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Air Force Field Guide For Inspecting Electrical
Air Force Field Guide For Inspecting Electrical
HANDBOOK
32-1282 VOLUME 1
1 JULY 1999
Civil Engineering
This handbook summarizes procedures and guidance to Air Force electricians for the inspection, evaluation, and
maintenance of substations, switchgear, and associated devices. It will also assist maintenance engineers and
quality assurance evaluators in specifying and inspecting contractor performance.
Contents
Chapter 1 Overview of the Guide
1-1 Scope............................................................. 1 Table 1-1 Equipment covered in this handbook.... 1
Table 1-2 Equipment covered in AFH 32-1282V2 8
1-2 Supplementary Information ........................... 8
1-3 Basis for Developing Field Procedures ......... 9
1-4 Preinspection Procedures ............................. 10
OPR: HQ AFCESA/CEOM (Capt Thomas E. Wahl)
Certified by: HQ AFCESA/CEO (Col William R. Pearson)
Pages 110/Distribution F
THIS PUBLICATION CONTAINS COPYRIGHTED MATERIAL
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Acknowledgment
The Air Force wishes to express their sincere appreciation to the many companies and their
representatives who kindly cooperated in supplying CAD illustration inputs and pictures for use in this
handbook. Inputs used for CAD illustration inputs were supplied by Siemens Energy and Automation,
Inc.; Square D Company/Groupe Schneider; and Westinghouse/Cutler Hammer. Some pictures were
supplied by Keller & Gannon. The Air Force expresses particular appreciation to Williams Learning
Network (formerly NUS Training Corporation) whose training videos were used to provide the rest of the
pictures.
NOTE: Product and manufacturer names are included in this handbook for the
purposes of illustration and do not carry the specific endorsement of the Air Force.
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1. Interrupters
1 2. Bushings
3. Control cabinet
4. Pressure gauges and operation counter
5. Current transformers
6. Steel base
5 7. Base legs
2
3 6
7
4
Figure 1-1
High-voltage SF6-gas-insulated circuit breakers
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1. Compressor 6
2. Pull rod
3. Control panel 7
1 4. Mechanism
2 5. Reservoir
6. Bushing 8
3 7. Oil level indicator
8. Oil vent
9. Tank
10. Mechanism housing
4 11. Local control
9
5 10
11
Figure 1-2
High-voltage oil-insulated circuit breakers
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7 8 9 10 1. Relays
2. Switches
3. Instruments/meters
4. Compartment barriers
5. Circuit breaker wheels
6. Circuit breaker rails
7. Drawout circuit breaker
8. Circuit breaker mechanism
6
9. Barriers
5
10. Automatic shutters
4
3
2
1
Figure 1-3
Medium-voltage metal-clad vacuum circuit breaker switchgear
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1. Switch operator
2. Padlock location
3. Inspection window 13
2 4. Main door 12
5. Door stop 14
3 6 6. Safety barrier 10
7. Door interlock 11
8. Switch interlock
7 9. Barriers 12
10. Switch position indicator
8
11. Padlock location
4 12. Key interlocks
13. Operating handle
9 14. Nameplates 7
2 1
5
Figure 1-4
Medium-voltage metal-enclosed load-interrupter switchgear
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7 8 12 13
19
6
18
9
5
4
10
1 2 3 1
1. Finger clusters
2. Extension rail 14 17
8. Stationary arcing 16 11 15
3. Levering arm 15. Main disconnect contacts
4. Moving contacts contact 11.Pole unit
12.Interface barriers 16. Sensors
5. Stationary contacts 9. Moving arcing 17. Drawout circuit breaker
6. Molded base 13.Secondary disconnect
contact 18. Switchgear
7. Arcing contact spring contacts
10. Insulation link 19. Rail mounted lifter
14. Levering device arm
Figure 1-5
Low-voltage air circuit breaker switchgear
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6
4
2
Figure 1-6
Low-voltage molded-case circuit breaker switchboard
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c. Safety. Refer to AFMAN 32-1185 (Electrical Safe Practices) which provides safety
standards for the work being done. Maintenance work should be done only by workers in accordance
with the electrical work classifications of AFMAN 32-1185, including AFSC 3E011 equivalent (helper),
AFSC 3E031 equivalent (apprentice), AFSC 3E051 equivalent (journeyman), or AFSC 3E071 equivalent
(craftsman). AFH 32-1285 (Electrical Worker Safety Field Guide) should be available to you to use in the
field.
1-3. Basis for Developing Field Procedures. This handbook is intended as summary
guidelines and procedures. Actual maintenance/repair program requirements should be adjusted as
appropriate for your specific electrical apparatus.
a. Handbook Information. This handbook covers generic apparatus performance, test
data, and generally applicable component element checks. Use this handbook as a reminder of general
maintenance requirements.
(1) Performance. Each component of major electrical apparatus performs essentially
a simple operation. Complexity in maintenance is caused by the large and varied types of electrical
components in the apparatus. This handbook provides figures and pictures to illustrate the most
important of these components.
