker the manufacturer can assign a rated conditional short-circuit current Inc. This being the maximum value of fault current (r.m.s.) without imparing its function. with MCBs MT NB 6-63A 6-63A B B

RCCB 2 poles 16A 25A 40A 63A 80A 100A 4 poles 16A 25A 40A 63A 80A 100A Table 35

short circuit current capacity of the RCCB only

NC 6-63A C

ND 6-63A D

A class

1500A 1500A 1500A 1500A 1500A 1500A

6kA 6kA 6kA 6kA 6kA 6kA

10kA 10kA 10kA 10kA 10kA 10kA

10kA 10kA 10kA 10kA 10kA 10kA

6kA 6kA 6kA 6kA 6kA 6kA Hi Disconnector

1500A 1500A 1500A 1500A 1500A 1500A

6kA 6kA 6kA 6kA 6kA 6kA

6kA 6kA 6kA 6kA 6kA 6kA

6kA 6kA 6kA 6kA 6kA 6kA

4.5kA 4.5kA 4.5kA 4.5kA 4.5kA 4.5kA

104

residual current device protection by residual current devices

Protection by Residual Current Devices Residual current devices in their many forms are used on electrical installations to provide protection against three types of hazard associated with electricity. (i) Direct contact, defined as contact of persons or livestock with live parts. (ii) Indirect contact, defined as contact of persons or livestock with exposed-conductive-parts which have become live under fault conditions. (iii) Electrical fires caused by arcing in high resistance earth faults. Protection against direct contact must be achieved using one of the basic measures detailed in regulation 412-01-01 of BS 7671. Where necessary, residual current devices can be used to provide additional supplementary protection, provided the requirements of regulation 412-06 are met, but they must not be used as the sole means of protection against direct contact. A residual current device will reduce the risk of electric shock provided it has a residual operating current not exceeding 30mA and an operating time not exceeding 40ms when a residual current of 150mA flows. These characteristics are derived from the graph shown in Fig 21 effects of current on the human body, which is taken from IEC 479-1.This illustrates that the human body can tolerate very small currents for reasonably long periods and moderate currents for very short periods. Regulation 471-16 Supplies for portable equipment outdoors. - Socket outlets rated at 32A or less reasonably expected to supply portable equipment for use outdoors, as detailed in regulation 471-16-01. Circuits supplying portable equipment for use outdoors, connected other than through a socket-outlet by means of flexible cable or cord having a current-carrying capacity of 32A or less as detailed in regulation 471-16-02.

Here a residual current device with the characteristics detailed in 412-06-02 must be used as the protection is against direct contact i.e. 30mA or less with a maximum disconnection time of 40ms when a residual current of 150mA flows. Section 413 Protection against indirect contact Residual current devices can be used where protection against indirect contact is provided by earthed equipotential bonding and automatic disconnection of supply and the conventional means of achieving automatic disconnection by fuses or circuit breakers cannot be met due to high earth fault path impedance preventing disconnection within the specified times. The selection of device sensitivity calculated using the formula Zs In 50 V from regulation 413-02-16 for TN supply systems.

If
f P.M.E. earthing conductor

If

C.P.C. If
M E T

If

Where circuits extend beyond the equipotential zone on a TN system and are protected by a residual current device, this section may be treated as TT. Residual current devices are the preferred method of achieving automatic disconnection of circuits on TT systems detailed in regulation 413-02-19. The selection of device sensitivity calculated using the formula RA In 50V from regulation 413-02-20 for TT supply systems.

If
Fig 21 In zone 2 a person would usually experience no harmful effects, so 20mA for 500ms or 100mA for 100ms would be deemed safe. If a 100mA current was allowed to flow for 200ms it would fall within zone 3. This is a more dangerous situation and if allowed to continue for 500ms or more it would enter zone 4, indicating a high risk of lethal effects. Requirements of the Regulations There is an increased risk from electric shock by direct contact when equipment is used outside the equipotential zone, due to the increased likelihood of persons being in hand-held contact with the equipment and the increased earth fault path impedance likely to be encountered.

If

C.P.C.
earthing conductor earth electrode
M E T

If

If If RA

RA

Relectrode

+ Rearthing conductor + RC.P.C.

Regulation 471-08 Protection by earthed equipotential bonding and automatic disconnection of supply. Where protection by earthed equipotential bonding and automatic disconnection is used to protect against indirect contact on TT systems, regulation 471-08-06 requires that all socket outlet circuits be protected by a residual current device.

