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INFRARED WINDOWS APPLIED IN SWITCHGEAR ASSEMBLIES:

TAKING ANOTHER LOOK
David B. Durocher David Loucks
Senior Member, IEEE Senior Member, IEEE
Eaton Corporation Eaton Corporation
26850 SW Kinsman Road 1000 Cherrington Parkway
Wilsonville, OR 97070 USA Coraopolis, PA 15108
[email protected] [email protected]

Abstract - Maintenance of electrical power distribution

assemblies applied in industry has been critical in
assuring facility uptime and reliability. One important
metric in assuring reliability is electrical terminations of
energized conductors. During normal energized service,
terminations both at conductor bus joints and at cable
terminations are subject over time to thermal expansion
and contraction, ultimately resulting in loosened
connections and excessive heat. Deteriorating
terminations left unchecked will ultimately fail, resulting
in electrical hazards for personnel and also costly loss of
production. Infrared (IR) inspection has proved to be an Fig. 1: The thermal image at left shows an elevated temperature
excellent maintenance method used to identifying and possible loose connection at the Phase A line terminal of the
problems with loose electrical terminations. However, the circuit breaker
design of Internal Arc Classified (IAC) switchgear
assemblies to address arc-flash concerns has changed one illustrated above. Fig. 2 shows a plant thermographer
assembly designs that now limiting line of sight access conducting a routine thermal scan using a hand-held camera,
necessary for IR inspection via windows. This paper will in this case inspecting a low-voltage motor control center unit
discuss global Standards, how they affect switchgear with the door open. This method although effective, can
designs and application of IR windows, then present present some risks to the person conducting the infrared (IR)
some alternative technologies that in some applications scan. The emerging understanding of arc-flash hazards of
may be more suitable. energized electrical systems has changed the way
maintenance personnel perform IR scanning of electrical
Index Terms – Thermal Imaging, Infrared Camera, IR systems. New globally accepted and applied standards such
Windows, Arc-Resistant Switchgear, Thermal Sensors. as IEEE Standard 1584 “Guide for Performing Arc-Flash
Hazard Calculations” [2] now have clearly defined the hazards
I. INTRODUCTION associated with working on or around energized conductors.
Application of this Standard includes calculations that
Infrared inspection has proved to be an excellent determine the magnitude of incident or potential heat energy
maintenance method used to identifying problems with loose should an arc flash event occur.
electrical terminations. As shown in Fig. 1, an infrared camera
can effectively survey energized systems and provide a
thermal image that identifies a potential problem, in this case
a loose terminal at the line side of the molded case circuit
breaker at Phase A. This method can be used to pinpoint a
potential problem and remedy this issue before a hot spot
becomes an equipment failure.
Many industrial manufacturing facilities have effectively
used infrared scanning of both medium-voltage and low-
voltage switchgear and motor control assemblies as a means
of predictive maintenance. Thermal imaging for electrical
systems will be performed on a rotational basis for the entire
facility and maintenance outages are scheduled on an as-
needed basis only after an electrical problem has been
identified. Some industry standards including IEEE Standard
1458 “Recommended Practice for the Selection, Field Testing,
and Life Expectancy of Molded Case Circuit Breakers for
Industrial Applications” [1] actually recommends the use of
infrared scanning as a means to detect issues such as the Fig. 2: Thermographer conducting an IR scan of a low-voltage
motor control center unit with the unit door open.

