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t ec h n i c a l pa p e r

MCCB applications
When to use a 100% rated circuit breaker

There are widespread

misconceptions around the topic of
80% and 100% rated circuit breakers.
In this technical paper, we will
examine the NEC rules and how they
impact circuit breaker selection.

Proper circuit breaker selection is not an easy task Article 240.20 (A) of the National Electrical Code
especially when the subject of “80% rated” versus (NEC), 2014 Edition states: (A) Continuous and
“100% rated” circuit breakers comes up. Always Noncontinuous Loads. Where a branch circuit supplies
sizing the circuit breaker at 125% of load, means that continuous loads or any combination of continuous
a larger, more expensive circuit breaker will always be and noncontinuous loads, the rating of the
required. There are widespread misconceptions overcurrent device shall not be less than the
around this topic of 80% and 100% rated circuit noncontinuous load plus 125 percent of the
breakers which we will try to clarify. In this technical continuous load.
paper we will examine the NEC rules and how they
impact circuit breaker selection. The emphasis will be Exception: Where the assembly, including the
on using the rules to your advantage and explaining overcurrent devices protecting the branch circuit(s), is
how to save money on an installation whenever listed for operation at 100 percent of its rating, the
possible. ampere rating of the overcurrent device shall be
permitted to be not less than the sum of the
National Electrical Code® (NEC) continuous load plus the noncontinuous load.
The NEC recognizes that the operation of overcurrent
protective devices may be affected by the heat in a Definition from Article 100 of the National Electrical
system. Because of this, it defines the concept of Code (NEC), 2014 edition
continuous loads and the 80% limitation in order to Before we can apply the electrical code rule, we must
try and offset the effects of heat in the system when know what constitutes a continuous load which the
sizing a circuit breaker. This is where we find an NEC defines as:
instance of an electrical code rule that describes how
to size the circuit breakers current rating based on the “A continuous load is defined as a load where the
amount of load current and how long the load will be maximum current is expected to continue for 3 hours
running at full capacity. or more.”
If we have to size the circuit breaker rating to 125% of ampacity. Both thermal-magnetic and electronic
the continuous load current then it stands to reason trip circuit breakers can be tested for 100%
that we are only utilizing 80% of the circuit breaker’s ratings. Although the trip characteristics of an
current carrying capacity. Since 80% is the inverse of electronic trip circuit breaker are not affected by
125% (0.80 = 1 divided by 1.25), this is the source of ambient temperatures, the conductors are
the common terminology “80% rated circuit breaker”. impacted by the temperature, thus the need for a
This does not mean that the circuit breaker is only special test for the 100% rating. If these
good for 80% of its rating but rather this is an additional tests are successful, then the circuit
application restriction imposed by the NEC to not breaker is allowed to be marked as a 100% rated
exceed 80% of the circuit breaker’s rating if it is being circuit breaker and can be used in an installation
used on a continuous load. If however, the circuit under the exception of NEC 240.20 (A).
breaker is only supplying noncontinuous loads, those
where the maximum current is expected for less than Marking requirements
3 hours, then the NEC rule does not impose this Distinguishing between a 100% rated circuit
limitation and the circuit breaker can be sized at 100% breaker and an 80% rated circuit breaker?
of its current rating.
A UL 489 100% rated circuit breaker must be
As with many rules, there are exceptions that can be marked by the manufacturer with the minimum
made and this NEC code article has the specific enclosure size and venting requirements needed
exception that says the circuit breaker may be used at for heat dissipation. These markings are present
100% of its rating if it is “listed” for operation at on the device so that a local electrical inspector
100%. Many circuit breaker manufacturers have gone can verify that all of the installation requirements
through the process of testing and obtaining UL are being met. These circuit breaker conditions
certifications which enables them to advertise their are:
products as UL Listed 100% rated. • Minimum enclosure size
• Temperature rating of the wire
This additional testing establishes that the correct • Ventilation requirements (if needed)
operation of the circuit breaker can carry the full rated
current without tripping and that it does not exceed Example of a circuit breaker marking:
temperature limits that could render it unsafe.

