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The Best Industrial Circuit Breaker Type for Your Application

by Simcona on Oct 10, 2023 7:03:02 PM

It’s relatively simple to pick an electronic component based on cost and supply availability. But that’s probably not what your operation needs when it comes to circuit breakers.

Industrial circuit breakers are a key player in protecting expensive electronic systems. That means you’ll have to seek a solution that’s convenient for not just today, but also 2 years from now (or more). There are many industrial and commercial circuit breaker types, and the wrong choice could cause production delays and safety hazards .

To simplify the buying process, check out these nine important criteria for choosing a breaker.

Types of Industrial Circuit Breakers

There are four main ways to classify breakers in industrial applications :

• Voltage – Can be low-, medium-, or high-voltage 
• Location – Only certain breakers are rated for outdoor use
• Interrupting mechanism – There are many systems for stopping current flow and power, including MCCB , vacuum, air, oil, & ICCB
• External design – Can be dead tank (has an enclosure at ground potential, housing interrupting & insulating mediums) or live tank (housing interrupters are at potential above ground, with insulation in between)

It’s helpful to understand the lingo and acronyms of all the breaker types out there. But more importantly, you’ll need to know the green and red flags that’ll make or, err … break your project:

9 Steps Toward the Best Industrial Circuit Breaker Type

The top criteria for selecting an industrial-grade circuit breaker are:

• Voltage rating
• Current rating
• Interrupting capacity
• Tripping current level adjustment ranges
• Environmental resistance
• Number of poles
• Testing/maintenance

1. Voltage Rating

Matching your breaker to your application’s needs is probably your first order of business. 

The rated voltage of a circuit breaker refers to the number of volts it can handle safely. A mismatch between the breaker’s rating and your system’s voltage levels can lead to inefficiency and may compromise safety.  

A circuit protector’s voltage rating depends on its insulation level, a trait that’s categorized into several levels. The level defines the thickness of the insulation within a single voltage rating. Common insulation levels include:

• 100% (grounded systems)
• 133% (ungrounded systems)

Always consult your assembly specifications and ensure that the circuit breaker can handle the voltage requirements.

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• Guide to terminal block types
• How to choose cables & wires
• How to choose cable/wire labels
• How to choose a PLC

2. Current Rating

Rated current is the maximum current that a circuit breaker can carry continuously in the ambient temperature where it was calibrated. 

Continuous current rating should align with the requirements of your system.

A too-high current rating may keep the breaker from tripping when it’s supposed to. This allows excessive current to flow through the circuit, potentially leading to overheating, equipment damage, and even a visit from the fire department.

A too-low current rating will cause the device to trip too easily, even under normal operating conditions. This can result in frequent production stoppages, with the breaker becoming the very thing it was meant to prevent – downtime.

Tip: Miniature breakers and residual current circuit breakers (RCCBs) have particularly low current ratings and may not be suitable for heavy-duty protection.

The 80% vs. 100% Rulebook

You may be wondering when to use 80% (standard) vs. 100% rated breakers since they’re two commonly talked-about options. 

First, remember that gradual heat buildup can hamper current-protection devices. NEC defines the concept of ” continuous ” as a max current at 3 hours or more, and as such has recommended the 80% limitation to offset the effects of heat. 

Generally speaking, there’s no need to protect 125% of a noncontinuous load requirement, and you can use a breaker size that meets 100% of the load. An 80% rated circuit breaker is usually the top choice in those situations.

3. Interrupting Capacity

You may know this concept as short-circuit rating, breaking capacity, or something similar.

The interrupting capacity is the highest amount of fault current that a circuit breaker can stop without sustaining damage. This is a critical safety feature, especially in industrial settings where high currents are common. 

A breaker’s interrupting capacity must be equal to or greater than the potential fault current your system may produce where the breaker is applied.

The number of appliances and electronics requiring a higher interrupting capacity is on the rise. With many facilities running multiple large appliances simultaneously, it’s become easy to trip the old standby of 10,000 A capacity.  Larger operations will value this spec more than others because it’ll allow them to function safely and avoid tripping the breaker repeatedly.

Tip: Molded case circuit breakers insulate all current-carrying parts and devices. They have higher interrupt ratings than miniature circuit breakers.

4. Frequency

The frequency rating of a circuit breaker should match the frequency of your electrical system. (Sound like familiar advice?) 

