PROTECTIVE DEVICES

Compiled and Presented by D.

Nedrick

Why Do we need Protective

Devices in Circuits?
Short

Circuit
A condition which exists in an electric
circuit when conductors of opposite
polarity come into contact with each other.
A circuit that contains almost no
resistance to limit the flow of current.
This condition results in excessive current
flow.
Dangers of short circuit: fire

Examples of Short Circuit

Why Do we need Protective

Devices in Circuits?
Overload
An

electrical condition in an excessive

amount of current flows. This condition
arises when too much utilization
equipment is connected into a circuit or
system or when a motor is starting.
When a motor is driving a load which
requires more horsepower than its rating,
it is overloaded and excessive current
flows.

Calculating Breaker size

What

size circuit breaker would BEST

protect a 3kW, 240V water heater?
P = V x I
3000W = 240V x I
I = 3000W/ 240V
= 12.5A
Hence a 15A fuse or circuit breaker
may be used

Sizing circuit conductors

Example

What is the maximum number of 150W

electric lamps that could safely be used on
a 250V supply which will be fused at 5A?
P=VxI
150W = 250V x I
I = 150/250
= 0.6A Each lamp draws
Therefore 5A 0.6A = 8.3 lamps
Hence the maximum number of bulbs is 8

Alternative Method
Max

power = fusing current x Voltage

rating
P = V x I
= 250V x 5A
= 1250W
Hence number of 150W bulbs is
= max power individual power rating
= 1250W 150W
= 8.3 or 8 bulbs

Circuit Breaker
is

a electro-mechanical device for

making and breaking a circuit both
under normal and abnormal condition
such as those of a short circuit, the
circuit been broken automatically.

Circuit Breaker contd

The

circuit breaker is generally opened

by hand (manually) but is
automatically opened under fault
conditions by an over-current release.

Over-current Release
The

over-current release is opened by the

magnetic effect of the line current flowing in
the circuit.
This current flows through a current coil
consisting of a few turns of heavy-gauge
copper wire or copper tape.
When a continual overload is placed on the
protected circuit the electromagnetic field,
due to the current flowing in the coil, draws
up a plunger which operates a mechanical
trip, thus isolating the circuit from the supply.

Overcurrent Release

Fig

6.9 shows the simplified layout of an

electromagnetically operated over-current
release. When an overload current flows
through the coil, the soft-iron plunger is lifted
high enough to open the control circuit.

Time Delay
Fig

6.10 shows an over-current release using

a piston fitted in an oil dashpot to retard the
movement of the soft-iron plunger, thus
providing a time-lag on the operation of the
over-current release.
The operating or tripping, current can be
varied by screwing the dashpot up or down;
it is generally set to operate at 1 times
(150 per cent) full load current.

Application of Time Delay

Over-current

releases are commonly

used in motor starter circuits where
very high starting currents (about six
times full loaded current) are
encountered. The time-lag action of
the dashpot allows sudden surges of
current in circuit without tripping,
although a continuous overload current
would operate the trip.

 Fig

6.11 shows the circuit of a

manually-operated 3-phase circuit
breaker which is fitted with
electromagnetic overload releases.
The circuit-breaker is closed by hand
and the operation of any type of the
over-current releases trips the switch
mechanism an open all the phases

 The

selection of the breakers should be

based on the ability to:
Provide the proper overload protection
Ensure a suitable voltage rating
Provide a sufficient interrupt current
rating
Provide short circuit protection
Co-ordinate the breaker(s) with other
protective devices
The choice of the overload protection is
based on the rating of the panel board

Fuse
A

fuse is a weak link in a circuit which

will break when too much current flows,
thus protecting the circuit conductors
from damage.
It must be remembered that the priority
of the fuse is to protect the circuit
conductors, not the appliance or the
user. Calculation of cable size therefore
automatically involves the correct
selection of protective devices.

Types of Fuses
A

fuse simply carries a metal element,

usually tinned copper, which will melt
and break the circuit when excessive
current flows.
There are three types of fuses:
The Rewireable or semi-enclosed fuse
The cartridge fuse and fuse link; and
The high-rupturing-capacity (h.r.c.)
fuse.