Circuit breaker testing requirements

UL 489, the UL Standard for Molded-Case Circuit
Breakers, Molded-Case Switches and Circuit-Breaker
Enclosures, requires all circuit breakers to carry 100% When a circuit breaker is listed for operation at
of their current rating when tested in an open air 100% of its current rating, the requirement to
environment. These tests are performed without an oversize the circuit breaker goes away. Instead,
enclosure, but they are typically inside a thermal the device simply has to be able to handle the sum
chamber where the ambient temperature is held at a of all the continuous and non-continuous loads.
constant 40ºC (approx. 104ºF). The circuit breaker is
designed to carry 100% of its rated current While using a 100% rated circuit breaker may
indefinitely without tripping under these standard always seem like the best choice, it is not always
test conditions. Since the wire size attached to the the case. An determination of whether the load
circuit breaker terminals can in some cases make a will be continuous or noncontinuous should be
difference in the tripping characteristics of the circuit made. If the load will be noncontinuous, there is
breaker, UL specifies what size and type of wire is to no need for protecting 125% of the load
be used during the test. In order to be third party requirement and the breaker size can be selected
certified by UL as a 100% rated circuit breaker, there to meet 100% of the load. In that case, the 80%
are additional testing requirements that must be met. rated circuit breaker may be the better choice.
The circuit breaker must undergo thermal testing
inside an enclosure of minimum size/volume without With continuous loads, the load current on each
tripping until it reaches temperature stabilization; the branch circuit must be determined in order to
temperature is monitored on various parts of the calculate the required ampere rating for each
circuit breaker to make sure the breaker does not circuit breaker type; 100% of load current for
exceed the temperature rise limits set forth in the 100% rated circuit breakers or 125% of load
standard. When the temperature at the circuit current for 80% rated circuit breakers. Typically,
breaker terminals exceeds 50ºC during the 100% the greatest cost savings comes when using the
rating test, but remains below 60ºC, UL requires the 100% rated circuit breaker precludes the need to
use of wire with 90ºC insulation, but sized at 75ºC move up to the next larger frame size circuit
 Example 1
breaker. This often makes the 100% rated circuit
Let’s consider the installation of a 300HP, 480V motor
breaker the most economical choice.
with a nameplate full load amp rating of 360 amps. If
this is a continuous load the NEC would have us size a
Total cost of the installation
standard 80% rated circuit breaker at: 360A * 125% =
In making the most cost effective circuit breaker
450A. This would cause us to use a 600 amp frame
selection, the total cost of the installation should be
circuit breaker with a rating plug or trip threshold
considered. This evaluation certainly includes the cost
setting of 450 amps. If however we were to use a
of the circuit breaker, but must also take into account
100% rated circuit breaker we could use a 400 amp
the size and cost of the enclosure or equipment that
frame circuit breaker with its smaller dimensions and
into which the circuit breaker is installed. The
lower cost. Now consider the additional costs
installation is not complete until the cable is
differences in using cable and conduit sized for 360
connected from the circuit breaker to the load. Since
amps instead of 450 amps, and you can see that the
the cable size is based on the circuit breaker rating,
cost savings can be significant and extend well
reducing the circuit breaker size by using a 100%
beyond the cost of the circuit breaker.
rated circuit breaker results in a reduction in the size
of the cable to match the lower circuit breaker rating.
Example 2
Other installation costs will also be reduced such as
In this case we have a combination of continuous and
using smaller diameter conduit and conduit fittings,
non-continuous loads; the non-continuous loads total
compression terminals, etc.
to 150 amps and the continuous loads are 600 amps.
The NEC says we should size the circuit breaker at
Application examples
100% of the non-continuous loads and 125% of the
The following are several application examples for the
continuous loads, so we have the equation; (100% *
use of 80% rated circuit breakers and 100% rated
150) + (125% * 600) = 900A. This means we would use
circuit breakers to show when it may be advantageous
a 1000 amp frame circuit breaker set at 900 amps.
to use one over the other. Many other configurations
Our other option is to use a 100% rated circuit breaker
are possible. Always refer to the manufacturer’s
and in this instance the equation becomes; 150 + 600
published data concerning 100% rated circuit
= 750A. Now we can use an 800 amp frame circuit
breakers to ensure compliance with all installation
breaker and as in the previous example, not only is the
requirements for their use.
circuit breaker smaller and less expensive, but the
overall installation costs are much less. The 80%
Notes for application examples:
rated 900A circuit breaker would need three per
• All wire size ampacity references are for copper con-
phase #350 kcmil cables for an ampacity of 930 amps,
ductors.
while the 100% rated 750A circuit breaker would only
• Conductor ampacities were taken from the 75°C col-
need three per phase #250 kcmil cables for an
umn of Table 310.15 (B) (16) in the 2014 Edition of
ampacity of 765 amps.
the National Electrical Code®.
• Although some 100% rated circuit breakers require
As you can see this is a large difference in cost
the use of conductors with insulation temperature
between the #350 and #250 conductors especially
ratings of 90°C, the ampacities must not exceed
since it takes three cables per phase. Theoretically,
those shown in the 75°C temperature column.
the savings are proportional to the length of the cable
• Circuit breakers are used in these examples, but
run with an increase in savings as the cable length
other overcurrent protective devices such as fusible
increases because a large portion of the savings is the
disconnect switches may also be used.
cost difference in the cable and installation products,
• No adjustments were made to the cable size based
i.e., the conduit and fittings.
on ambient temperature or excessive length, etc.
• The minimum enclosure sizes shown in the table are
Example 3
for three pole circuit breakers.
In this example we have a 480V 100HP pump motor
with a full load current of 124 amps that pumps liquid
through pipes as part of a batch process in a food and
beverage processing facility. The pump takes two
hours to fill the vats to begin the process. Then it
turns off until the batch is ready to be bottled. Since
the pump motor is only running for two hours at a
time, it is a noncontinuous load and can be sized at
100% of the load current and does not require the use
of a 100% rated circuit breaker. In this case you
should use the standard 80% rated circuit breaker
and the extra cost of the 100% rated circuit breaker is
not justified.
 Example 4 rating. Manufacturers perform additional testing to
If you have a continuous load with a load current of 80 be able to offer 100% rated circuit breakers that can
amps your options are to use an 80A 100% rated be used in accordance with the exception clause of
circuit breaker or a 100A 80% rated circuit breaker. the National Electrical Code. Understanding the
Since both the 80A and 100A ratings would be the difference between 80% and 100% rated circuit
same frame size circuit breaker there is most likely no breakers and their application requirements can often
big price difference between the two choices. Next save the user a substantial amount of money on the
we need to look at the installation cost; the 80 amp total cost of the installation.
circuit breaker will need #4 AWG copper wires while
the 100 amp circuit breaker needs #3 AWG copper With a proper understanding of 100% rated circuit
wire. Again this is not a huge difference in size, but breakers and how they are applied, an evaluation can
many times the #3 AWG wire is not readily available be made to point us to the best, most economical
which could cause the installer to go up in size to #2 selection. Advantages to using a 100% rated circuit
AWG wire. There is not likely to be an advantage to breaker may include a lower current rating and a
using the 100% rated circuit breaker for this smaller physical size circuit breaker, smaller cable, and
application unless the wire run is long enough that a potential to reduce the equipment size resulting in a
you can realize a savings on the total installation cost reduction of needed floor and wall space.
of wire, conduit and fittings by using the smaller #4
AWG wire. References
NFPA 70, The National Electrical Code (NEC), 2014.
Summary UL 489, Molded-Case Circuit Breakers, Molded-Case
A circuit breaker is designed to carry 100% of its Switches and Circuit-Breaker Enclosures, Twelfth
current rating, but the NEC rules limit the application Edition, Dated January 15, 2013.
for continuous loads to 80% of the circuit breaker’s

