SUBSTATION COMMISSIONING COURSE Page 1 of 46

SUBSTATION COMMISSIONING
COURSE

MODULE ONE

MEDIUM VOLTAGE
SWITCHGEAR ASSEMBLIES

Written by:
Raymond Lee, Technical trainer
Copyright ©2010

Electrical Industry Training Centre of Alberta

4234 – 93 Street
Edmonton, Alberta, Canada

Phone: (780) 462-5729

Fax: (780) 437-0248

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TABLE OF CONTENTS

Headings Page

Introduction:....................................................................................................3
1. Switchgear Standards..................................................................................4
1.1 Canadian Standards...........................................................................4
1.1.1 CSA Standards.................................................................................4
1.1.2 EEMAC and CEMA Standards.......................................................5
1.2 American Switchgear Standards............................................................6
1.3 International Standards..........................................................................7
2. Switchgear and Switchgear Assemblies.....................................................9
2.1 What is a Medium Voltage Switchgear?................................................9
2.2 Major Parts.............................................................................................9
2.2.1 Control devices:...............................................................................9
2.2.2 Switching and Interrupting Devices:.............................................10
2.2.3 Metering devices...........................................................................10
2.2.4 Protective Devices:........................................................................11
2.2.5 Regulating Devices:.......................................................................11
2.2.6 Interconnections:...........................................................................12
2.2.7 Supporting Structures:...................................................................13
2.3 Characteristics......................................................................................15
2.3.1 Electrical........................................................................................15
2.3.3 Metal-Clad Vs Metal-Enclosed.....................................................16
2.4 Basic Parts...........................................................................................19
2.4.1 Vertical Structure...........................................................................19
2.4.2 Compartments...............................................................................20
2.4.2.1 Circuit Breaker Compartment.................................................21
2.4.2.2 Main Bus Compartment..........................................................26
2.4.2.3 Line Compartment..................................................................29
2.4.2.4 Control Compartment.............................................................31
2.4.2.5 Auxiliary compartment...........................................................31
2.5 Installations..........................................................................................33
2.5.1 Indoor Installation.........................................................................33
2.5.2 Outdoor Installation.......................................................................34
3 Testing........................................................................................................36
4. Glossary of Terms.....................................................................................39
5. Self Test Quiz............................................................................................43
6. Acknowledgement, References and Suggested Readings:........................47

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Introduction:

Module One explains the construction aspects of the Medium Voltage (MV)
switchgear assemblies from its physical attributes to the various
compartmentalized functional sections

By the end of this module, the participants should be knowledgeable in the

construction aspects of the MV switchgear and be able to identify its major
and basic parts. This knowledge will prepare the participants to work
comfortably around the switchgear when performing commissioning tests.

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1. Switchgear Standards

Switchgear and control panels are found in power generating stations,

distribution substations, commercial and institutional buildings, industrial
plants, factories, paper mills and other facilities where electric energy is
utilized or electric power is distributed.

The major North American standards that govern the design, manufacture
and testing of the medium voltage switchgear assemblies are CSA,
ANSI/IEEE, IEC, EEMAC and NEMA.
 CSA - Canadian Standards Association (1919)
 ANSI - American National Standards Institute (1989)
 IEEE - Institute of Electrical and Electronics Engineers (1963)
 EEMAC - Electrical Equipment Manufacturers Association of Canada
(1976)
 NEMA - National Electrical Manufacturers Association (1926)
 CEMA – Canadian Electrical Manufacturers Association (1944),
became EEMAC with the merger of Electronic Association of Canada
which developed out of the Radio Manufacturers Association of
Canada (1929)

1.1Canadian Standards
Canada has two electrical standards, Canadian Standards Association (CSA)
and Electrical and Electronic Manufacturers Association of Canada
(EEMAC).

1.1.1 CSA Standards

Canadian Standards Association (CSA) Standard C22.2 No 31- 10 covers
deadfront indoor enclosed and outdoor enclosed assemblies of switchgear
devices, such as:
 Switches
 Interrupting devices
 Air circuit breakers
 Power circuit breakers
 Control, metering, protective and regulating equipment with
associated interconnections and supporting structures.

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CSA Standard C22.2 No 31-10 covers the construction and design features
required for equipment with nominal voltage of 46kV or less. The
components that are used to build the equipment must comply with the
applicable requirements of the Canadian Electrical Code that governs such
components.

CSA approval
Metal-clad switchgear approved for use in Canada will bear the CSA label.
CSA labels are affixed by the manufacturers that have passed the CSA’s
approval for their manufacturing process, and are subject to ongoing regular
inspection to be in compliance with the requirements of the applicable CSA
standards.

UL-C labels are affixed to equipment produced in the US that complies with
the Underwriter Laboratories product safety certification program but tested
to CSA standards. Switchgear with UL-C labels are accepted by the
Canadian inspection authorities.

Equipment installed which does not bear the CSA or UL-C label are
subjected to a special inspection by the Canadian inspection authorities for
use in Canada and if approved, will be affixed by a special inspection sticker.

1.1.2 EEMAC and CEMA Standards

CSA Standards references EEMAC standards within its writings which is the
Electrical and Electronic Manufacturers Association of Canada standards. In
turn, EEMAC standards have referenced many of the applicable ANSI /
IEEE standards for ratings, definitions and testing procedures.

