Air Force Field Guide For Inspecting Electrical

AIR FORCE
HANDBOOK
32-1282 VOLUME 1
1 JULY 1999
FIELD GUIDE FOR

INSPECTION,
EVALUATION, AND
MAINTENANCE CRITERIA
FOR ELECTRICAL
SUBSTATIONS AND
SWITCHGEAR
DEPARTMENT OF THE AIR FORCE

THIS PUBLICATION CONTAINS COPYRIGHTED MATERIAL
AFH 32-1282V1
BY ORDER OF THE AIR FORCE HANDBOOK 32-1282V1

SECRETARY OF THE AIR FORCE 1 JULY 1999
Civil Engineering
Field Guide for Inspection, Evaluation and Maintenance

Criteria for Electrical Substations and Switchgear
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
AFH 32-1282V1
Index AFH 32-1282V1
Chapter 2. General Substation Guidance

2-1 Use of Substation One-Line Diagrams.......... 16
2-2 Operating Information.................................... 20 Table 2-1 Installation electrical one-line
diagram deficiencies....................... 21
Table 2-2 Safety electrical one-line diagram
features........................................... 22
Chapter 3. Substation Support Elements
3-1 Substation Tests............................................ 23 Table 3-1 Recommended maintenance based
in IR temperature rises ................... 24
Table 3-2 Maximum acceptable ground
resistances ..................................... 25
3-2 Substation Support Elements EPM Reports . 26 Table 3-3 Substation support elements
general data ................................... 26
Table 3-4 EPM column headings.......................... 29
Table 3-5 Substation support element
readings or test values ................... 29
Table 3-6 Substation support element checks...... 30
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AFH 32-1282V1
Index AFH 32-1282V1
Chapter 4. Circuit Breaker Performance

4-1 Circuit Breaker Basics ................................... 31 Table 4-1 Circuit breaker normal ratings............... 32
4-2 Circuit Breaker Conducting Contacts and Arc
Extinguishing Processes .......................... 32
4-3 Circuit Breaker Operating Mechanisms......... 35 Table 4-2 Circuit breaker stored energy methods. 36
4-4 Circuit Breaker Elementary Diagrams ........... 40
4-5 Circuit Breaker Nameplates........................... 43 Table 4-3 Low-voltage circuit breaker minimum
nameplate information.................... 43
Table 4-4 Medium and high voltage circuit breaker
minimum nameplate information .... 45
Chapter 5. Circuit Breaker Testing
5-1 De-Energized Circuit Breaker General Tests 48 Table 5-1 Circuit breaker insulation-resistance test
values ............................................. 49
5-2 De-Energized Tests Specific to the Circuit
Breaker Type ............................................ 52
Chapter 6. Circuit Breaker Evaluations
6-1 Circuit Breaker EPM Reports ........................ 53
6-2 High-Voltage SF6 or Oil Insulated Circuit Table 6-1 Circuit breaker general data ................. 53
Breakers.................................................. 54 Table 6-2 Circuit breaker readings or test values . 54
Table 6-3 External high-voltage circuit breaker
checks ............................................ 55
Table 6-4 Internal high-voltage circuit breaker
6-3 Medium-Voltage Vacuum or Air Insulated tank procedures and checks .......... 56
Metal-Clad Switchgear Circuit Breakers . 56 Table 6-5 Medium-voltage metal clad switchgear
6-4 Low-Voltage Circuit Breakers ........................ 60 circuit breaker checks..................... 59
Table 6-6 Low-voltage circuit breaker checks....... 60
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Index AFH 32-1282V1
Chapter 7. Interrupter Switch Installations

7-1 Interrupter Switch Basics............................... 63 Table 7-1 Interrupter switch ratings ...................... 64
Table 7-2 Fuse ratings .......................................... 65
Table 7-3 Interrupter switch minimum nameplate
information...................................... 66
Table 7-4 Fuse minimum nameplate information.. 67
7-2 Interrupter Switch Operating Features .......... 67
7-3 Interrupter Switch De-Energized Device
Tests ....................................................... 71 Table 7-5 Interrupter switch test requirements ..... 72
7-4 Interrupter Switch EPM Reports .................... 72 Table 7-6 Interrupter switch general data ............. 72
Table 7-7 Interrupter switch checks ...................... 73
Chapter 8. Switchgear and Switchboard Assemblies
8-1 Assembly Performance ................................. 74 Table 8-1 Industry classification for assemblies ... 79
Table 8-2 MC/MEI switchgear major differences .. 80
8-2 De-Energized Assembly Tests ...................... 81 Table 8-3 Assembly test requirements ................. 81
8-3 Energized Assembly Tests ............................ 81
8-4 Assembly EPM Reports................................. 82 Table 8-4 Assembly general data ......................... 83
Table 8-5 Assembly checks .................................. 84
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AFH 32-1282V1
Index AFH 32-1282V1
Chapter 9. Battery Installation

9-1 Battery Installation Basics ............................. 85
9-2 Battery Installation Readings and Tests........ 89 Table 9-1 Battery installation readings.................. 90
Table 9-2 Capacity test procedures ...................... 92
Table 9-3 Battery capacity degradation ................ 92
Table 9-4 Integrity test procedures ....................... 93
9-3 Battery Installation EPM Reports .................. 93 Table 9-5 Battery installation general data ........... 94
Table 9-6 Lead-acid battery installation corrective
actions ............................................ 95
Table 9-7 Nickel-cadmium battery installation
corrective actions ........................... 96
Table 9-8 Battery installation checks .................... 96
Chapter 10. Protective Sensing, Processing, and
Action Devices
10-1 Device Performance ...................................... 97
10-2 Device Testing............................................... 99 Table 10-1 Relay tests ............................................ 100
Table 10-2 Relay pickup parameters ...................... 101
10-3 Installation-Wide Operating Systems ............ 102
10-4 Protective Sensing, Processing, and
Action Device EPM Reports.................... 102 Table 10-3 Device general data .............................. 102
Table 10-4 Instrument, metering and protective relay
general checks ............................... 105
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AFH 32-1282V1
AFH 32-1282V1
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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AFH 32-1282V1
Chapter 1. Overview of the Guide AFH 32-1282V1
CHAPTER 1. OVERVIEW OF THE GUIDE

1-1. Scope. The condition of electrical power apparatus found in substations is crucial to the
successful operation of all electrical power systems. Switchgear and related equipment are significant
components of the systems. This handbook identifies field procedures which allow early detection of
equipment degradation and other defects which will adversely affect reliability. Appropriate corrective
actions can then be accomplished.
a. General Categories of Substation Equipment. Table 1-1 lists the general categories of
substation equipment covered in this Air Force maintenance handbook. Figures 1-1, 1-2, 1-3, 1-4, 1-5,
and 1-6 have been provided to remind the technician of similar and differing features of various circuit
breaker and switchgear types. Substation equipment categories discussed in AFH 32-1282V2 (Field
Guide for Inspection, Evaluation, and Maintenance Criteria for Electrical Transformers) are listed in Table
1-2.
Table 1-1. Equipment covered in this handbook
Substation support elements providing area safety
Transmission/distribution power-line switching
! Circuit breakers
! Load interrupter switches
Power-line switching unit/assembly necessary sub-elements
! Switchgear/switchboard assemblies
! Battery installations
! Protective sensing, processing, and action devices
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AFH 32-1282V1
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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AFH 32-1282V1
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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3 1. Main circuit breaker

