At the cutting edge of

current control

CG International Division

MOULDED CASE CIRCUIT BREAKERS

MOULDED CASE CIRCUIT BREAKERS

Crompton Greaves Moulded Case Circuit Breakers are designed for circuit protection of
low voltage distribution systems. They are suitable for application as main breakers and
for protection of branch and feeder circuits and connected equipment. These MCCBs
provide overload and shot circuit protection for all circuit elements such as cables,
motors, starters and any other load/s. They are designed for use in switchboards, control
centres, panel boards, combination starters and separate individual enclosures. In these
various enclosures, they suit the requirements of lighting distribution and other power
circuits.
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Features of MCCBs :
MAXIMUM PERFORMANCE : INCREASED FLEXIBILITY
Breakers designed for ease for termination
The staggered / extended terminals terminals of the MCCBs have been designed to maintain adequate
clearances. Emphasising user friendliness and to cater to the varied needs of customers globally, these
terminals have been specially designed to accept both Copper and Aluminimum cables / busbars.
More flexibility in the system
Rotary handle operating mechanism (optional) which is direct mounting on MCCB has padlocking facility,
door interlock and defeat facility. The Handle position can be adusted at site to suit the various mounting
directions of MCCB. MCCB mounting RHOM is available up to 800A, 50KA and higher rating HOM is Panel
door mounting type.
QUALITY
These MCCBs are manufactured at the LT Control Gear Division whose quality systems have been certified
to the ISO 9001 standards. These MCCBs fully conform to IEC/Indian standards.
CONSTRUCTION
These MCCBs comprise switching mechanism, contact system, arc extinguishing device and the tripping
;unit, contained in a compact moulded case and cover.
Case and cover
The insulating case and cover are made of high strength, heat resistant, flame retardant thermosetting
material, providing. Interphase insulation of a very high dielectric strength, making the MCCB extremely
compact and lightweight. An insulated enclosure with high withstand capability against thermal and
mechanical stresses. Protection against secondary fire hazards. Enhanced safely of operating personnel.
Switching mechanism
The MCCB employs a Quick Make-Quick Break type of switching mechanism in which a definite speed of
travel of moving contacts is ensured, independent of the speed of operation of the operator. This trip free
toggle mechanism ensures that the trip command over-rides all other commands. This leads to increased
safety of operation.
Contact System
MCCBs employ a maintenance free contact system designed to minimise the let thru' energies while
handling abnormal currents. The special sintered contact tip provides a wiping action, high resistance to
erosion during interruption and a stable contact for normal service current, leading to highly reduced power
losses and therefore, reduced temperature rise.
Arc extinguishing device
A series of grid plates is mounted in parallel between supports of insulating material. The profile of the deion steel plates extend directly over the contacts and draws the arc from the moving contact up into the
divider chamber. The arc is thus confined, divided and extinguished.
Positive indication
The handle position gives positive indication of whether the MCCb is 'ON' (top), 'OFF' (bottom) or 'TRIPPED'
(midway).
TRIPPING SYSTEM
The tripping element provided on each pole of the MCCB operates on a common trip-bar because of which it
does not create single phasing in the event of a fault on any of the phases. The tripping device is factory
calibrated and tamperproof - the most faithful guard against power theft and unwanted tampering of the
overload setting. The base design ambient of these MCCBs is 40 degree centigrate. For higher or lower
ambient temperatures, refer ambient temperature curves. With the development of superior and light weight
materials, fewer mechanical linkages, together with a well co-ordinated switching mechanism, contact
system and arc extinguishing device, the inherent inertia of the tripping system is reduced such that the total
break time of the MCCB on the actuation of it's tripping mechanism is less than 20 milli seconds.

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Rates & Specifications

Rated Current
Frame
(lr) (Amperes) Series referenc
(a)
e

1, 1.5, 2, 2.5, 3
3.5, 4, 5, 6.5
8, 9, 10, 12
10, 15, 20, 30,
32, 40, 50, 60
63, 75, 90, 100

120, 150
110, 125, 140
150
160, 175, 200
225

KS50M
(g)

INTERRUPTING
CAPACITY
DC at
AC symm,
250V (kA)
RMS
L/R = 10
at 415V
ms
50/60 Hz
(d)
(kA)

Range of
Magnetic
short circuit
pick - up level
(Multiple of
Rated
Current - lr)

Weig
ht
(Kg)

50

----

1.85

10
(c)

5
(c)

0.5

7.5
10
25
25
35
50
85

10
--------40
---

KS150SSP
(b)

10
(c)

5
(c)

KS150R

10

10

R
S
D

KS200R
KS225S

10
10

--10

S
S
R
D
D
C
K
L

125, 140, 150

160, 175, 200
225

KS100SSP
(b)
KS100S
KS100R
KS100D
KF100D
KF100C
KF100K
KF100L

8lr - 15lr

1.2
1.2
1.5
2.5
2.5
2.5
3.5

Terminal
capacity
for cablr
Lugs
Sq. mm.

