MCCB: How to safely choose a new MCCB for

replacement?

The 3 phase Molded Case Circuit Breakers (mccb) used in commercial and industrial sites
handle much more energy than the average household single phase miniature circuit breakers
(mcb). It, therefore, poses a much greater risk during a fault if the component is not working
properly.
Do not simply replace a Molded Case Circuit Breaker with one that has the same rated current.
The most important consideration is the Ultimate short-circuit breaking capacity (Icu).
Incorrectly replacing MCCB will result in dangerous consequences. In this video, we will guide
you through the step by step process to do this.

5 Factors to Consider When Replacing an MCCB

Molded Case Circuit Breaker are trickier to replace as they typically handle more power than a
Miniature Circuit Breaker. They are often found in the Main Switchboard or a Distribution
Board
The important factors to consider are as follow:

1. Frame Size
2. Rated Current
3. Ultimate Short-Circuit Breaking Capacity (Icu)
Other factors that may be important for your application are as follow:

1. Operating short-circuit breaking capacity (Ics)

2. Shun trip option

Example MCCB to be replaced

Schneider Compax NSX100B

 NSX100 Frame Size (W x H x D) 140 x 161 x 86

 Rated Current 100A
 Breaking Capacity (Icu) (415V) 25kA

Frame Size
This determines the dimension of a circuit breaker. You will obviously have to select the
MCCB with the frame size that can fit the space. The Frame Size indicates the basic framework
of the Plastic shell of the MCCB that can hold the biggest rated current. It is the maximum
current that a particular frame housing is designed for.
There are varieties current ratings MCCB for the same frame size. The following Schneider
Electric Series has the same frame size:

 Compact NSX 100

 Compact NSX 160
 Compact NSX 250

Rated Current
The rated current is the current value which overload protection is tripped and disconnect the
circuit. You will obviously need to select the same rated current as the MCCB being replaced.

For an MCCB it is possible to have the option to adjust the Amp Trip (the current that the
breaker trip) to that below the Amp Frame (The maximum overload protection current)
When replacing an existing MCCB, be sure to check this!

Ultimate Short-Circuit Breaking Capacity (Icu)

This can be defined as the maximum current from a short-circuit fault that can be safely cleared
twice. This is tested according to the IEC 60947-2 standards. The MCCB will be reusable after
interrupting a short-circuit fault, this is, however, only tested for 2 interruptions.

After interrupting short-circuit fault two times, it does not mean that the circuit breaker will fail
to protect the circuit, it simply means that it has not been tested for.

It is also good to note that the higher the Icu for an MCCB is an indication of the higher MCCB
quality.
The MCCB to be replaced is rated at 20kA for the 3-phase 415V. This is a typical value used in
Singapore, however, please note that for different voltages the Icu values are different. Please
ensure that you look at the Icu value for your particular operation.

In this case, we assume that the electricity supply is 415V AC

Why is the Icu so important?
If you choose the kA value that is lower than the actual Short-Circuit current then there will be
dangerous consequences.

1 The contacts in the circuit breaker welded together preventing the circuit breaker from
tripping. This will heat up the cable in the circuit.

 The cable in the circuit is damaged breaking the circuit, or

 A fire is started.
2 The copper in the circuit breaker overheating and turning into dangerous plasma.

 The circuit breaker explodes

The consequences are very dangerous especially in the scenario 2 particularly if there are
people nearby, for example, the electrician who comes to reset the circuit breaker.
*Make sure you select the MCCB replacement with the same or higher Icu value to the one
being replaced*

The Shor-Circuit Current

You may wonder ‘What will the value of the short-circuit current be?‘. The short-circuit
current value on the first circuit breaker depends on the size of the transformer and the length
and size of the cable from the transformer to that Circuit Breaker.
The formula and the calculation of this are beyond the scope of this article. Here is a document
from Bussman by Eaton explaining how to calculate the short-circuit current.

Guide to 'Short-Circuit Current Calculations' - Bussman by

Eaton
The downstream circuit breakers short-circuit breaking capacity can be calculated from the
distance from the first and the cable used. In reality, most designers will use a software to help to
calculate the value.
In the case of a replacement, we will assume that the short-circuit current has been calculated
and the initial MCCB designed has been done correctly. So we will only need to match the kA
value of the breaker that has to be replaced.