5 2. Group-mounted circuit breakers
7
3. Vertical bus behind
4. Hinged wiring access panels
5. Side access panel
6. Removable cover plates
9 7. Ventilation grille
8. Blank filler plates
1
9. Warning and manufacturer’s labels
6
4
2
Figure 1-6
Low-voltage molded-case circuit breaker switchboard
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AFH 32-1282V1
Table 1-2. Equipment covered in AFH 32-1282V2

Power/distribution transformers Bushings
Instrument transformers Surge arresters
b. Purpose. Equipment deterioration needs to be identified before the equipment
malfunctions or fails (that is, preventative maintenance). This handbook allows local preparation of
electrical preventative maintenance (EPM) procedures. It does not cover catastrophic or operational
failures. Its purpose is to prevent equipment failures resulting from a lack of proper preventative
maintenance.
c. Technician Testing Limitations. The handbook is not a training guide. Air Force
technicians should not use testing/metering/scanning devices around or on energized equipment unless
they have been trained in their use and have satisfactorily demonstrated their knowledge of appropriate
safety precautions.
1-2. Supplementary Information. The maintenance technician should be familiar with and
have available Air Force electrical design, maintenance, and safety manuals.
a. Design. Refer to the installation requirements of AFMAN 32-1180(I) (Electrical Power
Supply and Distribution) which provides Air Force policy and guidance for design criteria and standards
for electrical power supply and distribution systems.
b. Maintenance. Refer to AFMAN 32-1280(I) (Facilities Engineering, Electrical Exterior
Facilities) which amplifies the maintenance and repair guidance of this handbook.
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AFH 32-1282V1
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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AFH 32-1282V1
(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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AFH 32-1282V1
(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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AFH 32-1282V1
! Manufacturer’s service manuals including practices and procedures for:

(a) Installation.
(b) Disassembly/assembly (interconnection).
(c) Wiring diagrams, schematics, bills of materials
(d) Operation (set-up and adjustment)
(e) Maintenance (including parts list and recommended spares)
(f) Software programs.
(g) Troubleshooting guidance.
(3) Systematic Evaluation of Apparatus Condition. Electric apparatus should receive
a systematic evaluation of its condition after an EPM which indicates repairs were necessary beyond
normal expected maintenance. The systematic evaluation should include:
! Reasons for the required repairs.
! Work required to complete the repairs.
! Assessment of the remaining service life.
! Determination of the need for a more frequent EPM.
c. Safety Requirements. Working on or near normally energized lines or parts requires
observance of rules applying to safe working distances, work methods related to whether the line has
been de-energized or left hot, and recognition of work hazards which require more than one worker for
safety. Workers must be qualified for the work and use approved work methods and equipment. Refer
to the requirements of AFH 32-1285 as amplified by AFMAN 32-1185. Always include a tailgate meeting
to address existing site conditions and the procedures to be followed. Work will be done de-energized
unless energized line work is specifically authorized.
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AFH 32-1282V1
(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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AFH 32-1282V1
! Test equipment such as an

(1) Automatic insulation test set (8) Motion analyzer
(2) Dielectric test set (9) Null balance (megohmmeter) earth
(3) Digital ground resistance test set test set (Megger7)
(4) Fault gas analyzer (10) Power factor test set
(5) Infrared imager (11) True root-mean-square (rms) digital
(6) Circuit breaker test set multi-electrical parameters meter
(7) Corona tester (12) SF6 gas moisture analyzer
! Measurement instruments and miscellaneous devices such as a
(1) Cycle counter or timer (4) Multirange noninductive load resister
(2) Digital thermometer (5) Phase shifter
(3) Multirange ac and dc voltmeters and (6) Phase angle meter
ammeters (7) Three-phase sequence indicator
! Contamination washing devices such as a portable nozzle washer truck
! Miscellaneous tools such as
(1) Binoculars (5) Tape recorder, tape, and batteries
(2) Flashlights (insulated) (6) Video camera and accessories
(3) Insulated fuse puller (7) Oil sample bottle and syringes and
(4) Magnifying glass gas sample bottles
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AFH 32-1282V1
! 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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AFH 32-1282V1
Chapter 2. General Substation Guidance AFH 32-1282V1
CHAPTER 2. GENERAL SUBSTATION GUIDANCE

2-1. Use of Substation One-Line Diagrams. A substation is an area or an equipment
group which contains switches, circuit breakers, buses, and transformers. It provides for the switching of
power circuits and for the transforming of electrical power from one voltage to another or from one
system to another. Stations without transformers are more properly called switching stations, but for
simplicity the word substation will be used to include switching stations.
a. Determine System’s Circuit Arrangement. A system is designed to meet load
requirements, reliability, and flexibility. The criticality of the load also means maintainability must be
considered.
b. Basic Circuit Arrangements. Various common distribution systems are shown on
Figures 2-1, 2-2, 2-3, 2-4, 2-5, and 2-6. Understanding how your facility’s distribution system is
configured is the key to providing safe clearing or isolating procedures for any portion of the system
needing maintenance and repair. Figure 2-1 is the simplest circuit arrangement. This simple system
provides no backup reliability and loads cannot be backfed as is the case with Figure 2-2. Selective
systems (Figures 2-3 and 2-4) provide alternate sources of input power. Network systems (Figures 2-5
and 2-6) provide the ultimate in service reliability.
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AFH 32-1282V1
SOURCE OF SOURCE OF
SUPPLY SUPPLY
CIRCUIT BREAKER
TRANSFORMER LOAD
TRANSFORMER CENTER
MAIN DISTRIBUTION BOARD LOOP DISCONNECT

CIRCUIT BREAKER PRIMARY SWITCH
FEEDER LOAD CIRCUITS FEEDER
LOAD CIRCUITS
LOAD UNITS
Figure 2-1 Figure 2-2

Radial system Primary loop system
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AFH 32-1282V1
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 TRANSFORMER
TO OTHER
LOADS

Primary selective system Secondary selective system
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AFH 32-1282V1
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

Spot network system Distributed network system
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AFH 32-1282V1
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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AFH 32-1282V1
Table 2-1. Installation electrical one-line diagram deficiencies

Inaccuracies
Generally not correct due to electrical system changes.
Illegibility
Generally not designed for field service under poor lighting conditions. Drawings may be faded with
small lettering and close linework obscuring safe switching (isolation) requirements.
Distinctive Identification
A unique component identification is not provided. Drawings may indicate only one apparatus item or
switchgear section while other items or sections are noted to be similar.
Unessential Safety Data
Design data such as instrument transformer ratios, surge arrester ratings, and other design information
only complicates understanding safety requirements.1
1
This information should be covered by the EPM apparatus documentation.
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AFH 32-1282V1
Table 2-2. Safety electrical one-line diagram features

Correctness
Diagrams must be kept up to date, otherwise they are useless.
Clarity
Diagrams should ensure that lines are heavy, at least a 1/4-inch (6.5-millimeters) apart, with printing at
least a 1/4-inch (6.5-millimeters) high, preferably done by computer-aided design (CAD). The
drawings will be used under less than desirable conditions so prepare them on the number of sheets
necessary to provide legibility, manageability, and durability.
Component Identification
Each component must have a unique identification shown on the diagram and placed on each
component. Identification means on the actual component must be durable and large enough to be
read at a distance. Place as often as necessary so that there is no question as to the component
being identified. Short alphanumeric designations are better than operating names. Avoid geographic
descriptions. Do not put special warnings on the identification means.
Components Shown
The components to be shown on a diagram are all sources of electrical energy, the devices that can
interrupt this energy, and other major components such as power conductors, power/distribution and
instrument transformers, surge arresters, capacitors, automatic controls, interlocks, and loads.
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AFH 32-1282V1
Chapter 3. Substation Support Elements AFH 32-1282V1
CHAPTER 3. SUBSTATION SUPPORT ELEMENTS

