Switching Behavior of Different Contact

Materials under Capacitive Switching Conditions

Florian Krner
1
, Manfred Lindmayer
1
, Michael Kurrat
1
, Dietmar Gentsch
2
1
Institut fr Hochspannungstechnik
und Elektrische Energieanlagen,
Technische Universitt Braunschweig,
Schleinitzstrae 23, 38106 Braunschweig, Germany
2
ABB AG,
Calor Emag Mittelspannungsprodukte,
Oberhausener Strae 33, 40472 Ratingen, Germany

Abstract- For vacuum circuit-breakers capacitive current
switching means a specific operating condition. Though it
differs notably from the short-circuit current interruption
situation, the circuit-breaker design needs to be
reconsidered and adapted. Capacitive switching combines
high inrush-currents at the connection of a capacitive load
and considerable low breaking currents at its
disconnection. A reliable dielectric performance of the
breaker is required since the occurrence of a restrike
under recovery voltage stress can cause voltage escalation.
In terms of a reliable performance of the circuit-breaker
the choice of contact design and material takes centre stage.
The behavior of various contact materials and designs are
studied during a series of tests, representing complete
switching cycles for a 24 kilovolt (kV) system voltage. The
test series is comprised of making operations and current
interruptions followed by a subsequent capacitive recovery
voltage. Under these conditions diverse variants of
copper-chrome composite materials are analyzed and
contrasted. Thereby the effect of additive materials is
observed.
The pre-arcing behavior and the occurrence of restrikes
are observed as an indication of the alteration of the
contact systems dielectric condition during the test series.
In this regard the tested CuCr contact types show a
distinctly differing behavior in their pre-arcing and
restrike performance. Furthermore a serious erosion of
the contact surfaces can be observed occasionally. This can
affect the dielectric condition of the contact system
significantly. In addition optical investigation of arcing
periods by high-speed movies show the localization of an
arc being established on the contacts and particles
escaping the contact gap can be noticed.

I. INTRODUCTION
Switching of capacitive currents represents a specific
operating condition for circuit-breakers representing a
high demand on the dielectric performance of the
breaker. The test specifications given by the relevant
IEC standards [1] comply with these conditions.
The connection of a capacitive load to the system
may involve inrush-currents of some kiloamperes (kA)
at a multiple of the power frequency [2]. Inevitably this
connection is associated by a pre-breakdown at the
circuit-breaker at a certain moment during contact
closing. The pre-arcing heats the contact surface locally
and can cause contact welding. Following breaking
operation this welding is ruptured and tips are left on the
contact surfaces. Some of these tips may be removed by
an arc during breaking operation. At the interruption of
capacitive loads, current is significantly lower than
short-circuit current, e.g. in the range of hundreds of
amperes. Hence the smoothing effect of the
circuit-breaking arc is distinctly reduced. Furthermore
the combination of contact welding and rupture can
produce a severe deterioration of the contact surface
structure in the macroscopic and the microscopic scale.
Subsequently under capacitive switching conditions the
circuit-breaker is stressed by a recovery voltage of up to
twice the system voltage. In the event of restrikes, a
voltage escalation can be caused due to the trapped
charge on the capacitor [3, 4]. Consequently, reliable
dielectric performance of the breaker is essential.
For the capacitive switching performance, the
occurrence and the probability of a breakdown of the
contact gap is an important factor. Firstly, the
breakdown at pre-arcing determines the duration of the
heat input into the contacts due to arcing. Hence, the
breakdown behavior affects the subsequent alteration of
the contact surface condition. Secondly the occurrence
of a breakdown in terms of a restrike after current
interruption is the limiting factor in view of the
capacitive switching capacity of the circuit-breaker [1].
Fig. 1: Basic synthetic test circuit.

