Marine electrical circuit devices

CHAPTER 10

CIRCUIT PROTECTION DEVICES

INTRODUCTION

An electrical unit is built with great care to ensure that each separate electrical circuit is fully insulated
from all the others. This is done so that the current in a circuit will follow its intended path. Once the
unit is placed into service, many things can happen to alter the original circuitry. Some of these changes
can cause serious problems if they are not detected and corrected in time. While circuit protection
devices cannot correct the abnormal current condition, they can indicate that an abnormal condition
exists and protect personnel and circuits from that condition. This chapter explains circuit conditions that
require protection devices and the type of protection devices used.

A circuit protection device is used to keep an undesirable current, voltage, or power surge out of a given
part of an electrical circuit. Some of the components protected by circuit breakers and fuses follow:

● Wiring - general reference used for the conductor that forms the link between the switchboard
and the loads or any portion of that link.
●

● Bus bars - the copper or aluminum bars located inside the main or emergency switchboard. These
heavy, rugged metallic conductors are usually insulated with a nonconducting paint and are used
to carry the large generator loads within the switchboard (Figure 10-1). Smaller versions of these
bus bars are located in power and lighting distribution panels and the motor control center (MCC)
controllers.
●

● Feeders - the cables that extend from the main switchboard to a secondary distribution panel or
switchboard. In some cases, these feeders will provide power directly to a load.
●

● Bus tie - a special cable that extends from the main switchboard to a second main or emergency
switchboard. A bus tie between generator and distribution switchboard, including one between

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main and emergency switchboards, is never considered a feeder.

●

● Feeder, branch, or connecting boxes - watertight boxes that permit the joining of two or more
continuous electrical wires or feeders.
●

● Distribution panels - panels that receive power from a distribution switchboard and distribute this
power to power-consuming devices, other distribution panels, or panel boards.
●

● Branch circuits - that portion of wiring extending beyond the final overcurrent device protecting
the circuit. Branch circuits are cables that extend from the distribution panel to the loads.
●

● Nonmotor loads - circuits that contain mostly resistive loads, such as lighting systems.

CIRCUIT CONDITIONS REQUIRING PROTECTION DEVICES

Many unwanted things can happen to the electrical circuits after they are in use. Previous chapters
contained information on how to measure circuit values. Some changes in circuit values can cause
conditions that are dangerous to the circuit itself or to people working near the circuits. Potentially
dangerous conditions that require circuit protection are direct shorts, excessive current, and excessive
heat.

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Direct Shorts

One of the most serious troubles that can occur in a circuit is a direct short. Another term for this
condition is a short circuit. These terms describe a situation in which full system voltage comes in direct
contact with the ground or return side of the circuit bypassing the load. This establishes a path for
current flow that contains only the negligible resistance present in the wires carrying the current. This is
an unintentional path of current flow. In certain situations, a direct short can terminate part of the
vessel's power supply.

According to Ohm's Law, if the resistance in a circuit is extremely small, the current will be extremely
large. Therefore, when a direct short occurs, there will be a very large current through the wires.
Suppose, for instance, that the two opposite polarity leads from a battery came in contact with each
other. If the leads were uninsulated at the point of contact, there would be a direct short. Any other
electrical component that could have received current from the battery is now shunted out. Shunting a
component out means that there is a parallel path around the component. The minimal resistance of the
direct short calls for the maximum current available from the batteries. In addition, the other high-
resistance electrical loads that would have received current from the batteries now become inoperative.
A direct short of this kind could result in a battery explosion.

The battery cables in this example would be very large conductors capable of carrying very high
currents. Most wires used in electrical circuits are much smaller, and their current-carrying capacity is
quite limited. The size of the wire used in any given circuit is determined by ambient temperature, cost,
and the amount of current the wire is expected to carry under normal operating conditions. Therefore,
any current flow in excess of normal would cause a rapid generation of heat in the wire.

If the excessive current flow caused by the direct short is left unchecked, the heat in the wire will
continue to increase until a part of the circuit burns. Perhaps part of the wire will melt and open the
circuit. In this case, only the original casualty is damaged. However, much greater damage may result.
The heat in the wire can char and burn the insulation of the wire and that of other wires bundled wit h it.
This can cause more shorts. Figure 10-2 shows the close proximity of groups of electrical cables. If fuel
or oil is near any of these hot wires, a disastrous fire will be started.

