Mechanical Breaker for 230VDC

3792 Views 19 Replies 11 Participants Last post by carambo46, Feb 7, 2011

Zuglet

Discussion Starter · Nov 25, 2010

I will be increasing my nominal pack voltage from 168VDC to 217VDC.

Currently, I am using an Airpax breaker as the mechanical emergency disconnect -- but it is only rated at 160VDC…
http://store.kta-ev.com/circuit_breakers_fuses_safety_switches/airpax_250amps.aspx

I like having a switch type (purely mechanical) breaker as an emergency disconnect -- but have not been able to find one with the appropriate ratings.

I am aware of the Kilovac contactors -- is there a mechanical type of breaker that will work with my new configuration.

Thanks for any thoughts.

1 - 20 of 20 Posts

dtbaker

· #2 · Nov 26, 2010

Zuglet said:
I will be increasing my nominal pack voltage from 168VDC to 217VDC.

I like having a switch type (purely mechanical) breaker as an emergency disconnect -- but have not been able to find one with the appropriate ratings.

this is right around where a typical photovoltaic array disconnect is rated... try looking on PV sites.

DIYguy

· #3 · Nov 26, 2010

Zuglet said:
I will be increasing my nominal pack voltage from 168VDC to 217VDC.

Currently, I am using an Airpax breaker as the mechanical emergency disconnect -- but it is only rated at 160VDC…
http://store.kta-ev.com/circuit_breakers_fuses_safety_switches/airpax_250amps.aspx

I like having a switch type (purely mechanical) breaker as an emergency disconnect -- but have not been able to find one with the appropriate ratings.

I am aware of the Kilovac contactors -- is there a mechanical type of breaker that will work with my new configuration.

Thanks for any thoughts.

Hey Zug...check out post #118 on my thread. 250 volts DC, adjustable trip limits, cable to remote set/reset and shunt trip...which is a really nice way to wire up the red mushroom button in the cab....

http://www.diyelectriccar.com/forum...mn-here-we-go-23492p12.html?highlight=breaker

Zuglet

Discussion Starter · #4 · Feb 5, 2011

DIYguy said:
Hey Zug...check out post #118 on my thread. 250 volts DC, adjustable trip limits, cable to remote set/reset and shunt trip...which is a really nice way to wire up the red mushroom button in the cab....

http://www.diyelectriccar.com/forum...mn-here-we-go-23492p12.html?highlight=breaker

Thanks for the tip DIYguy.

I found one of these (Cutler-Hammer KDB2400) on eBay and it certainly will do what I asked. I really like that I can break both legs of the battery pack.

What surprised me the most was how big and heavy it is. Since this is going into a car, I was hoping for something smaller and lighter -- but if I can't find anything smaller, I will find a way to make it fit. I know, some people are impossible to please

For comparison, the AirPax breaker is rated at 160VDC @ 250 amps, weighs about 1.75 lbs and measures 7" x 1.5" x 3"

This Cutler-Hammer breaker is rated at 250 VDC and 400 amps. weighs just short of 10 lbs and measures 10" x 5.5" x 3.5" -- it's much bigger in person than it appear in pictures. I've attached a picture of the two for a size comparison.

Thanks again for the suggestion.

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Woodsmith

· #5 · Feb 5, 2011

That's a nice looking breaker.

It looks like the sort of thing that should give a satisfying 'kerdunk' when the lever is flipped.

Where are you going to put it? It's not really pretty enough to be visible.

Zuglet

Discussion Starter · #6 · Feb 5, 2011

Woodsmith said:
It looks like the sort of thing that should give a satisfying 'kerdunk' when the lever is flipped.

Where are you going to put it? It's not really pretty enough to be visible.

It makes quite a 'kedunk' when flipped.

I will put it under the hood near the controller -- not totally sure exactly where it's going to fit.

DIYguy

· #7 · Feb 5, 2011 (Edited)

Hey Juglet,

Mine is actually smaller at 10"x4"x4". Its rated at 250 amps 600VAC/250VDC. Model HMCP2LWS10. still big enough, but narrower than yours. Probably a few pound lighter also. I put mine behind my Soliton and u cant see it unless u look. One other nice thing is the set-able instantaneous trip current limits. Mine has settings A thru I, 9 settings. The lowest one being 1125 amps and highest being 2250 amps. I have mine set on the lowest setting and have tripped it about 4 times...