Rewireable Fuse
This

consist of a plastic bridge and

base.
The bridge has two sets of copper
contacts which fit into contacts in the
base.

Rewireable Fuse (contd)

The

Fuse element, for example, tinned

copper wire, is connected between the
terminals of the bridge.
An asbestos tube, or pad, is generally
fitted in the fuse to minimize the effect
of arcing when the fuse element melts.
This type of fuse is termed a semienclosed fuse to distinguish it from the
older type of fuse which consisted
simply of a piece of wire connected
between two terminals.

Regulations
The

approximate sizes of tinned

copper wire to be used for elements in
semi-enclosed fuses includes:
0.2 mm
5A current rating
0.35 mm
- 10A Current rating
0.50 mm
- 15A Current rating

Fusing Factor
The

current rating is the current which

the fuse element will continuously
carry without deterioration.
The fusing current is the current at
which the fuse element will melt.
For the rewireable fuse, this is
approximately twice the current rating
of the fuse element (fusing factor = 2).
Fusing factor = fusing current/ current
rating.

Fusing Factor of Protective

Devices
Circuit

breaker -no more than 1.25

rating
Rewireable Fuse - 1.8
Cartridge Fuse - between 1.25 and
1.75
H B C Fuse
- up to a maximum
1.25

Advantages and
Disadvantages
Advantages
1.

Cheap
2. Easy to replace fuse element
Disadvantages
1.

Fuse element deteriorate in use

2. Any size of fuse wire can be fitted,
thus defeating the purpose of the fuse.

Disadvantages Contd
NOTE:

The fuse/CB must be capable of

protecting the smallest conductor in the
circuit.
Lacking in discrimination. It is possible
that a 15A fuse element may melt before
a 10A fuse element, depending largely
on the condition of the wire. Further the
rewireable fuse is not capable of
discriminating between a momentary
high starting current and a continuous
fault current.

Disadvantages contd
4.

Easily damaged, particularly with

short circuit currents.

Cartridge Fuse
This

type has come into common use

with the fused 13A plug used on the
domestic ring circuit.

Cartridge Fuse Contd

The

fuse element is contained in a

porcelain tube fitted with two
connecting caps and has a fusing
factor of 1.5.
The color code for these fuses is as
follows:
5A White,
13A Brown,
15A
Blue, 30A Red
60A Purple

High Breaking Capacity Fuse

Fig. 6.16 shows the construction of a high
breaking capacity fuse. This consist of the
following:
1. Porcelain tube.
2. Silver element.
3. Indicating element which ignites powder
under the label to show when the fuse
element has opened.
4. End caps.
5. Silica (fine sand) filling used to quench the
arc.

Regulation
Note. The fuse must always be placed in
the phase or non-earthed conductor of
the installation, never in the neutral
(earthed) conductor.

Thermal Tripping Device

The

thermal trip (6.17) is operated by using

the heating effect of an electric current.
Two flat pieces of dissimilar metals are join
together and placed inside a nichrome spiral
which carries the line current of the
protected equipment.

Thermal Tripping Device

When

the line current reaches a certain

pre-determined level, the heat from the
spiral distorts the bi-metallic strip
causing it to operate a push bar
mechanism which opens the switch.
This type of protection is generally on
low current circuits (for example:
fractional horsepower starters) because
the bimetallic strip tends to distort
permanently if heavily overloaded.

Regulation
All

fuses and single pole control

devices (e.g. circuit-breakers,
thermostats) must be fitted in the line
conductor in a 2 wire installation
where one pole is connected to earth

Overload Protection of an AC
Motor

Overload

or overcurrent protection is
provided by either thermal or magnetic
strips.
Thermal overload protection relies on the
heating effect of the load current to heat the
thermal coils which in turn cause movement
of a bimetallic strip.
This trip out a spring-loaded contact in the
control circuit.
The speed at which the tripping takes place
is adjusted to allow for normal starting
currents, which maybe four or five times as
large as running currents.

Overload Protection of an AC
Motor
Magnetic

protection uses the principle

of the solenoid to operate the tripping
mechanism. The time lag in this case
is achieved by the use of an air
dashpot which slows down the action
of the solenoid plunger