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Excessive Current

The circuit current can increase without a direct short. If a resistor, capacitor, or inductor changes value,
the total circuit impedance will also change in value. The impedance, which is the combined opposition
to AC flow, can come from many sources. If a resistor decreases in ohmic value, the total circuit
resistance (Rt) decreases. If a capacitor has a dielectric leakage, the capacitive reactance decreases. If an
inductor has a partial short in its windings, inductive reactance decreases. Any of these conditions will
increase circuit current (It). Since the circuit wiring and components are designed to withstand normal
circuit current, an increase in current would cause overheating, just as in the case of the direct short.
Therefore, excessive current without a direct short will cause the same problems as a direct short.

Excessive Heat

Excessive heat destroys electrical insulation and contact surfaces and reduces component longevity. In
addition to the presence of amperage and its relationship with temperature, two other problems generate
the heat that causes electrical malfunctions:

● Motor cleanliness. Dirty and oily machine windings and ventilation screens prevent the transfer
of heat from the current-carrying conductors. The heat accumulates and eventually deteriorates
the insulating material destroying the component.
●

● Excessive ambient temperatures. Electrical devices and components are selected according to the
environment of their placement. A component designed for 40° C applications cannot be placed
in an engine room (50° C environment) without detrimental effects. Excessive ambient
temperatures cause the same electrical casualty as the heat from excessive current.

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CIRCUIT PROTECTION

All of the above conditions are potentially dangerous and require the use of circuit protection devices.
Circuit protection devices are used to stop current flow by opening the circuit. To do this, a circuit
protection device must always be connected in series with the circuit it is protecting.

A circuit protection device operates by opening and interrupting current to the circuit. The opening of a
protective device shows that something is wrong in the circuit and should be corrected before the power
is restored. When a problem exists and the protection device opens, the device should isolate the faulty
circuit from the other unaffected circuits in time to protect unaffected components in the faulty circuit.
The protection device should not open during normal circuit operation.

Two types of circuit protection devices are fuses and circuit breakers.

A fuse is a simple circuit protection device. It derives its name from the Latin word "fusus," meaning to
melt. Fuses have been employed since the invention of electricity. The earliest type of fuse was simply a
bare wire between two connections. The wire was smaller than the conductor it was protecting and,
therefore, would melt before the conductor it was protecting was damaged. Some copper fuse link types
are still in use, but most fuses no longer use copper as the element (the part of the fuse that melts). After
changing from copper to other metals, tubes or enclosures were developed to hold the melting metal.
The enclosed fuse made possible the addition of filler material, which helps contain the arc that occurs
when the element melts.

WARNING

Never take anything for granted on board a vessel. There are many possible
circumstances of which you are not yet aware. Never work on a live circuit and never
"tempt fate."

WARNING

When servicing electrical circuits, always remove all fuses in that circuit.

While a fuse protects a circuit, it is destroyed in the process of opening the circuit. Once the problem
that caused the increased current or heat is corrected, a new fuse must be placed in the circuit. A circuit
protection device that can be used more than once solves the problem of replacement fuses. Such a
device is safe, reliable, and tamperproof. It is also resettable, so it can be reused without replacing any
parts. This device is called a circuit breaker because it breaks, or opens, the circuit (Figure 10-3).

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FUSES

Fuses are manufactured in many shapes and sizes. In addition to the copper fuse link, Figure 10-4 shows
other fuse types. Although there is a variety of fuses, there are basically only two types: plug-type fuses
and cartridge fuses. Both types use either a single wire or a ribbon as the fuse element (the part of the
fuse that melts). The condition (good or bad) of some fuses can be determined by visual inspection. The
condition of other fuses can only be determined with a meter.

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The only fuses used on Army watercraft are the cartridge, nonrenewable type conforming to the
Underwriters' Laboratories standard. The threaded plug-type fuses tend to vibrate out of place on board a
ship, leaving the electrical circuit de-energized.