3-1. Substation Tests. Tests of support elements are generally limited to infrared tests on
connections and grounding resistance tests on permanent ground systems.
a. Infrared (Thermographic) Testing. An infrared (IR) temperature measurement locates
high-resistance or hot spot thermal variations due to component failure, fatigue, and mechanical
misalignment.
(1) Precautions. The object being examined will radiate both emitted and reflected IR
energy. Only the emitted IR energy is a measure of the object’s temperature. Measurements will vary
as the geometry of observation varies the angle of incidence. Changing the angle of incidence changes
the reflected IR energy. The IR equipment used should be capable of detecting at least a 1 degree C
temperature difference between the object and the 30 degree C reference area by detecting emitted
radiation and converting it to a visual signal. The IR equipment should allow the user to mathematically
compensate for reflected energy. Correction may be made by entering an estimated emmissivity value
provided by the IR equipment manufacturer or based in the installation’s experience.
(2) Action. Scan all current-carrying equipment and conductor connections during
periods of maximum possible loading. Generally a reading for an equipment/conductor load below 40
percent of its rating will not locate any hot spots. Always measure the IR temperature from several
different positions to minimize the chance of error from reflected IR energy or from solar gain for outdoor
installations.
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AFH 32-1282V1
(3) Interpretation. Infrared hot-spot temperature gradients indicating possible

deficiencies are given in AFMAN 32-1280(I) for equipment. Table 3-1 lists temperature rises above
ambient which have been found practical in regard to equipment problems.
Table 3-1. Recommended maintenance based on IR temperature rises
Temperature rise
above ambient
(degrees C) Recommendation
<10 Repair in regular maintenance schedule; little probability of physical damage.
10-39 Repair in near future. Inspect for physical damage.
40-75 Repair in the immediate future. Disassemble and check for probable damage.
>75 Critical problem; repair immediately
b. Permanent Ground System Resistance Tests. A ground resistance test set can be
used to determine the effectiveness and integrity of the grounding system. See AFMAN 32-1280(I) and
AFMAN 32-1185 for the importance of adequate grounding in operating and maintaining electrical
systems safely.
(1) Precautions. Testings of grounds can create hazardous conditions as all electrical
conductive paths for overvoltage and fault currents are connected to the substation ground system.
Rubber gloves, blankets, and other protective devices are recommended.
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AFH 32-1282V1
(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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AFH 32-1282V1
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.
26
AFH 32-1282V1
Picture 3-1 Picture 3-2

Low-profile substation Bus structure
27
AFH 32-1282V1
Picture 3-3
Circuit
breaker bay
Picture 3-4
Transformer bays and secondary
underground line structures
28
AFH 32-1282V1
29
AFH 32-1282V1
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.
30
AFH 32-1282V1
Table 3-6. Substation support element checks

1. Fences and support structures 4. Buildings
a. Structural (security) a. General housekeeping
integrity b. Lighting
b. Grounding c. Ventilation
c. Surface condition d. Heaters
2. Yards e. Structure condition
a. Adequate warning signs f. Fire protection
b. Acceptable surface 6. Capacitors
treatment a. Operable fuses
c. General housekeeping b. Operable internal resistors
d. Workable lighting system c. Verify automatic operation
e. Environment compliance d. Test and reading per
3. Insulators and air disconnect AFMAN 32-1180(I)
switches 7. Electrical connections and buses
a. Fractures a. Tightness
b. Contamination b. Hot spots
c. Contamination
d. Corrective Action. Describe corrective actions taken. Deficiencies requiring action
beyond the technicians at the site should be indicated as “see note X.” “Note X” should explain reasons.
Such a note might indicate that an aerial bus, insulators, and air disconnect switches need suitable
washing to eliminate excessive contamination.
31
AFH 32-1282V1
Chapter 4. Circuit Breaker Performance AFH 32-1282V1
CHAPTER 4. CIRCUIT BREAKER PERFORMANCE

4-1. Circuit Breaker Basics. Circuit breaker switching is simple to understand. The
complexity arises from the diverse variety of available operating mechanisms and their associated
controls which direct the circuit breaker switching. Circuit breaker maintenance requires close checking
of the circuit breaker manufacturer’s instructions along with understanding the operating and protective
controls for the overall electrical system.
a. Actions. Circuit breakers are switching devices that can make (close), carry, and break
(open) an electrical circuit under both normal and abnormal conditions. Circuit breakers consist
essentially of make-and-break conducting contacts, an arc extinguishing system, an operating
mechanism, and an abnormal-conditions current-detection system.
(1) Normal conditions. Normal conditions are manual and automatic actions occurring
within the circuit breaker’s ratings and when operational conditions require circuit switching.
(2) Abnormal Conditions. Abnormal conditions are those where excessive or fault
current conditions require automatic opening and possibly automatic reclosing after an overcurrent
opening.
b. Ratings. Circuit breaker normal ratings are based on ANSI C37.06 (AC High Voltage
Circuit Breakers Rated on a Symmetrical Current Basis - Preferred Ratings and Related Required
Capability). Maximum ratings are given in Table 4-1. Other continuous current ratings not shown are
1200 and 2000 amperes. Check circuit breaker nameplates for rated short-circuit current.
32
AFH 32-1282V1
Table 4-1. Circuit breaker normal ratings

Maximum voltage kV rms Maximum continuous current, Interrupting time cycles2
amperes
4.76 3,000 5
8.25 2,000 5
15/15.51 3,000 5
25.8 2,000 5
38 3,000 5
48.3 3,000 5
72.5 3,000 5
121 3,000 3
1
First number is for indoor oiless circuit breakers. Second number is for outdoor circuit breakers.
2
Oil circuit breakers manufactured before 1975 may have an 8 cycle rating. This rating affects coordination and short
circuit studies; it does not affect maintenance requirements.
4-2. Circuit Breaker Conducting Contacts and Arc Extinguishing
Processes. Circuit opening of the conducting contacts causes an arc to form which is extinguished
by various methods. Examples of the various types of arc extinguishing media are shown on Pictures
4-1, 4-2, 4-3, and 4-4.
33
AFH 32-1282V1

Air-magnetic circuit breaker Oil-insulated circuit breaker
34
AFH 32-1282V1

Vacuum circuit breaker SF6-insulated puffer-type circuit breaker
35
AFH 32-1282V1
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.
36
AFH 32-1282V1
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
37
AFH 32-1282V1

Motor/spring operating mechanism Blocking a closing spring before
maintenance work
38
AFH 32-1282V1