Mismatches can lead to operational inefficiencies and may even damage the circuit breaker or the system it protects. For example, using a circuit breaker rated for 50 Hz in a 60 Hz system could reduce the system’s power rating and shorten the breaker’s life span.

Circuit breakers up to 600 A can be applied to frequencies of 50-120 Hz. Assemblies with frequencies of more than 120 Hz frequencies will force you to derate the breaker .

5. Tripping Current Level Adjustment Ranges 

Modern circuit breakers often come with adjustable tripping current levels for both overload and short-circuit protection. This feature allows you to better tailor the circuit breaker's performance to your needs. 

Examples include:

• For overload protection – Industrial settings where you plan to connect machinery with different current requirements to the same circuit
• For short-circuit protection – Complex electrical systems where short-circuit current levels can vary wildly depending on the location of the system fault

Being able to adjust the tripping current can be particularly handy in systems with variable loads, empowering you to optimize protection while minimizing nuisance trips. It’s also more cost-efficient to tweak an existing setup rather than replacing it every time you make changes to your electrical system.

6. Environmental Resistance

If it exists in a factory or in the wild, there’s a chance it might pose a risk to your electronics.

Maybe that’s an exaggeration, but there’s no shortage of threats to consider when learning how to identify circuit breaker types acceptable in your application.

• High temperature – UL (Underwriters Laboratories) defines the acceptable operating temperatures for industrial circuit breakers to maintain performance both mechanically and electronically. The max temp is 122 °F in standard breakers and 140 °F in 100% rated breakers.
• Corrosion – Use a breaker with a special moisture treatment if your application will expose it to humidity or other moisture. Fungus isn’t the only corrosion threat; you should also keep breakers away from dangerous chemicals. If your application makes that impossible, be sure to specify a chemical-resistant breaker.
• Shock – Certain breakers include an anti-shock device that allows for use in hazardous areas. Shock-protection devices introduce a counterweight over the center pole; this holds the trip bar latched in normal shock conditions. Shock resistance is a key feature of marine-grade circuit breakers.
• Altitude – Above 6,000 ft., you must derate a breaker’s current, voltage, and interrupting capacity ratings. Thinner air isn’t as good at diverting heat from components, plus it slows dielectric charging when a breaker needs to withstand voltage. If you’re building a project for an environment like this, consider a circuit with higher ratings.
• Dust – Most, but not all, modern breakers are enclosed. This keeps harmful dust and dirt out of the device, promoting smooth performance.

Environmental threats are of special concern if you’re in an industry like oil and gas, food, or mining. If your project includes a unique or extreme environment, look for circuit breakers that have relevant certifications. Examples include IP ratings for dust and water protection, as well as compliance certificates for chemical and flame resistance. 

An experienced electronics distributor and manufacturer can help you choose the component that’ll be safest in your application.

7. Number of Poles

What does the number of poles mean to a circuit breaker? It tells you how many separate circuits the breaker can protect at one time.

Breakers come in single-pole construction or multi-unit assemblies. Single-pole breakers are common in homes, but industrial applications often require multi-pole breakers for three-phase systems.

In the end, the choice between single and multi-pole will depend on the complexity of your electrical system. Consider also whether you’ll need to isolate individual phases for maintenance or troubleshooting.

8. Testing/Maintenance

Some models come with built-in testing features, while others may require external equipment. 

Fortunately, someone’s usually done the up-front work: Most heavy-duty circuit breakers are UL Listed , meaning they’ve passed quality and reliability tests.

Note that manually operated breakers require less maintenance. They need only a simple cleaning of their contacts and verification that their linkages operate freely. Consider the ease and cost of maintaining the circuit breaker when making your choice.

Physical dimensions and setup matter beyond just the current rating of the circuit breaker.

Breaker size is an oft-forgotten consideration for settings where space is at a premium. Make sure your industrial breaker fits your panel or distribution board while still meeting other electrical requirements.

When it comes time to install the breaker, there are several more steps, including mounting, wiring, and testing. Consider the complexity of the setup process and whether you'll need specialized tools or expertise for a successful installation.

There are more circuit breaker mounting types than you could imagine. You can mount most breakers in any position, vertically or horizontally, without affecting their function. 

In windy areas, the breaker should include an enclosure and be mountable on a surface that’s not overly rigid. A breaker attached to a stiff assembly may not perform as well in high winds.