In the cartridge fuse, the fuse link is enclosed in a tube of insulating material with metal ferrules at each
end (for contact with the fuse holder). Some common insulating materials are glass, bakelite, or a fiber
tube filled with insulating powder.

Figure 10-5 shows a glass tube fuse. View A shows the fuse link and the metal ferrules. View B shows a
glass tube fuse that is open. The open fuse link could appear either of the ways shown in view B.

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Cartridge fuses are available in a variety of physical sizes. They are used in many different circuit
applications. They can be rated at voltages up to 10,000 volts and have a current rating from .002
ampere to more than 10,000 amperes. Cartridge fuses may also be used to protect against excessive heat
and open at temperatures from 165 to 410 F.

All circuits protected by fuses must have a fuse for each current-carrying conductor. Even though one
break in the electrical circuit is sufficient to stop all current flow to the equipment, a difference in
potential exists between the wire connected to the power supply and the vessel hull. Although the hull is
not an intentional current carrier, the potential from the generator will complete a path to a natural
ground.

Rating Fuses

The physical size and type of a fuse can be determined by looking at it. However, to select the proper
fuse, other conditions must be known. Fuses are rated by current, voltage, and time-delay characteristics.

To select the proper fuse, consult the applicable technical, regulatory, or manufacturer's manuals. Do not
take for granted that the fuse being removed is in fact the type of fuse that should be reinstalled. An
example of this is the 24-volt battery-powered general alarm system. The fuse used, regardless of the

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system voltage, must be rated for 250 volts. The general alarm system is greatly overrated for operation
during marine casualty. When the current is finally sufficient to open the fuse, the system has achieved
an excessive current so great that the general alarm system itself may become an additional factor
working against the crew. The 250-volt rating prevents the lower voltages from arcing across the open
fuse, re-energizing an already endangered circuit.

Current Rating. The current rating of a fuse is a value expressed in amperes. It represents the current that
the fuse will carry without opening. The current rating of a fuse is always indicated on the fuse ferrules.
Fuses rated up to 200 amperes are commonly found on board vessels. The 200-ampere fuses are
generally restricted to special system applications such as emergency lighting battery cables. Otherwise,
circuit breakers should be used in place of 200-ampere or greater fuses.

Voltage Rating. The voltage rating of a fuse is not an indication of the voltage the fuse is designed to
withstand while carrying current. The voltage rating indicates the ability of the fuse to quickly
extinguish the arc after the fuse element melts and the maximum voltage the open fuse will block. In
other words, once a fuse has opened, any voltage less than the voltage rating of the fuse will not be able
to jump the gap of the open fuse. Because of the way the voltage rating is used, it is a maximum rms
voltage value. Always select a fuse with a voltage rating equal to or greater than the voltage in the
circuit to be protected.

Time-Delay Rating. Many types of electrical circuits and components require customized protection.
Some components are very current-sensitive and require fast-acting protection. In other instances, it is
unnecessary and impractical to provide a close tolerance overcurrent protection when the circuit
normally experiences momentary current increases without a time delay. A time delay prevents nuisance
fuse openings and protects the circuit after the specified time limit has elapsed. The three time-delay
ratings are delay, standard, and fast.

Figure 10-6 shows the differences between delay, standard, and fast fuses. It shows that if a l-ampere
rated fuse has 2 amperes of current through it (200 percent of the rated value), a fast fuse would open in
about .7 second. A standard fuse would open in about 1.5 seconds, and a delay fuse would open in about
10 seconds. In each of the fuses, the time required to open the fuse decreases as the rated current
increases.

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A delay, or slow blowing, fuse has a built-in delay that is activated when the current through the fuse is
greater than the current rating of the fuse. This fuse will allow temporary increases in current (surge)
without opening. Some delay fuses have two elements, which allow a very long time delay. If the
overcurrent condition continues, a delay fuse will open, but it will take longer to open than the standard
or fast fuse. Delay fuses are used for circuits with high surge or starting currents such as solenoids and
transformers.

Standard fuses have no built-in time delay. Also, they are not designed to be very fast acting. Standard
fuses are sometimes used to protect against direct shorts only. They may be wired in series with a delay
fuse to provide faster direct short protection. For example, in a circuit with a l-ampere delay fuse, a 5-
ampere standard fuse may be used in addition to the delay fuse to provide faster protection against a
direct short.

