MasterClad-Non-Arc-Resistant - NEMA Academy 2015

Selection and Application of
MV Metal-Clad Switchgear
Medium Voltage
NEMA Academy 2015
Metal-Clad Switchgear
●The Fundamentals
● Current rating above 1200A up to 3000A continuous
● Capable of interrupting fault currents
●Interrupting capacities from 25kA - 63kA
● Frequent Switching (up to 10,000 mechanical operations)
● Speed of Operation (3 cycles), Limits Fault Damage, I2T
● Apply Protective Relay Schemes w/unlimited combinations
● Re-usable interrupters
● Multi-shot Reclosing Capability
● Increased Safety
● Ease of Maintenance
Schneider Electric - NAOD – The Learning Center 2015 2

Common Applications
Utilities Industry Water Hospitals
Paper Mills, Steel and Pumping Stations, Critical Loads

Power Plants, T&D Chemical Plants Treatment Plants
● Service entrance equipment
● Applications requiring frequent switching
● Redundancy - Automatic transfer schemes
● Primary disconnect for:
- Substations - MV-MCC’s
- Metal Enclosed Lineups - Motor Feeds

One-line Diagram
Example

MetalClad
Switchgear

MasterClad ™
5/15 kV Metal-Clad Switchgear

MasterClad™
27 kV Metal-Clad Switchgear
Base Unit - 2-high

Vertical Section
Type VR Circuit
Breaker

8 Schneider Electric - NAOD – The Learning Center 2015
NEMA - National Electrical Manufacturers Association
• Guide for testing for internal arcing faults
C37.20.7
• Test procedure for AC high voltage generator C37.013
breaker
• Conformance test procedure for AC high voltage C37.09
C.B.
• Preferred ratings for AC high voltage C.B.
C37.06
• Rating structure for AC high voltage C.B.
C37.04
• Design standard for metal-clad switchgear
C37.20.2
& Electronic Engineers
ANSI/IEEE - American National Standards Institute/Institute of Electrical
Applicable Industry Standards
Metal-Clad - Standard Requirements
ANSI C37.20.2
●Removable circuit breaker
●Fully compartmentalized construction
●Grounded metal barriers
●Automatic shutters
●Insulated bus
●Mechanical interlocks
●Disconnect type voltage transformers
● Control power transformers (CPT) and voltage transformers (VT)
●Grounded breaker truck in and between test/disconnected
and connected positions
●Low voltage instrument/control compartment isolated from
primary voltage

10 Schneider Electric - NAOD – The Learning Center 2015
85oC Max
• Plated bus connecting to insulated cables
55oC Min
• Current transformers rating
110oC Max
• External surface (no access to personnel)
70o C Max
• External surface (access to personnel)
50oC Max
• External parts (access to personnel)
65oC Max
• Air in cable compartment
1000m (3300 feet)
• Altitude
- 30oC to 40oC(-22oF to 104oF)
• Ambient air temperature
Operating Conditions – C37.20.2
Temperature Correction Factors (calc)
ANSI C37.20.2 – Section 8.4.1
Ambient Ambient Temperature Example
Temperature Temperature Correction 2000A
o
C o
F Factor Breaker
40 104 1 2000A
45 113 0.95 1900A
50 122 0.89 1780A
55 131 0.84 1680A
60 140 0.77 1540A
65 149 0.71 1420A
70* 158 0.63 1260A
* Maximum temperature for trip unit

Altitude Correction Factors (ACF)
ANSI C37.20.2 – Section 8.3.1
Air insulated switchgears have higher temperature rise and lower BIL withstand
capabilities at higher altitudes.
ACF for Dielectric ACF For Continuous
Altitude(m) Altitude (ft)
Withstand Voltage Current
1000 3300 1 1
1500 5000 0.95 0.991
1800 6000 0.92 0.987
2000 6600 0.91 0.985
2400 8000 0.86 0.970
2700 9000 0.83 0.965
3000 10000 0.80 0.960
3600 12000 0.75 0.950
4000 13000 0.72 0.940
4300 14000 0.70 0.935
4900 16000 0.65 0.925
5500 18000 0.61 0.910
6000 20000 0.56 0.900