EEMAC has not supported the development or updating of any EEMAC

Industry Product Standards since 1994. While most EEMAC Standards are
inactive and out of date, a number of them continue to be referenced in CSA
standards.

CEMA sister organization in the US is NEMA and comparable standards in

Canada are the CEMA standards.

Current EEMAC Standard that are referenced in CSA standards are:

 EEMAC G8-3.2; 1989; Standard for Metal-Clad and Station-Type
Cubicle Switchgear
 EEMAC G11-1, 1972; Guide for Measurement of Corona in

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Switchgear Assemblies.
 EEMAC G14-1, 1987; Procedure for Testing The Resistance of
Metalclad Switchgear Under Conditions of Arcing Due To Internal
Fault

1.2 American Switchgear Standards

The evolution of the standards originated with the first written standard by
The Electric Power Club which today became NEMA.

NEMA was a merger between the Associated Manufacturers of Electric

Supplies and The Electric Power Club, September 1926.
The American Institute of Electrical Engineers (AIEE) was in existence at
the time and they also worked on their own switchgear standards. After
World War II, the various standard organization worked together to
consolidate the standards requirements. The resulting work culminated to
form AIEE Standard 27. Year later AIEE merged with IRE to form IEEE and
the AIEE Standard 27 became the IEEE 27, which formed the basis for
ANSI/IEEE C37.20 of today.

Note: American National Standard Institute (ANSI), is a membership

organization that coordinates the development of US voluntary standards
in both the private and public sector. It is the US member body to ISO
and IEC

C37.20 covered switchgear assemblies across the voltage spectrum. These

include:
 low voltage power circuit breaker switchgear to 600 Vac
 medium voltage metal-clad switchgear above 1000v up to 38k Vac
 metal enclosed load interrupter switchgear above 1000v up to 38k
Vac.

In 1987 C37.20 was revised into separate standards to produce 1 document

for each major equipment classes.
 C37.20.1 - IEEE Standard for Metal-Enclosed Low-Voltage Power
Circuit Breaker Switchgear
 C37.20.2 - IEEE Standard for Metal-Clad Switchgear
 C37.20.3 - IEEE Standard for Metal-Enclosed Interrupter
Switchgear
 C37.20.4 - IEEE Standard for Indoor AC Switches (1kV – 38 kV)

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for Use in Metal Enclosed Switchgear

Table 1 lists the principle standards that are applicable to Medium Voltage
Metal-Clad Switchgear of today. The standards listed is not all inclusive.
There are other standards that are applicable to relays, device numbers, wires
and other equipment or devices within the switchgear assemblies.

The more significant standards for switchgear are the switchgear standard
C37.20.2 and the breaker standards C37.04, C37.06, C37.09 and C37.010.

1.3 International Standards

The International Electrotechnical Commission (IEC) is the international
standards and conformity assessment body for all fields of electro-
technology. IEC standards are synonymous with International standards. IEC
was founded in 1906, based in Geneva and is made up of national
committees from over 60 countries.

IEC Standard 62271-200 ‘AC metal-enclosed switchgear and controlgear for

rated voltage above 1kV and up to and including 52kV’ is the comparable to
the ANSI / IEEE Standard C37.20.2.

IEC Standard related to metalclad switchgear, are quite different from what
is expected of switchgear designed and tested to the North American
Standards. Ratings and test results are also different. It is beyond the scope
of this module to discuss the difference and similarities of these two
standards, but it is notable to say that the IEC designed switchgears can be in
compliance to the requirements of the CSA standards. A special inspection
sticker is still required for approval by the electrical inspection authority.

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TABLE 1: NORTH AMERICAN SWITCHGEAR STANDARDS

STANDARD REV SPONSOR TITLE WORKING
GROUP
C37.04 1999 IEEE Standard Rating Structure for AC HV Circuit Breakers IEEE
C37.06 2009 IEEE Standard for AC HV Circuit Breakers Rated on a Symmetrical NEMA
Current Basis – Preferred Ratings and Related Required
Capabilities for voltages above 1000 V
C37.09 1999 IEEE Test Procedure for AC HV Circuit Breakers IEEE
C37.010 1999 ANSI / Application Guide for AC HV Circuit Breakers IEEE
IEEE Rated on a Symmetrical Current Basis
C37.20.2 1999 ANSI / Metal-Clad and Station-Type Cubicle Switchgear IEEE
IEEE
C37.20.6 2007 IEEE Standard for 4.76 TO 38 Kv Rated Grounding and Test Devices IEEE
Used in Enclosures
C37.54 2002 ANSI / Conformance Test Procedures for Indoor Alternating-Current NEMA
NEMA MV Circuit Breakers Applied as Removable Elements in Metal
Enclosed Switchgear Assemblies
C37.55 2002 ANSI / Metal-Clad Switchgear Assemblies – Conformance Test NEMA
NEMA Procedures
C37.85 2002 ANSI / Switchgear - Alternating-Current High Voltage Power Vacuum NEMA
NEMA Interrupters – Safety Requirements for X-Radiation Limits
C22.2 # 31 2010 CSA Switchgear Assemblies CSA
C22.2 # 58 1989 CSA HV Isolating Switches CSA
C22.2 # 193 1983 CSA HV Full-Load Interrupter Switches CSA
C22.2 # 253 2009 CSA MV AC Contactors, Controllers and Control Centres CSA
G8-3.2 1989 EEMAC Standard for Metal-Clad and Station-Type Cubicle Switchgear
G11-1 1972 EEMAC Guide for Measurement of Corona in Switchgear Assemblies
G14-1 1987 EEMAC Procedure for Testing The Resistance of Metalclad Switchgear
Under Conditions of Arcing Due To Internal Fault