A standard fuse can be used in any circuit where surge currents are not expected, and a very fast opening
of the fuse is not needed. A standard fuse opens faster than a delay fuse, but slower than a fast rated
fuse. Standard fuses can be used for automobiles, lighting circuits, and some electrical power circuits.

Fast fuses open very quickly when current through the fuse exceeds the current rating of the fuse. Fast
fuses protect components that are sensitive to increased current. A fast fuse will open faster than a delay
or standard fuse. Fast fuses are used to protect delicate equipment and solid state devices.

Identifying Fuses

Fuses have identifications printed on them. The printing on the fuse identifies the physical size and type
of the fuse and the fuse ratings. There are four different systems used to identify fuses. The systems are
the old military designation, the new military designation, the old commercial designation, and the new
commercial designation.

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All four systems are described below, so you can identify a fuse no matter which designation is printed
on the fuse. You may have to replace an open fuse that is identified by one system with a good fuse that
is identified by another system. You may find a fuse coded in one of the commercial designations
because Army vessels are often repaired in commercial shipyards. The designation systems are fairly
simple to understand and cross-reference once you are familiar with them.

Old Military Designation. Figure 10-7 shows a fuse with an old military designation. The tables in the
lower part of the figure show the voltage and current codes used in this system. The upper portion of the
figure is the explanation of the old military designation. The numbers and letters in parentheses are the
coding for the fuse shown in Figure 10-7.

The old military designation always starts with F, which stands for fuse. Next, the set of numbers (02)
indicates the style, which is the construction and dimensions of the fuse. Following the style is a letter
that represents the voltage rating of the fuse (G). The voltage code table in Figure 10-7 shows each
voltage rating letter and its meaning in volts. In the example shown, the voltage rating is G, which
means the fuse should be used in a circuit suitable for a 250-volt fuse. After this is a set of three numbers
and the letter R, which represent the current rating of the fuse.

The R indicates the decimal point. In the example shown, the current rating is 1R00 or 1.00 ampere. The
final letter in the old military designation (A) indicates the time-delay rating of the fuse.

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While the old military design is still found on some fuses, the voltage and current ratings must be
translated, since they use letters to represent numerical values. The military developed the new military
designations to make fuse identification easier.

New Military Designation. Figure 10-8 is an example of a fuse coded in the new military designation.
The fuse in Figure 10-8 is the same type as the fuse used as an example in Figure 10-7.

The new military designation always starts with the letter F, for fuse. The set of numbers (02) next to
this indicates the style. The style numbers are identical to the ones used in the old military designations
and indicate the construction and dimensions of the fuse. Following the style designation is a single
letter (A) that indicates the time-delay rating of the fuse. This is the same time-delay rating code as
indicated in the old military designation, but the position of this letter in the coding is changed to avoid
confusing the A for standard time delay with the A for ampere. Following the time-delay rating is the
voltage rating for the fuse (250V). In the old military designation, a letter was used to indicate the
voltage rating. In the new military designation, the voltage is indicated by numbers followed by a V,
which stands for voltage. After the voltage rating, the current rating is given by numbers followed by the
letter A. The current rating may be a whole number (1A), a fraction (1/500 A), or a decimal (1.5 A). If
the ferrules of the fuse are silver-plated, the current rating will be followed by the letter S. If any other
plating is used, the current rating will be part of the fuse identification. The new military designation is
much easier to understand than the old military designation.

Old Commercial Designation. Figure 10-9 shows the old and new commercial designations for the same
type of fuse that was used in Figures 10-7 and 10-8.

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Figure 10-9 view A shows the old commercial designation for a fuse. The first part of the designation is
a combination of letters and numbers (three in all) that indicates the style and time-delay characteristics.
This part of the designation (3AG) is the information contained in the style and time-delay rating
portions of military designations. In the example shown, the code 3AG represents the same information
as the underlined portions of F02 G lROO A from Figure 10-7 (old military designation) and F02A
250V1AS from Figure 10-8 (new military designation). The only way to know the time-delay rating of
this fuse is to look it up in the manufacturer's catalog or a cross-reference listing to find the military
designation. The catalog will give the physical size, the material from which the fuse is constructed, and
the time-delay rating of the fuse. A 3AG fuse is a glass-bodied fuse, 1/4 inch x 1 1/4 inch, with a
standard time-delay rating.

