Module 06
Module 06
Components
Frame
Operating Mechanism
Trip Unit
Trip Intelligence
Arc Extinguisher
4
5
5
5
6
7
7
7
9
9
10
11
Review 1
12
Ratings
Ratings and Standards Vary
Maximum Voltage
Continuous Current
13
13
14
14
14
14
15
15
16
Standards
18
19
19
19
Review 2
20
Glossary
21
Review 1 Answers
24
Review 2 Answers
24
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Like the other modules in this series, this one presents small, manageable sections of new material followed by a series of questions about that material. Study
the material carefully, then answer the questions without referring back to what
youve just read.
You are the best judge of how well you grasp the material. Review the material as
often as you think necessary. The most important thing is establishing a solid
foundation to build on as you move from topic to topic and module to module.
A Note on Font Styles
Printed versions have the glossary at the end of the module. You may also browse
the Glossary by clicking on the Glossary bookmark in the left-hand margin.
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To understand where the medium voltage power circuit breaker fits into the
scheme of things, you need to understand the basics of power distribution in an
industrial environment.
An industrial distribution system consists of:
protective devices
conductors
transformers
Power may be distributed through various Switchgear and Switchboards, transformers and Panelboards. The medium voltage power circuit breaker is found in
switchgear assembly. A switchgear assembly controls electric power circuits.
Figure 2. Typical Industrial Power Distribution
The Circuit Breaker is the main device the heart of the switchgear. It provides centralized control and protection of medium voltage power equipment and
circuits. Its operation covers load switching, control and fault protection for generators, motors, transformers, capacitors and all types of feeder circuits.
This type of power equipment is normally found in industrial, commercial
and electric utility installations. Typical applications include electric utility systems, industrial distribution systems, commercial buildings, municipal pumping
stations, and transportation systems.
Components
There are four main parts to a medium voltage power circuit breaker. These are:
Frame
Operating Mechanism
Trip Unit
Arc Extinguisher
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Frame
Operating Mechanism
The medium voltage power circuit breaker uses a stored-energy Operating Mechanism to open the circuit breaker. It has a motor-charged, spring-type, storedenergy closing mechanism. Closing the breaker charges the accelerating springs.
Protective relays on the control switch energize a shunt trip coil to release the
accelerating springs and open the breaker.
This is a trip-free design truly mechanically and electrically trip free. Breaker
contacts will not touch or close onto a fault, even when a mechanical or electrical
close command is issued.
The manual controls are usually accessed from the front of the circuit breaker.
Although medium voltage power circuit breakers are electrically operated, the
closing springs can be charged manually.
For more on operating mechanisms, see Module 5, Fundamentals of Circuit
Breakers.
Trip Unit
A Trip Unit is typically integral to a circuit breaker. But, the medium voltage
power circuit breaker uses externally mounted trip units to provide the operational intelligence. These devices are called Protective Relays.
The protective relays are normally wired to the circuit breaker and Current Transformers. They are mounted on a panel or door of the switchgear assembly. They
function to detect a defective line or apparatus, as well as dangerous or undesirable system conditions. The relay energizes the trip coil of the circuit breaker to
clear a fault.
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Trip Intelligence
The protective relay intelligence devices fall into two broad categories. These are:
ElectromagneticThe electromagnetic protective relay has been used widely in
the industry for many years, with a high degree of success. It functions to tell
the circuit breaker when to operate, based on the specific relay type selected.
Many different types of electromagnetic protective relays are available, and each
type performs rather specific functions.
Common relay types include: instantaneous overcurrent, time overcurrent
and overvoltage. Because these devices are limited in scope, a number of different relays (each with different protective capabilities) must be used to provide a
comprehensive protective package.
Microprocessor-BasedThe microprocessor-based protective relay is a
multi-function device. It can provide all the features of several electromagnetic
relays in one box. It is also easier to mount and wire. Overall, it is a smaller investment than an electromagnetic protective relay solution.