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2. Switchgear and Switchgear Assemblies

2.1 What is a Medium Voltage Switchgear?

When we say “medium voltage,” we are referring to a range of voltage from 1000
volts to 38 kV (as per ANSI / IEEE 1585 – 2002, ac assumed).

CSA standard C22.2 No 31-10 applies to deadfront indoor enclosed and outdoor
enclosed assemblies of switchgear devices such as switches and interrupting
devices, air circuit breakers, power circuit breakers along with control, metering,
protective and regulating equipment with associated interconnections and
supporting structure.

MV Switchgear Definition:
A MV switchgear are compartmentalized assemblies of switching and interrupting
devices operating from 1000V to 38 kV supplied from an insulated main bus
structure, along with control, metering, protective and regulating equipment with
associated interconnections and supporting structure.

2.2 Major Parts

The major parts of the switchgear are provided within its definition. They are listed
as:
 Control devices
 Switching and Interrupting devices
 Metering devices
 Protective devices
 Regulating devices
 Interconnections
 Supporting structure

2.2.1 Control devices:

Control devices provide local and / or remote control to operate the main switching
or interrupting devices. Local breaker control can be performed via with door
mounted push buttons, pistol grip breaker control switch or local centralized
breaker control panel. Load-break disconnects are normally operated by a manual
operating handle, they can be fitted with a electrical operator when required.

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Remote operations can be initiated via SCADA or other communication equipment

using interface / interposing relays or through a remote terminal unit (RTU) that
sends control signals in parallels with the local controls.

Control devices are:

 Local controls devices
 Remote controls devices

2.2.2 Switching and Interrupting Devices:

Switching and Interrupting devices are installed in the primary circuit to control
the flow electrical energy. The rating of the switching or interrupting devices will
determine if the device is able to make or break load current, overload current or
short-circuit current.

No-load / isolating disconnects are used for no-load operation. It main function is
to provide a visible break and a lockable point for isolation purposes for
maintenance / repair of downstream equipment.

Load break switches / disconnects are designed to interrupt normal load current.
They are fitted with a fast acting make / break mechanism and arc quenching
devices.

Load break switches / disconnects are able to make short circuit currents for
inadvertent situations when they are closed onto a faulted condition, they are not
designed to interrupt fault current. For those scenarios when load break switches
are closed onto a fault, the upstream protective device shall operate to interrupts
the short circuit currents and isolate the faulted part of the power system.

Switching and Interrupting devices are:

 Circuit breakers
 Load-break switches / disconnect; load interruptors / disconnectors
 No-load / isolating disconnects

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2.2.3 Metering devices

Metering devices monitors the system parameters such as voltage, current,
frequency and phasing through the use of instrument transformers which convert
and isolate the primary quantities into useable low voltage secondary quantities.
Metering devices enables the operators to quantify the operating conditions of the
system.
 Instrument transformers: Current transformers (CT), Voltage transformer
(VT), potential transformer (PT)
 Switchboard instruments: Voltmeter, Ammeter, Current Demand,Watt, Var,
Power Factor, Frequency, Synchroscope (120V, 5A)
 Transducers: Volt, Amp, Watt, Var, Frequency, Temperature
 Revenue Meters: Watt-hour meter and Var-hour meter

2.2.4 Protective Devices:

Protective devices monitor the system’s operating parameters for abnormal
operating conditions. Depending on its function, protective devices may trip the
supply breaker to isolate the faulted part of the power system or initiate an alarm to
signal the operator to take corrective action.

Examples of abnormal operating conditions are:

 Under-voltage / over-voltage
 Under-frequency / over-frequency
 Under-speed / over-speed
 High temperature
 High vibration
 Reverse power
 Overload
 Short-circuit

Some protective devices are:

 Fuses
 Overload relays
 Temperature relays
 Protective relays

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2.2.5 Regulating Devices:

Regulating devices are used to control the operating parameters of the power
system such as voltage, current, power, speed, frequency, temperature and loading
for machines, tie lines or other apparatus. These devices are commonly associated
with power generating equipment and become an integral part of the control
systems.

Regulating devices in switchgear are associated with forced air-cooled breakers

and with metal enclosed capacitor banks.

Forced air-cooled circuit breakers employed a current sensing relay which initiate
beaker cooling using fans when the load current approach 90-95% of the breaker
continuous current rating. The fan will stop if the load current drops below the set-
point value after a set time delay.
The control scheme for capacitor banks can utilize the reactive energy sensing,
under-voltage sensing or both to control the application of capacitors by vacuum
contactors. Capacitor banks are used to reduce the current demand during heavy
load periods and / or reduce the voltage drop.

