Application Paper AP01200008E Effective February 2010

UL listed 100%-rated
molded case circuit breakers
Introduction It is worth noting that thermal-magnetic and
electronic trip MCCBs can both be tested for
Reducing overall costs is a goal of every project. 100% ratings. Since a breaker’s main function is
100%-rated circuit breakers can help achieve to protect the conductors, even though the trip
this objective. This paper discusses the proper characteristics of an electronic breaker
application of 100%-rated circuit breakers are not as sensitive to elevated temperatures,
to aid in choosing the right product solution the conductors are impacted by temperature,
for protecting a distribution system. thus requiring the special test for 100% rating.

Evaluation
Requirements
The first step in evaluating the potential use of
Before addressing the 100%-rated topic, we 100%-rated devices requires an understanding
should start with a basic understanding of the of how the NEC addresses the rating of the
requirements set forth by the National Electrical overcurrent device.
CodeT (NECT) and Underwriters LaboratoriesT
(ULT) for rating overcurrent devices. It is important NEC 210.20(A): Where a branch circuit supplies
to know that all overcurrent devices are designed continuous loads or any combination of continuous
and tested at 100% of their nameplate current and noncontinuous loads, the rating of the
rating in open air (ref. UL 489 for MCCB). As a overcurrent device shall not be less than
result, that continuous current rating is printed the noncontinuous load plus 125% of the
on the device nameplate. continuous load.
When an overcurrent device such as a molded Exception: Where the assembly, including the
case circuit breaker (MCCB) or fuse is applied overcurrent devices protecting the branch
in an assembly, it must be sized at 125% of the circuit(s), is listed for operation at 100% of its
continuous load per NEC 210.20(A). This results rating, the ampere rating of the overcurrent device
in an overcurrent device being applied at 80% shall be permitted to be not less than the sum of
of its nameplate rating. This application sizing the continuous load plus the noncontinuous load.
rule accounts for the resulting higher ambient
temperatures found when an overcurrent device NNote: A continuous load as defined by NEC Article 100
is contained within an enclosure. For the sake is “a load where the maximum current is expected to
of this paper, the balance of the discussion will continue for three hours or more.”
be focused on MCCBs only, recognizing that the
same overcurrent device rules also apply to fuses. This exception can be expressed using the
When considering the total cost of a distribution following formulas:
system, a brief analysis shows that size and Standard 80%-rated design
ratings of components within the system
contribute heavily to the overall cost. If a breaker Noncontinuous load + 125% of continuous load
is applied at 100% of its nameplate rating, there = total minimum load
is a potential to reduce not only the breaker size, Special 100%-rated design
but also the conductor size and the size of the
enclosure. This size reduction may result in a less Noncontinuous load + continuous load
expensive distribution system. Where continuous = total minimum load
loads force the selection of a larger frame breaker,
100%-rated breakers may allow the user to remain Notice that the exception refers not only to the
in a smaller frame breaker. breaker, but also to the entire assembly. Since
most manufacturers do not label their enclosures
at 80% or 100%, the enclosures must either
meet the minimum enclosure size and ventilation
requirements spelled out by the overcurrent
device manufacturer or have the system tested
by UL for 100%-rated breaker operation.
Application Paper AP01200008E UL listed 100%-rated molded 
Effective February 2010 case circuit breakers

Next, the NEC addresses the rating of the conductor size for the
feeder-circuit.