Pneumatic operating mechanism Hydraulic operating mechanism
39
AFH 32-1282V1
b. Spring-Operating Mechanisms. The stored energy is usually provided by spring-

operating mechanisms. Motor-wound springs store closing/opening energy. Springs are latched either
in the closed or the open position until a manual or automatic direction releases them.
(1) Closing. A latch must hold against a large force to prevent the spring from
unwinding. By providing a main latch, an in-between latch, and a trip latch in series the necessary
releasing electromechanical devices becomes a low-energy system. The three latches act as a
mechanical amplifier. A small amount of corrosion, lack of lubrication, proper alignment on the low-
energy end of the amplifier can prevent the trip latch from operating. A much greater amount of these
defects are needed to prevent the main latch from operating.
(2) Opening. On energizing the trip coil a latch is released or a pilot valve is actuated
and the opening operation goes to completion without necessarily requiring the tripping coil to be
energized through the entire operation.
c. Pneumatic/Hydraulic Operating Mechanisms. Pneumatic/hydraulic amplifiers have a
main valve operated by a pilot valve (directed by the closing or tripping coil). Their design lowers the
electromechanical energy requirement.
d. Auxiliary Devices. Auxiliary contacts indicate the circuit breaker position by energizing
indicating lights. Auxiliary contacts signal the need for early replacement of stored energy spring winding
motors, hydraulic pump/air compressors, and other auxiliary devices when contacts are provided that
monitor the adequacy of that stored energy device.
40
AFH 32-1282V1
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.
41
AFH 32-1282V1
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
42
AFH 32-1282V1
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
43
AFH 32-1282V1
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
44
AFH 32-1282V1
Table 4-3. Low-voltage circuit breaker minimum nameplate information

(cont.)
Molded-case circuit breakers
Manufacturer’s name or trademark LINE and LOAD (if it is an interchangeable trip
circuit breaker or is not suitable for reverse
Type designation or identification number
connection)
Rated current
Rated short-time withstand current (if applicable)
Rated operational voltages with ON and OFF for indicating the closed and open
corresponding rated short-circuit breaking positions at the place of operation.3
1
current
Indication of a required barrier2
1
For circuit breakers rated 250 V maximum with short circuit breaking current of 5000 amperes, the short circuit breaking
current shall be permitted to be omitted.
2
If the proper operations or installation is a dependent upon an insulation barrier
3
If symbols are used, “O” will be used to indicate the open and “I” will indicate the closed position.
45
AFH 32-1282V1
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
46
AFH 32-1282V1
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
47
AFH 32-1282V1
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.
48
AFH 32-1282V1
Chapter 5. Circuit Breaker Testing AFH 32-1282V1
CHAPTER 5. CIRCUIT BREAKER TESTING

5-1. De-Energized Circuit Breaker General Tests. Always test circuit breakers in the
test position. If there is no test position (stationary circuit breakers) test only after the circuit breaker has
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 and
power factors from the test temperature to the reference temperature of 20 degrees C (AFMAN
32-1280(I)).
a. Contact Resistance Tests. Repeated arcing or excessive corrosion of circuit breaker
contacts increases contact resistance which is detrimental to the contact’s ability to carry current.
Increased contact resistance may also indicate loose joints or misaligned contacts.
(1) Application. Apply a direct-current source (of at least 100 amperes of current for
medium and high voltage circuit breakers) from the circuit breaker’s input terminal/bushing to its output
terminal/bushing. Close the circuit breaker and with a low-resistance instrument measure the resistance
of each pole. The average resistance values for 15-kV-class circuit breakers should normally be
between 200 and 250 micro-ohms.
(2) Test Values. The resistance should not exceed the values specified by the circuit
breaker manufacturer for the type, voltage, and current rating of the circuit breaker. Contact resistance
varies with low-voltage circuit breakers and usually is measured by millivolt drop rather than micro-ohm
resistance. In the absence of manufacturer’s data compare the measured pole’s contact resistance to
adjacent poles and/or to similar circuit breakers ratings. Investigate any deviations exceeding the
49
AFH 32-1282V1
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
50
AFH 32-1282V1
5001-15000 volts 2500 volts 5000

15001-25000 volts 5000 volts 20000
35,000 - 69,000 volts 15,000 volts 100000
c. Control Wiring Insulation-Resistance Tests. Perform insulation-resistance tests at
1000 volts direct current. Do not perform the test on wiring connected to solid-state components.
Insulation resistance should be a minimum of 2 megohms.
d. Insulation Power Factor Tests. Use an insulation power factor test set in accordance
with the test set’s instructions. The use of the set requires previous training and the set manufacturer
should supply test-data forms. Limit test voltages to below the line-to-line voltage rating of the circuit
breaker. Take measurements which allow computation of the power factor based on the measured
insulation watts loss divided by the volt-amperes applied. Check power factor for both open and closed
positions of the circuit breaker. Power factor test results should be evaluated on the basis of previous
results but any value above 1 percent warrants investigation.
(1) Precautions. Power factor measurement instrumentation must be well shielded if it
is used in a substation area where there may be a significant level of electrostatic interference. Using a
higher frequency power supply may help solve the interference problem.
(2) Advantages: The insulation power factor test can detect defective insulation in
series with good insulation, a condition that may be masked when using the insulation resistance test.
The insulation resistance test may indicate a false low value of resistance because of the many parallel
paths and the variation due to the volume of the insulation system. A negative power factor is an
indication of tracking across the insulation system.
51
AFH 32-1282V1
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.
52
AFH 32-1282V1
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.
53
AFH 32-1282V1
Chapter 6. Circuit Breaker Evaluations AFH 32-1282V1
CHAPTER 6. CIRCUIT BREAKER EVALUATIONS

6-1. Circuit Breaker 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 Circuit Breaker Information To Be Determined Before The Inspection. Provide
a suitable record header with blank spaces for insertion of the following data given in Table 6-1.
Table 6-1. Circuit breaker general data
Designation Voltage rating
Date of inspection Rated continuous amperes
Location Rated interrupting amperes
Serial no. Operation (manual, electrical, remote control)
Year installed Volts close: ac_____ dc______
Last inspection date Volts trip: ac_____ dc______
Manufacturer Assembly (switchboard, switchgear, none)
Instruction manual Type (stationary, drawout)
Insulation (air, vacuum, SF6, oil) Protective device type and settings
b. Basic Inspection Items To Be Checked. Provide an inspection listing with column
headings covering items to be checked off for each listed number as given in Table 3-4.
53
AFH 32-1282V1
c. Inspection Items To Be Covered. Inspection items to be covered will vary dependant

upon the voltage level and insulation type of the circuit breaker as covered in the following paragraphs of
this chapter. Table 6-2 indicates circuit breaker readings and appropriate evaluation paragraphs for
passing criteria applying to the various circuit breaker types. See AFH 32-1282V2 for bushing,
instrument transformer, and surge arrester requirements.
Table 6-2. Circuit breaker readings or test values
Readings or test value Evaluation reference paragraph
1. Ambient temperature .......................................................................... --
2. Number of operations ......................................................................... --
3. Peak indicating amperes .................................................................... --
4. Contact resistance pole-to-pole (microhms)....................................... 5.1a
5. Insulation resistance (megohms) open, closed1................................. 5.1b
6. Control wiring insulation resistance (megohms) ................................ 5.1c
7. Power factor ....................................................................................... 5.1d
8. Closing speed..................................................................................... 5.1e
9. Opening speed ................................................................................... 5.1e
10. Trip and close minimum operating voltage......................................... 5.1f
11. Low-voltage circuit breaker tripping times .......................................... 5.2a
12. SF6 moisture content ......................................................................... 5.2c
1
For six open terminals, and for three closed phases.
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.
54
AFH 32-1282V1
Table 6-3. External high-voltage circuit breaker checks