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The thermal energy calculation is performed for each point critical levels within just a few weeks or even days. Scheduled
of the electrical system and this energy is measured in thermal imaging using equipment mounted IR windows on an
calories per centimeter squared (cal/cm2). A safe working annual basis leaves the facility vulnerable to changes that
distance referred to as the Flash Protection Boundary is occur between scheduled IR surveys. Another issue centers
defined and working inside of this calculated distance required on the switchgear assemblies themselves. Changes in global
that the IR camera operator wear appropriate Personal standards for both power distribution and motor control
Protective Equipment (PPE). So referring back to the image in assemblies has resulted in design requirements for both
Fig. 2, if the thermographer is standing outside of the Flash medium-voltage and low-voltage systems that are “arc
Protection Boundary, then conducting the thermal scan is resistant” rated or tested for arc containment. In North
considered a low-risk activity. In higher voltage systems, and American markets, this typically means the switchgear
low-voltage systems that are becoming ever larger, often manufacturer tests to a special American National Standard
times the Flash Protection Boundary is ten meters or more Institute ANSI C37.20.7 Standard for Arc-Resistant
from the energized conductor. Simply opening a door or Switchgear [4]. Similarly, for International Electro Technical
removing a cover from energized equipment presents a risk to Commission IEC assemblies markets, this means the
the worker. assemblies are designed and tested for arc containment,
either IEC Standard 62271-200 for medium-voltage
II. REVIEW OF INFRARED W INDOWS switchgear assemblies [5], or IEC Standard 61439-1 [6]
coupled with IEC Standard 61641 [7] criteria 1 through 7 for
To solve these issues, several manufacturers have low-voltage assemblies.
introduced IR Windows. As shown in Fig. 3, there are two Fig. 4 shows the image of these assemblies, medium-
basic configurations of IR window media, crystal optics and voltage switchgear tested to IEC Standard 62271-200,
polymer/mesh optics. Crystal optics employs a broadband including details on the unique construction. Note from the
media which allows thermal infrared inspection. assembly side view in Fig. 4 that the switchgear design is
Polymer/mesh IR windows include a metal or plastic grid work “compartmentalized” meaning that the low-voltage control
this is only suitable for qualitative non-measurement based section, the breaker compartment, main bus compartment and
thermography. Both media are supplied with a protective cable compartment are all separated by steel barriers. This is
cover, designed to shield the crystal or polymer/mesh from necessary as the IEC arc containment test standard requires
impact. The two designs offer different performance that initiation of an arc in one section while the equipment is
characteristics in measuring thermal energy via non-contact energized cannot propagate to another section. The entire
imaging. Introduction of the window media between the target
and the camera introduces some error, as the total energy
measured is that which is transmitted and reflected from the Arc Plenum
target plus the energy emitted from the media itself. This is
discussed further in [3].

Bus
Compartment

Breaker
Compartment

Fig. 3: Two different types of infrared windows including crystal

optic at left and polymer/mesh at right.
CT’s

Problem solved? Well in many cases, this is in fact a valid

approach. As a result, many engineers now specify addition of
IR windows as a requirement for both low-voltage and
VT’s Cable
medium-voltage switchgear assemblies. However, there are Compartment
some technical considerations that need to be reviewed and
addressed. In a few instances, evolution of switchgear
assemblies tested to the latest Standards may be rendering
this “new” IR window approach obsolete.

III. LOOKING A LITTLE CLOSER

One recognized limitation of IR windows and periodic
thermal scanning is the intermittent nature of his maintenance Fig. 4: Typical internal arc classified MV IEC switchgear assembly.
discipline. Although hot spots at electrical terminations Each section is compartmentalized leaving few locations where IR
typically change gradually over time, some can elevate to windows could be effectively applied.

