DESIGN AND DEVELOPMENT OF ULTRAFAST CIRCUIT BREAKER USING

ACS712 CURRENT SENSOR FOR ANTI - OVERLOAD

A Thesis Presented to the

Faculty of College of Engineering

Camarines Norte State College

Daet, Camarines Norte

In Partial Fulfillment of the Requirements for the Degree of Bachelor of Science in

Electrical Engineering

By

Hernandez, Froilan
Latigay, Pamela
Obias, Gilbert B.
Olavario, Marvin A.
Verdera, Marco O.

February, 2023

i
 TABLE OF CONTENTS

CHAPTER I
Introduction 1
Background of the study 2
Statement of the problem 4
Objective of the study 4
Significance of the study 5
Scope and delimitation 6
Definition of terms 7
End notes 8
CHAPTER II
Review of related literature 9
Review of related study 12
Synthesis of the State of the art 16
Research Gap 17
Conceptual Framework 18
Conceptual Paradigm 19
Theoretical Framework 20
Theoretical Paradigm 21
End notes 22
CHAPTER III
Research design 23
Project development 25
I. Isometric drawing / context design 25
II. Different view / Data flow 26
III. Schematic / Circuit diagram 28

Gantt chart 30
Work breakdown structure 31
Total budgetary requirement 32
Bill of materials 32

ii
List of tools and equipment 33
Testing procedure 35
Research Procedures 35
System Assemblies 37
Evaluation procedure 38
Statistical Tools 40
End notes 42
CHAPTER IV
Result and Discussion
Project Description
Project Structure
Project Capabilities and Limitations
Project Evaluations Results
CHAPTER V
Summary of Findings, Conclusion, and Recommendations
Summary
Findings
Conclusions
Recommendations
APPENDICES
A. Nomination of Project Study Evaluation Committee
B. Application for Final Oral Defense
C. Permission to Conduct Study and To Use College
Facilities for the Conduct of Undergraduate Thesis
D. Curriculum Vitae

iii
 CHAPTER 1

THE PROBLEM AND ITS BACKGROUND

INTRODUCTION

Ever since electricity was discovered, it becomes one of the most essential things

in our daily and modern lives. Electricity is also the most versatile and easily controlled

form of energy that allows us to power the technology we use every day (IEC, 2021).

However, electricity can bring danger and hazards like fire, electrocution and even death

of a person if the electricity is not well managed.

According to Campbell (2022), the National Fire Protection Association (NFPA)

reported that 126 workers died due to exposure to electricity in 2020 and almost three in

five injuries (56 percent) were caused by direct exposure to electricity; this is defined as

injuries caused by direct contact with the power source, such as direct contact with a live

electrical wire or when the victim is struck by an electrical arc. The data above shows

that electricity could bring fatal injuries, electrocution, and death even though we have

practiced safety precaution. NFPA also reported that some cases of fire accidents at home

is due to electrical failures and malfunctions.

Any power system needs protection to protect it from any undesirable fault

currents and that’s why we have protection devices such as Circuit breakers which will

break the current during faults to protect the system. Circuit breakers break the current

during faults by opening the contacts which were closed during the normal operation

conditions, to isolate the fault part of the power system. But there are some cases that

circuit breakers did not do its job to protect circuitries, appliances and properties due to

age issue and malfunctions.

1
 Through these circumstances, the researchers were moved to conduct a study that

will minimize the number of fire accidents, electrocution, injuries and even death caused

by electrical fault. To come up with a proficient solution to the problem, the researchers

developed a monitoring and safety device entitled Design and Development of Ultrafast

Circuit Breaker using ACS712 Current Sensor for Anti - Overload that is automatically

operated using Arduino Uno, Magnetic contactor, and relay. The major components that

will use to provide instantaneous tripping are ACS712 current sensor and Arduino on

which will measure the amount of current passing through the circuit and when the

current exceeds to its maximum rating, the device will instantaneously trip. This study

aims to provide electrical safety and come up with a functional and reliable device.

Through the help of this project, the home owners will secure their appliances,

properties and even their lives from possible electrical fault that may occur on their

houses. In addition, the hazards, injuries and death that electricity may bring could be

lessen through this device.

BACKGROUND OF THE STUDY

A circuit breaker is an automatically operated electrical switch designed to protect

an electrical circuit from damage caused by overload or short circuit. The circuit breaker

is an essential device in the modern world, and one of the most important safety

mechanisms in your home. Whenever electrical wiring in a building has too much current

flowing through it, these simple machines cut the power until somebody can fix the

problem. Without circuit breakers (or the alternative, fuses), household electricity would

be impractical because of the potential for fires and other mayhem resulting from simple

wiring problems and equipment failures.

2
 The lingering risk of electrical fault scenarios (e.g., shorts and overloads) remains

a primary hurdle preventing the growth of DC markets. In AC networks, electricity

alternates direction periodically, naturally providing a “zero crossing” where no current

flows for a brief moment, which allows electrical faults to easily be extinguished. DC

networks, on the other hand, deliver power without zero crossings, which greatly

increases the likelihood of electrical arcs in conventional circuit breakers, making them

ineffectual in fault scenarios. Breakers projects will need to overcome this limitation

while supporting greater power and voltage ratings than traditional low voltage solutions.

Ultimately, innovations in MVDC circuit breakers could enable significant efficiency

improvements in the United States, transforming how electricity is delivered and

managed across the entire power grid, in transportation, and other valuable parts of the

economy, (Kizilyalli, 2018).

Power system protection is a time-critical task that must be accomplished within

the specified time limits to maintain the stability, reliability, and safety of the grid. As

modern substations embrace integrated communications using the IEC61850 standard,

network latency and reliability issues continue to influence decisions regarding moving

the critical protection tasks to Local Area Network-based substation automation systems

(SAS), thus eliminating the laborious and costly copper hard-wiring in the substations.