NEC 215.2(A): The minimum feeder-circuit conductor size, before

the application of any adjustment or correction factors, shall have
an allowable ampacity not less than the noncontinuous load plus
125% of the continuous load.
Exception: Where the assembly, including the overcurrent devices
protecting the feeder(s), is listed for operation at 100% of its
rating, the ampacity of the feeder conductors shall be permitted
to be not less than the sum of the continuous load plus the
noncontinuous load.
This exception tells us that an assembly listed for operation at
100% of its rating will also carry the full rating of the overcurrent
device and conductor. Therefore, the same formula that applies
to breakers can also be used for the conductors. UL provides
additional explanation about the conductor sizing in Section 9.1.2.14
where it says that the conductor must be applied using 90°C wire
based on the ampacity of 75°C-rated conductors when used with
a 100%-rated circuit breaker. In other words, 90°C wire must be
sized with the same circular mils as the associated 75°C wire
for a required ampacity. An example of this would be a required
conductor ampacity rating is 380A. In a 100%-rated application, the
choice of conductor would be 90°C 500 kcmil conductor, not 90°C
400 kcmil (NEC Table 310.16). The last detail for conductors is the
connectors or terminals that must be used. Per UL 489 9.2.14(b),
they shall either be provided on the circuit breaker by the
manufacturer or if the conductors are aluminum or copper-clad
aluminum, connectors shall be identified as AL9, CU9AL, or AL9CU.
Now that we have defined the rules for applying breakers and
conductors, we must understand how to determine the difference
between a standard breaker and one rated for 100% of its name- Application
plate current. As required by UL and shown in the example label
at right, a breaker manufacturer must include information on the We can now evaluate the steps to determine if 100%-rated
enclosure size that was used to achieve 100% rating during testing. breakers provide an economic benefit.

UL 489 9.1.4.4 A circuit breaker, having a frame size of 250A or Enclosure Size
greater, or a multi-pole type of any ampere rating rated over 250V;
and intended for continuous operation at 100% of rating, shall be This information is provided on the breaker label as seen above and
marked: Suitable for continuous operation at 100% of rating only in Table 1, which is based on testing that was performed with UL.
if used in a circuit breaker enclosure Type (Cat. No.) ____ or in If the enclosure that will house this breaker meets the minimum
a cubicle space ___ by ___ by ___ mm (inches). Equivalent dimensions and/or the ventilation requirements listed, proceed to
wording shall be permitted. The blanks are to be filled in with the load calculation.
the minimum dimensions.
Load Calculation

1. Examine each load in the system and determine if they are

primarily continuous (three hours or more) or noncontinuous
loads. If all of the loads are noncontinuous, both the standard-
rated and 100%-rated breaker can be size at 100% of the load,
so the standard-rated breaker would be the most economical
option.
2. If continuous loads are part of the system, a simple calculation
(formulas above) must be done to determine if using a 100%-
rated breaker will result in a financial benefit for the customer.
3. One consideration that should always be weighed is the
amount of future growth anticipated for the system. Load
calculations can be modified to simulate potential growth,
which will help improve the accuracy of estimating such
expansions. Keeping an eye on this detail will maximize
savings over the life of the system.

The example in Table 2 on Page 3 will best illustrate this calculation

and clarify the decision point, keeping in mind that the financial
savings could be found in the breaker, conductors, equipment,
or any combination of these places.

2 eaton corporation www.eaton.com

UL listed 100%-rated molded  Application Paper AP01200008E
case circuit breakers Effective February 2010

Table 1.  Available 100%-Rated Circuit Breakers

Frames Amperes Minimum Enclosure Size—In (mm) Rating at 480V Trip Units
JG-Frame 250A 26.00 x 18.00 x 8.00 JGE-C, JGS-C, 25 kA, 35 kA, Thermal-magnetic, DigitripE 310+
(660.4 x 457.2 x 203.2 mm) JGH-C, JGC-C 65 kA, 100 kA
K-Frame 125/250/400A 24.00 x 15.00 x 6.00 CKD, CHKD 35 kA, 65 kA Digitrip 310
(609.6 x 381.0 x 152.4 mm)
L-Frame 600A 24.00 x 15.00 x 6.00 CLD, CHLD, CLDC 35 kA, 65 kA, Digitrip 310
(609.6 x 381.0 x 152.4 mm) 100 kA
LG-Frame 600A 28.00 x 19.00 x 8.00 LGE-C, LGS-C, 35 kA, 50 kA, Thermal-magnetic, Digitrip 310+
(711.2 x 482.6 x 203.2 mm) a LGH-C, LGC-C 65 kA, 100 kA 
M-Frame 800A 42.00 x 18.00 x 7.50 CMDL, CHMDL 50 kA, 65 kA Digitrip 310
(1066.8 x 457.2 x 190.5 mm)
N-Frame 800/1200A 42.00 x 22.75 x 11.50 CND, CHND, 50 kA, 65 kA, Digitrip 310, Digitrip OPTIME
(1066.8 x 577.9 x 292.1 mm) b CNDC 100 kA
R-Frame 1600/2000A 21.50 x 18.00 x 13.00 CRD, CRDC 65 kA, 100 kA Digitrip 310, Digitrip OPTIM,
(546.1 x 457.2 x 330.2 mm) bc Digitrip 510/610/810/910
a Thermal-magnetic LG requires venting 7 square inches above and 7 square inches below on the front face of enclosure.
b 100%-rated NG-C and RG-C will be available soon.
c Use with 9-inch (228.6 mm) Tee connector.
d Contact Eaton for 100 kA applications.

