Welcome

Welcome to Module 6, which is about Medium Voltage Power Circuit Breakers.

By medium voltage, we mean a voltage range of 1000 volts to 38 kV. (Some consider
72.5 kV as the upper end of medium voltage, but we will work with 38 kV for the
purpose of this training module.)

Figure 1. Family of Medium Voltage Vacuum Circuit Breakers (ANSI and IEC Types)

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 you’ve 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

Key points are in bold.

Glossary items are italicized and underlined the first time they appear.

Introduction

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:

 metering devices to measure power consumption

  main and branch disconnects
 protective devices
 switching devices to start and stop power flow
 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

Figure 3. Typical Medium Voltage Vacuum Circuit Breaker

with Front Cover Removed, Exposing Operating Mechanism

Frame

A medium voltage power circuit breaker is essentially an assembly of parts on a rugged

metal Frame. Depending upon factors such as ratings and interrupting method, they come
in a variety of shapes, sizes and configurations.

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, stored-energy 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.

Figure 4. Typical Medium Voltage Switchgear Assembly with Protective Relays and
Other Devices Shown Mounted on Compartment Doors

Trip Intelligence

The protective relay intelligence devices fall into two broad categories. These are:

Electromagnetic –The 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-Based –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.

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 microprocessor-based 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).
Figure 6. Typical Sophisticated Microprocessor-Based Protective Relay

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

The vacuum interrupter (VI) was briefly discussed in Module 5, Fundamentals of Circuit
Breakers.
Figure 7. Schematic for a Typical Vacuum Interrupter

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.

Figure 8 depicts the important arcing and interruption phenomena within a vacuum.
Figure 8. Interruption in a Vacuum

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

The vacuum in the envelope is considered a Dielectric. The Dielectric Strength is the
maximum voltage the dielectric can withstand without breaking down. The Transient
Recovery Voltage (TRV) is the most severe waveform the interrupter will have to
withstand. This is why the speed of the dielectric recovery and the strength of the
dielectric inside the interrupter are critical issues for successful circuit interruption. If the
dielectric does not reach sufficient strength fast enough, the arc will re-ignite.

Vacuum interrupters for circuit breaker duty must be capable of interrupting currents of
12 to 50 kA (and up), at voltages up to 38 kV (Figure 11).

Figure 11. Rear View of Circuit Breaker with

Vacuum Interrupters Installed (One Per Phase)

Spiral Contacts

A newer technology is now being used in the vacuum interrupter. It involves using
spiral-shaped copper-chrome contacts inside the vacuum tube. They provide a self-
induced magnetic effect that moves the arc root around the contact periphery. This very
efficient arc control method prevents hot spots, minimizing contact erosion.

Figure 12. Spiral Contacts

SF6 Gas Technology

Another arc extinguishing technology is SF6 (sulfur hexafluoride) technology. It is

popular outside the United States. It is specifically associated with European
manufacturers of medium and higher voltage circuit breakers.

SF6 technology was briefly discussed in Module 5, Fundamentals of Circuit Breakers.

The main contacts are enclosed in a chamber of SF6 gas, which happens to be a very good
dielectric (Figure 13).
Figure 13. Enclosing Contacts in SF6 Gas

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

Puffer-Type SF6 Gas Technology

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

Figure 15. Typical SF6 Puffer Interrupter During Opening Sequence

High Current Arc on Left and Near Current Zero on Right

During current interruption, a piston compresses the SF6 gas in a cylinder, all of which is
enclosed in an epoxy-type enclosure. After the main current-carrying contacts part, the
current transfers to the arcing contacts. Once the arcing contacts part, the SF 6 gas in
the compression chamber blasts the arc through the nozzle. The heat created by the
arc breaks the SF6 molecules into fluorine and sulfur. Arc energy is absorbed and the arc
is cooled.
As current zero is approached, the heat energy subsides as more SF6 gas enters the
system. At current zero, the high-pressure SF6 gas flows through the nozzle and
extinguishes the arc.

Compressing the SF 6 gas requires significant mechanical energy. A circuit breaker

equipped with this type of technology requires a higher-energy operating mechanism than
is required by an equivalent vacuum circuit breaker. In addition, this interrupter type has
a large number of parts.