Backup protection functions, such as circuit breaker failure (CBF) protection, have

appeared as good candidates for implementation in SAS to gain operational experience

with the new paradigm. CBF protection, a time-delayed protection function, can tolerate

variations in network latency when designed properly. Because transformers are the most

3
critical and expensive pieces of substation equipment, evaluating transformer bay CBFs

specifically is crucial (Darabi, 2013).

An electrical fault detector system detects electrical faults in an electrical

distribution system by monitoring one or more conductors and producing an input signal

representing one or more electrical signal conditions in the circuit to be monitored. This

input signal is processed to develop a first signal representing the electrical current flow

through the monitored circuit and a second signal representing signal components in a

selected frequency range typical of arcing faults, and which exceed a predetermined

threshold. The system also detects ground faults in the circuit being monitored.

STATEMENT OF THE PROBLEM

To ensure the protection of properties, appliances and circuits, the researchers will

design a device to provide additional security in the properties and circuitry by the help

of Design and Development of Ultrafast Circuit Breaker using ACS712 Current Sensor

for Anti – Overload.

Specifically, it sought to answer the following questions:

1. What is the accuracy of the current sensor in measuring current from the circuit?

2. What is the reliability of the device in the sense of automatic trip off during overload

condition?

3. What is the significant difference of typical circuit breaker and the proposed device in

terms of fast overloading response?

4
OBJECTIVE OF THE STUDY

This study aims to develop a Design and Development of Ultrafast Circuit

Breaker using ACS712 Current Sensor for Anti - Overload which will protect properties

and appliances from damages caused by electricity, a device which is operated

automatically.

The following are the specific objectives of the study.

 To prevent fire accidents, cause by overload circuit.

 To prevent damages in electrical and electronic appliances.

 To prevent overloading.

 To lessen the fatal injuries and possible death caused by electrical fault.

SIGNIFICANCE OF THE STUDY

The Design and Development of Ultrafast Circuit Breaker using ACS712 Current
Sensor for Anti – Overload is a device that instantaneously trip when overload is
detected. The device is significant in order to protect lives and properties from possible
electrical fault.
The vital results of this investigation could be highly significant and beneficial

specifically to the following sectors:

Residential Home Owners. Most of the residential houses are made of light materials

which are highly flammable and very easy to burn. Hence, installing this device in

residential building will provide an efficient protection for their houses from fault in

electrical circuits.

Innovators. Generating great and considerable ideas could influence person’s thinking

ability. The efficiency, credibility and effectiveness of the study could be act as a chain

5
reaction which influences the students, planners, developers and professionals to produce

more ideas for the development in research and innovation.

Bureau of Fire Protection. The adaption and application of this study on the community

will help the agency on achieving their goal of reducing fire accidents caused by faulty

electrical circuit.

Researchers. The study will help the researchers to further investigate from research and

society in finding solutions the specific problems. They could use this study as their

reference in looking for related literature, and they could get an idea to improve or

innovate more devices related to this study.

SCOPE AND DELIMITATION

This study will focus on the development of Design and Development of Ultrafast

Circuit Breaker using ACS712 Current Sensor for Anti - Overload as well as its

functionality and efficiency during overload conditions. The device is instantaneously

trip off during overload condition to protect the circuit and to prevent the electrical

appliances. The purpose of the microcontroller and current sensor is to monitor the

current delivered in the circuit in order to prevent overload.

The study was delimited by using Magnetic contactor and relay in a purpose of

security automation in home power supply. The study also focused in 20A MCB type of

circuit breaker as mandated by PEC for convenience outlet circuit protection. The study

also focuses in ACS712 type of current sensor and by using convenience outlet. The

developed design of the device considered the laws and standards in wiring and material

quality as mandated by PEC. The study also delimited on one branch circuit only having

3 sets of 3 gang convenience outlet.

6
 DEFINITION OF TERMS

Arduino Uno - programmable device used to control and read the system when fault

occur.

ACS712 Current Sensor - A device used to measure the amount of current in the circuit.

Magnetic Contactor – a protective device used to disconnect the circuit when overload

occurs.

Miniature Circuit Breaker - an electrical safety device designed to protect an electrical

circuit from damage caused by an overcurrent or short circuit.

Magnetic Contactor – a protective device used to disconnect the circuit when overload

occurs.

Overloading – a condition when the current exceeds on its ampacity.

Relay module – an electromagnet designed to allow the arduino to break the circuit

instantaneously when overload occurs.

7
 END NOTES

Campbell, R. (2022). Fatal Work Injuries Caused by Exposure to Electricity in 2020.

Retrieved from NFPA:
https://www.nfpa.org/-/media/Files/News-and-Research/Fire-statistics-and-
reports/Electrical/osFatalElectricalInjuries.pdf.
 
Kizilyalli, I. (2018). Building Reliable Electronics to Achieve Kilovolt Effective Ratings
Safely. Retrieved from ARPA-E:
https://arpa-e.energy.gov/technologies/programs/breakers.

Darabi, Z. (2013). IEEE. Application of IEC61850-enabled SAS in CBF protection of

transformers. IEEE PES Innovative Smart Grid Technologies Conference (ISGT),
1-6.

8
 CHAPTER II

REVIEW OF RELATED LITERATURE AND STUDIES

This chapter presents and discusses different related literature and studies that are

closely related to the present research. It includes detailed and comprehensive reviews

which aid in identifying the research gaps and help in a better comprehension of the

study.

This part presents the different published books, professional journals, and the

like that were found to be related and substantial in supporting the present study.

RELATED LITERATURE

Circuit breakers are used in a power system to break or make current flow through

power system apparatus. The action of circuit breakers changes switching topology of a

power system. Reliable operation of circuit breakers is critical to the ability to

reconfigure a power system and can be assured by regular inspection and maintenance.