2.2.6 Interconnections:
Interconnection relates to the primary bus-bars connections between switchgear
cubicles or between switchgear sections via enclosed bus structures / bus ways /
ducts. The efficiency of all types of heavy current busbars depends upon careful
design.

Temperature rise is the main design criteria used for establishing the continuous
current rating for busbar design. The general requirements as per ANSI, IEEE and
NEMA standards for switchgear is a temperature rise of no more the 65°C,
although it may vary for different classes of equipment. The requirement is to
prevent overheating of the insulators and insulation support systems enclosing the
bus bars since high temperature will reduce the life of the insulation.

Factors affecting bus-bars temperature rise and bus bar design are:
 Size and type of materials used (copper or aluminum alloys)
 Insulated of un-insulated bars (insulated bars runs cooler from increased heat
radiation due to darker color)
 Maximizing the surface area for heat dissipation
 Size and material of the enclosure around the bus
 Air flow around the bus and enclosure

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 Not impeding the natural air currents due to busbars placement

 Achieving uniform current densities in all parts of the conductor
 Minimizing skin effects and proximity effects for busbars

Due to the complex interactions of the above and other factors, continuous current
tests are required as part of the standard to determine the temperature rise of a bus
system design.

 Insulated Main Bus and Connections

All main bus and connections are insulated in a medium voltage metal-clad
switchgear assembly. This is not necessarily the case with other types
of assemblies such as a panelboards, where the main bus is not separated with
the branch breaker distribution system.

2.2.7 Supporting Structures:

Supporting structure are the physical attributes of the switchgear enclosure. The
construction of the enclosures must be strong and rigid to withstand the operating
mechanical forces of the equipment it supports / houses and withstand the
magnetic forces that are produced from the flow of short circuit currents.

Insulators are integral to the design of the supporting structures which supports the
busbars.

Arc resistant switchgear are designed to resist the explosive forces generated
during an arc flash through the use of pressure relief vents to direct the rapidly
expanding air, hot metal and gases away from the operator’s working area.

Seimic rated gear is another design feature to consider for installations in

earthquake prone regions. Such features are standard for nuclear installations.

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Switchgear examples:

Switchgear brings a number of very important functions together in one package.

Figure 1. Typical Medium Voltage Switchgear Assembly, Consisting of 5

Vertical Structures

Figure 2. Typical 3 Vertical Structure Assembly with Upper

Compartment Vacuum Circuit Breaker Removed from its
Compartment on Extension Rails

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2.3 Characteristics

2.3.1 Electrical

Voltage Category
Medium voltage switchgear assemblies generally fall into one of four voltage
category, they are:
 5 kV
 15 kV
 27 kV
 38 kV

Current rating
The main bus continuous current rating is a function of the protective device
protecting the main bus. Frame sizes for circuit breakers are 1200, 2000 or 3000
amperes, making the continuous current rating of the bus rated at 1200, 2000 or
3000 amp. Higher ratings are available when fans are used to force-cool the
equipment.

Not all voltage levels offer the same continuous current ratings. The current ratings
are determined by the system requirements and the circuit breakers selected to
provide the protection.

Mechanical Aspects
A typical medium voltage metal clad switchgear assembly has:
 Removable / Draw-out circuit breakers
 Main bus compartment
 Incoming / outgoing compartments for line / cable connections
 Circuit breakers, control equipment compartments and other compartments
for auxiliary equipment (such as VTs)
 Insulated main bus and connections
 Metal barriers separating each vertical structure and each compartment
within each structure

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2.3.3 Metal-Clad Vs Metal-Enclosed

Medium voltage metal-clad switchgear has the structures and compartments within
each structure physically separated from each other by grounded metal barriers.
Medium voltage switchgear assemblies are metal-clad.

Metal enclosed assembly often associated with low voltage equipment encloses the
equipment in metal vertical structures. However, compartments are not separated
from one another with metal barriers.

Metal Enclosed Metalclad

Applicable Standards
ANSI C37.20.2 for Breakers ANSI C37.20.2 for Breakers
ANSI C37.20.3 for Switchgear CSA C22.2 # 31 includes Metalclad.
CSA C22.2 # 31 for Switchgear Assy. EEMAC G8-3-2 for Metalclad
Structural Attributes
Front and rear access (optional) Must have front and rear access
Shutters not required Shutters required
Comparmentalization not required All live parts are compartmentalized
Adjacent compartments can be open Adjacent compartments are isolated
Bus and primaries can be uninsulated Bus and primaries must be insulated
Switching devices can be fixed mounted Switching devices must be draw-out
Interrupting dev. Can be fixed mounted Interrupting dev. must be draw-out
Overcurrent Protection Device Types
Switches with or without fuses (typ) Vacuum circuit breakers with O/C PN.
Overcurrent Protection Device Features
Switches have low duty cycle Breakers have high duty cycle

Metalclad is metal enclosed, but metal enclosed is not metalclad

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Application Example

Figure 3. Application Example

The substation transformer steps the voltage down from 35 kV to 15 kV. It feeds a
15 kV medium voltage circuit breaker A. This is the main / incoming breaker of the
medium voltage switchgear assembly

Three other medium voltage circuit breakers B, C and D are performing other
functions. Breaker B and C are feeder breakers and breaker C is the transformer
breaker.