1 * 25
(W/O Extended
Terminal
upto 60A)
1 * 70
(With Extended
Terminals
Above 60A)

0.6
8lr - 15lr
1.5
8lr - 12lr
10lr - 14lr

1 * 95

2.0
3.0

KS225D

25

---

8lr - 14lr

1.9

1*95 w/o
Extended
Terminals
1*150 with
Extended
Terminal

125, 150,160
175, 200

KF200D

25

---

8lr - 12lr

2.6

1 * 150

125, 150, 160

175, 200, 225

D
C
K
L

KF225D
KF225C
KF225K
KF225L

25
35
50
85

----40
---

1 or 5

40 / 1.3

KF400C

35

---

KF400K

50

---

KF400LE

85

---

KF400L

85

---

250, 300, 350

400
250, 300
350, 400
250, 300
350, 400
250, 300, 350
400

7
8lr - 12lr

1 * 300
2 * 240

10.2
Adjustable
Lo:3lr- 6lr
Hi: 8 lr - 12 lr

20.0

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250, 300, 350

400, 450, 500
600, 630

700, 800
500, 600, 700
800
1000

1200

KF600C

35

---

KF600K

50

40

C
K

KF800C
KF800K

35
50

--40

KF800H

85

---

K
H

KF1000K
KF1000H

50
80

K
H

KF1200K
KF1200H

50
85

--40
(e)
--40
(e)

Adjustabel
Lo : (250A-400A)
3lr -6 lr
Lo : (500A-630A)
2lr - 4lr
Hi : 6lr : 12lr
Adjustable
Lo:1.5lr - 3lr
Hi : 6lr - 3lr
Adjustable
Lo : 3lr : 6lr
Hi : 8lr : 12lr
Adustable
Lo : 2.5lr -5lr
Hi : 6lr - 10lr
Adjustable
Lo : 2lr - 4lr
Hi : 5lr - 8lr

9.0

9.0

11

2 * 240

4 * 300
(f)

25

26

Notes :
a) MCCBs are available in both, AC and DC versions. However, they are not
interchangeable. AC and Dc MCCBs should therefore be separately ordered. The current
ratings mentioned are standard ratings. Intermediate ratings can also be offered on
request. In some cases, ratings lower than the minimum ratings mentioned for the
particular frame can also be offered. Ratings are for 40dgree centigrated ambient. MCCBs
for 50 degree centigrated application available on request.
b) Single pole MCCBs.
c) AC interrupting capacity at 240V AC and DC interrupting capacity at 125V DC; L/R = 5
ms.
d) DC MCCBs are available with two poles as standard. For 440V DC application, the
MCCBs would be supplied with three poles where 2 poles should be connected in series.
The interrupting capacity of 3 pole MCCBs at 440V Dc id same as 250VDC-2P.
e) With short circuit release only.
f) Use suitable extended links.
g) Only to be used as SCPD for starter and motor protection in co-ordinated systems.
4 POLE MCCBS UP TO 800A ALSO AVAILABLE

*************************************
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TYPE AND POSITION OF INTERNAL ACCESSORIES

MCCB FRAME
KS226S

KS50M KS225D
KS100S KS100R
KS100D KF100D
KF100C KF100K
KF100L KS150R
KF200D KS200R

ACCESSORIES

KF800H
KF1000H
KF1000K
KF1200K
KF1200H

KF400L
KF600C
KF600K
KF800C
KF800K

KF225D
KF225C
KF225K
KF225L
KF400C
KF400K
KF400LE
POSITION

LHS

RHS LHS

1. Undervoltage Trip (UTV)

UTV

--- ---

2. Shunt Trip (SHT)

3. Auxiliary Switch (AX)
(AX - 1C or AX - 2C)
4. Alarm Switch (AL)
(AL-1C or AL-2C)

--AC-1C

SHT ----- AL-1C

*AL-1C

--- AL-1C

--- ---

AL-1C AL-1C
or or
AL-2C

5. Alarm - Auxiliary
Switch (AL-XL)

---

--- ---

--- ---

6. Auxiliary Switch &

UV trip(AX+UTV)