Rotary Arc-Type SF6 Gas Technology

Rotary arc SF 6 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 coil’s magnetic field, produced
by the load current itself, causes the arc to rotate rapidly. The arc is cooled by
moving through the SF 6 gas.
The SF6 gas is normally at rest inside this interrupter. The arc’s 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.

Ratings

Ratings and Standards Vary

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 Medium Voltage Continuous Current Short Circuit Current

Type (kA rms) (Amps) (kA rms)
27 60012002000 16
270VCP-
W750
270VCP- 27 60012002000 22
W1000
270VCP- 27 60012002000 25
W1250

Figure 18. Partial Sample of a Medium Voltage IEC Ratings Chart

Breaker Type Voltage Class Normal Current Short Circuit Current (kA
(kA rms) (Amps) rms)
24 63012502000 16
240VCP-W16
240VCP-W20 24 63012502000 20
240VCP-W25 24 63012502000 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
 Short Circuit Current

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 breaker’s 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 amount of current the breaker can carry continuously at 60 cycles
without exceeding the temperature rise limit. It is termed Continuous Current on
ANSI charts and Normal Current on IEC charts. This maximum rating should always be
in excess of the utilization equipment rating to provide for a short-time overload
capability.

Typical continuous current currents encountered with ANSI applications are: 600, 1200,
2000 and 3000 amps. Typical normal currents encountered with IEC applications are:
630, 1250 and 2000 amps.

Short Circuit 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 breaker’s 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

The medium voltage power circuit breaker is always placed in a switchgear

assembly. The switchgear assembly is usually referred to as a Metal-Enclosed Assembly.
The phrase “metal-clad” means that compartments within the switchgear assembly are
separated by metal barriers (Figure 19).
Figure 19. Typical Medium Voltage Metal-Clad Assembly Structure with
Two Vacuum Circuit Breakers (Side View)

This is different from a metal enclosed assembly, where the equipment is enclosed, but
not necessarily separated by barriers. The metal enclosed assembly is typically associated
with low voltage equipment.

Figure 20. Typical Vacuum Switchgear Assembly with One Circuit Breaker in
Upper Compartment and One Below with Door Closed
Mounting

There are two methods for mounting a circuit breaker in the switchgear. These are:

 Fixed Mount
 Drawout Mount

Fixed 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.

This outdoor substation utilizes fixed medium voltage power circuit breakers to perform a
series of capacitor switching functions.

Fixed Medium Voltage Power Circuit Breaker

Installed in Outdoor Enclosure

Each breaker must be housed in a weatherproof enclosure to protect it from the elements.
Drawout Mount

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). The secondary and
primary electrical connections are automatically connected or disconnected as the circuit
breaker is levered from one position to another.
Figure 22. Medium Voltage Vacuum Circuit Breaker
Being Mechanically Levered Into Its Structure

Most drawout medium voltage power circuit breakers can be completely removed
from their compartments onto integral extension rails (Figure 23). This feature makes
the task of inspecting the circuit breaker and the compartment much simpler.

Figure 23. Medium Voltage Vacuum Circuit Breaker

Shown Removed From Compartment on Extension Rails
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.

Standards

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

In addition, UL is an important consideration in certain local areas.

Standards and testing to prove compliance are rather stringent. This is because of
the voltage and current levels associated with medium voltage equipment under abnormal
(and even normal) operating conditions.

The testing goes beyond just testing the circuit breaker itself. Because a medium
voltage power circuit breaker must function properly with a compatible housing, it is
tested separately and in combination with the structural assembly. For this reason, most
circuit breaker manufacturers are also switchgear assembly manufacturers.

Helping the Customer

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:

 Circuit Breaker Details

 Configuration and Accessory Details

Circuit Breaker Details

Before you can select a specific circuit breaker, get the following information from the
customer:

 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?

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 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?

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.