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The rest of the system comprised of a 5 kV isolating switch, 5 kV fussed motor

starter and a 5 kV motor load.

2.4 Basic Parts

A switchgear assembly consists of as many vertical structures / sections required
for the intended application. That could be one structure or many structures.

2.4.1 Vertical Structure

Width dimensions are usually 26, 36 or 42 inches, and height of 90 to 100 inches.
Vertical structures are all bolted together to form one rigid, continuous assembly.
The exact dimensions of the vertical structure are dictated by the voltage class and
specification requirements.

The front structures are normally hinged metal doors. Access from the rear is
provided through bolted, removable metal panels, or hinged doors.

Figure 4. Typical Medium Voltage Switchgear Assembly with

One Circuit Breaker Compartment Door Open

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Figure 5. Typical Medium Voltage Switchgear Assembly

Rear View, with Several Rear Covers Removed

2.4.2 Compartments
A medium voltage switchgear assembly is an integrated combination of a number
of compartments.

Compartment types are:

 Circuit Breaker Compartment (A)
 Main Bus Compartment (B)
 Cable Connection / Line Compartment ©
 Low Voltage / Control Compartment (D)
 Potential Transformer / Auxiliary Compartment (E)

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Figure 6. Sectional view of a Structure.

Figure 6 shows a lower breaker compartment, an upper VT compartment and a rear

bus bar compartment. Compartments and vertical structures are physically
separated from one another by metal barriers.

2.4.2.1 Circuit Breaker Compartment

The removable draw-out circuit breaker is the heart of the switchgear. Each circuit
breaker is provided with its own compartment, within which it performs its
function.

The circuit breaker compartment provides:

 an enclosure for one circuit breaker
 a means to physically move the circuit breaker into or out of the
compartment between connected and disconnected position
 a means to make primary electrical connections, self aligning and self
coupling
 disconnectable secondary control wiring connections
 interlock to prevent insertion into the wrong compartment, prevents insertion
of a closed breaker and prevent breaker operation until fully inserted.
 extension rails to support the circuit breaker as it is pulled out of the
compartment

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Enclosure
The circuit breaker compartment includes a top, bottom, right and left sides, and
rear portions of the compartment. When the circuit breaker is racked into its
connected position, the faceplate of the circuit breaker itself acts as the front part of
the compartment.

Figure 7. Circuit Breaker Shown Being Manually Levered into

Connected Position

In this position, the operating and current-carrying parts of the circuit breaker are
compartmentalized from the rest of the assembly structure.

Primary Electrical Connections

Circuit breakers have six primary electrical connecting devices. They are arranged
two per phase; Phase-A, Phase-B and Phase-C line and load side connections.

Each primary connecting device has multiple contact fingers which will mate with
the bus bar stationary primary connecting stabs. Breaker to primary bus
connections is made via spring pressured contact finger clusters. Connections are
automatically made as the circuit breaker is racked into position within the circuit
breaker compartment and automatically disconnected as the breaker is racked out
of the compartment.

Note: Do not move or handle the circuit breaker by the primary connecting
device as damage may occur.

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Figure 8. Rear View of Circuit Breaker, Showing Six Primary Finger

Clusters

When the circuit breaker is racked out of the connected position, the rear bus
connection points are covered via a closing shutter to prevent contact with the live
primary circuit. Conversely the shutters move out of the way during breaker
insertion for connection to the primary circuit. This safety device is called the
automatic shutter system.

Secondary Electrical Connections

When the circuit breaker is racked into the connected position, secondary male and
female contact plug engages. Control power is provided to the charging motor and
other auxiliary devices through the plug connections. When the circuit breaker is
racked out of the connected position to the disconnected position, the secondary
contacts plug disengages.

The secondary contact plugs can be manually engaged when the circuit breaker is
in the TEST position within its compartment (Figure 10). Once the plugs are
connected, the circuit breaker can be electrically operated while disconnected from
the primary circuit.

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Figure 9. Secondary Contacts Being Manually Engaged with Circuit

Breaker in Test Position

The secondary plug is often mounted on the underside of the circuit breaker, with
the compartment’s secondary plug mounted on the compartment floor.

Figure 10. Secondary Control Plug Shown Mounted on Floor of Circuit

Breaker Compartment

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Safety Interlocks
Safety interlocks are required by governing standards, and must be supplied by all
manufacturers. Safety interlocks in the compartment interact with matching circuit
breaker interlocks. There are both electrical and mechanical interlocks.

The purpose of these interlocks is to ensure:

 The circuit breaker cannot be removed from the test/disconnected to the
connected position unless the main contacts are opened and secondary
electrical connections are engaged
 The circuit breaker cannot be removed from the connected to the
test/disconnected position unless the main contacts are opened and
secondary electrical connections are engaged
 The secondary electrical connection cannot be broken when the circuit
breaker is in the connected position
 The circuit breaker cannot be removed from the compartment with the main
contact closed or with the closing spring charged
 Incorrect circuit breaker types are prevented from being inserted into the
wrong circuit breaker compartment

Extension Rails
Extension rails provide equipment support and permit circuit breakers and other
auxiliary devices such as large removable transformers to be withdrawn from the
compartment for inspection and maintenance.

