IDEAL INDUSTRIES, INC.

Branch Circuits Protected by AFCI Devices

And the IDEAL SureTest® Circuit Analyzers.
Includes information on testing AFCI devices.

Author: Patrick C Elliott

Field Sales Engineer
IDEAL Industries, Inc

August 2008, Version 3

Basics of Branch Circuit Testing 1

Branch Circuit Wiring

Branch circuit wiring rules are defined by the National Electrical Code. They are
necessary to ensure safe and efficient branch circuits. Hidden problems within a branch
circuit can result in fire, equipment failure or even electrocution .

Arc Fault Circuit Interrupters

AFCI requirements began when in 1999 the National Fire Protection Agency (NFPA),
Code Making Panel (CMP) 2 accepted a proposal that required the installation of Arc
Fault Circuit Interrupt breakers on branch circuits feeding bedroom outlets, with an
effective date of January 1, 2002.

An Arc Fault Circuit Interrupt device protects against arcing faults by recognizing the
unique characteristics of arcing in a branch circuit. These arcing faults may contribute to
residential fires.

UL 1699 defined types of AFCIs for branch circuits:

1. Branch/Feeder AFCI is the most common device in used today, this type of
AFCI detects parallel arcs on the branch circuit from its origin at the panel.
2. Outlet Circuit AFCI is an outlet that detects both parallel and series faults in
devices connected to that outlet only.
3. Combination AFCI Is a device that does the job of both the Branch/Feeder AFCI
Breaker and the Outlet Circuit AFCI in that it detects both parallel and series
arcing faults anywhere on the circuit.

What protection does a Branch/Feeder AFCI provide?

o Over current protection: The breaker will trip when the load current exceeds the
current rating of the breaker.
o Parallel arcing: An AFCI will trip when it senses a characteristic arcing between
line and neutral greater than 75 amperes.
o Leakage Current: Most AFCI devices will trip between 30mA to 50mA of
leakage current.

What protection does a Combination AFCI Breaker provide?

o The Combination AFCI Breaker provides all of the Branch Feeder protection and
adds the ability to detect series arcs from a level of 5 amps or greater.

High Resistance Faults: Parallel Arcs, Series Arcs, and Glowing Contacts

Parallel Arcing Faults 3 Parallel arcing faults can be the result of insulation failure
between a line to neutral or line to ground. The Parallel arcing fault current is limited by
the available short circuit current and the impedance of the fault.

Basics of Branch Circuit Testing 2

 4
Series Arcing Fault can occur when there is a partial or total failure in one of the
conductive paths in series with a load. This failure is characterized by completely opened
conductor (which would be infinite resistance) or by resistance alternating between
infinite to high resistance and back again. Intermittent connections, loose wire terminals,
poor splices, or poor contacts of quick-wired devices can cause high resistance faults.
.

Glowing Contact, or High Resistance Series Arcing Fault 3 is defined as the abnormally
high resistance in a wire, wire termination, wire splice of and type of connection,
resulting in reduce current flow and excessive heat at the fault.
o These high resistance series faults result from a build-up of copper or aluminum
oxide that creates a high resistance "glowing contact.“
o This high-resistance point can become extremely hot with temperatures exceeding
600° F causing insulation failures that can result in a damaging high-power
parallel arcing fault or ground fault.
o Glowing contacts can develop current carrying conductor. The current in the high
resistance fault, like the series arcing fault, is limited to the current being drawn
by the load—until the insulation degrades to the point where this type of fault
becomes either a parallel arcing fault or it causes fault current to flow.

Loose wire connections create

a high resistance point within
the electrical system, which
can lead to a breakdown in
insulation or even a fire.

Ground Fault Circuit Interrupters

Section 210.8 of the 2005 National Electrical Code (NEC) requires the installation of
ground fault circuit interrupters (GFCIs) in residential dwellings and guest rooms of
hotels to protect person(s) against shock.7

A GFCI is a device with a built in

circuit to detect leakage current to
ground on the load side of the device.
When the GFCI detects leakage
current to ground, it will interrupt
power to the load side of the device,
halting a hazardous ground fault
condition.

Basics of Branch Circuit Testing 3

These devices should be tested regularly, because they rely on mechanical parts that can
degrade over time. According to a recent study performed by the Leviton Institute, an
average 15% of GFCIs were inoperative when tested. “Voltage surges from lightning,
utility switching and other sources all take their toll on the devices, which is why
Underwriters Laboratories (UL) requires that GFCIs be tested monthly.”8

Using the SureTest® Circuit Analyzer to test branch circuits.

The IDEAL SureTest® Circuit Analyzer 61-165 has two functions.

1. Test the physical structure of the branch circuit. The SureTest® Circuit Analyzer
calculates Voltage Drop and Percent of Voltage drop at 12, 15, and 20 amp loads
in a matter of seconds. With its patented technology, it can perform this test even
if there are loads on the circuit, without tripping a breaker or interrupting the load.
The Available Short Circuit Current, and the resistance of each conductor Hot,
Neutral, and Ground are also measured and displayed.

Voltage drop at a
12,15, or 20
ampere load can
be easily taken by
simply plugging
the SureTest ®
into a receptacle
and performing
the Voltage drop
test.

2. The SureTest® Circuit Analyzer tests the performance of AFCI/GFCI protection

from different points on the branch circuit. The Models 61-165 and 61-059 tests
the branch circuit performance of the AFCI by simulating an arc fault between hot
and neutral. This simulated arc meets the present UL guidelines for AFCI testers.
The Model 61-165 can also test GFCI devices at 6mA and 30 mA per the UL
guidelines for GFCI testers.