An automated circuit breaker monitoring system is proposed to monitor circuit breaker's

control circuit. System is designed to enable deployment of system-wide applications that

utilize the data recorded by the system. An application of system wide data analysis is

demonstrated. It makes possible to track the circuit breaker switching sequences and

make conclusions about their performance and final outcome. Lab and field evaluation of

the designed system is performed and results are presented by Knezev, M. et al, (2017).

According to Campbell (2022), the NFPA reported the estimated average of

46,700 home fires involving electrical failure or malfunction each year in 2015–2019.

These fires caused an estimated average of 390 civilian deaths and 1,330 civilian injuries

9
each year as well as an estimated $1.5 billion in direct property damage a year. The

second leading cause of electrical home fire is electrical failures and approximately 13%

of home structure fires. Arcing served as the heat source in over three in five fires (63%)

of home fires involving an electrical failure.

Common Electrical Problems

The 10 most common electrical problems in homeowner namely Electrical

Surges, No RCCB, Circuit Breaker Keeps Tripping, Frequent Bulb Burnout, Problems

with Wires, Switches Don't Work Properly, Issues with Outlets, High Electricity Bills,

Lights are Too Bright or Too Dim, Electrical Shocks. She gives an advised to identify the

electrical problem happen in home and to call a professional when there are problems in

home appliances and circuit, Hasan (2021).

There are 7 common electrical problems, according to Easley (2021); Loose

Outlets, Ungrounded Outlets, Over-Lamping, Absence of GFCIs, Coverless Junction

Boxes, Faulty Switches, Over-Wired Panels. This common problem has its own solution.

She also shared the possible solution for these types of problems. In-wall wiring, circuit

breakers, outlets, and electrical fixtures are enough to think about, but in older homes,

there is also the possibility of dated wiring and materials that are no longer up to code.

Faulty components, electrical wiring problems, and old materials can lead to everything

from flickering lights to a full-on house fire.

Microcontroller

According to Louis (2016), arduino is an open-source microcontroller which can

be easily programmed, erased, and reprogrammed at any instant of time. Arduino was

designed to provide an inexpensive and easy way for students and professionals to create

10
devices that interact with their environment using sensors. It also allows you to create

new ideas by exploring programming and automation. It is also capable of receiving and

sending information over the internet with the help of various Arduino shields.

These days many people try to use the arduino because it makes things easier due

to the simplified version of C++ and the already made Arduino microcontroller

(atmega328 microcontroller) that you can programme, erase and reprogramme at any

given time, Badamasi (2014).

ACS712 Current Sensor

ACS712 Current Sensor is the sensor that can be used to measure and calculate

the amount of current applied to the conductor without affecting the performance of the

system. ACS712 Current Sensor uses Indirect Sensing method to calculate the current. To

sense current a liner, low-offset Hall sensor circuit is used in this IC. This sensor is

located at the surface of the IC on a copper conduction path. When current flows through

this copper conduction path it generates a magnetic field which is sensed by the Hall

Effect sensor. A voltage proportional to the sensed magnetic field is generated by the

Hall sensor, which is used to measure current. ACS712 can be used in applications

requiring electrical isolation as the terminals of the conduction path are electrically

isolated from the IC leads. Thus, this IC does not require any other isolation techniques.

This IC requires a supply voltage of 5V. Its output voltage is proportional to AC or DC

current. ACS712 has a nearly zero magnetic hysteresis.

Circuit Breaker

Mafi, H. et al. (2019), developed a Smart Residual Current Circuit Breaker with

Overcurrent protection that protects users and electrical and electronic devices against the

11
risk of overcurrent. Leakage current, overload and short-circuit are dangerous and

harmful effects in electrical appliances. It is necessary to install circuit protection in order

to prevent damages and fire accidents that may occur. This problem may cause

electrocution and fire accidents if the proper safety did not implement. The smart RCBO

is a programmable device that works based on microcontroller technology.

In the study of Marhoon et al. (2018), entitled Design and Implementation of

Intelligent Circuit Breaker for Electrical Current Sensing and Monitoring states that due

to the increasing problems such as burning of buildings or exposure to direct shock

because of electric short circuit or over loading and thus damaged the control panel.

Smart and faster response of circuit breaker in short circuit and overloading must

develop. They also stated that due to short circuit the home appliances absorbed high

current which leads to casualty of the devices.

RELATED STUDIES

Kommey et al, (2021), present an Intelligent Miniature Circuit Breaker (IMCB)

for residences. The system uses a microcontroller and current sensors (CTS) to provide

intelligence to a distribution system panel. The distribution system automatically detects

the current flowing through the circuit and trips the circuit if the current is higher than a

threshold. The current sensors keep monitoring the current and when the current falls

below the threshold, the circuit is reconnected. The system uses a GSM module to send

alerts to the user when the circuit trips. The proposed system operates automatically and

eliminates the need for the user to manually reconnect the circuit when there is a trip.

12
 According to BFP spokesperson SPT. Carbajal-Atienza, there were 2,103 fires

from January to March 1, which is higher by 12.88 percent compared to 1,863 incidents

during the same period last year. Among the leading causes of fires are faulty electrical

wiring. The usual causes of fires due to electrical faults are old wiring, improper

connections, and poor/damaged wire quality. Electrical overloading occurs when the

current being passed through the wires exceed the capacity limit the wires can handle;

this can heat up the wires and melt, leading to fire (Romero, 2022).

Based on the recent report by the Bureau of Fire Protection (BFP), fire incidents

jumped by almost 13% compared to the same period last year, mostly because of faulty

electrical wiring. A simple unorganized electrical wiring can cause a fire accident at

home. It can be an overloaded electrical outlet, exposed wiring that needs fixing,

improper connections, or something else (Billones, 2022).