105

residual current device - and special installations and locations

Part 6 special installations or locations The more onerous situations encountered on electrical installations are detailed in part 6 of BS 7671. Extra protective measures need to be taken in these areas. In many cases the use of residual current devices is a recognised method of achieving compliance with the regulations. Section 601 Locations containing a bath or shower Zones 0, 1,2 & 3 specified in 601-02-01. 601-08-02 for a shower cubicle installed in a room other than a bathroom or shower room e.g. bedsit room or guest bedroom any socket outlet that is not SELV or a shaver supply unit must be protected by an RCD with In 30mA. fixed current using equipment other than in (i), (ii) and (iv) installed in Zone 1 e.g. ELV transformer for lighting, must be suitable for conditions of that zone and the supply circuit is to be protected by an RCD with In 30mA. in zone 3 current using equipment other than fixed current using equipment e.g. wall mounted hair dryers, shall be protected by an RCD with In 30mA. If it is not possible to locate socket outlets outside Zone B then they may be installed inside, providing they comply with BS EN 60309-2 and meet all the requirements of 602-07-01. This requires them to be more than 1.25m (arms reach) outside the border of Zone A, at least 0.3m above the floor and protected by either an residual current device of 30mA or less, or by electrical separation with a safety-isolating transformer placed outside all three of the Zones. Other equipment installed in Zone C must be protected in accordance with 602-08-03 protection individually by electrical separation, SELV or a residual current device rated at 30mA or less.

601-09-02 (iii)

Due to the nature of the installation further protection by enclosures of a high IP rating is also required. Section 604 Construction site installations Regulation 604-04-01 requires that on TN systems the maximum disconnection times for circuits meet the times laid out in table 604A. For 230V circuits this means a reduced disconnection time of 0.2 seconds. Residual current devices may be used if the overcurrent protective devices cannot meet the disconnection times in table 604A. (604-04-07) Regulation 604-04-08 requires that for TN systems the formula in 413-02-16 be replaced by Zs In 25 V reducing the maximum touch voltage to 25V Regulation 604-05-01 requires that for TT systems the formula in 413-02-20 be replaced by RA In 25 V.

601-09-03

Although not a requirement of BS 7671 in Section 601, the use of RCDs to protect electric shower units is common. The manufacturers of electric showers often recommend the use of 30mA RCD to protect the shower supply circuit. It is also quite common to find RCD protection specified to protect immersion heater supplies, particularly where it is considered there is a risk of the end user gaining access to live parts of the terminal box on the water cylinder. Section 602 Swimming Pools The area in and around a pool is divided into zones. Zone A Zone B is effectively the basin of the pool and/or foot bath. extends 2.0 metres beyond the rim of the basin horizontally and 2.5 metres vertically. If there are diving boards, starting blocks or chutes the vertical measurements must be taken also from the plane of these items but the horizontal measurement is limited to 1.5 metres. extends a further 1.5 metres beyond zone B horizontally and 2.5 metres vertically above this plane.

RCD maximum Zs or RA values maximum touch voltage In (A) 0.01 0.03 0.1 0.3 1 3 25V 2500 833 250 83.3 25 8.33 50V 5000 1666 500 166.6 50 16.66

Zone C

Earth electrode resistances over 200 are likely to be unstable. For compliance with regulation 604-08-03 every socket outlet must be protected by one or more of the following automatic disconnection and reduced low voltage system A residual current device rated at 30mA or less SELV Electrical separation

Each Zone has specific regulations regarding the type of equipment and the measures of protection to be provided. The use of residual current devices may be used to provide protection. If a socket outlet, switch or accessory is to be installed inside the Zones then it is preferable for it to be in Zone C. 602-07-02 allows this provided it is either protected individually by electrical separation, protected by SELV, protected by a residual current device of 30mA or less or a shaver socket to BS 3535.

When using residual current devices to supply a complete installation, consideration should be given to S type or time-delayed devices, particularly if heavy cranes, for example, are to be operated. In this instance the use of a 30mA device to protect the whole system would be ill advised due to the potential loss of construction time if the device were to operate. The scope of section 604 does not extend to installations in construction site offices, cloakrooms, meeting rooms, canteens, restaurants, dormitories, toilets etc., where the general requirements of the IEE Wiring Regulations apply.