II. TEST PROCEDURE
The capacitive switching tests comprise both making
and breaking operations. The test currents and the
capacitive recovery voltage are supplied by a synthetic
test circuit as shown in Figure 1, which includes the test
23rd International Symposium on Discharges and Electrical Insulation in Vacuum, 15.-19. September 2008, Bukarest, Rumnien

switch S
TEST
connected to the high current circuit (left)
and the high voltage circuit (right). The former is
supplying the test current for both the making and the
breaking operation by discharging the capacitor bank C
1

over either inductance L
C
or L
O
. The high voltage circuit
supplies the capacitive recovery voltage, which is
applied to the test switch S
TEST
subsequent to a current
interruption.
At making operation the contact gap is stressed by
20 kV direct current (dc) voltage and an inrush-current
of 4.5 kA and 250 hertz (Hz) frequency is applied to the
circuit-breaker. The breaking operation is associated by
500 ampere (50 Hz) breaking current and subsequently
the contact gap is stressed by a capacitive recovery
voltage of 50 kV (50 Hz). It is referred to as the peak
voltage for 24 kV power systems. The configuration and
the operation of the synthetic test circuit are described
in detail in reference [5].

Fig. 2: Making operation oscillogram.

For all of the tests, a test switch is used which
comprises a vacuum test vessel and an electro-magnetic
drive. The drive provides the appropriate contact closing
and opening speed. The test vessel permits the
installation and investigation of various contact types.
All tested contacts are 45 millimeters (mm) in diameter.
The contact gap is adjusted to 12 mm and the contacts
are surrounded by a vapor shield mounted insulated
from either contact.
To evaluate the dielectric behavior of the
circuit-breaker under capacitive switching duty for each
of the contact types, a series of 100 making and
breaking operations is executed. During making
operation the moment of pre-arcing and the present
remaining contact gap are detected. Figure 2 shows a
typical oscillogram of a making operation.
The pre-arcing field strength is calculated by the
division of applied voltage through residual contact gap
at the moment of pre-arcing. A low pre-arcing field
strength corresponds to early pre-arcing with a bigger
residual contact gap. As a consequence, the pre-arc has
more time during closing operation to heat up the
contact material. The pre-arcing field strength gives
information about the actual dielectric condition of the
contact system and the welding possibility during the
present closing operation.
The observation of restrikes occurring after breaking
operation and under capacitive recovery voltage stress
reveals again the dielectric strength of the contact gap
but now after welding during closing and subsequent
rupture during opening operation. The current and
voltage curves of an exemplary opening operation with
a breaking peak current of 500 amperes (A) are plotted
in Figure 3.

Fig. 3: Breaking operation oscillogram.

III. EXPERIMENTAL RESULTS
A test series with 100 operations is carried out with
each of the contact types consisting of a making and a
breaking test. Moreover the number of tests refers to the
requirements of the relevant IEC standard [1]. Special
attention is given to the alteration of contact surface
condition and hence the dielectric strength of the contact
gap.
At making operation the contact cap is stressed by
20 kV dc voltage and the contact gap decreases
continually as the moving contact approaches the fixed
one. At a certain moment the electric field strength
exceeds the dielectric strength of the contact system and
a breakdown occurs [6, 7, 8].
Pre-arcing field strength in kV/mm
Pre-arcing field strength in kV/mm
Test series a
Test series b
Test series c
Test series d
Fig. 4: Cumulative frequency and Weibull Distribution function
of pre-arcing field strength in test series a through d.

The cumulative frequencies of the pre-arcing field
strength for test series a through d and the Weibull
Distribution functions are given in Figure 4. The
contacts are made of solid-state-sintered CuCr 75/25.
The contact pairs in the test series a, b, c, and d are from
two different material production lots. Test series a and
c have flat type contacts and test series b and d have
23rd International Symposium on Discharges and Electrical Insulation in Vacuum, 15.-19. September 2008, Bukarest, Rumnien

Continuous number of switching operations
Pre-arcing after field emission currents
p
r
e
-
a
r
c
i
n
g

f
i
e
l
d

s
t
r
e
n
g
t
h

i
n

k
V
/
m
m
spiral type contacts. The test results of two different
contact types with two different materials are shown.
The contact surface during the test series is affected
by the previous switching cycles. Thus, the making
operations are observed in turn with the subsequent
breaking operation and vice versa. The contacts are
opened implicating the breaking up of contact welding.
Due to the relatively low current conducted by the
evolving arc, the smoothing effect of the arc is
considerably reduced. This results with the possibility
of reignitions or restrikes after rising of the recovery
voltage following current interruption. The cumulative
frequency of restrike events over all test series as a
function of the continuous number of switching
operation during each test sequence is shown in Fig. 5.
Fig. 5: Cumulative frequency of all restrike events.