According to the study of Occeńo, K. (2016), the economy of the country affects

by the destructive electrical fire incidents. The objective of the study is to determine the

origin of the electrical fire and sought for possible solutions. The study showed that the

most common cause of electrical fire incidents in Region VI was electrical post-fire and

Aklan had the highest rate of electrical fire incidents caused by short circuit. Antique had

the highest rate of electrical fire incidents caused by overheat while Iloilo and Negros

Occidental had the highest rate of incidents caused by electrical post-fire. The structures

involved in electrical fire incidents were electrical posts, residential buildings,

commercial buildings, vehicles, and other structures. Furthermore, other appliances had

the highest involvement followed by electric fans, ceiling fans, flat irons, and electric

13
water heaters. The electrical post-fire and short circuit are mostly the causes of electrical

fire incidents.

Similar to the study of Gao et al, (2016), statistics shows that about 373,700

electrical fires occurred nationwide. Electrical fires occupied the first place of all types of

fires. Electric lines are the main fire sources (almost 50%) in the electrical fires.

Secondly, the use of electrical appliances, electrical equipment and electrical facilities is

also an important cause of electrical fires. In addition, the lighting apparatus is also very

prominent. The main cause of electrical fires is the short circuit fault (about 51%). Other

fire accidents are caused by non-electrical reasons, electrical facilities are in high flame

temperature effect, electrical insulation is destroyed, induced electrical accidents such as

short circuits continue to occur on the live lines which will leave corresponding residue

traces.

Deocar et al (2017), developed device that response faster when short circuit and

overload detected in power system. They introduce the ECB (Electronic Circuit Breaker)

which has less trip time of circuit whenever abnormal condition occur as compared to

mechanical or convectional circuit breaker such as MCB (Miniature Circuit Breaker)

which takes longer time to trip the circuit because of very slow action thermal bimetal

lever mechanism that used in MCB (Miniature Circuit breaker). Then voltage drop across

series element and preset voltage are compared in level comparator, resultant signal of

comparator is given to microcontroller, MOSFET is operated through microcontroller

and then operation of relay is decided by MOSFET and circuit is trip instantaneously.

Electronic Circuit Breaker (ECB) that trips the power supply instantaneously in

overload condition. Mechanically operated circuit breakers like MCB are based on very

14
slow action thermal bimetal lever trip mechanism. The activation time of MCB rely on

the overloaded percentage of the fault. They developed the device to determine that the

thermally operated circuit breakers such as MCBs take longer time to trip. The current

flow through the series element is sensed by ECB and the corresponding voltage drop and

the preset voltage is compared with a level comparator and the resultant signals are given

to the microcontroller through a MOSFET which drives the relay to trip the load.

Electronic circuit breaker is operated instantaneously with the tripping of relay, Abirami

et al (2016).

According to the study of Abhijith et al. (2017 ), entitled Smart Ultra-Fast Acting

Electronic Circuit Breaker, conventional circuit breakers like miniature circuit breaker or

a fuse is good at breaking the circuit when a short circuit fault occurs. But when an

overload fault occurs, the tripping time is slow and depends on the percentage of

overload. However, for sensitive loads it is very important to activate the tripping

mechanism at the shortest possible time, preferably instantaneously. The smart ultrafast

acting electronic circuit breaker proposes a new approach to over-current protection.

Conventional methods are very good at breaking short circuit currents. But when

overloading takes place, it could take a few seconds for the supply to be interrupted.

In the study of Cora et al (2012), they developed a device that saves energy, by

eliminating stand by power, acts as a surge protector, circuit breaker and residual current

breaker in which performs faster than the conventional protecting devices. It is stated on

their study that most of the houses are generally protected by mechanical circuit breakers

against over current and residual current circuit breakers to detect leakage currents but

mechanical protecting device may be insufficient in some case because it has slow parts.

15
Over voltage and over current may cause serious damages on electrical and electronic

appliances that is why it is way more important to protect them.

Husin et al (2022), developed Miniature Circuit Breaker (MCB) Current Detector

by using Microcontroller and Global System of Mobile (GSM) to monitor the electricity

usage to optimized system management and minimize hazards caused by electrical faults.

The study states that the main problem that had been solved is that electrical hazards in

residential areas are frequently linked with malfunctioning home appliances and surging

appliance demand, which occurred in overloading.

SYNTHESIS OF THE STATE OF THE ART

The researchers thoroughly reviewed various studies that are found to be

related and beneficial to the present study. Therefore, the following analyses were drawn

by the researchers:

In the study of P. Abirami et al (2016) and Kommey et al, (2021) their objective is

to develop electronic circuit breaker that trip off instantaneously when fault is detected.

They used same approach in current metering by using current sensor.

According to Campbell (2022) and Gao et al, (2016) present and data that shows

fire accidents caused by faulty electrical, they also present a data that determine a type of

fault that cause fire accidents nationwide. Romero (2022) present also a data that shows

that the most common cause of fire incident are faulty wiring, old wiring and

overloading, a while Occeńo, K. (2016) focuses in determining the origin of the electrical

fire accidents.

16
 Deocar et al (2017) and Abirami et al (2016), presented their study entitled

Electronic Circuit Breaker that instantaneously trips off when overcurrent is detected. It

is stated on their study that circuit breakers like MCB is based on very slow action

thermal bimetal lever trip mechanism. The response time of MCB rely on the overloaded

percentage of the fault. Similar to the study of Abhijith et al. 2017 entitled Smart

Ultrafast Acting Electronic Circuit Breaker, typical circuit breaker like miniature circuit

breaker or fuse is efficient as circuit breaker when a short circuit and overcurrent occurs.

They also stated that the tripping time of MCB is very slow when overload fault occurs.