Figure 5. Typical Medium Voltage Switchgear Assembly with
Microprocessor-Based Devices Shown Mounted
In most cases, only one device is required for each three-phase circuit, not
one device for each phase. One of the more sophisticated microprocessorbased protective relays is capable of replacing the normal complement of three or
four electromagnetic relays, as well as a number of associated meters and
switches (Figure 6).
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Because these are individual devices, apart from the medium voltage circuit
breaker itself, there will be no further discussion of the tripping intelligence in this
module.
Arc Extinguisher
The Arc Extinguisher extinguishes the Arc produced when the contacts are
pulled apart to interrupt current flow. The higher the voltage, the harder it is to
interrupt the flow of current.
There are a number of arc extinguishing technologies in use today. We will look at
the most prominent types in the next section.
Arc Extinguishing
Technologies
In a low voltage circuit breaker, using air or Arc Chutes is sufficient to extinguish
an arc. In the medium voltage range, a different technology needs to be used. The
main technology used today is the Vacuum Interrupter.
Vacuum Interrupter
Technology
Basically, the vacuum interrupter is a pair of separable contacts (called primary contacts) enclosed in a vacuum-tight envelope. The Envelope itself is a
ceramic material, with a metal end plate brazed to each end. The metal plates
seal the ends and provide support for the parts inside.
Of the two contacts (also called electrodes) inside, one is fixed. The other is
movable, through a bellows-type connection. Various shields inside the envelope
provide different types of protection to interrupter parts.
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When the circuit breaker is closed, the contacts within the interrupter touch, allowing current to flow.
When a fault occurs and interruption is required, the contacts are quickly
separated and an arc forms. An arc is formed because the voltage tries to keep
the current moving.
Figure 9. Enclosing Contacts in a Vacuum
The arc burns in the metal vapor evaporated from hot spots on the contact surfaces. This metal vapor continuously leaves the contact region and recondenses
on the contact surfaces and surrounding metal shield, which protects the ceramic
envelope.
At Current Zero, the arc extinguishes, contact vapor production stops, and the
original vacuum condition is restored. Current zero is a point in the AC current
sine wave where the value is zero.
Figure 10. Current Zero Points in an AC Cycle
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Spiral Contacts
Page 9
In short, this arc interruption technology results the in arc energy being used and
absorbed, while the arc is simultaneously cooled.
There are several SF6 interrupter designs, but only two types will be covered
here:
Puffer
Rotary Arc
The puffer-type of SF6 interrupter is the older of the two SF6 technologies. It is
more capable but more complicated than the rotary arc-type.
The interrupter is shown below in the closed position, and in the opening
sequence.
Figure 14. Typical SF6 Puffer Interrupter in Closed Position
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Rotary arc SF6 technology is less complicated in design than the puffer
type. It has fewer parts and does not require such a high-energy operating mechanism. However, it is not effective over as wide a range of short circuit currents
and voltages as the SF6 puffer or vacuum. Suitable applications are somewhat
limited.
Figure 16 shows a typical SF6 rotary arc interrupter.
Figure 16. Cross-Sectional View of Typical SF6 Rotary Arc Interrupter
As the contacts part, the arc transfers from the main contacts to an annular contact. This causes the current to switch into the coil behind it. The coils magnetic
field, produced by the load current itself, causes the arc to rotate rapidly.
The arc is cooled by moving through the SF6 gas.
The SF6 gas is normally at rest inside this interrupter. The arcs movement acts
like a mixer, mixing hotter and cooler gas. This helps cool the arc. Contact erosion is also reduced due to this rapid arc movement.
As current zero is approached, the dwindling arc must sustain enough speed to
be lost in the SF6 environment in order to withstand the transient recovery voltage.
(This is mentioned because the magnetic field produced by the load current
causes the all important arc rotation. As the current decreases, the magnetic field
decreases, and the arc rotation slows.)
At current zero, the arc is cooled and extinguished.
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Answer the following questions without referring to the material just presented.
Begin the next section when you are confident that you understand what youve
already read.
1. The ________ ________ is the heart of the switchgear.
2. There are four main parts to a medium voltage power circuit breaker. These
are:
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
3. A microprocessor-based trip intelligence is superior to an electromagneticbased trip intelligence. In your own words, explain why.