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assembly is designed to direct the arc-flash blast energy from One additional consideration is concerning the protective
the compartment where it is initiated up into the arc plenum cover for the IR window. The cover is designed to protect the
mounted at the top of the enclosure, above the height of crystal optics or polymer/mesh element and is closed and
persons near the assembly. With this arc rated design, there secured during the switchgear assembly arc testing. Of
are really no reasonable places that an IR window could be course, thermal inspection with and infrared camera requires
mounted in order to inspect live conductors. Perhaps an IR that the cover be removed or opened. Since the arc testing is
window could be installed in the lower front of this section to only conducted with the cover installed, there is really no way
inspect the outgoing cable terminations, but in this case, the to verify that the integrity of the IR window crystal or
optional VT drawer restricts the line of sight necessary for polymer/mesh will survive an arc event with the cover
inspection with an IR camera leaving no practical way to scan removed. Following completion of an arc flash hazard
these load cable terminations. A window could also be assessment, what would the calculated incident energy be at
mounted at the lower rear for visible access to cable this electrical point in the system with the cover open or
terminations, but this assembly is designed to be mounted removed? What personal protection equipment would the
against the wall. There also is no reasonable place to locate thermographer wear during inspection with the camera to
IR windows for visible access to the breaker or main bus assure safety from an arc flash event?
compartments. The low-voltage assemblies are similar as are While taking a closer look at IR window application, let’s
the IEEE/ANSI assemblies applied across North America and also consider some issues around application of IR windows
arc containment tested to IEEE/ANSI C37.20.7. in existing panels. Here, the user must also carefully consider
Another concern is the integrity of the IR window mounted some technical areas of concern. IR windows installed as a
in an arc rated switchgear assembly. In order to offer retrofit in an existing arc classified or arc tested panel have
switchgear assemblies that are certified and tested to arc obviously not been subjected to the testing criteria defined by
rated standard, the manufacturer is required to conduct an the standards for that existing panel. Users can install IR
arsenal of tests that assure an arc flash event will be windows in existing equipment that will function well as a
successfully redirected away from the enclosure front, rear predictive diagnostic tool for thermal imaging; however this
and sides and channeled to the top-mounted plenum. These will likely compromise the arc rating of the assembly. In some
tests include initiating an arc flash event in each compartment, cases, IR window manufacturers will offer test data to prove
resulting in extreme temperatures and pressures. The test the component has “survived” and arc flash event as defined
standard requires that pressure and heat from the arc be by the test standard. This must be validated to show testing
channeled 2 meters above floor level, up and out the top of was performed in the specific panel and mounting location
the enclosure, away from persons standing around the where it is proposed to be installed. It is often impossible to
perimeter of the assembly. If IR windows are to be applied in prove such testing, unless the IR window supplier has worked
the assembly, it is incumbent on the switchgear manufacturer directing with the switchgear manufacturer when the defined
to conduct arc tests with these mounted on the assembly battery of tests was performed. For assemblies that are not
during the tests. Therefore, it is important when specifying IR arc resistant or internal arc classified, there is generally not an
windows in switchgear assemblies that the user verifies arc application problem with IR windows. Test requirements for
testing has been performed with IR windows installed. these assemblies focus on interrupting and withstand ratings
Reputable switchgear manufacturers will publish IR window that are typically not associated with the enclosure structural
make and model numbers that have successfully passed type integrity during the interruption of an arc fault.
testing. Fig. 5 shows the results on one arc test where the
crystal optic failed after an arc was initiated in the panel. In IV. ALTERNATIVE TECHNOLOGIES IN THERMAL IMAGING
this case, the protective cover was closed during the test, but
the crystal was shattered due to the extreme pressure and Most certainly, IR windows offer unique advantages in
heat. thermal imaging. In an environment where there is increased
knowledge and awareness of arc flash hazards, IR windows
offer a true advantage in assuring a thermographer is not
exposed to energized conductors while conducting a thermal
survey. That said, there are some applications where IR
windows have limitations and alternatives should be
considered.
Most low-voltage motor control center assemblies include
multiple starter modules in each panel. The individual
modules typically include an incoming overcurrent protective
device (fuse or circuit breaker), a motor contactor and
protective relay, a control power transformer and other various
other electrical components. Each module is separated from
the other by steel barriers and includes a front mounted
hinged door. Referring to Fig. 2 as an example, a thermal
survey of this subassembly requires inspection of line and
load power terminations at up to fifteen electrical points (3-
phases of the protective device and motor starter line & load,
plus 3-phases a the motor load terminals). Although the field
of view for IR windows would allow for inspection of multiple
Fig. 5: IR window failure occurring during an arc test of a MV motor
control center incoming line compartment.

