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CIRCUIT BREAKERS (/US/EN-US/PRODUCTS/ELECTRICAL-CIRCUIT-PROTECTION/[Link])
Circuit breaker
fundamentals
What is a circuit breaker
A circuit breaker (/us/en-us/products/electrical-circuit-protection/[Link]) is an electrical switch designed to protect an
electrical circuit from damage caused by overcurrent/overload or short circuit. Its basic function is to interrupt current
flow after protective relays detect a fault.
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Circuit breakers explained
Take an indepth look at circuit breakers with a special emphasis on the Eaton's most
technologically advanced circuit breaker, the Power Defense molded case circuit
breaker.
Featured circuit breakers
Take a look at some of our latest and most technologically advanced circuit breakers.
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Power Defense molded Magnum with Power Xpert
case circuit breaker Release trip units
Overcurrents, overloads or short circuits
Overcurrents
NEC defines and overcurrent as any current in excess of the rated current of equipment of the ampacity of a
conductor. An over current is the result of an overload, short circuit, arc or ground fault. Effects of overcurrent include
fires, conductor insulation damage and equipment damage.
Overloads
According to NEC, an overload is the operation of equipment in excess of normal, full-load rating, or of a conductor in
excess of rated ampacity that, when it persists for a sufficient length of time would cause damage or dangerous
overheating. An overload is NOT a short circuit, ground or arc fault.
Short Circuits
A short circuit is an overcurrent which greatly exceeds the normal full load current of the circuit. Also, as the name
infers, a short circuit leaves the normal current carrying path of the circuit and takes a short-cut around the load and
back to the power source. A short circuit is an overcurrent but not an overload.
Difference between fuses and circuit breakers
Common overcurrent protection devices (OCPDs) include
circuit breakers and fuses. While the purpose of the fuses
and circuit breakers is the same, there are fundamental
differences, which are important to understand when making
selections for protection of equipment and personnel.
Fuses Circuit breakers
Must be replaced after it has interrupted an May be reset after interrupting an overcurrent
overcurrent event. event
Has less initial cost Has a higher initial cost
No maintenance required Requires maintenance
Only opens on overcurrent events Optional protective features (i.e. ground fault)
No capability for optional protective features
Predict and stop power failures before they happen
The latest circuit breaker technology, which is built into Power Defense MCCBs, delivers predictive diagnostics that help you better uncover,
diagnose and stop power outages before they happen.
Download the Circuit Breaker Health white paper
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Circuit breaker parts
Although low and medium voltage circuit breakers have
unique designs that are specific to amperage, voltage
and application, there are five main parts or components
that are universal across the different types of circuit
breakers.
Five universal circuit
breaker parts
molded case circuit breaker with parts labeled
1. Frame – Protects internal
parts of the circuit
breaker from outside
materials
2. Operating mechanism – Provides a
means of opening and
closing the circuit
breaker
3. Contacts – Allows the current
to flow through the
circuit breaker when
closed.
4. Arc extinguisher – Extinguishes
an arc when the circuit
breaker interrupts a
fault.
5. Trip unit – Opens the
operating mechanism in
the event of a prolonged
overload or short circuit.
Circuit breaker frames
The circuit breaker frame provides the rigidity and strength
required to successfully deal with the interruption process
and achieve the desired interrupting ratings. It insulates and
isolates the electrical current in order to protect people and
equipment during use or operation. Frames can be made
from metal or molded insulating materials.
Metal Frame Molded Insulated Frame
A metal frame is assembled from precise metal pieces (Molded Case)
that are bolted and welded together to form the
Molded case frames are made from strong insulating
frame. Eaton offers low voltage power circuit breakers
materials such as glass-polyester or thermoset
and medium voltage vacuum breakers with metal
composite resins (plastic frames). Eaton offers miniature
frames.
circuit breakers, molded case circuit breakers (/us/en-
us/products/electrical-circuit-protection/circuit-breakers/molded-
[Link]), insulated case circuit breakers
(/us/en-us/catalog/electrical-circuit-protection/power-defense-
[Link]) and low voltage power
circuit breakers in molded case frames.
Operating mechanism of a circuit breaker
There are two types of operating mechanisms, over toggle
and two step stored energy.
Over Toggle Two Step Stored Energy
The function of the operating mechanism is to provide a The two-step stored energy mechanism is used when a
means of opening and closing the circuit breaker. This large amount of energy is required to close the circuit
toggle mechanism is the quick-make, quick-break type, breaker and when it needs to close rapidly. The major
meaning that the speed with which the contacts snap advantages of this mechanism are rapid reclosing and
open or close is independent of how fast the handle is safety. Rapid reclosing is achieved by storing charged
moved. energy in a separate closing spring. Safety is achieved
by providing remote charging of the spring.
In addition to indicating whether the breaker is ON or
OFF, the operating mechanism handle indicates when The two-step stored energy process is designed to
the breaker is tripped by mobbing to a position midway charge the closing spring and release energy to close
between the ON and OFF. the circuit breaker. It uses separate opening and closing
springs. This is important because it permits the closing
Eaton’s residential, miniature and molded case circuit spring to be charged independently of the opening
breakers utilize over-toggle mechanism. process. This allows for an open-close-open duty cycle.
The closing spring can be charged (or recharged)
manually via a charging handle or electrically via a
motor. The motor can be operated remotely, allowing
maximum safety for the operator.
Breaker contacts
Contacts are found in the arc interruption chamber (in
low voltage circuit breakers) and in the vacuum
interrupter (in medium voltage vacuum circuit breakers).
The contact assembly consists of the movable contact,
the movable contact arm, the stationary contact and the
stationary conductor.
As the circuit breaker opens or closes, the fixed contact
moves to close (make) or open (break) the circuit. The
contacts are designed to protect against two fault
conditions
1. Overcurrent (thermal
overload)
2. Short Circuit (magnetic)
Arc extinguisher
An arc is a discharge of electric current crossing a gap
between two contacts. An arc extinguisher is the
component of the circuit breaker that extinguishes an arc
when the contacts are opened. Circuit breakers must be
designed to control them because arcs cannot be
prevented.
The six methods used in the electrical industry to
manage electrical arcs:
What is an arc flash
Arcs are formed when the contacts of a circuit breaker
open due to larger than normal current. Arcing is a
1. Arc chute condition that must be dealt with quickly and effectively
by a circuit breaker. The ability of the circuit breaker to
control the arc is key to its short circuit interrupting
capability
2. Vacuum interrupter
3. SF6
4. Minimum oil
5. Magnetic Coil
6. Puffer
Trip unit
The function of a trip unit is to trip or open the operating
mechanism in the event of a prolonged overload or short
circuit fault condition such as thermal overload, short circuit
currents and specialty faults. To accomplish this, an
electromechanical or a solid state trip unit is provided.
Electromechanical trip Electronic trip units
units Electronic trip units offer capabilities such as
programming monitoring diagnostics communications
Electromechanical trip units utilize bimetals and
system coordination and testing that are not available on
electromagnets to provide overload and short circuit
thermal magnetic trip units. Eaton’s molded case circuit
protection and do not include any specialty protection
breakers and low voltage power circuit breakers utilize
such as ground fault. They are commonly used in low
Electronic Trip Units (ETU).
voltage circuit breakers.
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