Example replacements
LV429550 (original model)

Can replace? YES

 Range name Compact NSX

 Model NSX100B
 Poles 3 Pole(s)
 Rated current 100A
 Ultimate short-circuit current breaking capacity (Icu)
o (380-415Vac) 25 kA
 Service short-circuit current breaking capacity (Ics)
o (380-415Vac) 25 kA
 Service short-circuit current breaking capacity as a percentage of Icu (Ics%)
o (380-415Vac) 100 %
 Dimension (WxHxD) 105x161x86 mm
 Brand Schneider Electric
EZC250F3100

Can replace? NO!

 Range name EasyPact EZC

 Model EZC250F3100
 Poles 3 Pole(s)
 Rated current 100A
 Ultimate short-circuit current breaking capacity (Icu)
o (380-415Vac) 18 kA
 Service short-circuit current breaking capacity (Ics)
o (380-415Vac) 9 kA
 Service short-circuit current breaking capacity as a percentage of Icu (Ics%)
o (380-415Vac) 50 %
 Dimension (WxHxD) 105x165x60 mm
 Brand Schneider Electric
1SDA066807R1

Can replace? NO!

 Range name Tmax XT
 Model  XT1B 160 TMD 100-1000 3p F F
 Poles 3 Pole(s)
 Rated current 100A
 Ultimate short-circuit current breaking capacity (Icu)
o (380-415Vac) 18 kA
 Service short-circuit current breaking capacity (Ics)
o (380-415Vac) 18 kA
 Service short-circuit current breaking capacity as a percentage of Icu (Ics%)
o (380-415Vac) 100 %
 Dimension (WxHxD) 76.2x130x70 mm
 Brand ABB
1SDA067397R1

Can replace? YES!

 Range name Tmax XT
 Model  XT1C 160 TMD 100-1000 3p F F
 Poles 3 Pole(s)
 Rated current 100A
 Ultimate short-circuit current breaking capacity (Icu)
o (380-415Vac) 25 kA
 Service short-circuit current breaking capacity (Ics)
o (380-415Vac) 25 kA
 Service short-circuit current breaking capacity as a percentage of Icu (Ics%)
o (380-415Vac) 100 %
 Dimension (WxHxD) 76.2x130x70 mm
 Brand ABB

Operating short-circuit breaking capacity (Ics)

Ics is expressed as a percentage ratio of Icu and is the maximum short-circuit current that a
circuit breaker can break three times. The manufacturers of the MCCB will test this according to
the IEC 60947-2 standard. It is also a marker of quality as the higher the Ics, the more reliable
the MCCB.
This is best explained with an example. The Molded Case Circuit Breaker has the following
Icu & Ics value:

 Icu = 40kA
 Ics = 50% (i.e. 20kA)
Case 1: the Short-circuit current is at 15kA
This is below both the Icu and Ics and therefore we can assume that it can clear a fault 3 times as
tested by the manufacturer.

Case 2: the short-circuit current is at 30kA

This is below the Icu value but higher than Ics value. This means that after the first fault there
will be permanent damage to the circuit breaker. The MCCB can be reset to use again but is not
tested to interrupt the short-circuit current again after the second interruption.

Case 3: the short-circuit current is at 45kA

The short-circuit current is above that of both Icu and Ics. In this case, the circuit breaker will fail
as previously mentioned and the consequences are very dangerous particularly if there are people
nearby, for example, the electrician who comes to reset the circuit breaker.

Shunt Trip from Protection Relays

A Shunt-Trip happens when the MCCB trip by receiving an external signal from a protection
relay. Protection Relay is the name given to a group of products, which are sensors that detects a
particular electrical fault and send a relay signal out. Example of these are as follow:

 Over Voltage Protection Relay

 Under Voltage Protection Relay
 Phase Lost Protection Relay
 Phase Sequence Protection Relay
 Earth Leakage Protection Relay
You will need to check if the MCCB to be replaced is connected to any protection relays and
purchase a replacement MCCB model that can accept the protection relay input and purchase
the optional accessories for the particular protection relays.
We have outlined the steps that one should look at when replacing an MCCB from the frame size, the
rated current, the ultimate short-circuit breaking capacity (Icu), the Operating short-circuit breaking
capacity (Ics) and the shun trip option. We hope that we have stressed the importance of looking at
the correct Icu value as the number 1 priority in the MCCB, or in fact any Circuit Breaker
replacement.