Component Inspection Component Inspection
1. Tanks 4. Protective device operation/calibration
a. Paint condition a. Control circuits
b. Bulging, cracking, leaks b. Relays
c. Gasketing or other sealing adequacy c. Alarms
d. Valves open or closed d. Gauges
e. Pressure, air or gas e. Relief devices
f. Support adequacy f. Calibrations
2. Operating mechanisms1 5. Oil insulation
a. General condition a. Filling
b. Control cabinet condition b. Filtering
c. Mechanical clearances c. Sampling
d. Pneumatic operating systems 6. SF6 insulation3
e. Hydraulic operating systems 7. Operation under load
3. Electrical connections a. Malfunctions
a. Tightness b. Friction
b. Hot spots2 8. Heater operation
1
May require lubrication, cleaning, adjusting, and aligning.
2
For infrared checking see Paragraph 3.1.a.
3
See Table 6-2.
55
AFH 32-1282V1
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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Closed protective shutters Open protective shutters
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Exposing arc chutes Cleaning an arc chute
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Table 6-5. Medium-voltage metal-clad switchgear circuit breaker checks

Component inspection Component inspection
1. Anchorage and grounding 3. Air magnetic unit inspections2
2. Operating mechanism check a. Main contacts wipe and gap3
a. Electrical operations functions1, tripping, b. Arcing contacts wipe3
closing, trip-free, antipump, and protective c. Finger clusters
relaying d. Secondary disconnect contacts
b. Mechanical operations, tripping, closing, e. Latches wipe and clearance3
charging, and contact alignment in all f. Contact travel4
positions g. Clearances3
c. Tightness of hardware h. Speed, opening and closing3
d. Cleanliness i. Moving parts, linkages, closing/tripping
e. Lubrication requirements mechanisms, freedom of movement position
f. Racking mechanism, cell fit, and element for quick actions
alignment j. Interlocks properly operating
g. Inspect wiring for security, damage, and k. Arc chutes
terminal connections 4. Vacuum unit inspections
a. Contact erosion and wipe5
b. Adequate vacuum
1
3
With circuit breaker in the test position and using a test coupler. 2Remove arc chutes for inspection
4
Record manufacturer’s recommendation, as found condition, and as left condition.
5
Measure overtravel and determine from manufacturer’s instructions if any measured overtravel is acceptable.
Provide a one-minute alternating-current high potential in accordance with the manufacturer’s instructions. See previous
caution.
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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
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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Molded case circuit breaker Power circuit breaker
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Power contact fingers Control contact fingers
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Chapter 7. Interrupter Switch Installations AFH 32-1282V1
CHAPTER 7. INTERRUPTER SWITCH INSTALLATIONS

7-1. Interrupter Switch Basics. Interrupter switches provide an economical alternative to the
use of medium-voltage circuit breakers.
a. Actions. Interrupter switches can make (close), carry, and break (open) electrical
circuits. They operate as well as circuit breakers under normal conditions. Under abnormal conditions
their fault-interrupting capabilities (fused interrupter switches) do not approach that of a similarly rated
circuit breaker. Closing in on faults can be dangerous if the switch does not have a duty-cycle fault-
closing rating (fault-initiating switch). Motor operators for remote opening/closing of switches are
available. Their use has diminished in recent years because of their many operating problems.
b. Ratings and Nameplates. Standard switch and fuse ratings from manufacturers are
given in Tables 7-1 and 7-2 respectively. Verify ratings with the applicable switch nameplate. Tables 7-3
and 7-4 show minimum switch and fuse nameplate information required by industry standards.
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Table 7-1. Interrupter switch ratings.

Rated Impulse Continuous and Fault-close and Rated short-
maximum kV withstand kV load-break momentary time current
amperes amperes (2 seconds)
kA rms asym. kA rms sym.
5 60 600 40 25
5 60 600 61 38
5 60 1200 61 38
15 95 600 40 25
15 95 1200 40 25
15 95 600 61 38
15 95 1200 61 38
27 125 600 40 25
27 125 600 60 38
38 150 600 30 25
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Table 7-2. Fuse ratings

Continuous Interrupting rating at kV
Current
4.8 kV 15 kV 25.8 kV 27 kV 38 kV
Range
Amperes kA symmetrical
Boric acid type
10-200 19 14.4 10.5 6.9 6.9
.5-400 37.5 29.4 --- --- ---
.5-400 --- 34.8 --- --- ---
.5-720 37.5 29.4 --- --- ---
.5-300 --- --- 21 16.8 16.8
.5-540 --- --- 21 16.8 16.8
Current-limiting type
20-450 50 --- --- --- ---
20-250 --- 50 --- --- ---
7-100 --- --- --- 35 ---
10-80 --- --- --- --- 12.5
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Table 7-3. Interrupter switch minimum nameplate information

Interrupter switches
Manufacturer’s name and address Rated interrupting current and the following,
Manufacturer’s type and designation number where applicable:
Rated maximum voltage ! Operating life expectancy
Rated continuous current 1 ! Rated switching current - single
1 capacitance
Short-time current ratings ! Rated switching current - parallel-
! Rated momentary current connected capacitance
! Rated three-second current ! Rated differential capacitance voltage
Rated impulse withstand voltage [basic (maximum)
impulse insulation level (BIL)] ! Rated differential capacitance voltage
Rated frequency (minimum)
Allowable continuous-current class 1 ! Rated capacitance switching transient
overvoltage ratio
Fault-initiating switches
All the above information except as noted Rated closing time
Rated making current Operating life expectancy
1
Not required for fault-initiating switches.
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Table 7-4. Fuse minimum nameplate information

Manufacturer’s name or trademark or monogram
Manufacturer’s type or identification number
Rated continuous current1
Rated maximum voltage
Rated maximum interrupting current
1
Type identification C, E, or R where applicable for fuse interchangeability
identification.
7-2. Interrupter Switch Operating Features. Operation may be electrically or

mechanically initiated. Safety interlocks may prevent operation. Optional monitoring devices are
available. Interrupter switches, like circuit breakers, have a contact and arc extinguishing system, an
operating mechanism, and an abnormal-conditions current-detection system. Air is the usual insulating
medium and switches are designed only for use on medium-voltage systems.
a. Contact and Arc Extinguishing Process. Generally switches are constructed with both
main and arcing contacts. The main contacts carry the continuous current and the arcing contacts break
the arcing current. Arc chutes are coated to generate a de-ionizing gas under the heat of the arc. The
design lengthens and thus cools the arc promoting rapid extinguishing.
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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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Interrupter Operating
switch door mechanism
open
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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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Table 7-5. Interrupter switch test requirements

Type Test reference Acceptable test value
1. Ambient temperature -- --
2. Contact resistance pole-to-pole (microhms) 5.1a 1001
3. Insulation resistance (megohms) 5.1b Table 5-1
1
Investigate any values which deviate from adjacent poles or similar switches by more than 50 percent.
7-4. Interrupter Switch 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 Interrupter Switch Information To Be Determined Before the Inspection.
Provide a suitable record header with blank spaces for insertion of the following data given in Table 7-6.
Table 7-6. Interrupter switch general data
Designation Last inspection date Short time currents
Date of inspection Manufacturer ! Momentary
Location Instruction manual ! Three-second
Serial no. Voltage rating Operation (manual, electrical)
Year installed Continuous current Type (stationary, drawout)
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headings covering items to be checked off for each listed number given in Table 3-4.
c. Inspection Items To Be Covered. List inspection items to be covered. Table 7-5
indicates interrupter switch readings and appropriate evaluation paragraph for passing criteria. Table 7-7
indicates interrupter switch components and appropriate inspection actions.
Table 7-7. Interrupter switch checks
1. Operating mechanism check 3. Interrupter
a. Mechanical operations a. Main and arcing contacts
b. Motor operations b. Finger clusters
c. Tightness of hardware c. Contact travel
d. Cleanliness d. Switch clearances
e. Lubrication requirements e. Moving parts, linkages, closing/tripping
f. Racking mechanism, cell fit, and mechanisms, freedom of movement
element alignment position for quick actions
g. Inspect wiring for security, damage, and f. Interlocks properly operating
terminal connections g. Arc chutes
2. Fuses and holders 4. Anchorage and grounding
a. Failure
b. Cleanliness
c. Contact surfaces
d. Dropout or expulsion feature
e. Fuse security
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Chapter 8. Switchgear and Switchboard Assemblies AFH 32-1282V1
CHAPTER 8. SWITCHGEAR AND SWITCHBOARD ASSEMBLIES