106

residual current device - and special installations and locations

Section 605 Agricultural & Horticultural Premises These require more careful consideration as there is increased danger from environmental conditions such as the presence of water, fire risk from storage of combustible materials such as straw and hay, and the susceptibility of livestock to the effects of electric shock. To safeguard against the risk of fire Regulation 605-10-01 requires that a residual current device having a rated residual operating current not exceeding 500mA protect circuits not essential to the welfare of livestock. A device of 300mA may be required for compliance with 482-02-06 where combustible materials are stored or processed. Regulation 605-05-09 requires that for TN systems the formula in 413-02-16 be replaced by Zs In 25 V reducing the maximum touch voltage to 25V. Regulation 605-06-01 requires that for TT systems the formula in 413-02-20 be replaced by RA In 25 V. Regulation 605-03-01 requires all socket outlets not supplied by a SELV source be protected by a 30mA RCD, even reduced low voltage sockets must be protected in these types of installation. Section 606 Restrictive conductive locations Section 606 outlines the extra precautions to be taken when equipment is intended to be used in locations where movement is restricted and contact with conductive parts is likely. Where the Class II equipment is used to provide protection against indirect contact, as detailed in 606-04-01, further protection must be provided by a residual current device rated at 30mA or less.

Section 608 division one caravans & motor caravans Regulation 608-03-02 requires all circuits not protected by Class II or equivalent insulation to be supplied by a residual current device with a maximum sensitivity of 30mA. If RCBO devices are used on the final circuits instead of one main 30mA RCCB then they must be of the two-module SPSN type that disconnects all live conductors in accordance with regulation 608-04-01. A live conductor can be phase or neutral.

Section 608 division two caravan parks Regulation 608-13-05 requires all socket outlets connecting to caravans to be protected individually or in groups of not more than three by a 30mA residual current device. As there is no way of discriminating between the devices in the caravans and on the site it is advisable to install the site device in the caravan pitch supply equipment enclosure adjacent to the socket to avoid unnecessary inconvenience to the consumers.

General Recent changes in BS 7671 : 2001, have addressed the issue of using RCDs to prevent the initiation of fires in areas of increased fire risk due to arc faults arising from a breakdown of insulation. 482-02-06 (i) requires wiring systems other than mineral insulated or busbar trunking to be protected by an RCD with In 300mA in accordance with 531-02-04 i.e. ensuring to minimise risk of nuisance tripping.

107

residual current devices discrimination

Discrimination To achieve discrimination only the protective device immediately upstream of a fault must disconnect, leaving the remainder of the installation energised. Regulation 533-01-06 requires that where necessary to prevent danger any intended discrimination must be achieved. Where residual current devices are used to supply multiple circuits, due to the very low residual operating currents it is impossible to guarantee time/current discrimination between the upstream RCD and the downstream fuses or circuit breakers. The use of builtin time delays will provide discrimination.
Upstream 100mA Downstream 30mA

Typical RCCB Time/Current Characteristics

Earth fault 150mA 30mA type device 100mA type device 100mA S type device 40ms 130ms 300ms 500ms

Discrimination between Circuit Breakers with add on RCCBs. Having decided on the type and the limit of discrimination of the circuit breakers in the system, it is very important to consider the discrimination between any add on RCCBs. In theory it is possible to achieve current discrimination between RCCBs but the limit of discrimination is too low for practical purposes. Time discrimination is by far the best method and is achieved by delaying the tripping of the upstream RCCB. Note that the limit of discrimination is the instantaneous setting of the associated circuit breaker. In other words if the earth fault current is greater than the instantaneous trip setting of the associated circuit breaker, the circuit breaker will trip regardless of the time delay on the RCCB.

Tripping Time

108

residual current devices discrimination

Where it is necessary to provide residual current protection to all or large numbers of circuits the best method is to install RCBO devices in parallel with each other. In this way compliance with 314-01-01 would be achieved and discrimination between residual current devices would not need to be considered.
SP&N RCBO

Regulation 531-02-09 dictates that where two or more residual current devices are in series, and discrimination is necessary to prevent danger, the characteristics of these devices shall provide the intended discrimination. This refers to selective type or time-delayed residual current devices. These incorporate an in-built or adjustable time delay, which allows upstream devices to use this delay to give downstream units sufficient time to operate. The discrimination achieved by using S type devices can be illustrated by referring to table 1 of BS EN 61008-1.
MCB