After current interruption the capacitive recovery
voltage is applied to the contact gap as it reaches its
final distance and the bulk of contact bouncing has
decayed. It is assumed that a cold vacuum gap is
stressed by the recovery voltage. The restrikes mainly
occur in the rising parts of the recovery voltage. The
most restrikes take part at a momentary voltage of more
than 37 kV as can be deduced in Figure 6 from the
increase of the cumulative frequency of restrike events.












Fig. 6: Cumulative frequency of all restrike events.

Rest nce of
pa

Fig. 7: Pre-arcing field ength and occurrence

ontact surface c for particle
fo
rike events are triggered by the occurre
rticles or field emission currents [7]. However, if
there are particles or field emission currents and no
restrike event takes place, the question arises if
influence on the subsequent pre-arcing field strength is
visible? Thus, for some test sequences the field
emission currents after breaking operation are measured
and compared to the subsequent pre-arcing field
strength. The result of one test series is shown in
Figure 7. The occurrence of field emission currents
during the preceding breaking operation results in small
pre-arcing field strength values.











-str
of field emission currents.
ondition is important
Switching operation
with restrike
The c Square root
approximation
rmation or field emission currents. During pre-arcing
and contact touch, the arc foot points are heating up the
contact which leads to local molten areas on the surface
and the formation of micro-welds. During contact
separation these welds are broken and result in material
displacement on the contact surfaces. After a complete
test series, an extensive tip is formed on one of the
contact surfaces whilst on the opposite contact surface a
crater has developed. Predominantly the contact
material is detached from the moving contact forming
the cathode and is deposited on the fixed contact. After
starting of material transfer at certain locations on the
contact surface, pre-arcs or restrikes primarily stress
these areas supporting the formation of a growing
material deposit and removal respectively. Thus, the
damage of the surface is centered on a particular area on
the contact. In Figure 8 these erosion areas are measured
at both contacts for test series a through d.
i
Continious number of switching operations
0
20
40
60
80
100
120
140
160
test series a test series c test series b test series d
e
r
o
s
i
o
n

a
r
e
a

i
n

m
m

anode cathode
Momentary recovery voltage just before restrike

Fig. 8: Erosion area of anode and cathode contact.


Figu type
contacts on the left side (test series a and c) and for the
th
dielectric strength of the contact system is
influenced by the e contact surface
co
re 8 shows the erosion areas for the flat
e spiral type contacts on the right side (test series b
and d).
IV. DISCUSSION
The
variation of th
nditions from numerous capacitive switching
23rd International Symposium on Discharges and Electrical Insulation in Vacuum, 15.-19. September 2008, Bukarest, Rumnien

switching operations
w
series using various contact
m
operations shows no significant correlation
be
faces. After many
sw
gap significantly. The eroded
co
apacitive switching duty has a significant impact on
the contact surface cuit-breakers. This
re
shows no significant correlation
b
faces. After many
sw
spiral type CuCr contacts
te
[1] IEC 62271-100:2003-05, High-voltage switchgear and
controlgear Pa tage alternating-current

[5] F
[6] E

[8] F

E-ma
M.Lindmayer@tu-bs.de
om
operations. Besides statistical distribution, the moment
of a dielectric breakdown is determined by the previous
history of the contact system.
The pre-arcing field strength is changing during the
test series. There are subsequent
ithin one test series of a contact pair with conditioning
or deconditioning effects. Low pre-arcing field strengths
correlate with long arcing times. Thus, the heat input
reaches maximum values. The lowest pre-arcing field
strength was 1.8 kV/mm, which is equivalent to a
contact gap of 11 mm.
During the breaking tests restrikes are observed.
Considering all test
aterials, between 2 and 15 restrikes can be counted
within 100 making and breaking operations illustrating
the high dielectric stress of capacitive switching. About
half of the restrikes take place during the first half
period of the recovery voltage. Sometimes field
emission currents occur during the recovery voltage
time. This field emission current can be changed by a
restrike event as the test results revealed. The reason is
an alteration of the contact surface because of the
restrike.
The comparison of subsequent making - breaking -
making
tween pre-arcing before or after one restrike.
However, strong field emission currents after breaking
operations correlate with early pre-arcing at low field
strengths. The pre-arcing represents the classical
dielectric breakdown in vacuum.
The inrush current during making operation causes
degradation of the contact sur
itching operations material transfer and contact
erosion become visible. There are two reasons for the
material transfer: 1) erupted metal particles from the
molten surface areas and 2) rupture of the welded areas
during opening operation. High-speed movies recorded
during switching operations and surface measurements
of the contacts after the test series support these
explanations. Therefore, it is assumed that the
occurrence of restrikes is caused by the particle induced
vacuum breakdown.
The material transfer after many switching operations
reduces the contact
ntact area becomes a preferred starting point for the
pre-arcs during making operation. In general, the spiral
type contacts show a better dielectric behaviour. Thus,
the erosion area of these contacts is bigger and the depth
of this area is shallower. The arc movement through the
radial magnetic field leads to a wider distribution of the
eroded area and reduced erosion of the contact. The
erosion is more distinguishable with flat type contacts.