(2) Tests. Electrical equipment must be tested to ensure its continuing operating
capability.
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(a) Test Descriptions. Descriptions of the most commonly used tests are
included in this handbook. Acceptable values of the tests are provided when possible. Reference to the
manufacturer’s literature may be required for other tests.
(b) Comparisons for Trends. All tests/readings should be compared to
previous values (acceptance, maintenance, or repair). This will assist in recognizing trends that indicate
a need for more frequent testing. Permanent changes to equipment/devices that are overloaded,
misapplied, or inadequate for the duty to which they are subjected may be required.
(3) Component Element Checks. Tables are included in this handbook which outline
the most important components to be checked. Additional information on these components can be
found in AFMAN 32-1280(I) and the manufacturer’s literature.
b. Locally Developed Field Procedures. Each facility should maintain a copy of all
applicable documents related to the installation, operation, and maintenance of electrical systems.
Locally developed EPM procedures are essential to proper maintenance.
1-4. Preinspection Procedures. Prior to performing any field work, review historical EPM
data and applicable safety requirements.
a. Apparatus Documentation. Assemble all documentation applying to the apparatus to be
checked.
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(1) Documentation Maintenance. The Base Civil Engineer (BCE) should ensure all
documentation is maintained for each specific item of electrical apparatus which makes up the facility
electrical power systems.
(a) Available From Design/Construction Files. The available data may include
all of the inspection and testing procedures for the facility, copies of previous reports, single-line
diagrams, schematic diagrams, electrical equipment plans, records of complete nameplate data, and
manufacturer’s service manuals and instructions.
(b) Locally Prepared. Prepare local EPM forms as necessary for installed
equipment. Each item of apparatus should be shown on an equipment location plan. (See Paragraphs
3-2, 5-1, 6-1, 7-4, 8-4, 9-3, and 10-4). Provide unique apparatus designations along with a locally
prepared safety electrical one-line diagram and equipment location plan. Table 2-2 summarizes the
minimum recommended features of a safety electrical one-line diagram.
(2) Specific Assembling of Data: Assemble the following data, if available, for each
specific item of apparatus.
! Locally prepared forms.
! As-built drawings for electric equipment layouts and elevations.
! Trend analysis data which should include:
(a) Installation acceptance data test results.
(b) Previous EPM reports including any previous systematic evaluations.
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(1) De-Energized Electrical Line Work. Follow the safe clearance (lockout/tagout)
procedures given in AFH 32-1285. Remember lines are considered energized if the de-energized
systems have not been provided with proper protective grounding. The safe clearance may require a job
hazard analysis.
(2) Energized Electrical Line Work. Work on energized lines and equipment only
when authorized by the electrical supervisor/foreman/lead electrician (per local organization) based on
the need to support a critical mission, to prevent injury to persons, or to protect property. Insulating
means must be provided to isolate workers from a source of potential difference. A job hazard analysis
is required for energized line work. (See AFH 32-1285).
d. Understanding Maintenance Frequencies. Frequency of maintenance should be locally
adjusted based on the application of the equipment. See additional guidance in NFPA 70B (Electrical
Equipment Maintenance). Adjust the frequency of inspection based on the criticality of the apparatus,
the severity of the loading conditions, and an environment where unusual service conditions stress the
equipment. Generally, usual service conditions extend only to elevations of not more than 3,300 feet (1
kilometer) and ambient temperatures of no more than 30 to 40 degrees C. Check with the manufacturer
for other than normal service conditions.
e. Inspection Materials/Devices. Basic items needed for an EPM include the following:
! A facility electrical truck
! Available documentation.
! EPM forms.
! Directions as to any input or approval needed from the appropriate using or
operating agency
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! Cleaning devices
(1) Vacuum cleaner
(2) Compressed air cleaner (not for use in medium or high voltage enclosures
or other locations where dust could cause flashover)
! Miscellaneous materials as necessary to clean, wipe, paint, insulate, solder, or for
other small field-fix repairs.
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SOURCE OF SOURCE OF
SUPPLY SUPPLY
CIRCUIT BREAKER
TRANSFORMER LOAD
TRANSFORMER CENTER
LOAD CIRCUITS
LOAD UNITS
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SOURCE OF SOURCE OF
SUPPLY SUPPLY
CIRCUIT BREAKER CIRCUIT BREAKER
SELECTIVE PRIMARY
SWITCH FEEDERS
DISCONNECT
SWITCH
TRANSFORMER LOAD CENTER
PRIMARY
FEEDERS
LOAD CIRCUITS
LOAD CIRCUITS
TO OTHER
LOADS
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SOURCE OF SOURCE OF
SUPPLY SUPPLY
CIRCUIT BREAKER
CIRCUIT BREAKER
PRIMARY
TRANSFORMER FEEDERS
DISCONNECT TRANSFORMER
SWITCHES
PRIMARY
FEEDERS LOAD NETWORK
CENTERS PROTECTOR
NETWORK
PROTECTOR LOAD
CIRCUITS
SECONDARY TIES
DISCONNECT
LIMITER
SWITCH LUGS
NETWORK
LOAD CIRCUITS PROTECTOR LOAD
CENTERS
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2-2. Operating Information. For maintenance to be done safely, operating information must
define energy paths and switching control components. Each component should be provided with a
unique identification and a specific location.
a. One-Line Diagram Preparation. As a part of the Apparatus Documentation (see
Paragraph 1-4) each installation should prepare safety electrical one-line diagrams. Develop safety
electrical one-line diagrams from the installation electrical one-line diagrams. Installation electrical one-
line diagrams are design documents made for construction and contain unnecessary installation data.