SP&N RCBO Disconnector SP&N RCBO

30mA RCCB

MCB

SP&N RCBO

MCB

MCB

The main drawback with this solution is cost, so a compromise would be to split circuits into smaller groups and use residual current devices in parallel. Devices of differing sensitivities can be utilised to provide the required level of protection.
MCB

100mA 'S' type RCCB

MCB

MCB

MCB 30mA RCCB MCB

MCB

MCB

MCB Disconnector

For simple single phase TT installations a good compromise would be to use a split-load time-delayed consumer unit with a 100mA S type RCD main switch feeding the entire board, but with a number of final circuits also fed through a 30mA general purpose G RCD.
SPSN RCBO
N

MCB

MCB 100mA RCCB MCB

SPSN RCBO 100mA 'S' type RCCB

N

SPSN RCBO
MCB
N

On TT systems where residual current devices are commonly used at the origin of the installation, the practice of having a main switch-disconnector feeding two or more residual current devices which each feed one or more final circuits is only one of several methods of achieving compliance. On larger installations the need for devices in series is often a requirement. Due to the very low operating currents of residual current devices, it is unlikely that current discrimination will be achieved between general purpose devices as the prospective earth fault current is likely to be much higher than the In settings of the devices installed.

SPSN RCBO
N

Where RCBO devices are to be installed downstream of an S type RCD the RCBO must disconnect all live conductors of the circuit. This is to prevent a loss of discrimination in the case of a neutral to earth fault, which would not be cleared by a device which only disconnected the phase conductors. Note: A neutral conductor is defined as a live conductor.

109

residual current device add-on blocks

RCCB add-ons RCCB add-ons 3 sensitivities 30mA, 100mA & 300mA instantaneous. 2 sensitivities 100mA & 300mA time delayed. RCCB add-ons can be associated with devices rated from 0.5 to 63A in 2 and 4 poles. Wiring diagram
1 3

Commercial applications connection capacity 63A = 16mm2

63A = 25mm2

characteristics easy coupling (drawer system) easy disassembly (without damage) conforms to BS EN 61009 Appendix G

MCB & RCCB add-on association chart 2 pole In sensitivity cat. ref. (standard) cat. ref. (time delayed) MCB suitability NB NC ND width when combined with MCB 30mA NM BD285 80 - 100A 6-63A 0.5-63A 6-63A 6-63A 0.5-63A 6-63A 4 module 70mm 300mA BF285 80 - 100A 5.5 modules 96.25mm 300mA time delay BP285 80 - 100A 30mA BD485 80 - 100A 300mA BF485 80 - 100A 6-63A 0.5-63A 6-63A 6-63A 0.5-63A 6-63A 6-63A 0.5-63A 6-63A 6-63A 0.5-63A 6-63A 7 module 122.5mm 300mA time delay BP485 80 - 100A 30mA BD264 63A 100mA BE264 BN264 300mA BF264 BP264 30mA BD464 4 pole 63A 100mA BE464 BN464 300mA BF464 BP464

10.5 modules 183.75mm

Mounting

In

110

residual current device commercial devices

On larger systems more than one level of time-delay devices may be required to achieve discrimination and Hager MCCB CBR & Earth Fault Relay ranges allow delays of up to 3 seconds. Where adjustable devices are used and someone other than a skilled or instructed person is likely to operate it, the device must be designed or installed in such a way that it is not possible to modify or adjust the settings without the use of a tool or key, and that the modification results in a visible indication of its setting or calibration as required by regulation 531-02-10. CBR devices are available for MCCBs up to 250A and offer adjustable settings for both sensitivity and time delay. Earth fault relays can be used for all MCCB devices Frame size125A Characteristics product number of poles electrical characteristics nominal current max (40) in A H125B 3, 4 125A 240-415V relays sensitivity In 0.03, 0.1, 0.3, 1, 3, 10A inst 0.06, 0.15, 0.3, 0.5,1 test button mechanical test button electrical reset button sensitivity selection optical scale fault indication 50% In contact indication anti transient cable capacities rigid mm2 flexible mm2 dimensions weight (kg) 4 pole mounting din rail fixing yes yes yes yes yes yes yes yes 70 70 101 x 140 x 74 2.5 yes lateral test button mechanical test button electrical reset button sensitivity selection optical scale fault indication 50% In contact indication anti transient cable capacities rigid mm2 flexible mm dimensions weight (kg) 4 pole mounting din rail fixing
2