MasterClad Switchgear Ratings
Nominal
4.16kV 7.2kV 13.8kV 27kV
Voltage
Maximum
4.76kV 8.25kV 15kV 27kV
Voltage
BIL 60kV 95kV 95kV 125kV
1200A, 1200A, 1200A, 1200A,
Continuous
2000A, 2000A, 2000A, 2000A,
Current
3000A*, 3000A*, 3000A*, 2750A#
Interrupting 40kA, 50kA, 40kA, 50kA, 16kA, 25kA,
40kA, 50kA
Current 63kA 63kA 40kA
Enclosure
NEMA 1, 3R NEMA 1, 3R NEMA 1, 3R NEMA 1, 3R
Type
* One-high construction
# 27.0 kV, 2750A Not UL Listed

VR Circuit Breaker
The VR is completely tested

and certified to all applicable
ANSI circuit breaker standards Open/Close
and is UL Listed Pushbuttons
Rating Nameplate
Spring Charged
Rail Rollers (Both Sides) Indicator
Status Indicator
Manual Charging Handle -
Permanently Mounted On The
Type RI Operating Mechanism

VR Circuit Breaker Features/Benefits
Features Benefits
● Permanently mounted spring ● State of the art vacuum
charging handle interrupter design
● Up to 5NO/5NC auxiliary ● Operating mechanism
contacts - min 2 sets for minimum life - 10,000
customer use mechanical & continuous
● UL label current operations
● Contact erosion indication on ●Except 3000A, 350MVA,
each interrupter pole 750MVA & 27kV - 5000
operations (ANSI)
● Optional dual trip or under-
● Short fault clearing time - total
voltage trip
3cycles (50 milliseconds)
● Lower breaker can be rolled
out directly on to the floor

VR Circuit Breaker
MOC Linkage
Opening & TOC Roller

Closing Springs
Operating
Anti-pump Relay Mechanism - RI
Auxiliary Switch Open/Close
Pushbuttons
Drive Bar & Operations
Crossbar Counter
Open-closed &
Floor Wheels Spring Charge
VR Circuit Breaker With Indicators
Front Cover Removed

VR Circuit Breaker
Primary Pole
Disconnect Assembly
Fingers
Breaker
Runbacks Vacuum
Interrupter
Erosion Gap
Secondary
(E-gap)
Disconnect
VR Circuit Breaker
Rear View Code Plate
Location

VR Circuit Breaker - Operation
● ‘Dumb’ switch waiting for a signal to open/close
● Intelligence provided by protective relays or control devices
● Electrically operated device, requires control power – AC or DC
● DC – Battery systems
●24V, 48V, 125V, 250V
● AC – Remote source or control power transformer (CPT) in switchgear
●120V, 240V
● Trip, Close and Spring-Charge circuits utilize control power
● Capacitor trip device for AC trip after loss of control power
● Connect / Disconnect / Test positioning (racking) by cell floor mounted
operating mechanism
● Mechanical / electrical interlocks prevent incorrect operation
● Required by ANSI/IEEE
● Code plate assures breaker ratings match the cell ratings

VR Circuit Breaker - Operation
Stationary Terminal
Condensing Shield
Stationary Contact
Movable Contact
Ceramic Envelope
Vacuum Dielectric
Moving Terminal
Metallic Bellows

VR Circuit Breaker - Vacuum Interrupters
● Designed for long life

● Vacuum – Protects contacts from dust, moisture, and other
possible contaminants
● Copper-chromium contacts – Hermetically sealed for life
● Arc develops as contacts part and plasma of metallic ions is
released by the contacts.
● Plasma – Path for the electron flow until the interruption occurs
● Condensing shield – Rapid condensation of the metallic vapor
and fast dielectric recovery
● Metallic vapor – Removes gas molecules, assisting in
maintaining the high vacuum

Questions?

