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paper: 120A Main Breaker Thermal Analysis
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120A Main Breaker Thermal Analysis by Ryan_Todd 
#2




Re: paper: 120A Main Breaker Thermal Analysis
First of all this paper was extremely helpful in building an accurate (I hope) breaker model (more on this in a sec). Thanks so much.
I think found a minor mistake in your paper, if you look at You'll see that you substituted 8 for C when it should be .08. Thus, your figure for specific heat is off by a factor of 100. 0.002716 degC / Joule is what you reported, .2716 is correct. This error cancels out because the only place you use it is in C*c*t. As C is 100x too high and c is 100x too low they cancel. So is correct. This mattered for me because I was using purely the differential equation with numerical integration and I put in the correct value for C. Again another minor flaw. I think your math around the benefits of precooling the breaker is slightly flawed. You don't take into account the thermal mass of the surrounding housing which would also be substantially cooled effectively modifying the ambient temperature. Thus, if the housing was cooled and potentially the metal the breaker was attached too, it is possible that the benefits could be slightly higher than you state. Maybe, (based on some napkin math) instead of lasting .4 additional seconds longer it lasts 1.4 additional seconds. Thanks for the help. 
#3




Re: paper: 120A Main Breaker Thermal Analysis
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That was left over from the original calculations, and it had an even bigger impact on the final result than you described. Because the factorof100 difference was in an exponent, it threw off everything else completely! This prompted me to go back and triplecheck all my sources and calculations, and I found another issue with my FahrenheittoKelvin conversion at the start of the paper as well. (d'oh!) Long story short: I posted an update (rev.1) with all the latest corrections. Quote:
My analysis is limited by what information I could glean from the internet, and it would be invaluable to (for example) bring in a proper CAD model and run some finite element (or even CFD) simulations and get some more useful data about the different paths that the heat can take in this system. If anyone wants to take this analysis further, I'd love to see the result! 
#4




Re: paper: 120A Main Breaker Thermal Analysis
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You would also want to ask how much variation in the trip point one can expect to see over different production batches and if there are any other effects on the trip point such as aging. This will determine how close to a calculated trip point you can push your application. Last edited by philso : 12072017 at 12:45 AM. 
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