Frame size 160 - 250A Characteristics product number of poles electrical characteristics nominal current max (40) in A H160B 4 160A 240-415V relays sensitivity In 0.03, 0.1, 0.3,1.3, 10A inst 0.06, 0.15,0.3, 0.5,1 yes yes yes yes yes yes yes yes 120 120 140 x 104 x 91 2.75 no direct to product 2.75 no yes yes yes yes yes yes yes yes 120 120 H250B 4 250A 240-415V

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residual current device

Residual current blocks for MCCBs Electromechanical versions are prevented from unwanted tripping caused by transient leakage currents (type AC) In addition to the electromechanical type, electronic version also affords protection against direct current faults (type A) Indication of a fault residual - upon detection of residual fault current: 1 the reset button of the RCD releases automatically 2 the breaker lever switches to position O - it is impossible to re-engage the breaker as long as the RCD has not been re-engaged, with the reset button depressed, or as long as the fault residual persists in the system - positive safety. Reset button permits the RCD to be re-engaged after tripping, thus also allowing the re-engagement of the breaker Test button permits periodic testing of the residual detection function. The maximum residual fault current which can be tested in In. LED display - an on display indicates the RCD is functioning correctly - a display 50% In indicated when a residual current of 50% of the setting is detected SD contact + 50% contact a fixed contact (3A-250V) allows remote indication of a trip, a further contact permits a signal to be transmitted indicating when the fault current level has passed beyond 50% of the set value In
N L1 L2 L3
ON ELECTRONIC CARD 125A 250A

L1

L2

L3

Release CA

Test button

125A

L1

L2

L3

L1

L2

L3

CA

50%

Test button

range of settings - sealable settings for both sensitivity and time delay - an RCD adjusted to a sensitivity of 30mA cannot support a time delay - the tripping must be instantaneous On 125A, 160A and 250A RCDs the mechanical test button also assures isolation of the RCDs electronic circuit, permitting risk free insulation tests up to 2500V

112

residual current device

RCD blocks 125A Electromechanical version
CA 12 11 14 50 % IDn 53 54 (3 A - 250 V M ) (0,1 A - 250 V M )

fixed sensitivity instantaneous trip anti-transient (nuisance trips) residual fault output contact reset button test button

HB 101 312101

test

Push to trip 230-415 V M 50/60 Hz In 125 A IEC 60947-2

Electronic version adjustable sensitivity (30, 200mA, 1, 3, 10A) adjustable trip delay anti-transient and DC sensitive contact for signalling trip contact for signalling 50% fault level LED indication of reset button test button - functioning - isolation level

RCD blocks 160A and 250A

HB 211 334211 1
Push to trip

adjustable sensitivity (30, 200mA, 1, 3, 10A) adjustable trip delay anti-transient and DC sensitive contact for signalling trip contact for signalling 50% fault level LED indication of reset button test button - functioning - isolation level

50 % I Dn ON

reset test

127-415 V M In 250A IEC 947-2

50/60Hz

VM

VM

50 % IDn (0,1 A - 250 VM)

54

1 2

14 12 11

53

CA (3 A - 250 VM)

113

residual current device

Breaker + RCD add-on block 400A Switch + RCD add-on block 400A electronic add-on RCD 320A and 400A adjustable sensitivity (30, 100, 300,500mA) trip delay 0 to 1s (inst, 60, 100, 250, 500ms and 1s) sealable settings test button trip signal terminal plus front display power supply from above (obligatory) anti-transient (nuisance trips) and DC sensitive

The RCD block causes the breaker to trip via a specific trip coil. The 3 wires make an SD signal contact when an RCD trip occurs.

N Blue

V~
N

6A

Black Red

2
HB 701 312701 5

The RCD block is mounted at the factory, and only on breakers of the electromechanical type

0,03 0,1 0,3 0,5

test

IDn (A)
30 10 3

0,15 0,2

Dt (s)
2

0,5 1

110/480 V M 50/60Hz In 400 A IEC 947-2

3
test button In adjustment delay adjustment

114

residual current device earth fault relays

Earth Fault Relays These residual current sensing devices are used in conjunction with either a contactor, an alarm or more typically, moulded case circuit breakers. They enable protective conductor protection to be provided on devices up to 800A. Earth fault relays are manufactured to and comply with IEC 755. non adjustable HR100 HR120 220-240V 500V max 5VA volt free contacts 10A / 250V AC1 0.03A 0.3A instantaneous instantaneous 50kA / 0.2s 50 metre maximum 1.5 to 10 1 to 6 1.5 to 4 1 to 2.5 -5C to +40C -25C to +40C -5C to +80C -40C to +80C adjustable HR200

supply voltage ~50/60HZ residual voltage ~50/60Hz power absorbed output contact rating sensitivity In instantaneous/time delay torroid withstand capacity distance between torroid and relay relay cable connection - rigid - flexible torroid cable connection - rigid - flexible relay working temperature storage temperature torroid working temperature storage temperature

