The Myth-Application of 100 Percent Rated Circuit Breakers

by Tony Parga, Gary Gluck and Dave Bradley, PE, LEED AP

With ever increasing building loads, 100 percent rated overcurrent protection devices are widely used in a number of commercial, industrial and residential installations. Many specifications include provisions that breakers larger than a certain frame size shall be 100 percent rated. Though the application of these devices might enable the use of smaller conductor sizes, sound economic analysis forces one to consider not only the benefits of design but the costs as well. This paper will discuss some misconceptions about 100 percent rated breakers and how to properly apply them. Myth #1: You can specify either 80 percent breakers or 100 percent breakers Wrong. There is no such thing as an 80 percent rated circuit breaker. The term 80 percent doesnt appear in the NEC, on any circuit breaker, or in manufacturers literature. There are regular circuit breakers, and there are 100 percent rated circuit breakers. The 80 percent reference is derived from the NECs required load calculation in Section 210.20(A) which states in part: Where a branch circuit supplies continuous loads or any combination of continuous and non-continuous loads, the rating of the overcurrent device shall not be less than the non-continuous load plus 125 percent of the continuous load. Exception: Where the assembly, including the overcurrent devices protecting the branch circuit(s) , is listed for operation at 100 percent of its rating, the ampere rating of the overcurrent device shall be permitted to be not less than the sum of the continuous load plus the non-continuous load. The 80 percent is simply the inverse of the 125 percent of continuous load requirement and is a common derating factor. Sizing circuit breakers based on an 80 percent derating assumes that all the connected design loads are continuous. It is up to the engineer to calculate the design loading of the overcurrent device based on the profile of its load, which is often a combination of continuous and noncontinuous loads. It is also up to the engineer to carefully determine which loads are continuous and account for the 25 percent margin required. Continuous load, as defined in NEC article 100, is a load where the maximum current is expected to continue for 3 hours or more. The table below illustrates some examples of continuous and non-continuous loads:
Continuous Loads Lighting, Computers, fixed electric heating loads, old style motorgenerator traction elevators. Non-Continuous Loads Hydraulic and VFD driven elevators, cyclical pumps, welders, copiers.

Please note that some residential load calculations are not intended to be considered continuous loads. For example, the calculation for the service size at a residential multi-family building is not considered a continuous load, but it is used to establish the minimum size service feeder capacity and over current protection required. This is also true on calculations for single family dwelling units. It is not the intent of this article to classify different types of load but to examine options for the overcurrent protective device.

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Myth #2: You cant load a regular circuit breaker to more than 80 percent of its rated value Not true. Heres an example of two circuits, each with 18A of load:
Total ampacity of loads 16A + 2A 18A 10A + 6A + 2A 18A Calculation based on NEC 210.20(A) 16A (1.0) + 2A (1.25) 18.5A 10A (1.25) + 6A (1.25) + 2A (1.0) 22A

Loads Copier (16A non-continuous) Desk Light (1.6A continuous) Computer (10A continuous) 2 monitors (6A continuous total) Pencil sharpener (2A non-continuous)

Results Use 20A regular breaker Use 25A regular breaker

percent of the 700A load, or 875A, and would require a 1000A breaker. NEC 240.4( C) would require that 3 sets of 500kcmil be used. However, an 800A, 100 percent rated breaker could be used and would only require 2 sets of 500kcmil. The savings of 100 of conductor and conduit would certainly more than offset the cost of the 100 percent rated breaker. Another example with savings in device costs is a service entrance scenario. Consider the case of a building with a 1000A main (regular rating), 480Y/277V service entrance with a design load of 400A of continuous load and 400A of non-continuous load. The NEC requires a ground fault device for this size main. An alternative would be to specify an 800A, 100 percent rated main ground fault protection would be no longer required. Myth #4: When specifications say All breakers are to be 100 percent rated, it means that 100 percent rated devices are required. This note frequently appears on plans and, while possibly applicable in certain limited situations, normally suggests confusion between the terms 100 percent rated and fully rated. While these two terms sound similar, their meanings in a strict electrical sense could not be more different. A fully rated system is populated with circuit breakers that are rated for the available fault current at each point in the system. In this context, it should be compared to series rated circuit breakers. By contrast, 100 percent rated circuit breakers have nothing to do with the fault current rating. In fact, calling for all breakers to have a 100 percent rating is incorrect since 100 percent rated breakers are only available in mid range and larger frame sizes, usually 400A or more. Myth #5: Using 100 percent rated circuit breakers always results in the use of smaller breaker frame sizes and smaller conductor sizes. This is not always the case. Consider the following example:

What is a 100 percent rated breaker? It is a circuit breaker that is rated to allow the use of the load calculation in the exception to NEC Section 210.20(A). Years ago, only low voltage power circuit breakers and bolted pressure switches were 100 percent rated devices. Today, many models of molded case circuit breakers are available with this option. Siemens offers both thermal magnetic and solid state circuit breakers with a 100 percent rating. The only devices that are not available with a 100 percent rated option are knife blade fusible switches. Myth #3: Specifying 100 rated breakers now is good insurance for the engineer because it will let you add more load in the future Not necessarily once again it all depends on the load profile and the required load calculation. Both a regular breaker and a 100 percent rated breaker can be loaded to their rating if the load is non-continuous. Circuit breakers rated 100 percent must be installed in enclosures or assemblies which meet the requirements for the increased temperature rise of the breaker, conductor and components. These assemblies or enclosures are modified in various ways depending on manufacturers design and need to be taken into consideration when planning the electrical rooms. Switchboards and panelboards containing 100 percent rated breakers may be sized larger than standard units with regular breakers. In many cases the bus material is increased in capacity and size, and in some cases, breaker placement on the units may be restricted. This is due to the increased heat generated by continuous loads. Unfortunately, there is no free lunch. Specifying 100 percent rated breakers costs more. These costs could be up to 25 percent higher than standard, so its advisable to evaluate the increased cost versus the expected savings from a reduction of the conductor size. An example of proper application of a 100 percent rated device that can result in cost savings is a long run to a large continuous load. Consider a 700A continuous load fed by a switchboard 100 away. If a regular circuit breaker is used, it must be sized for 125

MCB

CB1

CB2

CB3

1000A Rolling Mill Motors (Continuous)

150A lighting, 500A process motors (10min on, 20 min off)

800A Busway 800A Circulation Pumps (On during 8 hour morning shift only)

Circuit CB1(load cable) 1000Amp Continuous load

Outcome with standard circuit breakers Minimum req. ampacity = 1000 x 1.25 =1250A

Outcome with 100% rated circuit breaker Minimum req. ampacity = 1000A

Comments In this case there would be savings in both frame size and conductor choice using 100 percent rating In both cases a 700A breaker would be selected. A 100% rated breaker offers no savings in frame size or conductor choice Busway and breaker will remain 800A if 100% rated breaker is used. Significant size and cost advantages can be realized with 100% rated overcurrent devices

Myth #8: Insulated case breakers can be either 80 percent or 100 percent rated All insulated case (power) circuit breakers are 100 percent rated. Myth #9: Since 100 percent rated breakers are the same physical size as regular breakers, they can be installed in switchboards and panelboards the same way This varies with each manufacturer. It is best to contact the manufacturer when sizing a panelboard or switchboard containing 100 percent rated devices. When 100 percent circuit breakers are being used, the bussing in a switchboard section acts as a heat sink and there may be modifications required. Additionally, the number of 100 percent rated breakers and their positions may be limited. Myth #10: A standard rated breaker can be exchanged with a 100 percent rated breaker to attain higher circuit capacity. Unless the breaker being exchanged is mounted in an enclosure approved for use with the 100 percent rated breaker nothing is gained. Replacing a breaker mounted in a panelboard or switchboard may not allow extra loading either. The breaker is just a component of the 100 percent rated system. In addition to the special enclosure requirements, keep in mind that 90 degree C cable sized for 75 degree C MUST be used when connecting to a 100 percent rated device. Conclusion: There may be substantial savings that can be realized from the proper application of 100 percent rated breakers. However, application of these breakers needs to be evaluated carefully for each specific instance. In addition, there are other considerations such as the effect on equipment dimensions which must be taken into account when planning the electrical room. The specification of 100 percent rated breakers isnt a cure-all, but when properly applied will pay for itself.

CB2 (load cable) 150A continuous load + 500A non-continuous

Minimum req. ampacity = (150 x 1.25) + 500 = 687A

Minimum req. ampacity = 150 + 500 = 650

CB3 (800A load busway) 800A continuous load MCB

Minimum req. ampacity = 800 x 1.25 =1000A Minimum req. ampacity = 1250 + 687+1000 = 2937A

Minimum req. ampacity = 800A

Minimum req. ampacity = 1000 + 650 + 800 = 2450

If a standard breaker is used as the main, the incoming feeder as well as the breaker will need to be rated for 3000A. Using a 100 percent rated breaker we can provide a 2500A breaker and incoming feeder resulting on substantial cost savings. If our calculations for the 100 percent rated breaker would have resulted on a value larger than 2500A, then we would have had to use a 3000A frame breaker (next standard frame size). This 3000A breaker would not have to be 100 percent rated since it would comply with either calculation and the additional cost for the 100 percent rating would not be warranted. On breaker CB3 we can have substantial savings on the feeder cable as well as on the bus duct cost (bus duct can be loaded continuously to its rated value) by using a 100 percent rated 800A breaker. Myth #6: Using 100 percent rated circuit breakers means using solid state breakers As mentioned before, thermal-magnetic breakers and some fusible devices are available in 100 percent rated versions. Myth #7: All fused switches are 100 percent rated There is a great deal of confusion when it comes to fuses and the switches that house them. Fuses follow the same rules for derating as do circuit breakers. All knife blade switches are regular rated devices and this governs the application of the fuse. Bolted pressure (and High Pressure Contact) switches are 100 percent rated devices and, provided that a properly sized enclosure is selected, the switch/fuse combination can be rated for 100 percent operation.

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