• Zhejiang Huile Electric Co., Ltd

Configuration scheme of universal circuit breaker in industrial automation field

1. Load Analysis and Current Rating Determination

• Continuous and Peak Load Assessment: Thoroughly analyze the continuous and peak loads of all electrical equipment in the industrial automation system, such as motors, programmable logic controllers (PLCs), robotic arms, and conveyor systems. For motors, consider factors like starting current, which can be 5 - 10 times the rated current. Select UCBs with a rated current (In) that can safely handle the continuous load and withstand peak current surges. For example, if a motor has a rated current of 100A and a starting current of 600A, the UCB should have an In high enough to accommodate the starting current without tripping prematurely, while also being suitable for continuous 100A operation.

• Load Diversity Factor: Account for the diversity of loads in the system. Not all devices will operate at full capacity simultaneously. Apply a load diversity factor to calculate the actual required UCB current rating, reducing unnecessary oversizing and cost.

2. Short - Circuit Current Rating (SCCR) and Fault Protection

• Short - Circuit Study: Conduct a detailed short - circuit study to determine the maximum available fault current at different points within the industrial automation electrical network. Industrial environments often have complex power distribution systems, and fault currents can be extremely high. The selected UCBs must have an SCCR higher than the calculated maximum fault current at their respective installation locations. For example, in a large - scale manufacturing plant, the SCCR of UCBs may need to be 100kA or more to ensure reliable fault isolation.

• Multi - Stage Protection: Implement multi - stage protection using UCBs with advanced electronic trip units. These units can provide different levels of protection for overcurrent, short circuit, ground fault, and undervoltage/overvoltage conditions. For instance, set up instantaneous tripping for severe short - circuit faults, time - delayed tripping for overloads, and ground fault protection to detect and isolate leakage currents, safeguarding both equipment and personnel.

3. Selective Coordination

• Coordinated Protection Design: Ensure selective coordination between UCBs and downstream protective devices, such as molded - case circuit breakers (MCCBs) and motor starters. By carefully setting the time - current characteristics of UCB trip units, only the breaker closest to a fault will trip, minimizing the impact on the overall industrial automation process. This is essential for maintaining production continuity, as it prevents widespread power outages that could halt multiple production lines.

• Communication - Enabled Trip Units: In modern industrial automation systems, use UCBs with intelligent electronic trip units that support communication protocols (e.g., Profibus, Modbus TCP). These units can exchange data with the plant's supervisory control and data acquisition (SCADA) system, allowing operators to monitor breaker status, adjust protection settings remotely, and perform fault analysis in real - time.

4. Adaptability to Industrial Environments

• Environmental Ratings: Select UCBs with appropriate environmental ratings to withstand harsh industrial conditions. In dusty environments (e.g., cement plants, mines), choose UCBs with high ingress protection (IP) ratings, such as IP65 or IP66, to prevent dust ingress. In corrosive environments (e.g., chemical plants), opt for UCBs made of corrosion - resistant materials or with special coatings.

• Temperature and Vibration Resistance: Consider the ambient temperature and vibration levels in the industrial setting. UCBs should have a temperature rating suitable for the operating environment, and in high - vibration areas (e.g., near large - scale machinery), ensure that the UCBs are mechanically robust and can maintain reliable operation.

5. Integration with Industrial Automation Systems

• Control and Monitoring Integration: Integrate UCBs into the overall industrial automation control system. This can be achieved through the use of programmable logic controllers (PLCs) or distributed control systems (DCS). UCBs can be connected to the control system via input/output (I/O) modules, enabling remote control of breaker operations (e.g., closing, opening) and real - time monitoring of electrical parameters (e.g., current, voltage, power).

• Power Quality Management: Leverage the capabilities of UCBs with built - in power quality monitoring functions. These UCBs can detect issues such as voltage sags, swells, and harmonic distortions, which can affect the performance of sensitive industrial automation equipment. By monitoring and analyzing power quality data, operators can take corrective actions to optimize system performance and protect equipment.

6. Redundancy and Backup Solutions

• Redundant UCB Configuration: In critical industrial automation processes where downtime is unacceptable, implement redundant UCB configurations. This can involve parallel - connected UCBs or standby breakers that can automatically take over in case of a primary breaker failure. Redundancy ensures continuous power supply and enhances system reliability.

• Emergency Power Backup: Integrate UCBs with emergency power backup systems, such as uninterruptible power supplies (UPS) and diesel generators. Configure the UCBs to seamlessly transfer power to the backup source during power outages, protecting industrial automation equipment from damage and ensuring the safe shutdown of processes if necessary.