UTV

AL-1C
AX-1C
AX-1C
or

AL-1C
AX-1C
AX-1C
or

AX-1C
or
AX-2C
AL-1C
or
AL-2C
AL-1C
or
AL-1C
AX-1C
AL-1C
AX-1C
---

AX-1C
or
AX-2C
AL-1C
or
AL-2C
AL-1C
or
AL-1C

7. Auxiliary Switch &

Shunt trip (AX+SHT)
8. ALARM Switch + Shunt
trip (AL+SHT)
9. Alarm Switch & UV
trip (AL+SHT)
10. Alarm - Aux. Switch &
UV trip (AL- AX+UTV)
11. Alarm-Aux. Switch &
Shunt trip (AL-AX+UTV)
12. Alarm Switch &
Auxiliary Switch

AX-1C

UTV

*AL-1C

*AL-1C ---

--- ---

SHT SHT

--- UTV

SHT AL-1C

---

SHT SHT
--- ---

--- UTV

SHT AX-1C

--- ---

AX-1C

--- UTV

AX-1C ---

---

RHS LHS

SHT SHT
--- UTV
AX-1C
--- SHT

*AL-1C ---

--- ---

RHS LHS

RHS LHS

RHS

--- ---

UTV UTV

---

--- SHT
AX-1C ---

AL-1C
AX-1C
---

SHT ----- AX-1C

--- --AL-2C

AL-1C
or
AL-2C

--- ---

AL-1C
AX-1C
AX-1C
or

UTV UTV

SHT SHT

UTV UTV

SHT SHT
UTV UTV
AX-1C
SHT SHT
--- ---

AX-1C
or
AX-2C
AL-1C
or
AL-2C
AL-1C
or
AL-1C
AL-1C
AX-1C
---

NOTE :
1) These are standard positions. For any other position of internal accessories, kindly refer to us.
2) 1C - One changeover contact.
3) 2C - Two changeover contact.
4) Only a maximum of two internal accessories can be provided in the MCCB at a time
* Cannot be provided on KS225D
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EXTERNAL ACCESSORIES
FRAME
RCS
KS100S - SP
KS100S/KS100
R
KS100D
KF100D/C/K
KF100L/KS50M
KS150S - SP
KS150R
KS200R
KS225S
KS200D
KS225D
KF225D/C/K/
KF225L/KF400L
E
KF400C/K
KF400L
KF600C/K
KF800C/K
KH800H
KF1000K/H
KF1200H

External Accessories
RHOM
PK

RSC + IB

#
#

#
#

#
#

#
#
#

#
#

#
#

#
#
#
#
#

#
#
#
#

#
#
#
#
#*
#*
#*

EFR
3PHI - 3W

3PHI - 4W

#
#

#
#

#
#

# : Available
RCS : Rear Connecting Stud
IB : Insulating bushings
RHOM : Rotary Handle Operating Mechanism (MCCB Mounting type)
PK : Plug - In Assembly
EFR : Earth Fault Release
* : HOM : Handle Operating Mechanism (Panel door mounting type
NOTE : EFR can not be provided to MCCBs with RCS/ RCS + IB/ PK