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Figure 11. Vacuum Circuit Breaker Withdrawn from Compartment on

Extension Rails

2.4.2.2 Main Bus Compartment

The main bus comprised of a set of bus bars. They typically copper of aluminum
bus bars mounted on bushing. The bushings are made of an insulating material.
Two vacuum circuit breakers have been permitted to be installed in one vertical
structure since the arcing current during contact part is contained within the
vacuum bottles.

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Figure 12. Two Vacuum Breakers In One Vertical Structure (Side View)

Connections to the main bus within a vertical structure for circuit breakers and
other devices are called Bus Joints. Bus connections between compartments must
be insulated.

Figure 13. Three Main Bus Bars Extending Through Insulated Openings
in the Side of Vertical Structure.

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Main Bus
The main bus extends the length of the assembly from one vertical structure to
another through insulated openings in the sides of the vertical structures.
Depending upon the length of the assembly, main bus bars are not usually one
continuous piece or standard lengths bolted together.

The bus system must be supported and braced to withstand the stresses created by
short circuit currents. To minimize occurrence of faults, buses are insulated with
fluidized bonded epoxy insulation and bolted joints are covered with insulating
boots.

Isolating barriers are used within each vertical structure to compartmentalize the
main bus from other compartments and equipment. Access to the main bus is
provided by removing specific barriers.

Figure 14. Rear View of Partial Assembly with Barriers Removed to

Show Insulated Main Bus Bars

Main bus conductors are sized to handle the current, while maintaining the rated
temperature requirements established by standards. In medium voltage switchgear
assemblies, the rated continuous current of the main bus is usually 1200, 2000 or
3000 amperes, although higher ratings are possible using forced air cooling
consisting of fans controlled via thermostats.

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2.4.2.3 Line Compartment

The rearmost compartment is the line compartment. It is accessible via removable
bolted rear panels or rear doors. Space is provided in the compartment for
incoming cable connections or other connecting means. Assembly designs permit
entry and exit from the top or bottom. Surge arresters and large control power
transformers, can also be mounted in the line compartment. The line compartment
usually runs from top to bottom.

Figure 15. Two Vertical Structures of One-High Circuit Breaker

Switchgear, Rear Panels Removed (Rear View)

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Figure 16. One Vertical Structure of Two-High Circuit Breakers, Showing

How Cable for Top Compartment Gets Through Bottom
Compartment (Rear View).

Ground Bus
An un-insulated ground bus runs the length of the assembly, and is normally
located in the lower part of the line compartment. The ground bus is capable of
carrying the rated short circuit current of the system.

2.4.2.4 Control Compartment

The control compartment is considered to be the space between the front of the
circuit breaker face plate and the front door. Instruments, meters, relays and other
control equipment can be mounted on the rear door panel. Relays, indications,
control switches and other devices can be mounted in the door panel. The rear
portion of door-mounted devices protrudes into the compartment space. If there is
to be a large volume of control equipment, it can alternatively be mounted in a
dedicated auxiliary compartment.

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Figure 17. Typical Circuit Breaker Compartment, with Door-Mounted

Devices Protruding Through Door

2.4.2.5 Auxiliary compartment

Auxiliary compartment is usually located above or below a circuit breaker
compartment. An auxiliary compartment could be an entire full-height vertical
structure. Auxiliary compartments are frequently used to mount draw-out voltage
transformers and large power control transformer.

Figure 18. Auxiliary Compartment Transformer Mounting

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Figure 19. Entire Vertical Structure Dedicated to Auxiliary Equipment

2.5 Installations
The two main installation types are:
 Indoor
 Outdoor

Sub-classifications are based on enclosure types are:

 NEMA 1 non-gasketed
 NEMA 1A gasketed
 NEMA 2 drip-proof
 NEMA 12 dust-tight
 NEMA 3R non-walk-in
 NEMA 3R walk-in
 and others

Other sub-classification based of functionality are:

 Sprinkler proof
 Arc resistant
 Dust proof
 Seismic rated
 Weatherproof

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Switchgear assemblies are installed in a wide variety of locations under a wide

range of climatic conditions.

2.5.1 Indoor Installation

All medium voltage switchgear assemblies start out as indoor assemblies.
Configurations are designed to use the smallest amount of floor space and
materials taking into account such factors as temperature, humidity and other
environmental factors and still meeting design requirement. Not all manufacture
will come up with the same configuration.

Figure 20. Typical Two-High Configurations

2.5.2 Outdoor Installation

Outdoor switchgear incorporates and outdoor approved structure with an indoor
switchgear components. Longer life can be achieve if the environment within the
enclosure can be controlled to mimicked an indoor environment.

Three primary outdoor installations are:

 Aisle-Less switchgear
 Sheltered Aisle Switchgear
 Common Aisle Switchgear

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Aisle-Less Switchgear
Aisle-Less Switchgear are house in a weatherproof enclosure around an indoor
switchgear assembly. Weatherproof gasketed sealed doors are located on the front
to allow for the drawout and removal of the circuit breakers. Removable
weatherproof gasket panels or doors are provided for rear access. Additional
provision of added ventilation with space heater aids in minimizing condensation
of moisture.

