FOR A MOTOR, “RATED CURrent” means only a couple of clearly defined numbers: full-load amperes, and locked-rotor amperes. Except under certain transient conditions, those are the only two values of importance to the application. With upstream switching, control, and protection devices, however, it’s not so simple.
A motor is an end-of-the-line energy sink. The only current flowing to it is what results from the applied voltage and motor internal impedance. In contrast, a circuit breaker, fuse, or switch -as well as the conductors themselves-is subjected to whatever a downstream load (or a circuit fault) may demand. Hence, such devices can have several different current ratings depending upon the nature of that load.
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The basic rating is continuous current, the value of amperes intended to flow through the device. (This is sometimes described as “operational current” or “thermal current.”) When we speak of a “100 ampere fuse,” for example, we mean that a load drawing 100 amperes continuous current is the maximum for which that fuse is intended to provide fault protection. How long is “continuous”? “More than three hours,” according to one definition.
Although we tend to think of “inductive” and “resistive” circuits as two separate entities, the distinction is only one of degree. Whether a-c or d-c, all real circuits contain both resistance and inductance. Opening a current-carrying circuit will therefore always result in an arc across the opening contacts. How intense-and therefore how damaging-that arc may be depends upon the relationship between resistance and inductance, expressed by the circuit power factor.
As long as the current (and therefore the arc intensity) does not exceed a design level, a fuse or circuit breaker will snuff out the arc before too much damage is done. Current at that point is the interrupting capability of the device. Sometimes called the breaking current, it will far exceed the basic “continuous current rating.”
It’s often assumed that this is the amount of current that will actually cause the fuse or breaker to open the circuit. That’s not the case. As the National Electrical Code explains, in Article 100, this rating is “The highest current at rated voltage that a device is intended to interrupt under standard test conditions.” Those test conditions are outlined in UL standards. Suppose a voltage source can theoretically supply 50,000 amperes to a short-circuit. The complete circuit including that fault must have an impedance that includes the connecting wire from the power source to the breaker being tested, and that impedance will reduce the actual current the breaker sees during the test to something less than 50,000 amperes. Thus, there may be no contradiction in applying a circuit breaker tested to “only” 40,000 amperes, for example, in a power system capable of supplying 50,000 short-circuit amperes (see Figure 1 for typical relationship).