MasterClad Structure - Description
●The number of bays on a MasterClad Metal-clad

Switchgear assembly depends on customer specifications.
●Each bay is a separate rigid, self-contained, bolted
structure fabricated of heavy gauge steel.
●Each bay consists of:
● Front section with secondary control devices
● Circuit breaker cell and/or instrument compartment section
● Main bus compartment
● Cable compartment

MasterClad Structure - Features
●Standardization
● All ANSI defined features
● Each switchgear assembly consists of individually grounded, compartmentalized
steel structures to protect operating personnel
● Standardization of the design incorporates a series of basic modular units
● For most switchgear ratings, circuit configurations and functions, one basic size
unit is used
● These features provide applications flexibility, versatility, efficiency and
economy in minimizing engineering time to plan and lay out the switchgear
●Safety Barriers and Interlocks
● Full compartmentalization supplied with primary functions separated by
grounded metal barriers
● Bussing is insulated and live parts are not exposed
● Safety interlocks work with the breaker racking system

MasterClad Structure - Benefits
●Benefits
● Configurations
●Floor Space Economy and Application Flexibility
●Two tier configuration permits feeder breakers to be stacked two high
●One tier configuration combined with auxiliary units for application
flexibility
●Compartmentalization
●Ratings
● Short Circuit Current rating (Bus Bracing) meets or exceeds breaker
close & latch rating
● Continuous Current Ratings:
●1200A, 2000A, 3000A

MasterClad Structure - Types
● NEMA 1 - Indoor (5-15kV Shown)
● NEMA 1 - Gasketed & Filtered (Some derating may be required)

● NEMA 3R - Outdoor Non-Walk In (NWI)
● Sloped drip-proof Roof
● Front bulkhead door
● Rear doors
● 4” base channel
● Add breaker lift truck
5-15kV Structure

●NEMA 3R - Outdoor Walk In (WI)
● Front aisle - single row switchgear (5-15kV Shown)
● Center aisle - double row switchgear
● Aisle includes:
●Exhaust fan, lights, receptacle, switch and panel and wiring
●Un-insulated interior
●Options include AC panel, aisle heater w/ thermostat

MasterClad Structure
Relay &
Cable
Instrument Door
Compartment
Aux Section Or
Breaker
Compartment Barriers Compartment
Inter-bay Control
Wire Areas
Insulated Main Bus
Main Bus Barriers
Automatic Shutters
LV Control
Ground Bus Compartment
Circuit Breaker
Compartment Side View With
Side Cover Sheet Removed

MasterClad Structure - Circuit Breaker Cell
●Racking mechanism moves the circuit breaker from the

test/disconnect position to the connected position and vise
versa
● Cell mounted breaker racking mechanism on cell floor, gear driven
● Shutters driven directly by the racking mechanism - assures
interlocking with the circuit breaker position
● Breaker alignment by extruded aluminum guide rails - slotted to
securely capture the breaker rail rollers on each side of the breaker
● Simplified secondary control plug mounted on cell floor
● Closed door racking with breaker position indicator driven by the
racking mechanism is visible with front door open or closed
● Motor operated racking device - Optional

Breaker Compartment Floor Details
(Highlighted View)
Auxiliary Switch Control Wiring
M-O-C
Cell Switch T-O-C
Auxiliary Switch
Actuator
Insulating Bushing
Around Stationary Main
Current Transformers Bus Contact
Secondary Control
Ground Bus Receptacle
Racking Trip/Spring
Breaker Rating Block Discharge Interlock
Breaker Removal Secondary Control Plug

Latch Cam Operating Handle Used
For Test Position Only
Shutter Locking Provisions Breaker Position