In practice, one would try to have the exact model replacement, and when this is not possible, the
take away is to look at the kA value carefully to avoid any dangerous consequences.

What does it all mean?

While the definitions are pretty straight forward, perhaps a little discussion is worthwhile. 

Icu is really the maximum perspective fault which a circuit breaker can clear (with the fault current being
expressed as rms for ac).  This is verified by testing in accordance with the standard and is applicable at
a specific set of electrical and environmental conditions.  If these conditions change then it may be
necessary to derate the circuit breaker.  After clearing a fault the circuit breaker does not have to remain
serviceable and could be dangerous to operate.  This point is particularly important in circuit breakers
when the Ics is lower than the Icu.
Difference between Icu and Ics
When tested against the standard, circuit breakers under go the following tests:  

Icu is subject to an O-t-CO sequence. The breaker is then certified safe by a simple dielectric test. 
Ics is subject to an O-t-CO-t-CO sequence. The breaker is then subject to both dielectric withstand and temperature
rise tests.
O - breaking operation
CO - making operation followed by breaking
operation
t - time interval (short as possible, but minimum
of 3 minutes)
Tests are carried out at the specified fault current.

Ics is the maximum perspective fault current which the circuit breaker can clear and still remain
serviceable.  The standard does allow some minor welding of the contacts to take place, so after a large
fault it would still be necessary to inspect the breaker.  When specified as a percentage of Ics, the standard
proposes ranges of 25%, 50%, 75% and 100%.
Icw is the perspective fault withstand rating (rms for ac).  Circuit breakers may be subject to through fault
which they are not intended to clear.  While not clearing these faults, the breaker will still need to
withstand the thermal and mechanical stress imposed by the fault current.  The longer a fault is present
the more the effects build up and Icw always has a time element associated with it (i.e. 50 kA for 1
second).  The standard specified preferred time ranges of 0.05, 0.1, 0.25, 0.5 and 1 second (although 3
seconds is also often used in practice).
Icm is the peak current which the circuit breaker can safely break or make.  It is expressed as the maximum
perspective peak current at a rated voltage, frequency and power factor and is always greater than I cu. 
From a safety aspect this is particularly important as it will be the primary mechanism to protect the
operator if the circuit breaker is closed on to a fault.
All ratings are derived under specific electrical and environmental conditions and are verified with the
circuit breaker in free air.  As soon as the breaker is enclosed in in any kind of panel or cabinet the ratings
change and need to be re-assessed as part of the assembly testing. 

Applying the ratings

To end the post, a short discussion on applying the ratings in selecting a circuit breaker. 

It should now be obvious that all the fault parameters need to be considered in selecting the correct circuit
breaker. I think a lot of people reading this have seen specification clauses like, "circuit breakers shall be
rated at 50 kA for 3 seconds", with no other details.  When I see statements like this my first impression
(rightly or wrongly), is that I'm reading a poor specification.  I would encourage everyone to be specific in
their specification of what they require and address I cu, Ics, Icw and Icm as part of the specification.
I've also noticed that in general for most of the big manufacturers the majority of their ranges have an
Ics equal to the Icu.  If  I'm presented with a breaker where this is not the case, I immediately become
sceptical on the quality of the device.  The device may well be suitable for the application, but I would be
more vigilant on my appraisal of the circuit breaker.  I tend always specify that the Ics should equal the Icu -
to my mind, what is the point of a circuit breaker if it can't be readily reused after tripping.
Something else to bear in mind is that the rating vary depending on the voltage.  For low voltage, we are
talking anything from 1000 V down to zero.  The lower the voltage the higher the rating (for example, a
Schneider NW12 H2 breaker has an Icu = 100 kA at 415 V, and this drops to 85 kA at 525 V).  Icw is also
dependent on time (the longer the fault the lower will be the rating).  Often Icm is larger than Icu or Ics - make
sure you are looking at the right figures and if you are interested in the I cu it should be Icu you are being
shown and not Icm.
As a final bit of advice - always consult manufacturers catalogues and technical data.  Manufacturer's
produce a whole range of devices, and you need to select the correct one for your application.  There is
no point paying for higher rating if you don't need to.  At the same time compromising on ratings to have a
cheaper circuit breaker jeopardizes safety and operational reliability.