Glossary
ANSI American National Standards Institute. It was organized to simplify
and standardize production and construction.
Arc The effect generated when current is forced to be interrupted
between two contacts.
Arc Chute A component of the arc extinguisher in a low voltage circuit
breaker. It elongates and cools an arc.
Arc Extinguisher A component of a circuit breaker. It actually interrupts the flow of
current.
Circuit Breaker A reusable overcurrent protection device. After tripping to break
 the circuit, it can be reset to protect the circuit again.
Continuous Current The amount of current the breaker can carry continuously at 60
cycles without exceeding the temperature rise limit, according to
ANSI charts.
Current A step-down transformer that steps down supplied current to a
Transformer current usable by control components such as relays and meters.
Current Zero Also “Zero Point.” A point in the AC current sine wave where the
value is zero.
Dielectric The insulating medium between two contacts. Typical dielectrics
are air, gas, ceramic or gas and ceramic. A vacuum is the only
perfect dielectric.
Dielectric Strength The maximum voltage a dielectric can withstand without breaking
down.
Drawout Mount A mounting type for medium voltage power circuit breakers in
which the breaker can be completely removed from its
compartment onto integral extension rails.
Envelope Main component of a vacuum interrupter. A sealed, evacuated
ceramic enclosure, with a metal end plate brazed to each end.
Fixed Mount A mounting type for medium voltage power circuit breakers in
which the breakers are fixed in place. Usually found in outdoor
applications.
Frame A component of a medium voltage power circuit breaker. Its
primary function is to provide a rigid, mechanically strong,
insulated housing in which the other components are mounted.
IEC Abbreviation for International Electro-technical Commission. This
organization is associated with equipment used internationally.
IEEE Institute of Electrical and Electronic Engineers. A professional
organization of scientists and engineers whose purpose is the
advancement of engineering.
Magnetic Air Type A type of medium voltage power circuit breaker no longer in
Circuit Breaker common use.
Maximum Voltage The highest voltage at which the breaker can operate, according to
ANSI charts. The operating voltage where the circuit breaker is
applied should not exceed the circuit breaker’s rated maximum
voltage.
Medium Voltage A specific type of circuit breaker, used in a switchgear assembly,
Power Circuit with a voltage range of 1000 volts to 38 kV.
Breaker
Metal-Clad Equipment in the assembly is enclosed, and separated by metal
Assembly barriers into individual compartments. Typically associated with
medium voltage equipment.
Metal-Enclosed Equipment in the assembly is enclosed, but not necessarily
Assembly separated by barriers. Typically associated with low voltage
equipment.
NEMA Abbreviation for National Electrical Manufacturers Association.
An organization of manufacturers of electrical products.
Normal Current The amount of current the breaker can carry continuously at 60
cycles without exceeding the temperature rise limit, according to
IEC charts.
Operating Opens and closes the contacts of a circuit breaker.
Mechanism
Panelboard A wall-mounted electrical power distribution device for use in
commercial and industrial applications. It provides circuit control
and overcurrent protection for light, heat or power circuits.
Protective Relay The specific trip unit used with a medium voltage power circuit
breaker. Functions to detect a defective line or apparatus, as well as
dangerous or undesirable system conditions.
SF 6 An arc extinguishing technology involving the use of sulfur
hexafluoride gas.
Short Circuit A rating of the level of three-phase short circuit current that the
Current circuit breaker can safely interrupt. The short circuit current is a
rating at the circuit breaker’s maximum voltage (ANSI) or voltage
class (IEC).
Switchboard A floor-standing electrical power distribution device for use in
commercial and industrial applications. It divides large blocks of
electrical current into smaller blocks of current used by electrical
equipment.
Switchgear An assembly of switching and interrupting devices, along with
control, metering, protective and regulating equipment.
Transient Recovery The most severe waveform the vacuum interrupter will have to
Voltage withstand.
Trip Unit “brain” of a circuit breaker.
UL Underwriters Laboratory. An independent laboratory that tests
equipment to determine whether it meets certain safety standards
when properly used.
Vacuum An arc extinguishing technology. Features a pair of separable
Interrupter contacts enclosed in a vacuum-tight envelope. Because the
environment inside the interrupter envelope is a vacuum, an arc
cannot be sustained easily.
Voltage Class The highest voltage at which the breaker can operate, according to
IEC charts. The operating voltage where the circuit breaker is
applied should not exceed the circuit breaker’s rated voltage class.