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Hi! Im going to be as brief as possible in this question. Im currently trying to design a portable breaker testing device that has a very simple mechanism. Basically, this device must be very small and should be able to fit into something like this:http://goo.gl/BuZ6U When I insert this device the amperage would probably shoot up to around 400-500 amps albeit for a split second before the breaker trips. However, this is probably enough to melt copper and maybe even iron. I want to known what type of switch i have to use to withstand the extraordinarily high current caused by an intentionally short circuit. Im going to install a rc delay module into this device as well so that when i press the switch it will cause a 2-3 second delay before the solenoid/relay activates. So what switch/relay should I use? Additionally, what types of wires should I use? A copper wire surely would not be strong enough to withstand such high temperatures and pressure cause by a short circuit. What materials should I use instead? Also, what substance should I use to coat the area around the wires to prevent the case from melting? I willing to speed a maximum of 500 dollars which should be more than enough to purchase some rare/expensive materials suitable for my purpose since I will using a very small amount of it. I estimate that the temperature would probably heat up to around 500-700 Celsius for a fraction of a second when in use. Thanks.
And got the following answer:
The current rating of a switch or relay is limited by the surge that would be caused when the relay closes (and bounces), or opens. Ideally, on your prototype, you would design a circuit to make sure that the relay kicked in very near the zero crossing of the AC, to minimize current. If you have a product in mind, I have doubts about ever getting UL or other approval in such a small package, but never know. I think copper can withstand the surge, especially if you use a heavy gauge. Take a cue from heating devices like toasters, and you will see that they use fiberglass insulation on the wires near heat, and spot-weld instead of solder. If you get tired of this project, you could always just use two portable hair dryers plugged into the same outlet.
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