UL Listed 100% Rated Molded Case Circuit Breakers

Tmax, Tmax XT Circuit Breakers
Frame Size (Amps) Minimum Enclosure Size (mm) (Inches) 90°C Wire Required(1) Trip Unit Type (T/M, ELT)
XT1 (100A) (4)
370mm H X 216mm W X 72.5mm D Yes T/M
14.6”H X 8.5”W X 2.9”D
XT2 (125A)(3) 310mm H X 180mm W X 83.5mm D No T/M, ELT
12.2”H X 7.1”W X 3.3”D

XT3 (225A) 370mm H X 217mm W X 72mm D Yes T/M

14.6”H X 8.5”W X 2.8”D
XT4 (250A) 380mm H X 195mm W X 83.5mm D Yes T/M, ELT
15.0”H X 7.7”W X 3.3”D
T5 (300A, 400A) 506mm H X 381mm W X 153mm D No T/M, ELT
19.9”H X 15.0”W X 6.0”D
T6 (600A, 800A) 520mm H X 420mm H X 200mm W Yes T/M, ELT
20.5”H X 16.5”W X 7.9”D
T7 (1000A, 1200A) 704mm H X 554mm W X 173mm D Yes ELT
27.7”H X 21.8”W X 6.8”D
T8 (1600A, 2000A, 2500A, 3000A)(2) 1016mm H X 608mm W X 615mm D No ELT
40.0”H X 24.0”W X 24.2”D
1
90°C wire is required for installation but must be sized according to 75°C ampacity tables
2
T8 1600A, 2000A 80%-100% with front terminals, 2500A 80% with front terminals and 80%-100% with rear vertical terminals, 3000A 80%-100% with rear vertical terminals
3
Tmax XT2 100% rated up to 125A with electronic trip unit or 100% rated up to 100A with thermal-magnetic trip unit
4
Tmax XT1 100% rated up to 100A or 80% rated at 125A

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