The Best Circuit Breaker for Now … and 2 Years From Now

It’s not terribly tough to suss out 2024’s best circuit breaker brands when your only criteria are cost and supply availability . The true buyer knows how to look beyond the “right now” and find a match that’ll meet the application’s demands for both today and 2 years from now.

As always, make sure your desired breaker has the proper ratings to meet your system's levels. Too much or too little juice could put you back at square one, hunting for a new breaker again.

For more component-sourcing tips on quality, reliability, and on-time delivery, visit our resource hub . If you’re ready to hunt for breakers today, click below for a manufacturer list:

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Cutler Hammer BR2100ST Circuit Breaker, 2-pole 100-amp with Shunt Trip

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• Package Dimensions ‏ : ‎ 4.4 x 4.3 x 3.6 inches; 1.05 Pounds
• Item model number ‏ : ‎ BR2100ST
• Date First Available ‏ : ‎ August 6, 2016
• Manufacturer ‏ : ‎ Cutler Hammer
• ASIN ‏ : ‎ B0077DE26Q
• #487 in Thermal-Magnetic Circuit Breakers

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Product Description

• SHUNT TRIP BREAKER 120V
• ACCESSORY DEVICE
• NQ SERIES PANELBOARD USED ON
• UL, CSA APPROVAL
• APPLIANCE, LIGHTING APPLICATION
• 120/240 VAC AT 50/60 HZ (UL/CSA), 48 VDC VOLTAGE RATING
• 10 KILOAMPERE AT 120/240 VAC (UL/CSA), 5 KILOAMPERE AT 48 VDC INTERRUPTING RATING
• 100 AMPERE CURRENT RATING
• FRAME TYPE Q
• MOUNTING TYPE BOLT ON
• SIZE 2.25 INCH W X 2.91 INCH D X 3 INCH H
• TRIPPING METHOD THERMAL MAGNETIC, COMMON TRIP
• 14 TO 8 AWG (ALUMINUM/COPPER)
• WITH VISI-TRIP[R] INDICATOR, 120/208/240 VAC SHUNT TRIP

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Top 10 Circuit Breaker Manufacturers of 2023

We gathered the top 10 circuit breaker manufacturers in the market to help you choose a reputable one. Circuit breakers are designed to safeguard your electrical systems from damage caused by electrical overloads or short circuits. Choose your circuit breaker manufacturer intelligently to ensure the safety of your electrical systems!

Circuit Breaker Manufacturers Market Overview

The worldwide circuit breaker and fuse market was worth USD 15.05 billion in 2022 and is forecast to increase at a CAGR of 5.4% between 2023 and 2030. The rising need for effective networks and renewable energy sources is predicted to contribute to the domain’s expansion. As a result of increased safety concerns about short circuits and damage from power fluctuations, the electronics, automotive, and telecommunications sectors all require more innovative equipment. Circuit breakers and fuses will continue to increase significantly during the forecast period. These devices protect against unforeseen power fluctuations caused by problems such as overvoltage, overloads, and short circuits, which can damage equipment such as industrial machinery, household appliances, IT goods, and electric tools. The gadget minimizes energy usage by limiting and managing the equipment’s electric load. As a result, the growing use of these devices during the projection period will drive up demand.

Circuit Breaker Suppliers List

The following are the largest circuit breaker supplier list:

1.ABB Circuit Breaker

ABB is a Swiss-Swedish multinational firm specializing in power and automation technology and is one of the world’s major circuit breaker producers. ABB provides various circuit breakers for low, medium, and high-voltage applications, including air circuit breakers, molded case circuit breakers, tiny circuit breakers, and vacuum circuit breakers. Innovative technologies in ABB’s circuit breaker portfolio include the Emax 2 air circuit breaker, which provides advanced protection, monitoring, and communication features, and the Tmax XT molded case circuit breaker, which combines high breaking capacity with compact size and low power consumption. ABB also provides various digital solutions for its circuit breakers, including remote monitoring, predictive maintenance, and data analytics.

ABB Homepage: https://global.abb/group/en About ABB: https://global.abb/group/en/about ABB Circuit Breaker: https://new.abb.com/low-voltage/products/circuit-breakers ABB Other Products: https://new.abb.com/control-rooms

2.IGOYE Circuit Breaker

IGOYE has a strong history of invention and has pioneered new solar technologies as one of the most committed solar equipment providers. They satisfy the highest international standards and provide a wide range of options. This company was formed in 2007, more than 15 years ago. Since then, they have consistently provided businesses with top solar equipment for household and commercial installations worldwide.