Table 2.  Illustrative Example

Selection of either a 100%-rated design or standard design must result from a system analysis beginning with the lowest feeder and concluding with the system’s main device. For this
system example, assume that all assembly testing has been successfully completed and either the 100%-rated design or the standard design can be selected. Each system is hypothetical, and
either approach will meet safety requirements. Loads were arbitrarily selected. The load table includes the calculations for minimum total loads in conformance with NEC Section 210.20(A).
Load Feeder #1 Feeder #2 Feeder #3 Main Description
Noncontinuous 200A 0 600A 1000A Three-phase distribution system
Continuous 400A 800A 0 1000A line diagrams
Standard 80%-Rated Design—Noncontinuous Load + 125% of the Continuous Load = Total Minimum Load See line-diagram 1, below
Calculation per NEC of 200 + (1.25)(400) = 700A 0 + (1.25)(800) = 1000A 600 + 0 = 600A 1000 + (1.25)(1000) = 2250A a
minimum total load a
Breaker frame (F), trip (T) rating 800A (F) d 1200A (F) d 600A (F) 2500A (F) d
700A (T) 1000A (T) 600A (T) 2300A (T)
Bus/cable rating 800A d 1000A 600A 2500A d
100%-Rated Design—Noncontinuous Load + Continuous Load = Total Minimum Load See line-diagram 2, below
Calculation per NEC of 200 + 400 = 600A 0 + 800 = 800A 600 + 0 = 600A 2000A c
minimum total load b
Breaker frame (F), trip (T) rating 600A (F) 800A (F) 600A (F) 2000A (F)
600A (T) 800A (T) 600A (T) 2000A (T)
Bus/cable rating 600A 800A 600A 2000A
a (Noncontinuous Load) + (125%)(Continuous Load) per NEC Section 210.20(A).
b (Noncontinuous Load) + (Continuous Load) per NEC Section 210.20(A) Exception.
c Sum of all NEC calculated minimum feeder loads.
d Nearest standard size, not less than calculated value.

Line-diagram 1 Line-diagram 2

eaton corporation www.eaton.com 3

Application Paper AP01200008E UL listed 100%-rated molded 
Effective February 2010 case circuit breakers

Table 3.  The Results­
Design Minimum Total Load (Amperes)
Standard load 700 1000 600 2250
100%-rated load 600 800 600 2000
Results Economic advantages are achieved by Economic advantages are achieved by Calculations indicate that either The 100% approach results in the same frame
using the 100%-rated design. Savings using the 100%-rated design. Savings approach results in the same size size breaker with a savings in conductor
result from a smaller frame breaker result from a smaller frame breaker breaker and hardware. The final material cost. Eaton offers a 2000A frame
(M-Frame to L-Frame), smaller bus (N-Frame to M-Frame), smaller bus decision could rest on whether or 100%-rated breaker, which is less expensive
requirement, and reduced cable size. requirement, and reduced cable size. not future load growth is anticipated. than the 2500A frame 80%-rated.

With the proper understanding of 100%-rated circuit breakers

and knowledge of a particular application, a simple evaluation
can help point to the right solution. Advantages to a 100%-rated
solution may include lower rated and smaller sized circuit breakers,
less cable, and a potential to reduce equipment floor and wall
space. Additional foresight about future expansion could also weigh
heavily on the final decision. An understanding of all these facts
will help in choosing those components that provide the greatest
economic benefit.

Eaton Corporation
Electrical Sector
1111 Superior Ave.
Cleveland, OH 44114
United States
877-ETN-CARE (877-386-2273)
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Publication No. AP01200008E / Z9441 All other trademarks are property of their
February 2010 respective owners.