HR210 HR211 HR212 HR213 220V - 240V 500V maximum 5VA volt free contacts 10A/250V AC1 0.03A/0.1A/0.3A/1A/3A instantaneous or time delay 0.13s/0.3s/1s/3s 50kA/0.2s 50 metre maximum 1.5 to 10 1 to 6 1.5 to 4 1 to 2.5 -5C to +40C -25C to +40C -5C to +80C -40C to +80C

The devices monitor the residual current of a circuit by means of a separate torroid. This can be mounted remotely up to 50m from the relay and is sited where it is most convenient in respect of the circuit cables to be monitored, particularly useful where large conductors have been used. Regulation 531-02-02 requires that all live conductors of the protected circuit shall be enclosed by the magnetic circuit transformer, with the exclusion of the associated protective conductor. This is easily achieved with standard RCCB & CBR type devices. With Earth Fault Relays the sensing transformer or torroid is sited remotely and therefore more care needs to be observed when installing cables. The torroid will then sense any imbalance in the circuit conductors and when the value reaches the In setting the earth fault relay will provide a signal to operate the device, disconnecting the supply.

Regulation 531-02-06 states that when a residual current device is powered from an auxiliary source, it must either operate automatically in the case of failure of the auxiliary circuit, or one of the following conditions must be fulfiled. 1. Protection against indirect contact is maintained even in the case of failure of the auxiliary source, or 2. The device is incorporated in an installation intended to be supervised, tested and inspected by an instructed or skilled person.

control protective device

reset

test

11

13

%I n

reset
5 15 30 45 60 75
3 1 0,3 I n (A) t (s) 0,03

0,1 0,3

test

0,1 0,03

HR 213

BE

10

12

14

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residual current device

main characteristics Reset button When pressed, the output remains switched and return to normal is obtained by either: by pressing the reset clear pushbutton or cutting off the power supply. If the reset button is not pressed the device remains in the fault position. Test button Pressing the test button allows a fault simulation which operates the relay and the output contacts. The fault level display is shown by an LED on the front of the product. In selector sensitivity setting: 0.03A instantaneous only 0.1A/0.3A/1A and 3A instantaneous or time delay Time delay selector t adjustable time setting - instantaneous/0.13s/0.3s/1s and 3s Sealable settings a sealable cover prevents interference once the settings have been made. electrical connections Standard output (1 C/O contact) switching to state 1 on: failure of the core/relay connection fault current in the monitored installation Positive safety outlet (1 C/O contact) switching to state 1: switching on the power switching to state 0: failure of the core/relay connection fault current in the monitored installation failure of relay supply internal failure of relay Optical scale display by 5 LEDs of the fault in % of In Common pin 6: State 1 : output terminal 8 State 0 : output terminal 4

fed from either input or output side

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residual current device earth fault relay torroids

circular torroids
D 14 17 5,5

reference

type

dimensions (mm) A B 132 175 218 C 115 158 200 D 60.5 82 103.5 E 98 141 183
A C

HR911 HR912 HR913

70 105 140

70 105 140

1,5 B

33,5

rectangular torroids reference type dimensions (mm) A1 HR920 HR921 HR922 70x175 115x305 150x350 70 115 150 A2 175 305 350 B 172 232 281 C 258 400 456 D 85 116 140 E 225 360 415 F 22 25 28 G 40 50 50 H 8.5 9.5 10.5
G

E 14

A2 A1 B

D H F 2.5

mounting of circular torroids mounting of torroid upstream downstream

with cables

U 1000 RO2V SWA cables with internal sheath

U 1000 RO2V SWA cables with internal sheath removed

U 1000 RO2V insulated and sheathed singles torroid

HO7VK insulated single cables

torroid

torroid

torroid

type of torroid torroid torroid 70 105 4 x 95 4 x 240 4 x 150 4 x 300 4 x 70 4 x 185 4 x 120 4 x 240