Hasan (2021) and Easley (2021) discussed the different types of common

electrical problems. They stated that loose connections, faulty wiring, absence of circuit

protection and faulty switches are the most common electrical problems in residential

houses.

Husin et al (2022) and Marhoon et al (2018), developed a circuit breaker that has

electricity monitoring feature that protects the circuit from possible trouble. They

developed their device to solve the increasing problems in fire incidents and minimize the

hazards caused by electrical faults.

Research Gap

To sum up, the reviewed previous studies are similar to the present study in the

approach of current sensing, micro-controlling and overloading protection. All the

previous study mentioned above undergone series of testing and evaluation in a purpose

of its accuracy and reliability of the designed project. This study is different since they

used Magnetic contactor and channel relay for power supply automatic disconnection
17
during overload condition. In addition, this study also used ACS712 current sensor to

monitor and read the current in the circuit and used relay module for faster tripping of the

circuit. With this synthesis, the researchers assure that the study was not duplication of

the previous studies conducted.

CONCEPTUAL FRAMEWORK

In this section involves the three main factors the input, process, and output that

shown in the paradigm of the study. This section used by researcher as guide to visualize

and conceptualize the research procedures.

Input. It is the important part of the study. As stated in the figure above the main

input of the study are gathered information about the study and materials needed. Data

gathering is the step to generate and identify problems that exists, it is also the stepping

stone to find a solution for a particular problem. For the construction there are several

materials are needed mainly in creating prototype. It is very essential to choose and

condition of materials for the purpose of effectiveness and functionality. Electrical

concepts are needed for the fabrication of this study.

Process. In this procedure, the process includes the series of tests and trials that is

needs to be done to achieve a desire output. Application of the different principles of

theories will help the process to create a useful and effective solution for the particular

problem. In this study, programming and coding are needs to be done correctly in order

for the device working very well. Testing and evaluation are included in the process.

18
Series of tests and evaluation are important to be done mostly in programming and

coding to guarantee the effectiveness of the output.

Ouput. It is the expected outcome of the study. The problems are about solved by

this research.

PROCESS OUTPUT
-Planning Design and
INPUT -Designing Development
-Preparation of
- Electrical Safety
Materials and
of Ultrafast
Risk Assessment Equipment Circuit Breaker
-Electrical and -Fabrication using ACS712
Fire Accident
-Modification Current Sensor
-Testing
Prevention for Anti -
-Evaluation
Overload

FEEDBACK
Figure 1. Conceptual Paradigm

19
20
THEORETICAL FRAMEWORK

This study was based on the Principle of Automation, Monitor Theory and Digital

Communication Theory shown in the figure 1.

Principle of Automation. The purpose of this study is to create a Design and

Development of Ultrafast Circuit Breaker using ACS712 Current Sensor for Anti –

Overload with the help of microcontroller specifically Arduino Uno which is the heart of

the whole process and also used for automation of the power supply. Arduino Uno

monitor the current that measure by current sensor.

Monitor theory. The study used current sensor to measure the current in the

circuit. The whole circuit contains only one current sensor to measure the whole current

delivered by different appliances or loads. Once the current exceeds in the maximum

rating, current sensor immediately sends a signal to Arduino to break the circuit.

Communication Theory. Communication theory studies the scientific process of

sending and receiving information. The proposed study used microcontroller, relay,

contactor, and current sensor where in microcontroller is the brain of the system that

process the received signal and current sensor to monitor and measure the current in the

circuit, once the current exceeds in maximum rating, the sensor sends a signal to the

Arduino. The Arduino will read the transmitted signal and give a command to relay to

break the circuit.

21
THEORETICAL PARADIGM

PRINCIPLE OF MONITOR COMMUNICATION

AUTOMATION THEORY THEORY

Design and Development

of Ultrafast Circuit
Breaker using ACS712
Current Sensor for Anti -
Overload

Figure 2. Theoretical Paradigm

22
 END NOTES
Knezev, M. (2007). IEEE. Automated Circuit Breaker Monitoring. 2007 IEEE Power
Engineering Society General Meeting, 1-6.

Campbell, R. (2022). Fatal Work Injuries Caused by Exposure to Electricity in 2020.

Retrieved from National Fire Protection Association:
https://www.nfpa.org/-/media/Files/News-and-Research/Fire-statistics-and-
reports/Electrical/osFatalElectricalInjuries.pdf.

Hasan, M. (2021). What Are the Most Common Electrical Problems?”. Retrieved August
2022 from Angi: https://www.angi.com/articles/electrical-threat-hiding-your-
walls.htm.
Easley, E. (2021). Top 7 Common Electrical Problems and Solutions. Retrieved from
Liberty Home Guard: https://www.libertyhomeguard.com/top-7-common-
electrical-problems-and-solutions.
Louis, L. (2016). Working principle of Arduino and using it. International Journal of
Control, Automation, Communication and Systems (IJCACS), 1(2), 21-29.
Badamasi, Y. A. (2014). IEEE. The working principle of an Arduino. 014 11th
International Conference on Electronics, Computer and Computation (ICECCO),
1-4.
Mafi, H. (2019). IEEE. Smart Residual Current Circuit Breaker with Overcurrent
protection. 2019 IEEE 2nd International Conference on Renewable Energy and
Power Engineering (REPE), 6-9.

Marhoon, H. (2018). Design and Implementation of Intelligent Circuit Breaker for

Electrical Current Sensing and Monitoring” by Marhoon et al (2018). Al-Esra’a
University College, Karadah, Baghdad, Iraq.

Kommey, B. (2021, October). Intelligent Miniature Circuit Breaker” by Kommey at al

(2021). Kwame Nkrumah University of Science and Technology, Kumasi, Ghana.