Figure 26. Typical Outdoor Aisle-Less Construction (Side View)

Sheltered Aisle Switchgear

An outdoor enclosure is constructed around an indoor switchgear assembly. An
aisle is constructed as part of the enclosure at the front of the assembly.
Weatherproof gasketed doors are normally at both end of the enclosure.

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Figure 27. Typical Outdoor Sheltered Aisle Construction (Side View)

Common Aisle Switchgear

This is a large assembly and installed in two parts on both sides of the aisle.

Figure 28. Typical Outdoor Common Aisle Construction (Side View)

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3 Testing

The design and proof testing and the production testing of a medium voltage
switchgear assembly varies, depending upon whether it is compliant with ANSI or
IEC standards. A medium voltage switchgear assembly is built and tested in
accordance with a specific set of engineering standards. Depending of the
geographical location some of the applicable standards may be ANSI, IEEE,
NEMA, CSA or EEMAC.

Unlike an individual component, which also must meet certain specific standards,
the manufacturer must know and be able to prove by testing that each and every
component functions properly when installed in the assembly. This is quite a task,
considering the vast number of different devices and pieces that make up an
assembly.

Figure 29. Dominant Regional Standards Throughout the World

In addition to regional standards, an assembly may frequently be required to meet

specific local standards. Very specific tests could even be required for the
equipment before it can be permitted for use in certain areas or applications.
Two such applications are seismically-qualified and arc-resistant equipment. The
design of arc-resistant equipment is dedicated to the safe control and release of arc-
related overpressures.

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Design and Proof Testing

The design and proof testing of the assembly to show compliance with applicable
standards includes, but is not limited to:
 Short circuit testing
 BIL testing
 Dielectric testing
 Continuous current testing
 Mechanical life testing
 Thermal testing
 Environmental testing

Production Testing
Production testing of an assembly is performed in compliance with specific
standards for the circuit breaker and the assembled housing individually. These
production tests are also referred to as “routine tests.”
Circuit breaker testing includes, but is not limited to:
 Control wiring insulation test
 Charging motor insulation test
 Operation of switches, control devices, latches and interlocks
 Breaker operation at minimum, maximum, and rated control voltages
 Vacuum interrupter operation and withstand tests
 Breaker contact resistance
 Closing and opening timing tests
 Dielectric tests

The assembled housing’s testing includes, but is not limited to:

 Component nameplate verification for compatible application
 Dielectric tests
 Mechanical testing of all operational parts and devices
 Control wiring continuity verification
 Operation of all relays, instruments, meters and other devices
 Control wiring insulation tests
 Instrument transformer polarity verification tests
 Sequence of operation tests, if applicable

A medium voltage switchgear is a built-to-order product with many details to be

considered and many selections to be made. Selecting each component and device
to do the job, be acceptable to the customer, and comply with all regional and local
standards is an undertaking. Every detail, from the electrical and mechanical

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requirements, down to the finish and composition of the structure must be

considered.

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4. Glossary of Terms
Aisle Part of a sheltered aisle switchgear installation. Connected
accessway for multiple vertical enclosures in an outdoor
installation. Weatherproof access doors are normally supplied at
both ends of the aisle.
ANSI American National Standards Institute. It was organized to
simplify and standardize production and construction.
Arc-Resistant A special certification that equipment must have for use in
certain circumstances. The design of arc-resistant equipment is
dedicated to the safe control and release of arc-related
overpressures.
Automatic Circuit breaker compartment safety feature. When the circuit
Shutter System breaker is removed from its compartment, the compartment’s
fixed primary conductors are automatically covered to prevent
contact with live primary current-carrying parts.
Auxiliary An optional compartment in a medium voltage switchgear
Compartment assembly, usually located above or below a circuit breaker
compartment. Used when there is a significant volume of
auxiliary and/or control equipment required in the assembly.
Bus Joint The connection between the main bus and a circuit breaker (or
other devices). Bus joints must be insulated.
Circuit Breaker A reusable overcurrent protection device. After tripping to break
the circuit, it can be reset to protect the circuit again.
Circuit Breaker A compartment in a medium voltage switchgear assembly that
Compartment contains and electrically connects one or more circuit breakers.
Common Aisle An outdoor installation solution for very large assemblies. A
Switchgear variation on sheltered aisle switchgear, in which vertical
structures are on both sides of the aisle.
Continuous The amount of current the breaker can carry continuously at 60
Current cycles without exceeding the temperature rise limit, according
to ANSI charts.
Control The space between the front of the circuit breaker and the front
Compartment doors of the assembly. This is where instruments, meters, relays
and other control equipment are usually mounted.
Control Power A transformer that provides a safe, reasonable low voltage
Transformer source for relays, contactors and other devices.
Extension Rails A common feature of the circuit breaker itself. Allow the circuit

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breaker slide out of its compartment easily for inspection.