Safety electrical one-line diagrams should be prepared by facility personnel and should show only data
relevant to safe operating procedures. Table 2-1 indicates installation electrical one-line diagram
deficiencies that make this document a poor substitute for a safety electrical one-line diagram.
Installation electrical one-line diagrams may still need to be consulted for design information for
replacements. Table 2-2 summarizes the minimum recommended features of safety electrical one-line
diagram
b. Equipment Location Plan Preparation. As a part of the Apparatus Documentation (see
Paragraph 1-4) each installation should prepare a simplified electric equipment layout corresponding to
the safety electrical one-line diagram. The plan should locate all the components shown on the safety
electrical one-line diagram using the same identification. Also show power circuit routing which cannot
be observed at the site.
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(2) Action. Measure the ground path resistance of all branches of the grounding
system from ground connections at support structure, equipment enclosures, and neutral conductors to
the ground system. Measure other resistances covered in Table 3-2 which indicates maximum
acceptable ground resistances.
Table 3-2. Maximum acceptable ground resistances
Resistances Measured
1
1 to 25 ohms Substation
0.5 ohm Gates and gateposts2
0.5 ohm Operating rods and handles of group operated
switches and their supporting structures
1
In accordance with departmental standards.
2
Measurement of flexible gate ground connection adequacy.
(3) Recommendations. Where no departmental standards are available it is
recommended that substations of 1,000 kVA or less have a maximum ground resistance of 5 ohms and
substations over 1,000 kVA have a maximum ground resistance of 3 ohms.
c. Corona. Check for corona as covered in Paragraph 8-3.
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3-2. Substation Support Elements EPM Reports. Each installation should prepare
local blank EPM report forms to be filled out by the inspecting technicians. (See Paragraph 1-4). The
following tables indicate the data to be recorded.
a. Basic Substation Support Elements Information to Be Determined Before the
Inspection. Provide a suitable record header with blank spaces for insertion of the following data given
in Table 3-3. Pictures 3-1, 3-2, 3-3, and 3-4 show actual substation support elements.
Table 3-3. Substation support elements general data1
General Type
Designation Switching only
Date of inspection High- to medium-voltage
Location Medium- to low-voltage
Single line diagram drawing no(s) Aerial service
Equipment location plan drawing no(s) Underground service
System voltages and design kVA
Approximate area
Year installed
Last inspection date
1
For guidance on EPM reports covering bushings, instrument transformers, and surge arresters see
AFH 32-1282V2.
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Picture 3-3
Circuit
breaker bay
Picture 3-4
Transformer bays and secondary
underground line structures
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b. Basic Inspection Items to be Checked. Provide an EPM inspection report with column
headings covering items to be checked off for each listed item number given in Table 3-4.
Table 3-4. EPM column headings
Item no. (for easy referral) Passing criteria (list)
Inspection item (name) Inspection method (visual, test, or other)
Operating mode (in-service or de-energized Corrective action (if necessary)
and grounded)
c. Inspection Items to be Covered. List inspection items to be covered. Table 3-5
indicates substation support element readings or test values and appropriate evaluation paragraphs for
passing criteria. Table 3-6 indicates substation support element components and appropriate inspection
actions.
Table 3-5. Substation support element readings or test values
Readings or test values Evaluation reference paragraph
1. Ambient temperature --
2. Infrared temperature rise 3-1a1
3. Ground resistance 3-1b1
1
Readings should identify location or be provided with such identification in a separate report.
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a. Conducting Contact Opening. An energized circuit breaker draws an arc when its
conducting contacts are separated. The temperature of the arc ionizes the insulating medium and
sustains the arc. On current zero, arcing ceases and the voltage across the contacts increases. The
voltage buildup results in an arcing restrike from the electric field and from thermal effects of the initial
arc’s charged particles Only when the arc is cooled well below its ionization temperature at current zero
will the arc be fully extinguished and current interruption accomplished.
b. Extinguishing Methods. Various methods provide arc extinguishing. All methods
involve either cooling the arc or providing an insulating atmosphere unfavorable to ionization or to
reionization. Arc chutes in air magnetic circuit breakers with their barriers use side-by-side fins through
which the arc is drawn by the establishment of a magnetic field. This longer arc is then cooled by
convection. Air magnetic circuit breakers have both main and arcing contacts. (See Paragraph 7-2.a.)