Occeńo, K. (2016). Electrical Post Fire as Cause of Fire Incidents in Region VI,
Philippines. Capiz State University, Capiz, Philippines.
Gao, D. (2016). Review of the Research on the Identification of Electrical Fire Trace
Evidence. Retrieved August 2022 from Science Direct:
https://www.sciencedirect.com/science/article/pii/ S1877705816000795.
Deocar, T. V. (2017). IEEE. Ultrafast acting Electronic Circuit Breaker for overload
protection. 2017 Third International Conference on Advances in Electrical,
Electronics, Information, Communication and Bio-Informatics (AEEICB), 29-32.

23
Abirami, P. (2016). IEEE. Electronic Circuit Breaker for overload protection. 2016
International Conference on Computation of Power, Energy Information and
Communication (ICCPEIC), 773-776.

Abhijith, S, (2017). Smart Ultrafast Acting Electronic Circuit Breaker. Mar Anthanasius
College of Engineering Kothamangalam, Kerala India.

Cora, A. (2012). IEEE. A complete solution for the problem of eliminating residential
stand-by power and protecting them against over voltage and over current. 2012
International Symposium on Innovations in Intelligent Systems and Applications,
1-5.
Husin (2022). Miniature Circuit Breaker (MCB) Current Detector by using
Microcontroller and Global System of Mobile (GSM). Retrieved October 2022
from https://penerbit.uthm.edu.my/periodicals/index.php/eeee/article/view/6661.
Romero, A. (2022). BFP: Fires up by 13%. The Philippine Star. Retrieved from The
Philippine Star: https://www.philstar.com/nation/2022/03/02/2164301/bfp-fires-
13.

24
 CHAPTER III

RESEARCH METHODOLOGY

This chapter describes the procedures and methods that the study will employ in

the conduct of research. This part composes research design, project development, and

research procedures,

RESEARCH DESIGN

 Sirisilla S., (2023). Experimental research design is a framework of protocols and

procedures created to conduct experimental research with a scientific approach using two

sets of variables. Herein, the first set of variables acts as a constant, used to measure the

differences of the second set. The design of this research is Experimental research design.

Experimental research helps a researcher gather the necessary data for making

better research decisions and determining the facts of a research study.

The project study is all about Design and Development of Ultrafast Circuit

Breaker using ACS712 Current Sensor for Anti - Overload. The working principle of

device is to open the circuit instantaneously when overloading condition. In order for the

device to act instantaneously during overload condition, ACS712 current sensor are being

used to measure the amount of current passing through the circuit. The trip current value

is set to arduino and when the current in the circuit is much higher than the ampere rating

or trip current value, the device will instantly open. The ultrafast circuit breaker will

achieve by the help of ACS712 and Arduino. The researchers come up with the study in

order to solve the problem about increasing fire accidents cause by electrical fault.

25
 This part involves the core and organized procedures in the development of the

study such as planning, designing, preparation of the materials and equipment,

fabrication, modification and evaluation. In planning, the researchers collect information

and data to identify the different factors need to be considered in the study in order to

provide efficient and effective output.

I. ISOMETRIC DRAWING/CONTEXT DESIGN

The study is all about Design and Development of Ultrafast Circuit Breaker using
ACS712 Current Sensor for Anti - Overload. Below is the ideal prototype of the study

The prototype design consists of three key parts: 1) a panel board; 2) a control panel; and
3) convenience outlets. The Circuit Breaker (CB) is located on the panel board. The
control panel is the core part of the device, containing the major components, namely the
microprocessors, current sensor, relay and contactor. It covers the device's processing and
execution functions. The last major part is the socket sections, which are mostly
composed of convenience outlets with current sensors that act as detectors of the device
on the load attached. The figure below shows the proposed overall design of the device.

Circuit
Control Panel
Breaker

Indicator
lights

Junction
Box

Convenience
Outlet

Figure 3. Ideal Prototype

26
II. DIFFERENT VIEW/DATA FLOW

The following figures show the different perspective view of the prototype system
and devices of the study Design and Development of Ultrafast Circuit Breaker using
ACS712 Current Sensor for Anti - Overload. The device has 3 indicator lights to
determine the condition of the circuit. Red means the device is overload, Green means the
device is on/operated, orange means the current in the circuit exceed its 80% safety
factor. The device also provided of LCD to display the current measured by ACS712
current sensor.

Figure 4. Perspective view of the study

27
Figure 5. Perspective view of the study

Figure 6. Perspective view of the study

28
SCHEMATIC DIAGRAM

Schematic Diagram of the Circuit

Figure 7. Schematic Diagram

29
BLOCK DIAGRAM

Figure 8. Block Diagram

30
IV. PROJECT MANAGEMENT

GANTT CHART

The fundamental content of the planning and designing is the Gantt chart, which

is used to show how the research is carried out. This section provided a clear explanation

of the activity plan and its arrangement to determine the research's outcome. The test and

experiment results were used as the foundation for the device’s development.

Activities October November December January

2022 2022 2022 2023

Brain
storming for
Research
Title
Background
Research and
gathering of
necessary
literature

Planning and
designing of
the device
Purchased
materials

Preparation
of necessary
tools and
equipment
Construction
of the device

Fabrication

Testing the

31
 device
Evaluation
and analysis
of results
Finalizing
the papers

Table 1. Gantt Chart

WORK BREAKDOWN STRUCTURE

Activities Time allotment

Data Gathering 3 Days All members

Planning
Target Date & Designing
Actual Date 10 Days All members

Paper works All members

Testing & Evaluation 5 Days All members

Fabrication 5 Days All members

Construction of the device 15 Days All members

Prototype development 10 Days All members

Paper Revision 3 Days All members

Table 2. Work Structure

TOTAL BUDGETARY REQUIREMENT

This section shows the total cost of materials needed in construction of the device.