V. CONCLUSION
C
s of vacuum cir
sults from the severe stress on the contact surfaces as
a result of the capacitive current switching operations.
In the course of numerous operations a serious material
transfer between the contacts becomes visible. This
macroscopic surface deterioration and the developing
microstructure determine the dielectric condition of the
contact system.
The comparison of subsequent making - breaking -
making operations
etween pre-arcing before or after one restrike,
However, strong field emission currents after breaking
operations correlate with early pre-arcing at low field
strengths. The pre-arcing represents the classical
dielectric breakdown in vacuum.
The inrush-current during making operation causes a
degradation of the contact sur
itching operations material transfer and contact
erosion become visible. There are two reasons for the
material transfer: 1) erupted metal particles from the
molten surface areas and 2) rupture of the welded areas
during opening operation.
Therefore, the different pre-arcing and restrike
behaviors of the flat and
sted clearly shows the importance of the pre-arc
energy input into the contact surfaces. Besides this, the
material properties affect the contact welding and the
surface formation. Additionally the properties
determining the probability of particle detachment
during recovery voltage are of particular relevance. The
difference between the two tested CuCr 75/25 contact
material production lots is of minor importance.

REFERENCES

rt 100: High-vol
circuit-breakers, Edition 1.1, 2003
[2] I. Bonfanti et al., Shunt Capacitor Bank Switching Stresses
and Test Methods, lectra No. 182, pp. 165-189, 1999
[3] C. Slver et al., Capacitive Current Switching State of the
Art, lectra No. 155, pp. 33-63, 1994
[4] R. P. P. Smeets, A. G. A. Lathouwers, Capacitive Current
Switching Duties of High-Voltage Circuit Breakers:
Background and Practice of New IEC Requirements, Proc.
IEEE Power Engineering Society Winter Meeting, Singapore,
Vol. 3, pp. 2123-2128, 2000
. Krner, M. Lindmayer, M. Kurrat, D. Gentsch Contact
Behavior in Vacuumunder Capacitive Switching Duty, IEEE
Trans. on Dielectrics and Electrical Insulation, Vol. 14, Issue
3, pp. 643-648, J une 2007
. Dullni, D. Gentsch, I. Kleberg, K. Niayesh, W. Shang,
Switching Capacitive Currents, Proc. 21
st
ISDEIV, Yalta,
1 pp. 407-4 0, 2004
[7] E. Dullni, D. Gentsch, I. Kleberg, K. Niayesh, W. Shang,
Switching of Capacitive Currents and the Correlation of
Restrike and Pre-ignition Behavior, IEEE Trans. on Dielectr.
and Electrical Insulation, Vol. 13, No. 1, pp. 65-71, 2006
. Krner, M. Lindmayer, M. Kurrat, D. Gentsch,
Requirements for VacuumCircuit-Breakers under Capacitive
Switching Duty 19th International Conference on Electricity
Distribution (CIRED), Paper 0579, Vienna, 2007
il of authors: F.Koerner@tu-bs.de;
M.Kurrat@tu-bs.de
Dietmar.Gentsch@de.abb.c
23rd International Symposium on Discharges and Electrical Insulation in Vacuum, 15.-19. September 2008, Bukarest, Rumnien