)) (I'm rather proud of that.... ) lol
U'll love the remote shunt trip also.

It is rather large...but there is no other breaker I've seen at 250VDC. The guys running higher voltage don't typically use a breaker from what I've read.

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2

Roy Von Rogers

· #8 · Feb 5, 2011

Take a look here...........

http://www.filnor.com/tech/literature/knifeswitch/Knife-Switch-Catalog-Full.pdf

Roy

Woodsmith

· #9 · Feb 5, 2011

Roy Von Rogers said:
Take a look here...........

http://www.filnor.com/tech/literature/knifeswitch/Knife-Switch-Catalog-Full.pdf

Roy

That is just what I am looking for to make my 'steampunk' reversing switch.

coryrc

· #10 · Feb 5, 2011

dtbaker said:
this is right around where a typical photovoltaic array disconnect is rated... try looking on PV sites.

Be wary of the peak break current, as PV panels don't have high short-circuit currents, unlike batteries.

PhantomPholly

· #11 · Feb 5, 2011

Zuglet said:
It makes quite a 'kedunk' when flipped.

I will put it under the hood near the controller -- not totally sure exactly where it's going to fit.

Maybe not a bad idea to have it automatically trip any time you pop the hood as a safety feature? That way you could just have the hood pop cable in series with the breaker - first detent, breaker; second detent, hood. That would preclude the necessity for a new and possibly ugly lever inside the cabin.

DIYguy

· #12 · Feb 5, 2011

PhantomPholly said:
Maybe not a bad idea to have it automatically trip any time you pop the hood as a safety feature? That way you could just have the hood pop cable in series with the breaker - first detent, breaker; second detent, hood. That would preclude the necessity for a new and possibly ugly lever inside the cabin.

Not too handy for working on stuff.
I did hook up the lever and mounted it under the hood. It has a lockout hasp which is nice. It has remote shunt trip so, you connect this to a mushroom button inside the cabin. That's it.

Woodsmith

· #13 · Feb 6, 2011

DIYguy said:
Not too handy for working on stuff.
I did hook up the lever and mounted it under the hood. It has a lockout hasp which is nice. It has remote shunt trip so, you connect this to a mushroom button inside the cabin. That's it.

But it would be safe.
You could still reset the trip after the hood is propped open if you needed to power up.

PhantomPholly

· #14 · Feb 6, 2011

Woodsmith said:
But it would be safe.
You could still reset the trip after the hood is propped open if you needed to power up.

Yes - that is what I was trying to say. Most hood releases are spring-loaded, so once you let go of the lever you could re-set the breaker if you actually intended to have full power available.

jackbauer

· #15 · Feb 6, 2011

Any sources for these breakers? Only one on ebay i could find was 1500usd

DIYguy

· #16 · Feb 6, 2011

jackbauer said:
Any sources for these breakers? Only one on ebay i could find was 1500usd

Yes, they aren't cheap. Look for any place that has used automation for factories, particularly spot welding panels. I guess, u don't have much in the way of manufacturing there any more though eh? Isn't it becoming the IT capital of the world or something>? I have another one...but I don't really want to part with it..

As for the hood switch... for sure, it would work and be safe, yup. All depends what u like. You would just have to have a way to reset the switch.

jackbauer

· #17 · Feb 6, 2011

I'll keep my eyes open. More like the bankrupcy capital of the world

toddshotrods

· #18 · Feb 6, 2011 (Edited)

Me likey those Filnor contraptions!

Weisheimer

· #19 · Feb 7, 2011

jackbauer said:
Any sources for these breakers? Only one on ebay i could find was 1500usd

I don't think that this one has the remote trip feature, but otherwise is similar.

http://cgi.ebay.com/GE-Industrial-C...uit_Breakers_Transformers&hash=item2c563029a9

carambo46

· #20 · Feb 7, 2011

http://cgi.ebay.com/Cutler-Hammer-D...uit_Breakers_Transformers&hash=item483df34655

http://cgi.ebay.com/Westinghouse-40...uit_Breakers_Transformers&hash=item588bff8d49

I beleive cutler hammer and Westinghouse are the same.

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