Oil in oil-insulated circuit breakers vaporizes and forms air bubbles whose hydrogen is unfavorable to ion
production. Sulfur hexafluoride (SF6) in SF6-insulated circuit breakers is about 100 times more effective
than air in extinguishing the arc. Vacuum in vacuum circuit breakers is an even better arc extinguisher
since its high dielectric does not allow ionization to maintain itself and restrike after a current zero.
4-3. Circuit Breaker Operating Mechanisms. An operating mechanism needs some
form of energy to open and close the circuit breaker contacts at the required speed. The circuit breaker
mechanism must cause acceleration, movement, and deceleration at each opening and closing stroke.
Equally important the circuit breaker must stay open or closed until directed either manually or
automatically to perform otherwise.
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a. Operating Energy. All operating mechanisms use some form of stored energy for
opening and closing the circuit breaker. Pictures 4-5, 4-6, 4-7, and 4-8 show examples of various
operating mechanisms.
(1) Stored Energy Methods. Table 4-2 indicates some of the various methods of
stored energy used to open and close circuit breakers. The method used to close the circuit breaker
may not be the same method used to open the circuit breaker. It takes more energy to close a circuit
breaker than to open the unit. In both cases the contact motion is slowed by dampers at the end of the
stroke.
Table 4-2. Circuit breaker stored energy methods
Electrical energy inputs to electrical operators
System Voltage to operate
1. Batteries dc
2. Control power transformer (CPT) ac
3. CPT charging a capacitor supplying a dc
half-wave rectifier
Electrical operators
1. Motor wound charged springs 2. Solenoids
Compressed gas methods
1. Hydraulic systems 2. Pneumatic systems
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e. Interlocks. Interlocks prevent releasing the closing spring when the circuit breaker is
already closed or operating the unit as it is moved from the connected position to the test or to the
disconnected position.
f. Safety. Isolate control and current, and voltage instrument transformer secondary circuits
to protect against unintentional operation.
(1) Control Circuits. Understand the control method including interconnecting circuits
and remove control fuses, open test switches, and disable any other control inputs. Lockout/tagout
precautions should cover all isolating requirements.
(2) Closing/Opening. Circuit breakers are both opened and closed with stored energy
mechanisms which may remain charged even when a circuit breaker has been withdrawn from its
enclosure. The mechanisms may be still capable of operating the circuit breaker in the withdrawn
position. If the circuit breaker is closed, make sure the opening device circuit is discharged before you
approach it with your tools or fingers. If the circuit breaker is open, block it and wire the trip latch to
prevent the circuit breaker from closing. Above all, read the manufacturer’s instructions so that you can
predict the condition of the circuit breaker.
4-4. Circuit Breaker Elementary Diagrams. Review the circuit breaker elementary
diagram provided in the manufacturer’s instructions. Check any modifications given in the operations
manual for the specific system. The effect of open-close-trip actuators, control operating power input,
open and close activating and monitoring devices, and safety interlocks all impact on the circuit breaker
operating mode. That impact can affect the safety of the maintenance technician and the continued
operation of the device. An elementary diagram of a spring-operated circuit breaker mechanism is
shown on Figure 4-1 and the mode of operation discussed in Figure 4-2.
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WL CS GL RL CS PR
SPRING
C T
CHARGED
INDICATING
ABBREVIATIONS OPERATION
LIGHT
1 2 3 4 5 6 CS - BKR. CONTROL SWITCH - CLOSE LS1 OPEN UNTIL SPRINGS
7 C aa ARE FULLY CHARGED
D 3 3A 9
C Y CS - BKR. CONTROL SWITCH - TRIP LS1 CLOSED UNTIL SPRINGS
b 13 52 a T bb ARE FULLY CHARGED
S M Y
SR ST Y - ANTI PUMP RELAY LS2 OPEN UNTIL SPRINGS
O 1 aa ARE FULLY CHARGED
U SR - SPRING RELEASE COIL (CLOSE COIL)
R PS2 52 b 52 b 52 a LS2 CLOSED UNTIL SPRINGS
M - SPRING CHARGING MOTOR bb ARE FULLY CHARGED
C
E LC ST - SHUNT TRIP COIL LC OPEN UNTIL MECHANISM IS
PR - PROTECTIVE RELAY RESET
LS1 LS1 PS1 Y LS2 LS2 14 10
a PS1 OPEN IN ALL EXCEPT
bb 4 aa bb aa V - SECONDARY DISCONNECT
6 V BETWEEN “TEST” AND
52 - CIRCUIT BREAKER “CONNECTED” POSITIONS
24 21 20 19 a - OPEN WHEN 52 IS OPEN PS2 CLOSED IN ALL EXCEPT
BETWEEN “TEST” AND
N b - CLOSED WHEN 52 IS OPEN “CONNECTED” POSITIONS
Figure 4-1
A typical circuit breaker elementary diagram
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As soon as the secondary disconnects engage, the spring charging motor automatically starts
charging the closing springs provided the control power is available. When the springs are
charged, the motor cut off (LS1/bb and LS2/bb) switch turns the motor off. The breaker may
be closed by making the control switch close (CS/C) contact. Automatically upon closing of the
breaker, the motor starts charging the closing springs. The breaker may be tripped any time by
making the control switch trip (CS/T) contacts.