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terminations using a single window, several windows would can be set should temperatures exceed pre-set critical levels.
be needed for each starter module. It is easy to see due to These miniature infrared thermal sensors are commercially
both space and cost that choosing an IR window here would available and typically are offered at a slightly higher price
not be practical. Most industrial users conduct this type of point than their IR window counterparts. Because the IR
inspection with the unit door open. Depending on the sensor component has a very narrow field of view, one sensor
connected system, maintenance personnel may need to wear is required for each bus connection that is to be thermally
appropriate PPE while opening the unit door with the circuit interrogated. So, unlike IR windows where one device can
energized. However, thermal imaging can be safely performed often be mounted on an exterior panel in a location where
without PPE if the thermographer is some distance way, multiple phases are in the field of view, a single IR sensor
outside of a zone referred to as the arc flash protection device is required for each phase conductor. All the same,
boundary. In this application, the author recommends there are advantages when applied to interrogate temperature
additional protection through the use of an upstream incoming of bus joints that are not easily accessible using an external
circuit breaker with an arc flash reduction maintenance setting camera to record a thermal image via and IR window. The IR
[8], similar to would be applied when electricians are sensor can be mounted virtually anywhere in the assembly
performing energized work such as testing or troubleshooting. and unlike IR windows, it does not require mounting on an
Arc rated low-voltage and medium-voltage switchgear external cover so testing as a part of the assembly arc
assemblies also present a challenge for application of IR certification is not an issue (albeit the device would likely be
windows as discussed in previous sections. The balance of destroyed during an arc event that occurred in close
this paper will focus on three alternative thermal measurement proximity).
technologies which may be better suited, in light of these
limitations.
A. Thermal Monitoring via Infrared Sensors
One technology that looks promising which addresses
some of the IR window issues for arc rated assemblies
discussed previously is a miniature infrared thermal sensor as
shown in Fig. 6. Note that this device mounts inside the
switchgear assembly and can be positioned within the various
compartments, eliminating the line of sight requirement
necessary for an infrared camera inspection through an IR
window. The sensor can be focused on bus joints and
terminations that are likely to present the most problems. A
companion thermal monitoring device shown in Fig. 7 is
designed specifically for sensing of cable temperature for
terminations at terminals, bus bars or circuit breakers. Both
devices are self-powered and produce a millivolt output
proportional to temperature rise over ambient. The device
twisted-pair cable millivolt output signal connects directly to a
data card which converts the millivolt signal to Modbus RS485
where the information can be connected to a network. Real-
time temperature data can then be monitored from a local
personal computer using the manufacturer’s standard
software or connected to a host supervisory system such as a Fig. 7: A sensor with a millivolt output is used for temperature
detection of cable terminations.
SCADA or DCS. With the advent of 24 X 7 X 365 monitoring
in lieu of periodic scheduled inspection via an infrared
camera, temperature data can be trended and system alarms There are some challenges when applying the IR sensor
or cable sensor millivolt devices in existing panels. As
previously discussed, assemblies designed and tested to arc
classified standards have compartmentalized sections, so
adding sensors to areas such as the main bus compartment
would be fairly difficult. Installation in new switchgear is a
better application; understand again that due to limited
access, maintenance or replacement of a failed sensor may
prove difficult.
B. Thermal Monitoring via Piezoelectric Acoustic Sensor
Similar to the infrared sensor used to measure the bus
temperature, another sensor product that makes contact with
the energized bus in switchgear assemblies is also in stages
of early development. This sensor detects loose bus joints
Fig. 6: An infrared non-conductive, non-contact sensor can be and loose connections via measuring an acoustic “signature”
mounted inside a switchgear panel offering 24 X 7 thermal
which occurs as microscopic particles of the bus conductor
monitoring.

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melt and then cool. Thermal cycling of molten metal delivers a

reliable and repeatable acoustic signal that can be measured
and continuously monitored. A relatively small piezo acoustic
sensor as shown in Fig. 8 can be connected directly to the
bus conductor and an Event Time Correlation (ETC) algorithm
is used to confirm a bus overheated condition. The non-
metallic sensor makes contact with the energized bus at a
single location; however the measured acoustic signal is able
to travel for some distance away from the sensor. This
distance is typically from 5 to 10 feet, dependent on the
conductor geometry. At the time of installation a calibration
device connected to the switchgear bus determines the
required sensor spacing. The on-board electronics in this
sensor derives power parasitically from the energized bus
based on continuous currents in the range of 100 amperes
through 5000 amperes.

Acoustic Coupler

Fig. 9: Acoustic sensor attached to energized bus bar in low-voltage

metal-enclosed switchgear.

C. Thermal Monitoring via Conductor Resistance

Recently another thermal detection solution [9] was
revealed that also looks to be an alternative to infrared
thermal imaging. This approach continuously measures the
Fig. 8: Piezoelectric Acoustic Sensor with mounting strap and acoustic
resistance of the conductors using normal load current. In
coupler.
effect this method converts the conductor itself into an RTD
The sensors operate independent of bus voltage and can sensor. Using voltage, current and phase angle data
be applied on any type of bus material including epoxy collected from a group of metering devices, the per-phase
insulated for both new and existing switchgear installations. A resistance between each metered point is calculated. When a
wireless transmitter in each of the sensors communicates termination or junction (e.g. shipping split splice) degrades, a
status to a central receiver so temperatures across an entire detectably larger voltage drop develops across that junction.
switchgear assembly line-up can be trended over time via any This appears as an increase in that conductor’s point-to-point
standard industrial network, most typically Modbus resistance. By trending this calculated per-phase resistance
Transmission Control Protocol/Internet Protocol (Modbus and normalizing to current (since the balance of the conductor
TCP/IP) or Ethernet Internet Protocol (Ethernet IP). The itself changes with temperature as a result of current
piezoelectric acoustic sensor would perhaps be a better changes), anomalous deviations in phase conductor
choice for retrofit in existing switchgear assemblies than the resistance are detected.
infrared sensor discussed previously. An industrial facility Similar to a differential relay protection scheme where
could schedule installation of the sensors during a scheduled multiple protective devices are sensing voltage and current to
rotational outage when the bus covers were removed while protect the distribution system, this method uses metering and
the main us bars are inspected. At this time, the wireless other devices such as solid state motor overload protective
receiver would also be installed and communications with devices to measure temperature via impedance. Use of a
each device established before replacing the bus covers. typical 1.0% accuracy class meter offering time stamped
Similar to the infrared non-conductive, non-contact sensor, the voltage, current and phase angle or power factor allows real-
advantage using this technology versus IR windows is that time measurement of conductor temperature. It is important to
real-time bus temperature can be monitored and trended over note that application of this approach will most typically
time, offering a continuous predictive method the identify include an energy management system and accompanying
possible hot spot failures before they occur. The non-metallic software to perform the calculations and deliver reliable
sensor is connected or strapped directly to the energized temperature trending. With the advent of lower cost electronic
conductor as shown in Fig. 9 metering and a drive toward energy management including
sub-metering for downstream loads, many new industrial