Following the style designation is a number that is the current rating of the fuse (l). This could be a
whole number, a fraction, or a decimal. Following the current rating is the voltage rating, which is
followed by the letter V, which stands for voltage (250V).

New Commercial Designation. Figure 10-9 view B shows the new commercial designation for fuses. It
is the same as the old commercial designation except for the style portion of the coding. In the old
commercial system, the style was a combination of letters and numbers. In the new commercial system,
only letters are used. In the example shown, 3AG in the old system becomes AGC in the new system.
Since C is the third letter of the alphabet, it is used instead of 3. Once again, the only way to find out the
time-delay rating is to look up this coding in the appropriate manuals. The remainder of the new
commercial designation is exactly the same as the old commercial designation.

Identifying Fuse Holders

For a fuse to be useful, it must be connected to the circuit it will protect. Some fuses are wired in or
soldered to the wiring of circuits, but most marine applications use the fuse holder. A fuse holder is a
device that is wired into the circuit and allows easy replacement of the fuse.

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Fuse holders are made in many shapes and sizes, but most fuse holders are either a clip- or post-type.
Figure 10-10 shows typical clip- and post-type fuse holders.

Clip-Type Fuse Holders. The clip-type fuse holder is used for cartridge fuses. The ferrules or knife blade
of the fuse are held by the spring tension of the clips. These clips provide the electrical circuit
connection between the fuse and the circuit. If a glass-bodied fuse is used, the fuse can be inspected
visually for an opening without removing the fuse from the fuse holder. The clips may be made for
ferrules or knife blade cartridge fuses. While the base of a clip-type fuse holder is made from insulating
material, the clips themselves are conductors. The current through the fuse goes through the clips.
Therefore, be careful not to touch the clips when power is applied or else a severe shock or short circuit
will occur.

Post-Type Fuse Holders. Post-type fuse holders are made for cartridge fuses. The post-type fuse holder
is much safer because the fuse and fuse connections are covered with insulating material. The post-type
fuse holder has a cap that screws onto the body of the fuse holder. The fuse is held in this cap by a
spring-type connector. As the cap is screwed on, the fuse makes contact with the body of the fuse holder.
When the cap and fuse are removed from the circuit, there is no danger of shock or short circuit from
touching the fuse.

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Post-type fuse holders are usually mounted on the chassis of the equipment they are protecting. After
wires are connected to the fuse holder, insulating sleeves are placed over the connections to reduce the
possibility of a short circuit. Figure 10-10 shows two connections on a post-type fuse holder. The
terminal on the right is called the center connector. The other connector is called the outside connector.
The outside connector will be closer to the equipment chassis. (The threads and nut shown are used to
fasten the fuse holder to the chassis.) The possibility of the outside connector coming in contact with the
chassis (causing a direct short) is much greater than the possibility of the center connector contacting the
chassis. The power source should always be connected to the center connector so that the fuse will open
if the outside connector contacts the chassis. If the power source were connected to the outside
connector and the outside connector contacted the chassis, there would be a direct short, but the fuse
would not open.

Checking and Replacing Fuses

A fuse, if properly selected, should not open unless something is wrong in the circuit the fuse is
protecting. When a fuse is found open, the reason the fuse is open must be determined. Replacing the
fuse is not enough.

Before looking for the cause of an open fuse, determine if the fuse is open. There are several ways of
checking for an open fuse. Some fuses and fuse holders have indicators built in. Also, a multimeter can
be used to check fuses.

Using a Fuse Indicator. Some fuses and fuse holders have built-in indicators to show when a fuse is
open. Figure 10-11 shows examples of open fuse indicators. View A shows a cartridge-type fuse with an
open fuse indicator. The indicator is spring-loaded and held by the fuse link. If the fuse link opens, the
spring forces the indicator out. Some manufacturers color the indicator so it is easier to see in the open
fuse position.