Note the position switch (PS) contact in spring release (SR) circuit in the scheme. This contact
remains made while the breaker is being levered between Test and Connected position.
Consequently it prevents the breaker from closing automatically even though control switch
close contact may have been made while the breaker is levered to the Connected position.
When the CS/C contact is made, the SR closes the breaker. If the CS/C contact is maintained
after the breaker closes, the Y relay is picked-up. The Y/a contact seals in Y until CS/C is
opened. The Y/b contact opens the SR circuit so that even though the breaker would
subsequently open, it could not be re-closed before the CS/C were released and remade. This
is the anti-pump function.
Figure 4-2
Operating control modes for Figure 4-1
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4-5. Circuit Breaker Nameplates. Circuit breaker nameplate data can provide useful
information when Apparatus Documentation data is not available or has been lost. Tables 4-3 and 4-4
show minimum circuit breaker information required on circuit breaker nameplates for low-voltage circuit
breakers and for medium and high voltage circuit breakers respectively.
Table 4-3. Low-voltage circuit breaker minimum nameplate information
Power circuit breakers
Manufacturer’s name Rated short-time current (where applicable)
Type of circuit breaker Suitable fuse type and sizes (where applicable)
Rated continuous current of trip devices Rated frequency
(where applicable) and type designation Rated control voltage (where applicable)
Frame size Year of manufacture, by date or code
Rated maximum voltage(s) Identification number
Rated short-circuit current at each rated maximum Manufacturer’s data sheets or instruction book
voltage
reference
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Table 4-4. Medium and high voltage circuit breaker minimum nameplate
information
Circuit breaker
Manufacturer’s name Rated line closing switching surge factor
Manufacturer’s type designation Rated short-circuit current
Manufacturers serial number Rated interrupting time
Year of manufacture Normal operating pressure
Rated frequency Minimum operating pressure
Rated continuous current Gallons of oil per tank or weight of gas per breaker
Rated maximum voltage (kV) Weight of circuit breaker complete (with oil or gas)
Rated voltage range factor K Instruction book number
Rated full wave impulse withstand voltage (kV) Parts list number
Rated switching-impulse withstand voltage Assigned out-of-phase switching current rating
! Terminal to ground - circuit breaker closed
! Terminal to terminal - circuit breaker open
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Table 4-4. Medium and high voltage circuit breaker minimum nameplate
information (cont.)
Ratings for capacitance current switching
Transient overvoltage factor Back-to-back shunt capacitor bank current
Open-wire line charging current Transient inrush current peak
Isolated shunt capacitor bank current Transient inrush current frequency
Operating mechanism
Manufacturer’s name Compressor control switch closing and opening
Manufacturer’s type designation pressures
Manufacturer’s serial number Low pressure alarm switch closing and opening
Year of manufacture pressures
Closing control voltage range Low pressure lockout switch closing and opening
pressures
Tripping control voltage range
Wiring diagram number
Closing current
Instruction book number
Tripping current
Parts list number
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Table 4-4. Medium and high voltage circuit breaker minimum nameplate
information (cont.)
Current transformers1
Manufacturer’s name Connection chart showing:
Manufacturer’s type designation ! Full winding developing
Rated frequency, if other than 60 cycles ! Taps
American National Standard accuracy class ! Ratio in terms of primary and secondary
Instruction book number currents
Curve sheet ! Polarity
! Pole and pocket location
Accessories
Identification Pertinent operating characteristics
1
Nameplates located at respective terminal blocks. Includes mutual reactance and self-impedance (resistance, reactance, and
impedance) for linear couplers.
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manufacturer’s tolerance or any deviation of more than 50 percent if compared to similar circuit breakers
or adjacent poles.
b. Insulation Resistance Pole-to-Pole Tests. This test is meaningful only on a
comparative basis. A gradual decline in resistance with age is normal; however, a sudden decline
means insulation failure is imminent. A continued downward trend indicates insulation deterioration,
even through measured resistance values are above the minimum acceptable limits.
(1) Application. Use a megohmeter to measure insulation resistance with the circuit
breaker in both the open and closed positions.
(a) Circuit Breaker Open. Connect the megohmeter lead to one input or output
pole terminal of the circuit breaker with all other five pole terminals grounded. Repeat for the other five
terminals.
(b) Circuit Breaker Closed. Connect the megohmeter lead to one closed pole
(either input or output) terminal of the circuit breaker with either the input or output of the other two
closed pole terminals grounded. Repeat for the other two phases.
(c) Test Values. Take the ambient temperature during measurements.
Correct the measured insulation resistance and record. Compare with acceptance and previous test
values. See Table 5-1 for test voltages and minimum insulation resistances.