IGOYE Homepage: https://igoyeenergy.com/ About IGOYE: https://igoyeenergy.com/about/ IGOYE Circuit Breaker: https://igoyeenergy.com/product/residual-current-circuit-breaker/ IGOYE Other Products: https://igoyeenergy.com/products/

3.Schneider Circuit Breaker

Schneider Electric is a global firm headquartered in France specializing in energy management and automation systems. Since its inception in 1836, the firm has become a global leader in its sector, employing over 160,000 people in over 100 countries. Schneider Electric is dedicated to sustainability and has set lofty targets to cut carbon emissions, promote renewable energy, and improve energy efficiency. Additionally, the company has been recognized for its efforts in diversity and inclusion.

Schneider Homepage: https://www.se.com/us/en/ About Schneider: https://www.se.com/us/en/about-us/company-profile/history/schneider-electric-history.jsp Schneider Circuit Breaker: https://www.se.com/us/en/product-category/4200-circuit-breakers/ Schneider Other Products: https://www.se.com/us/en/all-products

4.Circuit Breaker Wholesale

CBW provides the most comprehensive assortment of circuit breakers on the web, ready to meet our clients’ every electrical requirement. Great rates and same-day shipment to national destinations solve your electrical problems quickly, efficiently, and affordably. There are circuit breakers for sale that you won’t find from other providers. You may be guaranteed continuous, dependable performance after installation by using quality used and refurbished circuit breakers inspected, tested, and certified by CBW.

Circuit Breaker Wholesale Homepage: https://www.circuitbreakerwholesale.com/ Circuit Breaker Wholesale Circuit Breaker: https://www.circuitbreakerwholesale.com/collections/circuit-breakers Circuit Breaker Wholesale Other Products: https://www.circuitbreakerwholesale.com/collections/transformers

5.Nat'l Switchgear Circuit Breaker

National Switchgear is a market leader in power distribution equipment and services, providing a diverse range of new and reused electrical equipment from our expansive inventory and supplier network. They also provide essential power system shops, engineering, and on-site services, such as remanufacturing circuit breakers, switchgear, associated components, maintenance, testing, power system studies, and disaster recovery operations. National Switchgear is dedicated to providing first-rate solutions while considering the advantages of ecologically friendly methods. They endeavor to address today’s requirements without jeopardizing future generations’ needs.

National Switchgear Homepage: https://nationalswitchgear.com/ About National Switchgear: https://nationalswitchgear.com/About/About-National-Switchgear.aspx National Switchgear Circuit Breaker: https://nationalswitchgear.com/Departments/Catalog/Circuit-Breakers.aspx National Switchgear Other Services: https://nationalswitchgear.com/Services/Service-Center-Support.aspx

6.Eaton Circuit Breaker

Eaton is an Irish global power management corporation operating in over 175 countries. The firm started in 1911 the United States and has since evolved to become a prominent producer of energy-efficient solutions for various sectors. Electrical, hydraulic, and mechanical power management systems, as well as aerospace and automotive solutions, are among the products and services offered by Eaton. Manufacturers, utilities, infrastructure operators, and commercial and residential structures are among the company’s clients.

Eaton Homepage: https://www.eaton.com/us/en-us.html About Eaton: https://www.eaton.com/us/en-us/company/about-us.html Eaton Circuit Breaker: https://www.eaton.com/us/en-us/products/electrical-circuit-protection/circuit-breakers.html Eaton Services: https://www.eaton.com/us/en-us/services.html

7.Camsco Circuit Breaker

Camsco Electric, situated in Taiwan, was founded in 1979 as a manufacturer and circuit breaker supplier of professional electrical system components and electrical parts. In 1990, they established a branch office in Wenzhou, China, and two factories in Wenzhou and Zhangzhou. They operate in one-step precision molding and provide clients with the most comprehensive goods and services using cutting-edge processing equipment and manufacturing lines.

Camsco Homepage: https://www.camsco.com.tw/ About Camsco: https://www.camsco.com.tw/aboutus.htm Camsco Circuit Breaker: https://www.camsco.com.tw/circuit-breakers.htm Camsco Other Products: https://www.camsco.com.tw/products.htm

8.Rockwell Automation Circuit Breaker

Rockwell Automation is a global American corporation that provides industrial automation and information solutions. The firm was established in 1903 and is based in Milwaukee, Wisconsin. Rockwell Automation offers a comprehensive range of solutions and services to assist clients in increasing production, reducing downtime, and increasing operational efficiency. Rockwell Automation is dedicated to sustainability and has established targets to minimize its carbon footprint, enhance energy efficiency, and encourage environmentally friendly practices throughout its operations.