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View B shows a plug-type fuse holder with an indicating lamp in the fuse cap. If the fuse opens, the
lamp in the fuse cap will light. View C shows a clip-type fuse holder with an indicating lamp.

Using a Meter. The only sure method of deter-mining if a fuse is open is to use a meter. An ohmmeter
can be used to check for an open fuse by removing the fuse from the circuit and checking for continuity
(0 ohm) through the fuse. If the fuse is not removed from the circuit and the fuse is open, the ohmmeter
may measure the circuit resistance. A low resistance might lead you to think the fuse is good.

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A voltmeter can also be used to check for an open fuse. The measurement is taken between each end of
the fuse and the power supply end of another fuse. If voltage is present on both sides of the fuse (from
the voltage source and to the load), the fuse is not open. Another method commonly used is to measure
across the fuse with the voltmeter. If no voltage is indicated on the meter, the fuse is good (not open).
There is no voltage drop unless there is a resistance. An open fuse has a great deal of resistance.

To check for voltage on a clip-type fuse holder, check each of the clips. The advantage of using a
voltmeter to check for an open fuse is that the circuit does not have to be de-energized, and the fuse does
not have to be removed.

Observing Safety Precautions. Since a fuse has current through it, be very careful when checking for an
open fuse to avoid being shocked or damaging the circuit. The following safety precautions and prudent
maintenance practices will protect you and the equipment you are using:

● Turn power off and discharge the circuit before removing the fuse.
●

● Use a fuse puller (Figure 10-12) when removing a fuse from a fuse holder.
●

● When checking a fuse with a voltmeter, be careful to avoid shocks and short circuits.

Replacing Open Fuses

After an open fuse is found and the trouble that caused the fuse to open has been corrected, the fuse must
be replaced. Before replacing the fuse, be certain that the replacement fuse is the proper type and that it
fits correctly.

To be certain a fuse is the proper type, consult the technical manual for the equipment. The parts list
gives the proper fuse identification for a replacement fuse. Obtain and use the exact fuse specified.

If a direct replacement cannot be obtained, use the following guidelines:

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● Never use a fuse with a higher current rating, a lower voltage rating, or a slower time-delay rating
than the specified fuse.
●

● Use the best substitution for a fuse with the same current and time-delay ratings and a higher
voltage rating. (If a lower current rating or a faster time-delay rating is used, the fuse may open
under normal circuit conditions.)
●

● Use substitute fuses that have the same style (physical dimensions) as the specified fuse.
●

● Regularly inspect the circuit and substitute fuse during operation.

●

● Return the circuit to a like-new condition when arriving in the next port.

When a proper replacement fuse has been found, make certain it will fit correctly in the fuse holder. If
the fuse holder is corroded, the fuse will not conduct current properly and will increase resistance or
heating. Clean corroded terminals with fine sand paper so that all corrosion is removed. Do not lubricate
the terminals. If the terminals are badly pitted, replace the fuse holder.

If the fuse clips do not make complete contact with the fuse (Figure 10-13), try bending the clips back
into shape. If the clips cannot be repaired by bending, replace the fuse holder or clip clamps.

CIRCUIT BREAKERS

A circuit breaker is a circuit protection device that, like the fuse, will stop current in the circuit if there is
a direct short, excessive current, or excessive heat. Unlike a fuse, a circuit breaker is reusable. The

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circuit breaker does not have to be replaced after it has opened and broken the circuit. Instead of
replacing the circuit breaker, it is reset.

Circuit breakers can also be used as circuit control devices. By manually opening and closing the
contacts of a circuit breaker, the power can be selectively switched on and off. This is of practical use
when trying to isolate a circuit ground.

Circuit breakers are available in a great variety of sizes and types. Army marine circuit breakers are of
the molded case, trip-free type. They must be arranged so that they can be removed without
disconnecting the copper or cable connections or de-energizing the power supply to the circuit breaker.
The circuit breaker rating should be the value of current the breakers will carry continuously without
exceeding the specific temperature rise.

CIRCUIT BREAKER COMPONENTS

Circuit breakers have five main components (Figures 10-14 and 10-15). The components are the frame,
the operating mechanism, the arc extinguishers, the terminal connectors, and the trip elements.