Table 5-1. Circuit breaker insulation-resistance test values
Voltage rating Minimum dc test voltage Recommended minimum insulation
resistance in megohms
0-250 volts 500 volts 50
251-600 volts 1000 volts 100
601-5000 volts 2500 volts 1000
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e. Dynamic Travel Tests. Use a motion analyzer to check mechanical operation of the
circuit breaker at full speed. Compare circuit breaker travel and velocity values to the manufacturer’s
acceptable limits and with the historical record for the circuit breaker. Small variations in speed or travel
can indicate deteriorating conditions of the circuit breaker’s closing mechanism, stored energy system,
shock absorbers, and other mechanical parts.
f. Trip and Close Coil Minimum Operating Voltage Tests. For circuit breakers without
integral diagnostic capabilities, connect a switch and rheostat in series with the coil circuit (trip or close)
being checked and across the terminals to the applicable remote control switch. Connect a voltmeter
across the coil. Starting at below 50 percent of rated coil voltage, gradually increase the voltage until the
coil plunger picks up and successfully operates the circuit breaker. Make several trial operations of the
circuit breaker, and record the minimum operating voltage.
(1) Tripping. Most circuit breakers should trip at about 55 percent of rated trip-coil
voltage. Measure the trip-coil resistance and compare it with the factory test value to disclose shorted
turns. Many modern circuit breakers have trip coils which will overheat or burn out if left energized for
more than a short period. An auxiliary switch is used, in series with the coil, to open the circuit as soon
as the circuit breaker has opened. The auxiliary switch must be properly adjusted to successfully break
the arc without damage to the contacts.
(2) Closing. Follow the same procedure for determining the minimum closing coil
voltage. Record the minimum voltage that will close the breaker and the closing coil resistance.
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5-2. De-Energized Tests Specific to the Circuit Breaker Type. The voltage rating
and the type of insulation requires tests specific to the circuit breaker design.
a. Low-Voltage Circuit Breakers. The protective tripping device is an integral part of the
circuit breaker. The unit may be equipped with an electromechanical trip unit or a static trip unit.
Electromechanical units may have a thermal (inverse time overload) protection, magnetic (instantaneous
short-circuit) protection, or a thermal-magnetic combination. Static units are solid-state electronic
devices which provide many additional protective features. All tripping times should be checked to
assure they meet the manufacturer’s time-current characteristic tolerance band. Use a circuit breaker
test set and make field adjustments in accordance with the test set’s instruction. Do not compromise the
protection by exceeding the trip unit’s adjustable range. Field repair is not recommended. If the trip unit
is not functioning properly it should be replaced. It may also be advisable to replace the entire circuit
breaker.
b. Oil-Insulated Circuit Breakers. Check oil dielectric strength, power factor, interfacial
tension, and color in accordance with requirements given for insulating liquid tests in AFH 32-1282V2.
c. SF6-Insulated Circuit Breakers. Check for moisture content. Service-aged moisture
content should be less than 300 parts per million (ppm) by volume (10 ppm new). Do not energize any
gas-insulated equipment where the gas density is less than 50 percent of nominal or if the moisture
content exceeds 1,000 ppm. Moisture content should be checked with a moisture analyzer approved for
SF6 gas. Follow the procedures in and as often as recommended by the manufacturer’s instructions.
Some SF6 bottles have a sample valve. Some SF6 bottles are sampled through a filling valve using a
valved sampling tube arrangement which prevents contaminants from entering the SF6 bottle. It is
recommended that trained contract personnel do the checking.
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6-2. High-Voltage SF6 or Oil Insulated Circuit Breakers. Inspection includes both
external and internal inspections. External inspections are covered in Table 6-3. Follow procedures of
Table 6-4 for internal tank inspections.
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Table 6-4. Internal high-voltage circuit breaker tank procedures and checks
1. Accessing the tank d. Replace any desiccant material, if
a. Remove covers, lower tank, extract oil or applicable
gas and transfer to approved storage or 2. Seal the tank and:
processing equipment a. Refill oil-insulated units to the proper
b. Ventilate and wipe down oil-insulated units. level and inspect for leaks
Pull a vacuum on gas insulated units. b. Pull a vacuum per manufacturer’s
c. Check, measure, adjust, lubricate, align, specified time for gas-insulated units
and repair: and if no leaks are present refill tank
(1) Contacts to the proper pressure
(2) Interrupters
(3) Internal current transformers
(4) Resistors, capacitors, and lift rods
6-3. Medium-Voltage Vacuum or Air Insulated Metal-Clad Switchgear Circuit
Breakers. Pictures 6-1 and 6-2 indicate protective features on all metal-clad switchgear. Pictures 6-
3 and 6-4 indicate details of air-magnetic arc chutes. Table 6-5 indicates circuit breaker components and
appropriate inspection actions for circuit breakers withdrawn from the switchgear and de-energized
unless indicated to be in the test position. BE CAUTIONED THAT HIGH POTENTIAL TESTING OF
VACUUM BOTTLES CAN CAUSE X-RAY EMISSION. USE MANUFACTURER’S SAFETY
PRECAUTIONS.