8-1. Assembly Performance. These assemblies (indoor or outdoor) provide metal
enclosures; supporting structures; electrical interconnections and switching; and interrupting, control,
metering, and protective devices. Industry standards provide technical and physical distinctions between
the various classes of medium and low voltage switchgear and those units defined as low-voltage
switchboard. For your safety be aware of these differences when providing maintenance. Pictures 8-1,
8-2, 8-3, and 8-4 show examples of metal-clad medium-voltage switchgear. Pictures 8-5, 8-6, 8-7, and
8-8 show examples of metal-enclosed low-voltage switchgear.
a. Function. In all cases the purpose of the assembly is to provide a degree of protection to
the enclosed conductors and equipment and also a degree of protection to personnel against incidentally
contacting live parts. Switchboards may not provide individual metal compartments. Switchboard
drawout units are not required to provide the automatic shutters and mechanical interlocks required for
drawout switchgear. Switchgear is designed to meet IEEE standards. Switchboards are designed to
meet NEMA and UL standards.
b. Treatment. Assemblies are enclosed on all sides and the top with sheet metal. They are
normally constructed in modules or cubicles which contain one or more (some switchboards) interrupting
devices or auxiliary equipment. Access is provided by doors or removable covers. Remember that even
for insulated bus THE INSULATION IS NOT DESIGNED TO PROTECT AGAINST ELECTRICAL
SHOCK. Check the general features of assembly construction to assure that enclosures, supporting
structures, protective barriers, and buses provide the overall equipment and personnel protection which
is their principle function.
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Medium-voltage switchgear Rolling out a circuit breaker
75
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Circuit breaker operating mechanism Open contacts
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Low-voltage switchgear Rear of switchgear
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Racking out a circuit breaker Removing control fuses
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c. Construction Requirements. Assemblies are built to specific minimum industry

standards as covered by Table 8-1. Major medium-voltage switchgear differences are given in Table
8-2.
Table 8-1. Industry classification for assemblies
Classification Voltage level Device requirement Bus
requirement
Standard Title
IEEE Metal-clad switchgear1 Medium, Type Drawout circuit Insulated
C37.20.2 MC breakers
IEEE Metal-enclosed Medium, Type Stationary or drawout Bare2
C37.20.3 interrupter switchgear MEI switches
IEEE Metal-enclosed low- Low Stationary or drawout Bare2
C37.20.1 voltage power circuit circuit breakers
breaker switchgear
NEMA PB-2 Deadfront distribution Low Stationary or drawout Bare2
and UL 891 switchboards switching devices
1
Metal-clad switchgear is also classified as metal-enclosed.
2
Insulated bus in some cases may be available as an optional manufacturer’s provision, but bare bus is the minimum
requirement.
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Table 8-2. MC/MEI switchgear major differences

Item MC MEI
Switching device Drawout circuit breaker Fixed or drawout interrupter switch
Compartments Barriered Open
Operation Electrical Manual or optional electrical
Protection Resettable relays Replaceable fuses
Load current switching permitted 1,000 30
Mechanical operations permitted 10,000 500
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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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AFH 32-1282V1
a. Corona Discharges. Electrically charged bodies exert forces (electrostatic) on one

another. If the potential gradient between bodies is high enough, the breakdown level of air (as affected
by pressure, temperature, and humidity) can be exceeded. This breakdown can cause an electric
discharge which results in the formation of corona. Any formation of corona indicates an insulating
deficiency. In switchgear, corona (if it occurs) is usually localized in the tiny air gaps between bus bars
and its insulation or, between two contiguous insulating members.
b. Corona Actions. Corona ionizes the surrounding air converting oxygen to ozone (O3)
and nitrogen and humidity to nitric acid (HNO3). These two by-products along with ion and electron
bombardments of organic materials will damage assemblies. Corona should be checked for using a
detector at each assembly EPM review. Do not wait until the distinct smell, the popping, spitting,
crackling or frying noise, or communication reception interference indicates corona formation.
8-4. Assembly 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 8-4.
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Table 8-4. Assembly general data

Designation Voltage rating
Date of inspection Bus rating
Location Operation (manual, electrical, both)
Serial no. Switching devices
Year installed Type (circuit breaker, interrupter switch)
Last inspection date Elements (stationary, drawout)
Manufacturer Assembly (metal-clad or metal-enclosed
Instruction manual switchgear or switchboard)
c. Inspection Items To Be Covered. List inspection items to be covered. Table 8-3
indicates assembly readings and appropriate evaluation paragraph for passing criteria. Table 8-5
indicates switchgear/switchboard assembly components and appropriate inspection items.
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Table 8-5. Assembly checks

1. General 3. Hardware
a. Heaters a. Security
b. Ventilation b. Lubrication
c. Electrical distress 4. Electrical connection and
d. Corona buses
e. Tracking a. Tightness
f. Thermal damage b. Hot spots
2. Enclosure c. Contamination
a. Structural Integrity d. Insulations
b. Grounding 5. Miscellaneous
c. Surface condition a. Spare equipment
d. Leaks b. Handling devices
e. Internal moisture c. Interior lighting
f. Dust
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Chapter 9. Battery Installations AFH 32-1282V1
CHAPTER 9. BATTERY INSTALLATIONS

9-1. Battery Installation Basics. Storage batteries along with their supporting devices are
necessary for the protection of electrical distribution systems. Equipment damage is prevented by
electrically actuated protective devices. These devices must still sense problems during an electrical
power outage. A battery installation provides the necessary back-up electrical source.
a. Operation. A battery installation contains rechargeable electrochemical type cells. A full-
float operating battery charger continuously connected to the battery acts to maintain the cells in a
charged condition. Battery systems provide low currents for long periods and high currents for short
periods. The battery system’s reserve capacity requirements are based on a duty cycle (usually an 8-
hour operating time period) for which all continuous and momentary loads must be supplied by the
battery with no recharging available from the battery charger. Cells are mounted on racks to eliminate
vibration and connected to minimize voltage drops. Installations must be housed for protection from the
elements and to maintain the optimum operating temperature of 77 degrees F (25 degrees C) for which
they are designed.
b. Battery Electrochemical and Construction Types. A battery cell is composed of the
container, the positive plate (electrode), the separator or retainer, the negative plate (electrode), and the
electrolyte. The two electrochemical types use either a lead-acid or nickel-cadmium electrolyte. The cell
is constructed as either a vented (flooded) or valve-regulated (sealed) unit. For specific information on a
particular type, refer to the manufacturer’s instructions. This chapter is applicable to both electrolyte
types, except as noted. Tests for valve-regulated construction types are not covered in this handbook.
See AFMAN 32-1186, Valve-Regulated Lead-Acid Batteries for Stationary Applications.
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AFH 32-1282V1
(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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Battery and charger High and low level electrolyte marks
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Cleaning a battery terminal Cleaning a battery cell
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c. Precautions. Safety precautions cannot be ignored, since every station battery