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The Frame. The frame provides an insulated housing and is used to mount the circuit breaker
components (Figures 10-14). The frame determines the physical size of the circuit breaker and the
maximum allowable voltage and current.

The Operating Mechanism. The operating mechanism provides a means of opening and closing the
breaker contacts (turning the circuit on and off). The toggle mechanism in Figure 10-15 is the quick-
make, quick-break type, which means the contacts snap open or closed quickly, regardless of how fast
the handle is moved. In addition to indicating whether the breaker is on or off, the operating mechanism
handle indicates when the breaker has opened automatically (tripped) by moving to a position between
on and off. To reset the circuit breaker, first move the handle to the OFF position, then to the ON
position.

Arc Extinguishers. The arc extinguisher confines, divides, and extinguishes the arc drawn between the
contacts each time the circuit breaker interrupts current. The arc extinguisher is actually a series of
contacts that open gradually, dividing the arc and making it easier to confine and extinguish. This is
shown in Figure 10-16. Arc extinguishers are generally used in circuit breakers that control a large
amount of power, such as those found in distribution switchboards. Small power circuit breakers, such
as those found in lighting panels, may not have arc extinguishers.

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Terminal Connectors. Terminal connectors are used to connect the circuit breaker to the power source
and the load. They are electrically connected to the contacts of the circuit breaker and provide the means
of connecting the circuit breaker to the circuit.

Trip Element. The trip element is the part of the circuit breaker that senses the overload condition and
causes the circuit breaker to trip or break the circuit. Thermal, magnetic, and thermal magnetic trip units
are used by most circuit breakers. Some circuit breakers use solid state trip units with current
transformers and solid state circuitry.

Thermal trip element. A thermal trip element circuit breaker uses a bimetallic element that is heated by
the load current. The bimetallic element is made from strips of two different metals bonded together.
The metals expand at different rates as they are heated. This causes the bimetallic element to bend as it
is heated. Figure 10-17 shows how this can be used to trip a circuit breaker.

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Figure 10-17 view A shows the trip element with normal current. The bimetallic element is not heated
excessively and does not bend. If the current increases (or the ambient temperature around the circuit
breaker increases), the bimetallic element bends, pushes against the trip bar, and releases the latch. Then
the contacts open (Figure 10-16 view B).

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The amount of time it takes for the bimetallic element to bend and trip the circuit breaker depends on the
amount the element is heated. A large overload will heat the element quickly. A small overload will
require a longer time to trip the circuit breaker.

Magnetic trip element. A magnetic trip element circuit breaker uses an electromagnet in series with the
circuit load (Figure 10-18). With normal current, the electromagnet will not have enough magnetic force
on the trip bar to move it, and the contacts will remain closed (view A). The strength of the magnetic
field of the electromagnet increases as current through the coil increases. As soon as the current in the
circuit becomes large enough, the trip bar is pulled toward the magnetic element (electromagnet). The
contacts are opened, and the current stops (view B).

The amount of current needed to trip the circuit breaker depends on the size of the gap between the trip
bar and the magnetic element. On some circuit breakers, this gap (and therefore the trip current) is
adjustable.

Thermal-magnetic trip element. The thermal-magnetic trip element circuit breaker, like a delay fuse, will

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protect a circuit against a small overload for a long period of time. The larger the overload, the faster the
circuit breaker will trip. The thermal element portion will protect the circuit against ambient temperature
rises. The magnetic element portion will trip instantly when the preset current is present. In some
applications, both types of protection are desired. Rather than using two separate circuit breakers, a
single trip element combining thermal and magnetic trip elements is used. Figure 10-19 shows a thermal-
magnetic trip element.

In the thermal-magnetic trip element circuit breaker, a magnetic element (electromagnet) is connected in

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series with the circuit load, and a bimetallic element is heated by the load current. With normal circuit
current, the bimetallic element does not bend, and the magnetic element does not attract the trip bar
(view A).

If the temperature or current increases over a sustained period of time, the bimetallic element will bend,
push the trip bar, and release the latch. The circuit breaker will trip as shown in view B.

If the current suddenly or rapidly increases enough, the magnetic element will attract the trip bar, release
the latch, and trip the circuit breaker (view C). (This circuit breaker has tripped even though the thermal
element has not had time to react to the increased current.)