-Padlock/Key Interlock Indicator
Breaker Alignment Rails

●Primary HV contacts & insulating tubes

● Glass polyester tubes std. - optional porcelain
● Epoxy tubes only for 27.0 kV
●Ground bar assures breaker is grounded
in all operating positions
●Mechanism Operated Contact (MOC)
● 5NO/5NC Form C contacts, non-convertible
● Additional contacts to trip/ close breaker or
indicate breaker status
●Truck Operated contacts (TOC)
● 5NO/5NC Form C contacts, non-convertible
● Contacts indicate breaker position in cell

●Current Transformers CT Ratios Accuracy Max

●Window type mounted on Thickness
Single Ratio Standard 3.38”
insulating bushing around
Single Ratio High 6.75”
stationary main bus
Multi-Ratio Standard 3.38”
contact*
Multi-Ratio High 6.75”
● Mounting: Two standard
accuracy CTs or one
high-accuracy CT on
each set of bushings i.e.
each side of breaker
*Bar type CTs can be supplied for special applications. Window type CTs can be
mounted in cable compartment in special cases. Consult factory

MasterClad Structure - Main Bus
Compartment
● Located in center of switchgear

● Has removable access plates
● 5/15 kV, 1200A & 2000A main buses in aluminum
or copper
● 3000A main bus is always copper
● 27kV bus is always copper,
● Bus bars are epoxy insulated
● Glass polyester barriers support bus & separate
between sections
● Optional porcelain inserts available
● 27kV is always epoxy supports
● PVC boots insulate connections

MasterClad Structure - Cable
Compartment
● Each circuit breaker has a separate cable
compartment
● PVC boots insulate connections
● Rear bolted access covers (upper and lower)
● Optional rear door for NEMA 1
● Outdoor is always full height padlockable door
● Load bus includes NEMA 4-hole pattern
● Optional lugs
● Common ground bus with lug
● Cable barrier (chimney) for 2-high breaker
sections isolates 2 sets of cables in the same
compartment
● Options: Cable support bracket, bus duct
connections

MasterClad Structure - Surge Arresters
● Safely divert damaging voltage transients
induced by lightning or system switching,
to ground
● “Insulator” with non-linear resistor. High
resistance at normal voltage, while low
resistance at high voltage. Inactive during
normal system operation. Operate only under
HV transients. Arresters
● Can handle high current surges
● System voltage and design determines their
type and justification
● Classes: Distribution class*, Intermediate
class, Station class
● Mounted in cable compartment
*27kV Gear - Intermediate & Station class only

MasterClad Structure - Surge Capacitors
● Absorb and store surge energy, and release back into the system
● Offer high impedance at power frequency while low impedance for
surges which result in high frequency waveform
● Very fast response time as continuously active
● Cannot absorb high current surges. Usually applied along with surge
arresters to protect against high current surges
MasterClad Structure – Snubbers
ZORC Surge Suppressor Operation
● Voltage and frequency dependent
● Comprises capacitors, resistors and
Zinc Oxide (ZnO) non-linear arresters
● Normal mains frequency conditions:
● Capacitive elements offer high
impedance effectively “disconnecting”
the resistive components and
minimizing heat dissipation
● High frequency transient conditions:
● Capacitive elements offer low
impedance effectively "inserting" the
resistive components in the power
system as a cable-terminating network,
i.e. voltage refraction and reflection of
steep wave-fronts are minimized,
voltage doubling is avoided, and high
frequency re-strike current zeros in the
switch are eliminated

MasterClad Structure – Snubbers
ZORC Surge Suppressor - Benefits
Performance Without ZORC Surge
Suppressor
● Protection of motors and transformers
from steep wave-front, short rise-time,
high magnitude, spikes, surges and
other transient voltages, generated by
switching, lightning and other sources
● Eliminates multiple pre-striking and re-
striking transients associated with
switchgear
Multiple Pre-striking During Routine Motor Switch-on
Multiple Re-striking During Interruption Of A

Motor Starting Current. I.E. Stalled Tripping Clean Switch-on Of Motor With ZORC Surge