It is important to note that AFCI devices cannot detect a glowing contact, which is a high
resistance fault in either the hot or neutral conductor unless it is arcing. You can detect
possible glowing contacts and locate series arcing points with the 61-165 SureTest, which
has the ability to measure the resistance of the Hot, Neutral and Ground. By measuring
and comparing the resistance of the hot and neutral conductors, you will see a resistance
fault as a difference between what should be two very similar resistance readings. By
measuring at different points in the branch circuit, you can pinpoint the location of the
high resistance connection.

Basics of Branch Circuit Testing 4

Troubleshooting a Standard Circuit.
Measure the voltage drop at the furthest receptacle from the panel on the branch circuit
under test. Use 12 amps for a 15 amp circuit, 15 amps for a 20 amp circuit. If the
voltage drop is greater than 5%, or the voltage drops below 108 volts, then further
investigation is necessary.

Test the receptacles in an organized way, working towards the panel from the furthest
point. This will help you pinpoint a high resistance fault, loose connection, or faulty
device.

A sudden change in voltage drop from one receptacle to the next indicates a problem
somewhere between the two receptacles. Check everywhere wires are joined. The fault
may be in a defective device as well.

If the high voltage drop reading steadily decreases as you get closer to the panel with no
significant decreases between receptacles, then the wire may be undersized for the length
of the branch circuit.

In this example there is a High

Resistance Fault between the
2nd and 3rd receptacle. The
Voltage drop increased from
the 2nd to the 3rd. The high
resistance was identified as a
poor connection between the
two devices.

The IDEAL SureTest® can measure

the resistance of the Line, Neutral, and
Ground conductors. This can be very
helpful when trying to locate a high
resistance fault in a branch circuit.

Basics of Branch Circuit Testing 5

Maintaining a Low Impedance Ground

A good electrical ground must meet NEC requirements, and it must also be low
impedance. The IEEE recommends that each conductor be less than 0.25 ohms, or 0.5
ohms for the circuit. It is also important to ensure all bonds are very low resistance, so
that all the grounds and bonded parts of interconnected systems are about the same
resistance to earth and to each other. Corroded, loose, or missing connections,
undersized wiring, and old age cause high resistance grounds and bonds.

False Grounds

The neutral conductor can only be bonded to the ground conductor at the service
entrance. Sometimes through error or ignorance, the neutral and the ground conductor
are connected or unintentionally touch downstream from the service entrance.
This is called a false, or bootleg ground. A 3-bulb receptacle tester will show this circuit
as wired normally when in fact this is a hazardous wiring condition. The ground and all
bonded metal can become part of the neutral return path. This false ground condition
goes undetected in many cases. One consequence of the new AFCI requirement is that
false ground conditions cause AFCI devices to trip because of unbalanced return current
on the line. This will cause intermittent problems on AFCI protected circuits depending
on the load on the circuit. Without the Sure Test, the AFCI breaker would probably be
blamed for nuisance tripping.

The SureTest 61-165 will detect a connection between ground and neutral when placed
within 15 feet of the connection. That means an outlet that is closer than 15 feet to the
service entrance will indicate False Ground.

SureTest® Circuit Analyzer can detect a

false ground condition within 15 feet of a
receptacle under test or within 15 feet of
the panel.

Earth Ground

Grounding Electrodes provide the electrical system reference to earth. The rods and the
soil form an effective ground system. The system could be a single ground rod, multiple
ground rods, a mat, or a grid system. Section 250-56 states that if the effective resistance
of a single ground rod is greater than 25 ohms, then a second ground rod must be added

Basics of Branch Circuit Testing 6

at least 6 feet from the first.6 The grounding system can be tested with a three-pole earth
resistance tester, or a ground resistance clamp meter.

A ground resistance clamp meter

enables electricians to measure the
resistance of the ground electrode in a
fraction of the time required using the
traditional three-point fall of potential test.

While testing the resistance of the ground electrode with a three pole or four pole tester, it
is necessary to completely disconnect the ground electrode system from the electrical
service. A ground clamp meter can test the ground electrode system while it is still
connected to the service.
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1
Fact Sheet on Fire in the US and Canada, National Fire Protection Agency (NFPA)
1997
2
1997 Residential Fire Loss, Consumer Product Safety Commission, 1997
3
Technology for Detecting and Monitoring Conditions that Could Cause Electrical
Wiring System Fires. UL Report for CPSC, contract #CPSC-C-94-1112, September 1995.
4
NEC code Articles {210-19(a) FPN No. 4} {215-2(d) FPN No. 2},
5
Kinney, Larry "Assessing the Integrity of Electrical Wiring"
Home Energy Sept/Oct 1995: 5,6
6
NEC code Article {384-20}
7
NEC code Article {210-8 (a)}
8
Study Identifies potential GFCI weaknesses,
Electrical Marketing, August 18, 2000
9
NEC code Article {285}
10
NEC code Article {250-148}
11
NEC code Article {250-146(d)}
12
NEC code Article {250-146(a) through (d)}
13
NEC code Article {384-20}

Basics of Branch Circuit Testing 7

IDEAL 61-051 Receptacle Testers

IDEAL 61-165 SureTest® Circuit Analyzers

IDEAL 61-092 Vol-Con® Elite Digital Voltage Tester

IDEAL 61-310 Resi-Pro Multimeter

IDEAL 61-340 Test-Pro Multimeter

IDEAL 61-920 Clamp-on Ground Resistance Tester

IDEAL 61-796 3-Pole Ground Electrode Tester

IDEAL 61-534 Circuit Breaker Finder

IDEAL 61-956 Circuit Tracer

IDEAL 61-795 Insulation Tester

IDEAL Term-a-Nut® Grounding Products

Basics of Branch Circuit Testing 8