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residual current device avoidance of unintentional operation

Avoidance of unintentional operation In order to maintain the continuity of supply to an installation, it is important to select the most appropriate equipment and components at the design stage before work is undertaken. Every installation should be divided into circuits to avoid danger and minimise inconvenience. This requirement is particularly important where residual current devices are to be used due to the relatively low operating currents. Consideration must be given to circuit protective conductor currents and to earth fault currents. Nuisance tripping One of the most widely experienced problems with residual current devices is nuisance tripping. This is the unwanted operation of the device causing inconvenience to the end user due to protective conductor currents, transients or switching of capacitive circuits. The best way to safeguard against this is to use devices only where they are necessary for compliance with BS 7671 or where it is deemed necessary due to the nature of the installation. The practice of connecting general purpose circuits to the portion of a split-load protected by a residual current device on a standard domestic distribution board could increase the possibility of nuisance tripping and lead to subsequent non-compliance with BS 7671. Regulations 314-01-01 & 314-01-02 require that circuits be subdivided to avoid danger and minimise inconvenience and danger that can arise from loss of supply, especially to lighting circuits. Protective conductor Current When selecting devices care should be taken to avoid unwanted tripping, making it necessary to consider protective conductor currents. These are currents that flow to earth, or to extraneous conductive parts, in a circuit that is electrically sound. This current may have a capacitive component including that resulting from the deliberate use of capacitors. Filters used in IT equipment to protect against transients are a typical example of equipment that as a normal function of its operation use the circuit protective conductor as a functional earth to dissipate protective conductor currents safely. The protective conductor currents for each piece of equipment are generally very low, usually less than 3.5mA, but their effects will be cumulative, particularly on socket outlet circuits in offices where a number of items of equipment incorporating filters are to be used.
1mH Ph 230V~
Protective conductor current

Typical causes of unwanted RCD tripping problems. The cause of intermittent tripping problems can often be difficult to determine and resolve, the cause can come from within an installation or from the electrical supply entering the installation. Possible causes upstream of the device Loose connections Mains borne disturbances, the effect of these can be worse when the device is under no load. Switching of large machinery or plant. Lightning activity

Possible causes downstream of the device Loose connections Mains borne disturbances, the effect of these can be worse when the device is under no load. Incorrectly selected (too sensitive) Standing protective conductor currents from equipment and appliances Wet plaster on new installations Moisture ingress or condensation Old appliances with insulation breaking down (particularly fridges and freezers) Mineral insulated cables Heating elements, electric cookers etc. Neutral to earth faults (TT & TN-S systems - trip, TN-C-S system - no trip) Crossed neutrals on split-load consumer units Highly capacitive circuits Faulty appliances, appliances such as washing machines have a program cycle, it is possible that the earth fault is only present during particular parts of that cycle. Damage or deterioration to cable insulation, particularly to old cables. Capacitance in long cable runs Interference by radio transmitters

47 nF

Xc =

I
cpc

1 = 67.7k at 50Hz 2 fC

47 nF 1mH N

Z = XL + X C

I = V = 230 = 3.39mA Z 67700

Regulation 607-07-01 states that when more than one item of equipment having a protective conductor current exceeding 3.5mA in normal service is to be supplied from an installation incorporating a residual current device, the circuit arrangement shall be such that the residual current which may be expected to occur, including switch on surges, will not trip the device.

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residual current device testing residual current devices

Testing of devices To ensure that all devices operate correctly and that all intended safety measures are covered, it is imperative that the devices are tested after they have been installed and at regular intervals throughout their service life. Initial testing of the residual current device should be undertaken before connecting the outgoing circuit cables to the device to ensure that only the device is being tested and that no parallel fault paths which may exist in the circuit wiring interfere with the results. The need to disconnect the load conductors before testing is even more important when testing S type devices, as a potentially dangerous voltage could be present on exposed- and extraneous-conductive-parts. Regulation 713-13-01 requires residual current devices to be tested independently of any internal testing facility on the device, such as the test button. Testing must be carried out with a proprietary residual current device test meter, which is regularly calibrated and is suitable for the devices installed. The procedure recommended by Hager is; 1. 1/2 In trip test 2. 100% In trip test 3. 5 x In trip test (if applicable) 4. DC test (if applicable) 5. operation of the test button The test results should be within the parameters set out in the applicable standard. Standard Type In 30mA BS EN 61008 G S BS EN 61009 G S BS4293 Table 37 The new Harmonised Standards of BS EN 61008 & BS EN 61009 allow the device to operate within 300ms at 100% In. The previous Standard BS 4293 had a limit of 200ms. When testing devices care must be taken to ensure that the test results are compared to the correct Standard. Guidance can be found in the lEE on-site guide. The trip time parameters at a test current of 5 x In remain unchanged and are 40ms for all Standards. G Time-delay > 30mA 30mA > 30mA < 30mA 2000ms > 30mA 200ms 300-400ms 2000ms
1