MasterClad Structure - Zero Sequence or
Ground Current Transformers
● Monitor the sum of all phase and neutral

currents to determine zero-sequence vector
of the system. The vector represents
ground fault current.
● Unlike individual phase CTs, one ground CT
surrounds all phases and neutral
● Under normal conditions, the sum of all the
currents should be zero as all incoming and
outgoing current pass through the CT
● Under ground fault conditions, some of the
current passes through ground and does
not return through the ground CT resulting
in a non-zero output
● Lower ratios (50:5) used to gain sensitivity

MasterClad Structure Cable
Compartment
●Infrared Windows
● Enable thermographers to safely
inspect electrical installations for
faulty conditions
● Standard make and model –
IRISS VPT-50, VPT-75, VPT100 *
(Other options available as special) Fault With An Electrical Fuse Block
● Useful Temperature Rating:
IRISS VPT-50,
-40°C (-40°F) to 200°C (392°F) VPT-75, VPT100
● Water and dust ingress: IP65 / IR Windows
NEMA 4: closed and when in use
● IRISS VPT Datasheet
* Source - Source - http://en.wikipedia.org/wiki/Thermography

GNU Free Documentation License
MasterClad Structure - Aux Draw-out Units
●5 & 15 kV - VT, CPT, & Fuse Truck

Draw-out Units
● Consists of self contained drawers
● Drawers roll on two sliding extension
rails
● Barriers prevent access to HV
stationary contacts
● VT’s up to 3 per drawer, w/primary &
secondary fuses
● CPT up to 15KVA in drawer w/primary
fuses & secondary breaker
● Use fuse truck for CPT above 15kVA
and all 3 phase

MasterClad Structure - Aux Draw-out
Units
●27 kV - VT, CPT, & Fuse Truck Draw-out Units

●Consist of self contained draw-out unit
●Cell mounted racking mechanism (similar to circuit
breaker racking mechanism)
●CPT units are all fixed mount with fuse trucks (full
section required)
●Half a section required per draw-out VT
●Hard bussed primary connections

MasterClad Accessories
Breaker Lift Truck
●Upper circuit breaker

compartment and
auxiliary draw-out
locations A, B, C and D
●Lift truck capacity rating
● 950 lbs capacity

Type VR Electric Racking Device

Wall Mounted Test Cabinet
● External control power
● Small enclosure with a power on-
off toggle switch
● White power-on indicating light
● Red circuit-breaker-closed
indicating light
● Green circuit-breaker-open
indicating light
● CLOSE and OPEN push buttons
● 8 ft. (2.4 m) cable with a
secondary control receptacle that
can be
● Plugged directly into the circuit
breaker control plug

Breaker Remote Control Box
●25 feet cable

●Open, Close and
Permissive pushbuttons

Ground & Test Device
●Manual or automatic
●Safety devices
●Grounding of circuits
during maintenance
periods
●Connection points for
applying voltage for hi-pot
testing and cable testing
●Access to both line-side
and load-side circuits for
phase sequence testing

Masterclad 15kV Layouts
1” Door
Breaker / Breaker Structure Auxiliary / Breaker Structure

Masterclad 27 kV Layouts



Competitive Comparisons
Medium Voltage MetalClad Competition
Eaton (non arc-resistant)
● MasterClad’s Weaknesses
● 5-15kV 4000A continuous current
● 5-15kV 63KA interrupting & bracing
● 26” wide, 5kV, 1200A
●Optional low profile version
– 26” wide, 5kV, 1200A
– 80” high, 72” deep (top cables,
80” deep (bottom cables)
● 38KV
● Marketed as “Corona-free” design
● Active optional corona monitoring
● VCP-WG generator rated breakers
● MasterClad’s Strengths
● 3 cycle breakers, optional for VCP-W
● Standard-lower breakers roll directly
onto floor without truck or breaker rails.
Optional for VacClad-W.
● 27kV N1 2750A (non forced air)
● 27kV N3R 2-high
● 27kv 2-high depth (110.5” vs. 118.75”)
● 5-15kV N1 91” deep vs. 96.25”
● 5-15kV Arc Terminator
Schneider Electric - NAOD – The Learning Center 2015

