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A circuit breaker is an electrical safety device designed to protect an electrical circuit from damage caused by an overcurrent or short circuit. Its basic function is to interrupt current flow to protect equipment and to prevent the risk of fire. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation.
Circuit breakers are made in varying sizes, from small devices that protect low-current circuits or individual household appliance, up to large switchgear designed to protect high voltage circuits feeding an entire city. The generic function of a circuit breaker, or fuse, as an automatic means of removing power from a faulty system is often abbreviated as OCPD (Over Current Protection Device). There are different types of Circuit Breaker like bAC Miniature Circuit Breaker, AC Earth Leakage Circuit Breaker, Air Circuit Breaker, Moulded Case Circuit Breaker and Earth Leakage Moulded Case Circuit Breaker. All circuit breaker systems have common features in their operation, but details vary substantially depending on the voltage class, current rating and type of the circuit breaker.
The circuit breaker must first detect a fault condition. In small mains and low voltage circuit breakers, this is usually done within the device itself. Typically, the heating or magnetic effects of electric current are employed. Circuit breakers for large currents or high voltages are usually arranged with protective relay pilot devices to sense a fault condition and to operate the opening mechanism. These typically require a separate power source, such as a battery, although some high-voltage circuit breakers are self-contained with current transformers, protective relays, and an internal control power source.
Once a fault is detected, the circuit breaker contacts must open to interrupt the circuit; this is commonly done using mechanically stored energy contained within the breaker, such as a spring or compressed air to separate the contacts. Circuit breakers may also use the higher current caused by the fault to separate the contacts, such as thermal expansion or a magnetic field. Small circuit breakers typically have a manual control lever to switch off the load or reset a tripped breaker, while larger units use solenoids to trip the mechanism, and electric motors to restore energy to the springs.
The circuit breaker contacts must carry the load current without excessive heating, and must also withstand the heat of the arc produced when interrupting (opening) the circuit. Contacts are made of copper or copper alloys, silver alloys and other highly conductive materials. Service life of the contacts is limited by the erosion of contact material due to arcing while interrupting the current. Miniature and molded-case circuit breakers are usually discarded when the contacts have worn, but power circuit breakers and high-voltage circuit breakers have replaceable contacts.
Unlike circuit breaker, a contactor or switch is an electrically-controlled switch used for switching an electrical power circuit. A contactor is typically controlled by a circuit which has a much lower power level than the switched circuit, such as a 24-volt coil electromagnet controlling a 230-volt motor switch.
Without general-purpose relays, contactors are designed to be directly connected to high-current load devices. Relays tend to be of lower capacity and are usually designed for both normally closed and normally open applications. Devices switching more than 15 amperes or in circuits rated more than a few kilowatts are usually called contactors. Apart from optional auxiliary low-current contacts, contactors are almost exclusively fitted with normally open ("form A") contacts. Unlike relays, contactors are designed with features to control and suppress the arc produced when interrupting heavy motor currents.
Contactors come in many forms with varying capacities and features. Unlike a circuit breaker, a contactor is not intended to interrupt a short circuit current. Contactors range from those having a breaking current of several amperes to thousands of amperes and 24 V DC to many kilovolts. The physical size of contactors ranges from a device small enough to pick up with one hand, to large devices approximately a meter (yard) on a side. It also has many different types like Knife Switch, Disconnector Switch, CJ20 Contactor, CJ19 Contactor, etc. Contactors are used to control electric motors, lighting, heating, capacitor banks, thermal evaporators, and other electrical loads.