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TRIPPING SYSTEMS
FULL MAGNETIC TYPE :
This system makes use of the electromagnetic effect of current to provide both, overload
as well as short circuit protection. The tripping system consists of a cylinder assembly,
current carrying coil and an armature supported on a yoke. A resetting spring and a
moving core immersed in silicon fluid are contained inside
The sealed cylinder, yoke and an air gap. The coil surrounding the cylinder, carrying the
circuit current provides the required magnetomotive force.
The overcurrent flowing through the coil initiates the movement of the moving core,
reducing the reluctance of the magnetic circuit. The armature is attracted when the
moving core reaches the top of the cylinder, thereby delatching the mechanism. During
the overload, the movement of the moving core however,
Depends on the extent of the overload, and is opposed by the viscosity of the silicon fluid.
The combined effect of these phenomena produce the required inverse time current
characteristics.
During flow of the short circuit current, the magnetomotive force is so high that the
armature is attracted without the movement of the moving core and trips the MCCB
instantaneously.
CHARACTERISTICS
The operating current for tripping at temperatures other than 40 degree celcius will
remain unaltered. However, the operating time will change according to the compensation
curve. The example shown, illustrates that if this tripping device is adujsted at an ambient
temperature of 40 degree celcius, then the operating time will be reduced to 85% of the
standard time when it is employed at a site ambient temperature of 50 degree celcius.
THERMAL MAGNETIC TYPE :
The tripping system makes use of the heating effect of current to provide protection
against overload and short circuit conditions, respectively.
The heater bimetal set in each phase of the MCCBs actuates the tripping system
following inverse time-current characteristics, depending upon the severity of the
overload. During short circuits, the fixed core attracts the moving core, tripping the MCCB
instantaneously.
CHARACTERISTICS
The operating current for temperature other than 40 degree celcius varies according to the
compensation curve. The example shown illustrates that the rated current of the device
adjusted at a base ambient temperature of 50 degree celcius.
EXTRA CURENT LIMITING TYPE :
This type of MCCB consists of an additional pair of contacts in series with the main pair of
contacts. The construction of these additional pair of contacts is such that the fixed and
moving contacts carry current in opposite directions, thereby producing a repulsive force
between them. The contact separation by this repulsive force results in added arc
resistance, which greatly limits the prospective short circuit current. Further, the tripping
system operates to delatch the mechanism and trip the MCCB within 4-8 milliseconds. The
use of such a principle reduces not only the cut-off current but also the let thru thermal
and dynamic stresses to a very large extent.
Another technique employed to achieve the Extra Current Limiting feature is by the use of
Non-Linear Resistor, in series with main contacts.
The following MCCB frames have extra current limiting type releases : KS50M, KF100L,
KF225L, KF400L.

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TRIPPING SYSTEMS

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Applications
Note : Crompton Greaves also offers special
motor protection MCCBs that are type 'C'
co-ordinated as per IEC 292 1A.
Details / Specification chart can be provided on request.
REC APPLICATION
Crompton Greaves MCCBs also conform to REC sepecifications 18 /1981 ( Revised ) dated
30.11.82 for LT Circuit Breakers for protection of Distribution Transformers.
FEEDER PROTECTION
MCCBs are ideally suited for outgoing feeder circuits on distribution boards. The selected MCCB
should have adequate interrupting capacity and the MCCB current rating should be equal to that
of the load.
CAPACITOR CONTROL
MCCBs are suitable for controlling LT capacitors for power factor correction. To avoid tripping
during switching ON of the capacitors, the MCCB rating should be around 1.5 - 2 times the rated
current of the capacitors.
DG SET PROTECTION
MCCBs can be used for effective protection and control of Diesel Generating sets against
overloads and short circuits.
HOIST / ELEVATOR / CRANE CONTROL
MCCBs can withstand continuous vibrations of 2g and shocks upto 15 g without affecting their
performance. As such they offer the best protection for hoist / elevator / crane applications.
FURNACE CONTROL
MCCBs are suitable for high frequency systems upto 400 Hz. Hence they can be ideally used for
control of high frequency furnaces. A derating factor of 0.8 is to be employed for arriving at the
rated current of the MCCB. However it must be noted that full magnetic MCCB are not suitable for
this application.
DC CONTROL
Rectifier panels which act as source of DC supply can be conveniently protected by MCCBs.
Moreover, MCCBs being suitable for both AC as well as DC systems, control and protection of
input as well as output sides of the rectifier is also possible.
MARINE APPLICATION
MCCBs are ideally suitable for a variety of marine applications. These have cleared the most
stringent performance, durability and environmental tests as per the Joint Services Specifications
JSS 55555, JSS 50101 and JSS 59201.
The performance tests include all the type tests laid down by the relevant Indian Standards.
The durability test include Vibration test at 10 g. Bump test at 40 g and Shock test at 7o g.
The environmental tests include the Damp Heat (steady state) Test, Damp Heat (cyclic) Test,
Mould Growth Test and the Corrosive Atmosphere (salt spray) Test.
These tests have proved beyond doubt, the capability of the MCCBs to perform reliably in
extremely difficult adverse and extremely humid and saline conditions.
Crompton Greaves MCCBs are also approved by the Lloyds Register of Shipping (LRS), the
American Bureau of Shipping (ABS) and the Indian Register of Shipping (IRS).

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