When periodically testing a residual current device with a meter, it is often advisable to undertake the 5 x In test first. If the device fails this test, it is a good indication that the quarterly test button check has not been carried out and that dirt or dust on the contacts may be causing a slower operation than normal. Before rejecting the device completely, the test should be carried out twice more, as it is quite usual for the device to operate properly after these two subsequent operations. In the same way as when testing the device initially, the outgoing or load cables should be removed before the test is carried out. To ensure the device continues to operate within the defined parameters it is important that the device is tripped periodically by operating the test button. This should be done at regular intervals not exceeding three months.

2 x In (t)

In (t) 300ms 130-500ms 300ms 130-500ms

5 x In 40ms N/A 40ms N/A 40ms N/A

2000ms

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residual current device fault finding with residual current devices

Fault finding with residual current devices There are many problems that may be encountered whilst fitting and testing residual current devices. The problems can be encountered at the installation stage or at anytime after installation. The majority of problems are installation related. A simple flowchart is provided to aid problem solving. Access to live parts is required to carry out the complete sequence therefore it should only be carried out by a competent electrician.

Electricians RCD fault diagnosis chart

Device trips (will not reset)

Device trips intermittently Disconnect all loads

Device does not trip (test button)

Repair Yes obvious fault fault

No

Test device with RCD Tester

Test device with RCD Tester

No

socket circuit?
Yes

pass 50% In test? Yes pass 100% In test? Yes

No

pass In test? Yes

No

Unplug all appliances reset the device

No

pass 5 x In test? Yes

No

Locate & repair Yes device resets? faulty appliance

No

Remove load cables & retest

Remove load cables press test button

Remove load cables & retest

Switch off or disconnect circuit phase conductors & reset the device

Device OK Yes check for circuit / external faults Disconnect all circuit neutral conductors

pass tests?
No

pass tests?
No

Yes

earth fault on circuit wiring

device resets?
Yes

No

device resets?
Yes

No

Replace RCD

Switch on or reconnect circuit phase conductors one at a time

Re-connect circuit neutral conductors one at a time and reset device

device resets?
No

Yes

Yes

device resets?
No

Intermittent fault

Phase to earth fault on switched circuit

Neutral to earth fault on switched circuit

Locate & repair fault in circuit wiring

Fig 22

120

residual current device maintenance

Maintenance Chapter 34, Maintainability Regulation 341-01-01 requires that an assessment be made of the frequency and quality of maintenance that the installation can reasonably be expected to receive during its intended life. This assessment shall, wherever practicable, include consultation with the person or body who will be responsible for the operation and maintenance of the installation. Having regard to the frequency and quality of maintenance expected, the requirements of Parts 4 to 7 shall be applied so that during the life of the installation: (I) any periodic inspection, testing, maintenance and repair likely to be necessary can be readily and safely carried out, and (ii) any protective measure for safety remains effective, and the reliability of equipment is sustained. Before an installation is handed over to a client, proper instruction on the use and maintenance of residual current devices must be given and precise written instructions should be left with the installation operating manual or user instructions Regulation 514-12-02 requires that a label be fixed at or near the origin of the installation, with the wording shown, in every installation that includes a residual current device.

Accessibility of equipment The correct and adequate sitting of residual current devices is very important if the end user is to be able to operate the trip button on the device. For compliance with BS 7671, positioning of residual current devices must take into consideration Regulation 513-01-01 which states that every piece of equipment that requires operation or attention by a person shall be so installed that adequate and safe means of access and working space are afforded for such operation or attention. Compatibility Radiated immunity: For residual current devices: Do not put a high intensity cable close to the device: In < 200A for a cable in contact with the side of a device. In < 300A for a cable at 1 cm from the side of the device. In < 400A for a cable at 2cm from the side of the device. Do not put a high breaking capacity MCB (Icu > 25kA) side by side with the RCD. Do not put a transformer side by side with the RCD.

121