Eaton VacClad-W 53
Powell (non arc-resistant)
● 26” wide, 5kV, 1200A
●72” deep 1-high, 84” deep 2-high
● 38KV
● “OnBoard Racking”
● 27kV N3R
● 27kv N1 depth (110.5” vs. 116.5”)
● 5-15kV N1 91” deep vs. 96.25”
● Automatic engagement of secondary
harness
● Relaying & Metering offers within SE

Powell PowlVac 54
Siemens (non arc-resistant)
● 38KV
● 3 cycle breakers, optional for GM-
SG
● 5-15kV N1 91” deep vs. 98.5”
● 27kV offer

Siemens GM-SG 55
ABB (non arc-resistant)
● AMVAC
●Magnetically actuated mechanism
●See next slide
● 5-15kV N1, 1-high, 85 deep”
● Advance’s unique construction

●galvanic steel, Marketed as
surface shall not peel, scratch,
rust or corrode
● 5-15kV N1, 2-high, 91” deep vs. 92”

ABB Advance 56
ABB AMVAC Circuit Breaker
● Operating mechanism rated for 100,000
operations
● 10 times ANSI requirement
● Interrupter assemblies rated for 30,000 full
load operations
● Eaton is now offering magnetically (linear)
actuated breaker in Metal Enclosed MEF
breaker platform

Competitive Comparison - Summary
Product Feature Square D GE/Powell Eaton Siemens ABB
27kV offer + - ++ -- -
63kA/1500 MVA rating + + + + +
3500A / 4000A (fans) + + + + -
Corona-Free w/P.D. Sensors + - + - -
26” Width / 5 kV - + + - -
38kV MC Switchgear -- ++ ++ + -
5-15 kV AR gear (passive) ++ - - - +
5-15 kV AR gear (active) ++ - - - -
Complete OEM/Retrofit Offer ø + + ø ø
Mag Actuated Breaker - - + - ++
“+ +” - Superior & Competitive Advantage “- -” - A Significant Weakness and Competitive Disadvantage

“+” - A Strength & Competitive Advantage “-” - A Slight Weakness and Competitive Disadvantage
“ø” - Neutral

Competitive Comparison - MetalClad
Other Considerations
Issues Alternative
● 3000A N3R NWI enclosures  Specify a Power Zone Center
● Competitors meters  Prefer Powerlogic
● Competitors relays  Prefer Sepam, DC control power
● VT’s/CPT above 3000A breaker  Place in adjacent section
● Utility metering sections  Prefer our std metering sections

Questions?

Thank you!

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Selection and Application of

Schneider Electric - NAOD – The Learning Center 2015 2

Paper Mills, Steel and Pumping Stations, Critical Loads

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Base Unit - 2-high

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* Maximum temperature for trip unit

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The VR is completely tested

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Opening & TOC Roller

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● Designed for long life

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●The number of bays on a MasterClad Metal-clad

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●Racking mechanism moves the circuit breaker from the

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Breaker Removal Secondary Control Plug

Shutter Locking Provisions Breaker Position

Breaker Alignment Rails

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●Primary HV contacts & insulating tubes

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●Current Transformers CT Ratios Accuracy Max

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● Located in center of switchgear

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*27kV Gear - Intermediate & Station class only

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Multiple Re-striking During Interruption Of A

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● Monitor the sum of all phase and neutral

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* Source - Source - http://en.wikipedia.org/wiki/Thermography

●5 & 15 kV - VT, CPT, & Fuse Truck

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●27 kV - VT, CPT, & Fuse Truck Draw-out Units

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●Upper circuit breaker

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●25 feet cable

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