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systems will already specify this system capability. Similar to imaging while standing away from the energized conductors,
the permanently mounted infrared sensors described above, outside of the flash protection boundary. Another limitation
this method does not require periodic thermal scanning and involves application in arc rated low-voltage and medium-
resolves the issue of locating IR window in metal-clad or arc voltage assemblies. Arc testing as defined by global
resistant power distribution assemblies. Both offer a predictive standards requires that the arc blast pressure and thermal
maintenance platform with a capability to trend elevated energy be redirected above 2 meters from the panel base. IR
thermal activity, warning the user to intervene before the windows must be tested in the specific arc rated panel as a
measured hot spot results in failure. Fig. 10 shows a simplified part of the standard to assure compliance with the specified
single-line diagram illustrating this impedance sensing standard. Retrofit applications are more problematic as the IR
method. window manufacturer must have test data that proves the
device has passed the tests in the specific switchgear already
installed. In some cases, other thermal detection technologies
available today and/or in the near future offer a better
alternative to IR windows. The right solution should be
selected based on the application.
The intension of the authors is not to dissuade the use of
infrared windows, but instead to provoke thought in
consideration of alternative approaches for applications
discussed here. In some cases, an IR window is not the best
choice. It depends on what you are looking for!

VI. REFERENCES
[1] IEEE Standard 1458 Recommended Practice for the
Selection, Field Testing, and Life Expectancy of Molded
Case Circuit Breakers for Industrial Applications, IEEE IAS
2005
Fig. 10: Measurements of V, I and φ at each of these three meters [2] IEEE Standard 1584: Guide for Performing Arc Flash
provides sufficient data to detect hot spots on the bus
interconnecting these meters.
Hazard Calculations. 2002 Edition
[3] T. Holliday, J.A. Kay, Understanding Infrared Windows and
Their Effects on Infrared Readings, Conference Record,
V. CONCLUSIONS IEEE IAS Pulp & Paper Industry Conference, 2013.
[4] ANSI/IEEE Standard C37.20.7 Guide for Testing Metal-
Thermal imaging via infrared cameras and sensors of any Enclosed Switchgear Rated Up to 38kV for Internal Arcing
type has greatly improved the reliability of electrical power Faults, 2007 Edition
distribution systems around the world. With the advent of an [5] IEC Standard 62271-200AC Metal-Enclosed Switchgear
enhanced focus on electrical arc flash hazards, it has become And Controlgear for Rated Voltages above 1 kV and up to
untenable for maintenance personnel to open doors or and Including 52 kV, 2003 Edition
remove covers to conduct thermal surveys using an infrared [6] IEC Standard 61439-1 Low-voltage Switchgear and
camera. Introducing the hazard of exposed energized Controlgear Assemblies, 2011 Edition
conductors and the possibility of an arc flash event has ruled [7] IEC Standard 61641 Enclosed Low-Voltage Switchgear
out this option in many applications. and Controlgear Assemblies - Guide for Testing Under
Infrared windows are often the best choice for thermal Conditions of Arcing Due to Internal Fault, 2008 Edition
imaging and predictive diagnostics in industry, but there are [8] C.G. Walker, “Arc Flash Energy Reduction Techniques
limitations in some applications. One such limitation is in low- Zone Selective Interlocking & Energy-Reducing
voltage motor control center applications. Often times, Maintenance Switching”, Conference Record, 2011 IEEE
individual compartment doors offer limited space for IR IAS PPIC, Pgs 42-54.
windows, as control devices occupy much of the available [9] D.G. Loucks, “A Step Closer to Maintenance Free Gear”,
door area. Because these assemblies typically include many IEEE Transactions on Industry Applications, Vol 47, No. 2,
power connections where a thermal survey would be required, March/April 2011, Pgs 688-694.
it is often a better choice to open the starter module door
(after darning appropriate PPE) and then conducting thermal

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