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
4. Vacuum interrupters for circuit breaker duty must be capable of interrupting
currents of ___ to ___ kA (and up), at voltages up to ___ kV.
5. SF6 arc extinguishing technology is popular outside the United States. The
two mostly commonly used types are __________ and __________
__________.
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Medium voltage power circuit breaker ratings vary in different parts of the
world. As a matter of fact, medium voltage is not uniformly defined around the
world. Although the standard we are using in this training module defines medium
voltage as 1000 volts to 72.5 kV (a commonly accepted medium voltage range in
the United States, as well as other parts of the world), one foreign country considers 1000 volts and above to be high voltage.
Medium voltage power circuit breaker ratings charts specify many different
types of ratings. Usually, a chart indicates the ratings required by the governing
standards where the circuit breaker is applied.
ANSI or IEC is normally the governing standard for medium voltage power circuit
breakers. ANSI is associated with U.S. standards, and IEC is associated with
international standards. However, neither the standards nor the ratings charts are
identical. Charts also vary from manufacturer to manufacturer (Figures 17 and
18). To give an idea of the differences, consider the following example.
Figure 17. Partial Sample of a Medium Voltage ANSI Ratings Chart
Breaker Type
Medium Voltage
(kA rms)
270VCP-W750
27
270VCP-W1000
27
270VCP-W1250
27
Continuous
Current (Amps)
600
1200
2000
600
1200
2000
600
1200
2000
Short Circuit
Current (kA rms)
16
22
25
Voltage Class
(kA rms)
Breaker Type
240VCP-W16
24
240VCP-W20
24
240VCP-W25
24
Normal Current
(Amps)
630
1250
2000
630
1250
2000
630
1250
2000
Short Circuit
Current (kA rms)
16
20
25
All of the indicated ratings are important. A number of them are merely calculations. For the sake of this discussion, we will cover only three of them.
These are:
Maximum Voltage
Continuous Current
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These three ratings are common to both ANSI- and IEC-rated circuit breakers. In
most instances, a grasp of these three ratings will allow you to assist a customer
with a medium voltage power circuit breaker selection.
Maximum Voltage
This is the maximum voltage at which the breaker can operate. It is termed
Maximum Voltage on ANSI charts and Voltage Class on IEC charts. The operating
voltage where the circuit breaker is applied should not exceed the circuit breakers
rated maximum voltage.
Typical maximum voltage ratings encountered with ANSI applications are: 4.76,
8.25, 15, 27 and 38 kV. Typical voltage classes encountered with IEC applications
are: 3.6, 7.2, 12, 17.5 and 24 kV.
Continuous Current
This is the level of three-phase short circuit current that the circuit breaker
can safely interrupt. The Short Circuit Current is a rating at the circuit breakers
maximum voltage (ANSI) or voltage class (IEC).
Typical short circuit currents encountered with ANSI applications are: 16, 29, 33,
37 and 63 kA. Typical short circuit currents encountered with IEC applications are:
16, 25, 31.5, and 40 kA.
Enclosure and
Mounting
Enclosure
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Mounting
Fixed Mount
There are two methods for mounting a circuit breaker in the switchgear. These
are:
Fixed Mount
Drawout Mount
Fixed Mount circuit breakers are usually found in outdoor applications. When
installed outdoors, a special type of housing must be provided to protect the
equipment from the elements. This outdoor protection is provided in a number of
ways.
Fixed medium voltage power circuit breaker designs exist for a limited range of
applications and voltages.
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The Drawout Mount (or removable) type is by far the most common medium
voltage power circuit breaker in use. It is used almost exclusively through 38 kV.
Prior to the introduction of vacuum designs, medium voltage power circuit breakers were much larger (Figure 21). For example, one vertical structure could
accommodate one Magnetic Air Type Circuit Breaker. The circuit breaker was
removable, typically rolled out of the structure on wheels.
Figure 21. Typical Medium Voltage Magnetic Air Circuit Breaker (Front Barrier Removed)
Today, medium voltage power circuit breakers are frequently small enough to be
stacked two units high in one vertical compartment.