installation presents hazards. The importance of using safety equipment, such as rubber gloves,
goggles, aprons, and of having an eyewash water bottle present, cannot be overemphasized. The three
major hazards are from the electrolyte in the battery, the gases emitted by the battery, and the potential
electrical short circuit capability available from the battery’s stored energy.
9-2. Battery Installation Readings and Tests. Readings and tests must be done in
accordance with the safety requirements for energized electrical line work given in Paragraph 1-4.
Convert indicated readings from the test temperature to the reference temperature of 77 degrees F (25
degrees C) (see AFMAN 32-1280(I)). Also see suggested test accessory list for battery maintenance in
AFMAN 32-1280(I).
a. In-Service Energized Readings. The following readings should be taken at not less than
the indicated interval as given in Table 9-1. Methods for checking resistances include using low-
resistance ohmmeters or measuring the millivolt drop during capacity testing. Resistance values may
vary greatly, from less than 10 micro-ohms to 100 micro-ohms. If significant changes in resistances (20
percent above installation value) occur, or manufacturer’s recommended limits are exceeded, workers
should take corrective action. Maintenance personnel should refer to manufacturer’s recommendations
regarding cleaning and re-torquing connections.
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Table 9-1. Battery installation readings

Interval Reading
1. Ambient temperature.
2. Float voltage measured at the battery terminals.
3. Charger output current and voltage.
Monthly 4. Pilot cell data:
a. Cell voltage.
b. Cell specific gravity and electrolyte temperature, corrected for temperature1.
c. Electrolyte level.
1. Ambient temperature.
2. Float voltage measured at the battery terminals.
3. Charger output current and voltage.
Quarterly 4. Measure 10 percent of intercell connection resistances chosen at random.
5. Voltage of each cell.
6. Specific gravity of each cell, corrected for temperature1.
7. Electrolyte temperature and level of one out of each six cells chosen at random.
1. All of the quarterly readings.
Annually 2. All cell-to-cell and cell-to-terminal connection resistances.
3. Infrared readings.
1
Does not apply to flooded nickel-cadmium cells.
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AFH 32-1282V1
(1) Importance of Correct Conductive Path Resistances. The majority of catastrophic

battery failures can be traced to problems within the conduction path of the battery system. The
conduction path includes all internal buses, terminal posts, and connecting straps between cells.
(2) Connections. All connections must remain tightened to manufacturer’s
recommended torque specifications to avoid sparking or excessive heat buildup, possibly resulting in a
battery fire. All connections should be checked for proper torque requirements annually and after a
heavy discharge. Cell-to-cell and cell-to-terminal resistances should be checked and recorded after
torquing.
b. Out-of-Service Energized Tests. The objective of battery testing is to ensure that the
battery system can store the required energy and deliver it efficiently when the need arises. A capacity
test can evaluate the battery’s ability to store the required energy and deliver constant current over
extended periods. An integrity test can determine whether internal battery deterioration or connection
path problems (such as corrosion) would prevent efficient delivery of energy. Each of these tests
requires that the battery be disconnected from the battery charger and tested using an artificial load. The
test disconnection period must have been approved and scheduled so that equipment operation affected
by these tests is not jeopardized. This means an approved and specific date and period for the test.
(1) Capacity Load Test. Capacity test duration should be equal to the duty period for
which the battery was sized (usually 8-hours). The procedure is given in Table 9-2. Provide at least
every 5 years until the battery shows signs of degradation or has reached 85 percent of its life
expectancy. Then provide the test every year. Sufficient degradation capacity to warrant annual
capacity testing varies among battery types. (See Table 9-3.)
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Table 9-2. Capacity test procedures

1. Pre-test conditions, test criteria, parameters, and “stringency” are decided in advance.
2. Battery is isolated from charger and normal load.
3. Constant artificial load is applied through final test voltage or the test duration.
4. Constant current or power loading depends on the application and published data.
5. The objective is to derive the percent actual capacity by comparing actual time to reach a final
test voltage to specified nominal time.
Table 9-3. Battery capacity degradation1

Battery type Degradation
Flooded lead- A drop of 2 percent per year in capacity from the previous capacity test, or the
calcium capacity is below 90 percent of the manufacturer’s rating.
Flooded nickel- A drop in capacity in excess of 1.5 percent per year of rated capacity from the
cadmium previous capacity test.
Valve-regulated The intervals between battery capacity tests are left to the discretion of the
maintenance personnel. Although no drop in battery capacity should occur
during the lifetime of the battery, a battery capacity test should be performed
at specific intervals as a part of the routine maintenance of the battery system
or as abnormal conditions warrant.
1
Indicating a need for yearly capacity tests.
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AFH 32-1282V1
(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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AFH 32-1282V1
a. Basic Battery Installation Information To Be Determined Before the Inspection.

Provide a suitable record header with blank spaces for insertion of the following data given in Table 9-5.
Table 9-5. Battery installation general data
Battery
Designation Cell type
Location Cell size
Last inspection date No. of cells
Date of inspection Ampere-hours at ______ hour rate
Year installed Nominal specific gravity at 77
Manufacturer degrees F1
Serial no. Nominal system float voltage
Instruction manual
Battery charger
Designation Manufacturer
Location Serial no.
Last inspection date Instruction manual
Year installed Nominal system
Date of inspection Float voltage
1
Does not apply to flooded nickel-cadmium cells.
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c. Inspection Items To Be Covered. List inspection items to be covered. Tables 9-1, 9-2,
9-3, and 9-4 indicate battery installation readings and tests and appropriate evaluation paragraph for
passing criteria. Tables 9-6, 9-7, and 9-8 indicate battery installation components and appropriate
inspection actions.
Table 9-6. Lead-acid battery installation corrective actions
Electrolyte level Add water to the high water line
Cell temperatures Deviation of more than 3 degrees C requires determination of cause1,
Resistance Increase of more than 20 percent above installation value, clean, retorque, and
retest connections
Float voltage Adjust to be in recommended operating range
Specific gravity Provide equalizing charges if individual cell or average for all cells specific gravity
drops more than 10 points2
Cell voltage Provide an equalizing charge immediately if any cell voltage is below 2.13 volts at
the time of inspection
1
Replace for short-circuited units. Adjust environment if caused by outside conditions.
2
Adjusted for temperature and electrolyte level. Drop is for difference of individual cells from average of cells at time of
inspection or for all cells from the average installation value.
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Table 9-7. Nickel-cadmium battery installation corrective actions

Electrolyte level Add water to the high water line
Resistance Increase of more than 20 percent above installation value, clean, retorque, and retest
connections
Float voltage Adjust to be in recommended operating range
Cell voltage Provide a high-rate charge if possible if any cell voltage is found to be 1.35 volts or less.
Table 9-8. Battery installation checks

1. Batteries 3. Battery Chargers
a. Physical damage a. Accuracy of meters
b. Cleanliness b. Operation of timers
c. Corrosion or leakage c. Temperature (by touch)
d. Tightness of connections d. Fuse failure
e. Cell cracks e. Alarms
f. Unintentional ground f. Proper relay settings
g. Verify vent cap and flame arresters in place1 g. Cleanliness/corrosion
h. Electrolyte appearance h. Connections
2. Racks
a. Cleanliness/corrosion
b. Structural integrity
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Chapter 10. Protective Sensing, Processing, and Action Devices AFH 32-1282V1
CHAPTER 10. PROTECTIVE SENSING, PROCESSING, AND ACTION