It includes the quantities and specifications of materials and its unit and cost. It presents

the total budgetary requirement for materials used in constructing the project. For the

estimation cost of the device, the researchers used the updated price of each of every

material. The estimated total price needed in the construction is Php. 4,125.

32
BILL OF MATERIALS

The table presents the bill of materials needed in the study.

QUANTITY UNIT ITEM UNIT PRICE AMOUNT

1 pc CB (20A) with Php 450 Php 450

cover and case

1 pc Magnetic Php 500 Php 500

Contactor
1 pcs Arduino Uno Php 400 Php 400

3 pc Channel Relay Php 150 Php 450

1 pc Current sensor Php 100 Php 100

20 mtrs THHN Wire #12 Php 30 Php 600

1 pc Electrical Tape Php 50 Php 50

3 pcs Utility box Php 25 Php 75

3 pcs Convenience outlet Php 250 Php 750

8 pcs Flexible Hose Php 12 Php 96

Connector
3 m Flexible Hose (1/2) Php 14 Php 42

6 pc C-clamps Php 2 Php 12

1 pc Bolt-on Panel Box Php 200 Php 200

1 pc Plyboard (1/4) Php 400 Php 400

Total PHP 4,125

Table 3. Bill of Materials

LIST OF TOOLS EQUIPMENT

33
 The materials and equipment to be used should be functional and in good quality

and condition. The table presents the specifications of each tool and instrument used in

constructing the device.

Specification Remarks
Multi-meter Good Condition
Pliers Safe and Good Condition
(Combination, long nose and
side cutter)

Soldering iron Safe and Good Condition

Hack Saw Safe and Good Condition

Claw Hammer Safe and Good Condition
Screw Drivers Safe and Good Condition
(Philip Screw and Flat Screw)
Drilling Machine Safe and Good Condition

Grinder Safe and Good Condition

Table 4. Tools & Equipment

Typical Circuit Breaker (MCB) Vs. Ultrafast Circuit Breaker

Typical Circuit Breaker (MCB)

Miniature circuit breaker operates as an automatic switch that opens in the event

of excessive current flowing through the circuit and once the circuit returns to normal, it

can be reclosed without any manual replacement. Miniature circuit breaker is an

electromagnetic device that embodies a complete enclosure in a molded insulating

material. The main function of miniature circuit breaker is to switch the circuit, i.e., to

open the circuit (which has been connected to it) automatically when the current passing

34
through it (MCB) exceeds the value for which it is set. MCBs are time delay tripping

devices, to which the magnitude of overcurrent controls the operating time. This means,

these get operated whenever overloads exist long enough to create a danger to the circuit

being protected. Generally, these are designed to operate at less than 2.5 milliseconds

during short circuit faults and 2 seconds to 2 minutes in case of overloads (depending on

the level of current).

Operating Knob

Solenoid
Bimetal strip

Lever Supply Terminal

Load Terminal

Figure 9. Circuit breaker parts

The figure 9 shows the important parts of circuit breaker. The thermal tripping of

the circuit breaker is based on the temperature of the bimetallic strip and excessive

amount of current. When there is an overload, the increased current flow heats the

bimetal and causes it to bend. As the bimetal bends, it pushes the lever to release from its

position causing the circuit breaker to trip.

Ultrafast Circuit Breaker

35
 The working principle of Ultrafast Circuit Breaker is to break the circuit

instantaneously when overloading condition. In order for the device to act

instantaneously during overload condition, ACS712 current sensor are being used to

measure the amount of current passing through the circuit. The trip current value is set to

arduino and when the current in the circuit is much higher than the ampere rating or trip

current value, the device will instantly open. The ultrafast circuit breaker feature will

achieve by the help of ACS712 and Arduino.

Significant Diffirence of trip time

Current Rating25A
(A)

23A

20A

15A

10A

0 1 2 3 4 5 6 7 8 9

Time (s) Propoesed Device Typical CB

Graph 1. Trip time

TESTING PROCEDURE

After constructing the whole project, next is testing and evaluation. In this stage

the researchers present the method of testing to measures the performance of the device.

Accuracy Test

36
 The test plugged in different home appliances to determine the accuracy and

ACS712 in measuring current.

Number of Trial Current Sensor Effective Clamp Ammeter Current

Reading Reading
Trial 1
Trial 2
Trial 3
Trial 4
Trial 5
Table 5. Accuracy of ACS712

The accuracy of the device was based on the table presented above. The

convenience outlet is subjected to plug in different loads or home appliances and read it

by the current sensor. After sensor reads the current in the circuit, the result will compare

it to the effective reading of the clamp ammeter to determine if they have the same

reading or have very minimal difference.

The score table below is used to determine the accuracy and the

percentage error of the proposed device.

Score Interpretation
80.1% - 100% Inaccurate
60.1% - 80% Fairly Accurate
40.1% - 60% Moderately Accurate
20.1% - 40% Accurate
0.1% - 20% Very Accurate

Table 6. Test Score

RESEARCH PROCEDURES

The study was subjected to different processes such as the gathering of

data, planning and designing, preparation of materials and equipment, Fabrication &

modification of the device, testing and evaluation.

37
 START Gathering of Planning
Data and Designing

Fabrication & Preparation of

Testing
modification Materials and
of the device Equipment

Evaluation END

Figure 10. Flow Chart

Gathering of Data. This part of the study was intended to gather the necessary

information needed by the researcher to conduct the proposed title Ultrafast Circuit

Breaker Using ACS712 Current Sensor for Overcurrent and Fire Protection.

Planning and Designing. The researchers collect information to determine the different

factors to be considered in the study and design the overview of the project. It aims to

manage all the requirements needed for the entire period of the study. With this, the

researchers will be able to achieve the proposed study by planning all the needed data and

information to meet the desire output.