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6-4. Low-Voltage Circuit Breakers. Table 6-6 indicates circuit breaker components and
appropriate inspection actions. Drawout circuit breakers should be removed from their enclosures.
Stationary circuit breakers should be de-energized and grounded. Pictures 6-5 and 6-6 show the two
usual type of low-voltage circuit breakers. Pictures 6-6 and 6-7 show drawout contacts for power and
control respectively.
Table 6-6. Low-voltage circuit breaker checks
Component inspection Component inspection
1. General 2. Drawout units
a. Mounted properly and grounded a. Racking mechanism, cell fit and element
b. Undamaged and clean alignment. Verify contact wipes and
c. Operates correctly other adjustments are correct.
d. Tight connections b. Operating mechanism functions both
e. Arc chutes and contacts1 electrically and mechanically
c. Lubrication requirements
d. Control devices
1
On nonsealed units.
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b. Operating Mechanism. Stored energy from a heavy-duty spring provides the force
necessary to open or close the switch. The switch handle charges the spring when operated either up
for closing or down for opening. The stored energy of the spring operates independently of the operator.
Switches cannot be teased into any intermediate position. All mechanisms can be manually operated.
Many interrupter switches are provided with motor operators controlled by the current-detection system.
Motor operators have a well documented history of operating problems.
c. Current Detection Systems. The drawback to interrupter switches as compared to
circuit breakers is their current-detection system under abnormal operating conditions.
(1) Overloads. On overloads fuses will operate to open the circuit.
(2) Fault Conditions. Fuses will operate properly on line-to-line faults. They may not
operate on line-to-ground faults. Therefore safety precautions must be observed when manually opening
switches.
d. Precaution in Opening or Closing Switches. These operations can be extremely
dangerous if they are performed when there is an uncleared fault condition at the switch. Safety orders
should be very clear that the operator must stand to the side of the switch and wear a blast suit and fire-
resistant clothing.
e. Safety Interlocks. Interlocks are required by industry standards to prevent contact with
energized switch components. Pictures 7-1, 7-2, 7-3, and 7-4 show features that ensure energized parts
are isolated from operating personnel.
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Picture 7-4
Interrupter
operating
mechanism
exposed
Picture 7-3
Interrupter switch fuses exposed
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(1) Standard Switch Interlock Safeguards. Fuses are not accessible unless the switch
is open. The switch cannot close when the fuses are accessible. Access to the switch compartment is
prevented unless the stored energy mechanism is discharged or blocked.
(2) Drawout Switch Interlock Additional Safeguards. Movement of the removable
element is prevented when the switch is in the closed position. The switch cannot be closed
(mechanically or electrically) when the removable element is at any intermediate point between the
disconnected and connected positions. Movement of the removable element to and from the connected
position is prevented if the operating spring is in the charged position.
f. Optional Monitoring Devices. Fuses are often provided with blown fuse indicators.
Surge arresters, instrument transformers, meters, relays, and additional interlocks may be installed to
protect and monitor the interrupter switch.
7-3. Interrupter Switch De-Energized Device Tests. Perform contact-resistance tests
across each switch blade and fuse holder and insulation resistance tests on each pole phase-to-phase
and phase-to-ground for one minute with a test voltage in accordance with Table 5-1. See Table 7-5 for
test requirements. Always test interrupter switches in the test position. If there is no test position
(stationary interrupter switches) test after the interrupter switches have been de-energized and
grounded. Tests must be done in accordance with the safety requirements for de-energized electrical
line work given in Paragraph 1-4. Convert measured insulation resistances from the test temperature to
the reference temperature of 20 degrees C (see AFMAN 32-1280(I)).
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8-2. De-Energized Assembly Tests. Tests are generally limited to ground resistance tests
on permanent ground systems, and insulation resistance tests on buses and control wiring. See Table 8-
3 for test requirements.
Table 8-3. Assembly test requirements
Readings or test value Evaluation reference paragraph
1. Ambient temperature...........................................................................--
2. Infrared ................................................................................................3-1a1
3. Corona.................................................................................................8-3
4. Ground resistance ...............................................................................3-1b1
5. Bus insulation resistance ....................................................................5-1b2
6. Control wiring insulation resistance.....................................................5-1c
1
Readings should identify location or be provided in a separate report.
2
See Table 5-1 for insulation resistance test values.
8-3. Energized Assembly Tests. Always test assemblies in accordance with the safety
requirements for energized electrical line work given in Paragraph 1-4. Convert measured insulation
resistances from the test temperature to the reference temperature of 20 degrees C (see AFMAN
32-1280(I)). Use a hand-held corona tester to determine if corona is being produced. If corona is
present investigate insulation and insulators for corrosion, tracking, or dirt buildup and replace if
necessary. Infrared tests should be done as covered in Paragraph 3-1.