DEVICES
10-1. Device Performance. Electrical systems operate because control devices or systems
function:
! to sense and indicate operating parameters within design requirements for user
information (instruments and meters)
! to process the data when operating parameters have increased to values in excess of
design requirements (protective relays and alarms)
! to actuate protective devices when such action is needed to prevent equipment damage
(overcurrent and fault interrupting protective and switching devices).
a. Indicating Devices. Indicating devices include instruments and meters.
(1) Electrical Instruments. Industry standards define electrical instruments as devices
used to measure the present value of electrical quantities under observation. An instrument may be an
indicating instrument or a recording instrument. By this definition ammeters, voltmeters, and frequency
meters are instruments, not meters.
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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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c. Alarms. A predefined change in the condition of equipment or the failure of equipment to

respond correctly can operate audible or visual indications to announce that the condition needs
personnel attention. Alarms can vary from target indications or relays or contact closures operating
audible gongs with silencing switches or annunciators with nonautomatically reset devices.
d. Safety Items. Isolate control circuits, that is remove control fuses, open test switches,
and operate selector controls as required.
(1) Other Circuits. Keep other overlapping and interconnecting control circuits
associated with operating equipment de-energized if necessary for safety.
(2) Secondary Control Circuits. Isolate control, current, and voltage transformer
secondary circuits to protect against unintentional operation from tests on the device being checked.
10-2. Device Testing. Always test devices in the test position. If there is no test position operate
after the device has 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. Electrically confirm that
current transformer and voltage transformer secondary circuits are intact.
a. Instruments and Motors. Calibration and adjustment are required to meet the
requirements of AFMAN 32-1280(I) and to meet the manufacturer’s published data on accuracy.
b. Protective relays. Verify satisfactory performance of each control, protective functions
and alarm in accordance with the protection scheme and manufacturer’s instructions. Perform the tests
given in Table 10-1.
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AFH 32-1282V1
Table 10-1. Relay tests

Test Criteria
Insulation resistance test on each circuit to frame1 Manufacturer’s instruction manual
Pickup parameters on each operating element System protective requirements
Timing test on at least two points on the time current curve System protective requirements
Pickup target and seal-in unit operation System protective requirements
1
Do not perform this test on solid-state relays.
c. Pickup Parameters. Relays are selected to perform certain functions. To standardize on
reference use, they are given device function numbers by IEEE C37.2 (Standard Electrical Power system
Device Function Numbers). (Device function numbers also describe other electrical power apparatus
equipment in addition to relays.) Device function numbers readily identify devices in drawings, diagrams,
instruction books, publications and specifications. The use of “52” for circuit breakers, “51” for an ac time
overcurrent relay, “65” for a governor, and “86” for a lockout relay provides a simple brief method of
designating the device’s operational performance. Table 10-2 indicates the usual pickup parameters for
relays found in substation switchgear.
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AFH 32-1282V1
Table 10-2. Relay pickup parameters

Device no. Function Parameter settings
21 Distance Ohmic reach/angle of maximum torque
25 Synchronism Maximum closing (phase) angle/closing time
27 Undervoltage Undervoltage pickup
32 Directional power Power pickup and direction
49 Thermal Temperature pickup
50 Instantaneous overcurrent Instantaneous overcurrent pickup
51 Time overcurrent Time overcurrent pickup
59 Overvoltage Overvoltage pickup
63 Pressure Pressure pickup
67 Directional current Per 50 and 51 and direction
81 Frequency Frequency pickup
86 Lockout Lockout/reset features
87 Differential Differential settings
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AFH 32-1282V1
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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AFH 32-1282V1

Plunger-type electromechanical relay Solid-state relay
103
AFH 32-1282V1

SCADA controls Digitally controlled Air Force switchgear
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AFH 32-1282V1
b. Basic Inspection Items to Be Checked. Provide an inspection listing with column

c. Inspection Items To Be Covered. Table 10-1 indicates relay tests and appropriate
criteria. Table 10-4 indicates instrument, metering, and protective relay general checks. For specific
repairs and replacements see the manufacturer’s maintenance instructions.
Table 10-4. Instrument, metering, and protective relay general
checks
Cleanliness Freedom of movement
Connections Contacts
Calibration Gasketing
Multipliers Targets
Alignment Bearing
Damage Operation
JOHN W. HANDY, Lt General, USAF

DCS/Installations & Logistics
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Notes AFH 32-1282V1
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Notes AFH 32-1282V1
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Notes AFH 32-1282V1
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Notes AFH 32-1282V1
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Notes AFH 32-1282V1
110

Air Force Field Guide For Inspecting Electrical

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AIR FORCE

FIELD GUIDE FOR

DEPARTMENT OF THE AIR FORCE

BY ORDER OF THE AIR FORCE HANDBOOK 32-1282V1

Field Guide for Inspection, Evaluation and Maintenance

Index AFH 32-1282V1

Chapter 2. General Substation Guidance

Index AFH 32-1282V1

Chapter 4. Circuit Breaker Performance

Index AFH 32-1282V1

Chapter 7. Interrupter Switch Installations

Index AFH 32-1282V1

Chapter 9. Battery Installation

Chapter 1. Overview of the Guide AFH 32-1282V1

CHAPTER 1. OVERVIEW OF THE GUIDE

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

3 1. Main circuit breaker

Chapter 1. Overview of the Guide AFH 32-1282V1

Table 1-2. Equipment covered in AFH 32-1282V2

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

! Manufacturer’s service manuals including practices and procedures for:

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 1. Overview of the Guide AFH 32-1282V1

! Test equipment such as an

Chapter 1. Overview of the Guide AFH 32-1282V1

Chapter 2. General Substation Guidance AFH 32-1282V1

CHAPTER 2. GENERAL SUBSTATION GUIDANCE

Chapter 2. General Substation Guidance AFH 32-1282V1

MAIN DISTRIBUTION BOARD LOOP DISCONNECT

Figure 2-1 Figure 2-2

Chapter 2. General Substation Guidance AFH 32-1282V1

TO OTHER LOADS TRANSFORMER

Figure 2-3 Figure 2-4

Chapter 2. General Substation Guidance AFH 32-1282V1

Figure 2-5 Figure 2-6

Chapter 2. General Substation Guidance AFH 32-1282V1

Chapter 2. General Substation Guidance AFH 32-1282V1

Table 2-1. Installation electrical one-line diagram deficiencies

Chapter 2. General Substation Guidance AFH 32-1282V1

Table 2-2. Safety electrical one-line diagram features

Chapter 3. Substation Support Elements AFH 32-1282V1

CHAPTER 3. SUBSTATION SUPPORT ELEMENTS

Chapter 3. Substation Support Elements AFH 32-1282V1

(3) Interpretation. Infrared hot-spot temperature gradients indicating possible

Chapter 3. Substation Support Elements AFH 32-1282V1

Chapter 3. Substation Support Elements AFH 32-1282V1

Chapter 3. Substation Support Elements AFH 32-1282V1

Picture 3-1 Picture 3-2

Chapter 3. Substation Support Elements AFH 32-1282V1

Chapter 3. Substation Support Elements AFH 32-1282V1

Chapter 3. Substation Support Elements AFH 32-1282V1

Chapter 3. Substation Support Elements AFH 32-1282V1

Table 3-6. Substation support element checks

Chapter 4. Circuit Breaker Performance AFH 32-1282V1