CIRCUIT BREAKER CLASSIFICATIONS

Circuit breakers are classified as being trip-free or nontrip-free. A trip-free circuit breaker will trip
(open) even if the operating mechanism (on-off switch) is held in the ON position. A nontrip-free circuit
breaker can be reset and/or held on even if an overload or excessive heat condition is present. In other
words, a nontrip-free circuit breaker will remain closed by holding the operating mechanism on.

Trip-free circuit breakers are used on circuits that cannot tolerate overloads and on nonemergency
circuits. Examples of trip-free applications include precision or current-sensitive circuits, nonemergency
lighting circuits, and nonessential equipment circuits.

TIME-DELAY RATINGS

Circuit breakers, like fuses are rated by the amount of time delay. In circuit breakers, the ratings are
instantaneous, short time delay, and long time delay. The delay times of circuit breakers can be used to
provide selective tripping.

Selective tripping is used to cause the circuit breaker closest to the faulty component to trip. This will
remove power from the faulty circuit without affecting other, nonfaulty circuits.

Figure 10-20 shows a power distribution system using circuit breakers for protection. Circuit breaker 1
(CB1) has the entire current for all seven loads feed through it. CB2 feeds loads 1, 2, 3, and 4 (through
CB4, CB5, CB6, and CB7), and CB3 feeds loads 5, 6, and 7 (through CB8, CB9, and CB10). If all the
circuit breakers were rated with the same time delay, an overload on load 5 could cause CB1, CB3, and
CB8 to trip. This would remove power from all seven loads, even though load 5 was the only circuit
with an overload.

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Selective tripping would have CB1 rated as long time delay, CB2 rated as short time delay, and CB4
through CB10 rated as instantaneous. With this arrangement, if load 5 had an overload, only CB8 would
trip. CB8 would remove the power from load 5 before CB1 and CB3 could react to the overload. In this
way, only 5 would be affected, and the other circuits would continue to operate.

PHYSICAL TYPES OF CIRCUIT BREAKERS

All the circuit breakers described above have been physically large, controlling large amounts of power,
and using a type of toggle operating mechanism. Not all circuit breakers are of this type. The circuit
breaker in Figure 10-21 is physically large and controls large amounts of power, but the operating
mechanism is not a toggle. Except for the difference in the operating mechanism, this circuit breaker is
identical to the circuit breakers already presented.

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Circuit breakers used for low-power protection, such as 28 volt DC, 30 amperes, can be physically
small. With low-power use, arc extinguishers are not required and so are not used in the construction of
these circuit breakers. Figure 10-22 shows a low-power circuit breaker. This circuit breaker has a
thermal trip element (the bimetallic disk) and is nontrip-free.

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There are other physical types of circuit breakers. They are found in power distribution systems, lighting
panels, and even on individual pieces of equipment. Regardless of the physical size and the amount of
power through the circuit breaker, the basic operating principles of circuit breakers apply.

CIRCUIT BREAKER MAINTENANCE

Circuit breakers require careful inspection and cleaning at least once a year. Before working on circuit
breakers, check the applicable technical manual carefully. Before working on shipboard circuit breakers,
obtain the approval of the electrical officer. Be certain to remove all power to the circuit breaker before
working on it. Tag the switch that removes the power to the circuit breaker to ensure that power is not
accidentally applied while working on it.

Once approval has been obtained, the incoming power removed, the switch tagged, and the technical
manual checked, you may begin to check the circuit breaker. Manually operate the circuit breaker
several times to be sure the operating mechanism works smoothly. Inspect the contacts for pitting caused
by arcing or corrosion.

Under normal circumstances, replace the damaged or worn out circuit breaker as an assembly. Follow
the contact servicing section in Chapter 11 if the circuit breaker must be reused. Before installing any
item that has been reconditioned, ensure the chief engineer or the electrical officer has made a final
inspection of the component.

Check the connections at the terminals to be certain the terminals and wiring are tight and free from
corrosion. Check all mounting hardware for tightness and wear. Check all components for wear. Clean
the circuit breaker completely.

When you have finished working on the circuit breaker, restore power and remove the tag from the
switch that applies power to the circuit.

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