Preparation of the Materials and Equipments. The researchers will prepare all the

materials and equipment needed in construction of the device. The materials and

equipment used in this study are in good quality and condition.

Fabrication & modification of the device. It is the critical part of the study. In this part,

the researchers apply their knowledge about the system in terms of fabricating, modifying

38
and coding. Also, the data and information gathered will review and apply the data in

order to provide effective and efficient output.

Testing. The researchers performed series of test to ensure the accuracy and reliability of

the device and also examine the system to determine each individual part is working well.

Evaluation. The last process to be considered in the development will be the evaluation

procedure. This will determine the performance and of reliability the Design and

Development of Ultrafast Circuit Breaker using ACS712 Current Sensor for Anti –

Overload in terms of its output device as a whole.

SYSTEM ASSEMBLIES

System assembly is the collection of materials that are built together to create

desire output. Assembly is the finishing touch process for product realization where

component parts and subassemblies are integrated together to form the final products.

1. Prepare all the materials, tools and equipment used in constructing the prototype.
2. Construction of the base part of the device performed the researchers at home.
3. Installation of the materials in plyboard.
a. CB, Control panel, Panel board, junction box and utility box were installed
using screws.
b. Arduino Uno, Magnetic contactor ACS712 current sensor and relay
installed inside the control panel.
4. Connect proper wiring in accordance with schematic diagram.
5. Program the system using Arduino Uno.
6. Perform testing to ensure the system’s functionality.
7. Modifying will take place when encounter technical error especially in
programming.

In this assembly, the researchers followed the PEC requirements in installing

electrical devices in order to provide safety electrical circuitry.

39
EVALUATION PROCEDURE

1. Reliability of the device in terms of automatic trip off during overload condition.

Number of Trials

Interpretation 1 2 3 4 5

Successful

Failed

Table 7. Reliability test

In this test, the researchers will use different types of appliances in order to
overload the circuit. The device will undergo 5 number of trials and count the number of
successes that the circuit will trip off when overloaded. The score below will use to
determine the reliability of the device in the sense of automatic trip off during overload
condition.

Score Interpretation
1 Not Reliable
2 Fairly Reliable

3 Moderately Reliable

4 Reliable
5 Very Reliable

Table 8. Reliability test score

40
 Types of Loads Power Rating Total Wattage
C.O #1

C.O #2

C.O #3

Total

Table 9. List of appliances and power rating

The table above shows the different home appliances and power rating used to

overload the circuit and to determine the accuracy of the device in terms of automatic trip

off during overload condition.

2. Significant difference of typical circuit breaker and the proposed device in terms

of fast overload response?

Trip Curve of type B MCB

A type B MCB trips when the current is 3 to 5 times the rated current with an

operating time of 0.04 to 13 Seconds. It is used for purely resistive loads that are non-

inductive loads or with a very small inductive load which has no considerable amount of

inductance.

41
 Figure 9. MCB trip curve

For the Ultrafast tripping time of the device, the researchers used current sensor to

measure the current passing through the circuit and when the threshold is higher than the

ampere rating, the device will instantaneously trip.

STATISTICAL TOOLS

The following statistical tools were used during the conduction of the study:

Percentage Error. The percentage error was used to measure the divergence of the

values of actual and theoretical readings. In this study, the actual reading pertains on the

42
values of clamp-on meter and the theoretical reading pertains on the values of load meter

indicator.

%P.E.=¿ ¿

Where:

%P.E . = percentage error

value Load meter =¿ reading of the load current meter

value meter=¿ reading of the clamp-on meter

The arithmetic mean was used to determine the average value of a certain

parameter. In this study it was used to compute the average percentage error for each test

setup.

Arithmetic mean was expressed by the formula:

Where:

43
 END NOTES
Suryabarata (2003). Research Design. Retrieved August 2022, from Repo:
http://repo.iain-tulungagung.ac.id/499/4/Chapter%20III.pdf\.
Rais, S. (2018, November 5). Experimental Research Design. Scribd. Retrieved from
Scribd: https://www.scribd.com/document/394079366/Experimental-Research-
Design.

44
 CHAPTER IV
RESULT AND DESCUSSION

This chapter includes the project description, project structure and project

evaluation results of the study entitled “Design and Development of Ultrafast Circuit

Breaker Using ACS712 Current Sensor for Anti - Overload”.

Project Description
The researchers moved to conduct a study by developing a device that monitors

the circuit in residential houses. The researchers will use an automatic disconnection

system device consisting the major parts of the device including circuit breaker, magnetic

contactor, ACS712 current sensor, arduino and relay that helps to achieve the ultrafast

circuit breaker function when overload occurs. This study is about ultrafast circuit

breaker load monitoring that will give security to the circuit, properties and to prevent

fire caused by overloading circuit. The device has also a feature where load in the circuit

can be monitor by display the current value in LCD display. In addition, the device also

has different indicator lights that has its own function in load and system monitoring. Red

light when the system is overload, green light when the system is in use or operated,

orange light when the current exceeds its 80% safety factor as mandated by Philippine

Electrical Code. Other than load monitoring, the device will instantaneously trip off when

the current in the circuit exceeds its maximum capacity. The study will use ACS712

current sensor to measure the amount of current in the circuit, arduino uno to receive and

send signal to/from other devices specially in relay module that assign to instantaneously

break the circuit during overload.

45
Design of Ultrafast Circuit Breaker Using ACS712 Current Sensor for Anti-
overload.
This part of the study discussed the simulated model design of Ultrafast Circuit

Breaker Using ACS712 Current Sensor for Anti-overload. The actual photos of the model

as well as the electronic and electrical devices/ components are shown in this part.

The figures 10 and 11 shows the actual model of prototype used this stusdy. It

willl serve as a simulated model that represents a cetralized wireless controlled sytem for

building power supply at Camarines Norte State College-Main Campus.

46
47