The circuit breaker has three positions: DISCONNECT, TEST and CONNECT.
Normally, the circuit breaker is manually pushed to the TEST position, then
mechanically levered between the TEST and CONNECT positions (Figure 22).
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If the circuit breaker must be lifted from the extension rails onto the floor, integral
wheels permit it to be rolled around outside of its structure.
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The testing required and the standards that must be met by a medium voltage power circuit breaker depend on the area of the world where the circuit
breaker is applied.
A medium voltage power circuit breaker must meet the requirements of ANSI,
IEC, IEEE and NEMA to be considered world-class (Figure 24).
Figure 24. Dominant Worldwide Standards
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Now you should be ready to assist a customer in matching a product to an application. When you meet with the customer, conduct a short interview to obtain
information in these two areas:
Before you can select a specific circuit breaker, get the following information from
the customer:
This information alone should be enough to allow you to select an appropriate circuit breaker. However, the more information you have, the better.
Configuration and
Accessory Details
It is also important to know how the circuit breaker is to be configured. Ask the
customer these three questions:
Will circuit breakers be stacked two to a vertical structure, or mounted one per
structure?
Medium voltage circuit breakers do not normally have a large number of accessory items. However, you should make yourself aware of anything additional the
customer expects.
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Answer the following questions without referring to the material just presented.
1. For each rating type, identify it as being ANSI, IEC, or both.
Normal Current __________
Short Circuit Current __________
Maximum Voltage __________
2. In your own words, explain the difference between a metal-clad assembly and
a metal enclosed assembly.
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
3. There are two methods for mounting a circuit breaker in the switchgear.
These are:
____________________________________________________________
____________________________________________________________
4. A medium voltage power circuit breaker must meet the requirements of
______, ______, ______ and ______ in order to be considered world-class.
5. There are seven main questions to ask a customer when attempting to match
a product to an application. Name three of them.
____________________________________________________________
____________________________________________________________
____________________________________________________________
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Arc
Arc Chute
Arc Extinguisher
Circuit Breaker
Continuous Current
Current Transformer
Current Zero
Dielectric
Dielectric Strength
Drawout Mount
Envelope
Fixed Mount
Frame
IEC
IEEE
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Medium Voltage
A specific type of circuit breaker, used in a switchgear
Power Circuit Breaker assembly, with a voltage range of 1000 volts to 38 kV.
Metal-Clad Assembly Equipment in the assembly is enclosed, and separated
by metal barriers into individual compartments. Typically
associated with medium voltage equipment.
Metal-Enclosed
Assembly
NEMA
Normal Current
Operating
Mechanism
Panelboard
Protective Relay
SF6
Short Circuit Current A rating of the level of three-phase short circuit current
that the circuit breaker can safely interrupt. The short
circuit current is a rating at the circuit breakers
maximum voltage (ANSI) or voltage class (IEC).
Switchboard
Switchgear
Transient Recovery
Voltage
Trip Unit
UL
Page 22
Voltage Class
Page 23
1. Circuit breaker
2. Frame
Operating Mechanism
Trip Unit
Arc Extinguisher
3. Answer should basically say: The microprocessor-based protective relay is a
multi-function device. It can provide all the features of several electromagnetic
relays in one box. It is also easier to mount and wire. Overall, it is a smaller
investment than an electromagnetic protective relay solution.
4. 12, 50, 38
5. Puffer, Rotary Arc
Review 2 Answers
1. IEC
Both
ANSI
2. Answer should basically say: A metal-clad assembly has internal compartments which are separated by metal barriers. A metal enclosed assembly
does not necessarily have internal separation barriers
3. Fixed mount, Drawout mount
4. ANSI, IEC, IEEE and NEMA
5. Any three of the following:
Which set of standards (ANSI or IEC) apply to the circuit breaker?
What maximum voltage (ANSI) or voltage class (IEC) is required?
What continuous current (ANSI) or normal current (IEC) is required?
What short circuit current is required?
Will the circuit breaker be drawout or fix mounted?
Will the circuit breaker be used indoors or outdoors?
Will circuit breakers be stacked two to a vertical structure, or mounted one per
structure?
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