Rockwell Automation Homepage: https://www.rockwellautomation.com/en-us.html About Rockwell Automation: https://www.rockwellautomation.com/en-us/company/about-us.html Rockwell Automation Circuit Breaker: https://www.rockwellautomation.com/en-us/products/hardware/allen-bradley/circuit-and-load-protection.html Rockwell Automation Other Products: https://www.rockwellautomation.com/en-us/products.html

9.S.B. Electrotech Circuit Breaker

S.B.ELECTROTECH is a market leader in electrical and electronic testing and measurement tools. Established in 2010, the firm has been noted for its advanced technologies and innovative ideas. S.B.ELECTROTECH is a well-known producer that distributes quality instruments worldwide and the necessary services such as installation and repair. They are concerned about our client’s needs and do our best to meet them. They are lucky to have skilled and informed staff and some specialist designers in the company. They have continued to invest in technology innovation and product development to provide better experiences for their clients. Since its inception, our organization has had a magnificent past. It is working hard to make the future even brighter in the coming years.

S.B. Electrotech Homepage: https://www.sbelectrotech.com/ About S.B. Electrotech: https://www.sbelectrotech.com/about-us/ S.B. Electrotech Circuit Breaker: https://www.sbelectrotech.com/circuit-breaker-timer/ S.B. Electrotech Other Products: https://www.sbelectrotech.com/our-products/

10.Naugra Circuit Breaker

Naugra is an Indian firm specializing in designing, manufacturing, and distributing scientific and laboratory equipment. Since starting in 2003, the firm has become a prominent provider of laboratory instruments and equipment—tools and kits for physics, chemistry, biology, electronics, civil engineering, and mechanical engineering. The company’s products include laboratory glassware, microscopes, spectrophotometers, centrifuges, and balances.

Naugra Homepage: https://www.naugra.com/ About Naugra: https://www.naugra.com/about.php Naugra Circuit Breaker: https://www.naugra.com/power-circuit-breaker

Factors to Consider When Selecting A Circuit Breaker

It’s more complicated to get the correct circuit breaker for your business. Many other aspects to consider while picking a circuit breaker have significant effects. A circuit breaker’s purpose is to avoid a power surge; each building is unique and contains varied equipment, some of which are more sensitive than others. It would help to have a durable and functional circuit breaker to keep your building from power surges and electrical overloads.

Testing And Maintenance

Testing is an important thing to consider while selecting the correct circuit breaker. A suitable circuit breaker should be tested at least once a year. Consider trying it more regularly if you live in a region prone to harsh weather. Aside from testing, you want a simple circuit breaker to maintain. If testing shows a problem, you must repair your circuit breaker or hire an expert to keep it and identify any issues.

Maximum Interrupting Capacity

Another critical consideration is maximum interrupting capacity (MIC). The MIC is the maximum current that the breaker may interrupt. Therefore more excellent MICs are required for more appliances and gadgets. A 10,000 amp MIC is standard. However, it is simple to trip this while utilizing many devices simultaneously.

Voltage Rating

Voltage is another consideration because the circuit breaker should avoid current abnormalities. The voltage rating is critical for safety, ensuring the circuit breaker trip safely when overloaded. While most residences have low-voltage circuit breakers, medium or high-voltage circuit breakers are used in circuit breaker manufacturing companies and locations with power lines. When a short circuit occurs, look for a circuit breaker with the same or more excellent rating as the open-circuit voltage since this can avoid explosions or arcing.

Another crucial consideration is frequency, which should be less than 60 Hertz. Stay within the frequency range of most circuit breakers, which is 50 to 60. Going beyond 60 Hz regularly might deteriorate the circuit breaker and diminish its power rating. A lower power rating might harm and prematurely age your circuit breaker.

In conclusion, various criteria, including the unique application, the needed standards, and the budget, determine the correct manufacturer. The top ten circuit breaker manufacturers mentioned above are well-known and provide high-quality devices for various residential, commercial, and industrial applications. Before deciding on a circuit breaker manufacturer, conducting an extensive study and evaluating all criteria is critical.

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