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(1) Electrolytes. Lead acid batteries have an acidic electrolyte solution of sulfuric acid
(H2SO4) and their nominal voltage is 2.0 volts per cell. Nickel cadmium batteries use an alkaline
electrolyte (potassium hydroxide) and their nominal voltage is 1.2 volts per cell.
(2) Construction. The physical size of a vented battery will generally be larger than a
valve regulated battery providing the same energy because of the difference in construction.
(3) Details. Pictures 9-1, 9-2, 9-3, and 9-4 show equipment and maintenance details.
(a) Vented Batteries. Vented (flooded) cells are constructed with the liquid
electrolyte completely covering (flooding) the closely spaced plates, so that there is a large volume of
free electrolyte. Vented units are characterized by a removable vent cap which allows the electrolyte to
be checked and adjusted as needed. Overcharge will produce gases which vent through the cell,
requiring regular water replacement. Vent caps must be accessible and are provided with flame
arresters. Gassing requires ventilation to avoid explosive possibilities and possible corrosive damage to
battery terminals.
(b) Valve-Regulated Batteries. Valve-regulated cells are sealed, with the
exception of a valve that opens periodically to relieve excessive internal pressure. Once the pressure is
relieved the valve closes and reseals. No cell check of an electrolyte level nor the specific gravity of
each cell can be made. These batteries are not maintenance-free as some 10 or more maintenance
checks are still necessary. Outgassing of these batteries is low at normal charge rates, but it can occur
when there is a battery or battery charger failure. Cells can pose a hazard if enclosed so as to inhibit
cooling air, or installed so as to place them in the heat flow of electronics which may occupy the same
enclosure.
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(2) Integrity Load Test. Provide anywhere from quarterly to annually depending on
the relative importance of the equipment that the battery supports. The procedure is given in Table 9-4.
Table 9-4. Integrity test procedures
1) The charger/rectifier is disabled, that is removed or the output disconnected.
2) The battery remains connected to normal load and is forced to supply power to the normal load.
Where the normal load is slight, a momentary artificial load should be added.
3) The depth of discharge is very shallow - typically 0.33 to 0.75 amperehour will be consumed. The
critical test parameter is the magnitude of the BATTERY’S momentary load current. It must be
great enough to detect abnormal path resistances. Duration of the discharge is just long enough
to measure each cell’s voltage under load.
4) Conduction path problems are detected by comparing test data of repeated tests over time, or
analyzing cell to average cell data of a specific test.
9-3. Battery Installation EPM Reports. Each installation should prepare local blank EPM
report forms to be filled out by the inspecting technicians. (See Paragraph 1-4.) The following tables
indicate data which may need to be recorded. Evaluate the extent of data required based on your
installation needs and maintenance ability.
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(2) Electrical Meters. Industry standards define electrical meters as devices used to
measure and register the cumulative value of electrical quantities with respect to time. For example, a
watthour meter is used to measure and register the amount of average electrical power over a period of
time.
(3) Electrical Measurements. Many units measuring ac values will do so using
average, peak, or effective values, based on the assumption that the system provides a pure sine wave.
With the growing use of solid-state equipment, the waveforms being measured are increasingly less like
a pure sine wave. Resulting measurements made from equivalent rms instruments or meters can be
misleading, but such results are not necessarily the fault of the measuring device. Whenever possible
use true rms instruments or meters.
b. Protective Relays. A relay is an electrical device designed to interpret input data in a
prescribed manner. When specific input conditions occur, the relay responds to cause contact operation
or a similar sudden change in associated electric control circuits. Protective relays are designed to
operate circuit breakers and contactors, usually medium-voltage units. Relays can be set more precisely
than fuses. Relays are adjustable with respect to both time and current, a feature that also applies to
solid-state, direct-tripping, low-voltage circuit breakers. Input data analyzed is usually electrical, but may
be mechanical or thermal, or evaluate other conditions or a combination of conditions. Electrical
conditions can be overcurrent, overvoltage or undervoltage, a combination of current and voltage, current
balance, direction of current flow, frequency, impedance, or other electrical data.
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d. Pictures 10-1 and 10-2 show an electromechanical relay and a solid-state relay
respectively.
10-3. Installation-Wide Operating Systems. Systems include supervisory control and data
acquisition (SCADA) systems and digitally-controlled Air Force switchgear systems. Perform
maintenance in accordance with Operations and Maintenance Manuals furnished with the systems.
Pictures 10-3 and 10-4 show installation-wide operating systems.
10-4. Protective Sensing, Processing, and Action Device EPM Reports. Each
installation should prepare local blank EPM report forms to be filled out by the inspecting technicians.
(See Paragraph 1-4.) The following tables indicate data which may need to be recorded. Evaluate the
extent of data required based on your installation needs and maintenance ability.
a. Basic Assembly Information To Be Determined Before the Inspection. Provide a
suitable record header with blank spaces for insertion of the following data given in Table 10-3.
Table 10-3. Device general data
Designation Last inspection date
Date of inspection Manufacturer
Location Instruction manual
Serial no. Device type
Year installed
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