Feeder Circuit A reusable overcurrent protection device designed to protect a
Breaker panel downstream from a medium voltage switchgear assembly.
Finger Cluster A configuration of spring-loaded conductive fingers mounted on
the circuit breaker, often made of silver-plated copper. When the
circuit breaker is levered into the CONNECTED position, its
finger clusters engage the circuit breaker compartment’s
stationary primary conductors to make electrical connection.
Ground Bus A grounded bus that runs the length of the assembly, and is
normally located in the lower part of the line compartment. For
safety reasons, the ground bus is capable of carrying the rated
short circuit current of the installed circuit breakers for a certain
amount of time.
IEC Abbreviation for International Electro-technical Commission.
This organization is associated with equipment used
internationally.
IEEE Institute of Electrical and Electronic Engineers. A professional
organization of scientists and engineers whose purpose is the
advancement of engineering.
Lever A term to describe the act of moving a circuit breaker from one
position to another.
Line Space is provided in this compartment for line terminations or
Compartment other special devices. Assembly designs usually permit entry
and/or exit of cable or bus from the top or bottom of the
compartment.
Main Bus A set of electrical conductors, usually three per set. These
individually insulated conductors provide for multiple
connections into the electrical system. In medium voltage
switchgear assemblies, the main bus usually takes the form of
solid copper bars.
Main Bus A compartment in a medium voltage switchgear assembly
Compartment through which the main bus runs.

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Main Circuit Also “Main Breaker.” A reusable overcurrent protection device

Breaker designed to protect an entire medium voltage switchgear
assembly.
Medium Voltage An integrated assembly of compartmentalized, removable circuit
Switchgear breakers with an insulated main bus, associated control devices,
Assembly and auxiliary equipment designed to provide medium voltage
circuit protection
Metal-Clad Equipment in the assembly is enclosed, and separated by metal
barriers into individual compartments. Typically associated with
medium voltage equipment.
Metal-Enclosed Equipment in the assembly is enclosed, but not necessarily
separated by barriers. Typically associated with low voltage
equipment.
NEMA Abbreviation for National Electrical Manufacturers Association.
An organization of manufacturers of electrical products.
Outdoor Aisle- An outdoor installation solution. Basically, the assembly of a
less Switchgear weatherproof enclosure around an indoor switchgear assembly.
Outdoor Control An outdoor installation solution. Encloses all the equipment in
Room one weatherproof house. Normally, the construction takes place
at the manufacturer’s location and then moved to the installation
site
Safety Interlock A feature of both the circuit breaker compartment and the circuit
breaker itself. Helps ensure safe and proper interfacing between
the circuit breaker and its compartment. Interlocks are required
by governing standards, and must be supplied by all
manufacturers.
Seismically- A special certification that equipment must have for use in
Qualified certain earthquake-prone zones.
SF 6 An arc extinguishing technology involving the use of sulfur
hexafluoride gas.
Sheltered Aisle An outdoor installation solution. An outdoor enclosure is
Switchgear constructed around an indoor switchgear assembly with an aisle
constructed as part of the enclosure at the front of the assembly.
Surge Arrester A device that protects equipment from electrical surges.

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Switchgear An assembly of switching and interrupting devices, along with

control, metering, protective and regulating equipment.
Vacuum An arc extinguishing technology. Features a pair of separable
Interrupter contacts enclosed in a vacuum-tight envelope. Because the
environment inside the interrupter envelope is a vacuum, an arc
cannot be sustained easily.
Vertical A metal enclosure for the other switchgear components. A switch
Structure gear assembly can consist of practically any number of adjacent
vertical structures.
Voltage Also “potential transformer.” A step-down transformer that steps
Transformer down supplied voltage to a voltage usable by control components
such as relays and meters.

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5. Self Test Quiz

Quiz 1:

Answer the following questions without referring to the material.

1. Medium voltage refers to a voltage range from __________ to __________.

2. In your own words, define the generic term “switchgear.”

_____________________________________________________________
_____________________________________________________________
_____________________________________________________________

3. A medium voltage switchgear assembly can be composed of as many as five

different types of compartments. The circuit breaker compartment is one of
them. Name three others.
____________________________________________________________
____________________________________________________________
____________________________________________________________

4. The exact dimensions of the vertical structure are dictated by the

__________ _______ and _____________ _______________ for the
application.

5. The circuit breaker compartment accommodates the circuit breaker with a

number of provisions. Name three of them.
____________________________________________________________
____________________________________________________________
____________________________________________________________

6. Medium voltage switchgear is defined by its metal _______ construction.

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Answer to Quiz 1:

1. Medium voltage refers to a voltage range from 1000 to 38 Kv.

2. Switchgear is assemblies of switching and interrupting devices, along with

control, metering, protective and regulating equipment.

3. Types of compartments other than the breaker

 Main Bus Compartment, line Compartment, control Compartment Area,
auxiliary Compartment

4. The exact dimensions of the vertical structure are dictated by the voltage
class and specification requirement for the application.

5. The circuit breaker compartment accommodates the circuit breaker with a

number of provisions, Name 3 of them:
 An enclosure for the breaker, means to move the breaker in and out of the
enclosure, means to make primary and secondary connections, safety
interlocks and extension rails.

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Quiz 2:

Answer the following questions without referring to the material just presented.

1. Main bus conductors are sized to handle the __________, while maintaining
the rated ______________ _______________ established by standards.

2. In your own words, describe where controls are generally found in a

switchgear assembly.
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________

3. There are two primary approaches to outdoor switchgear assembly

installations. Name two of them.
____________________________________________________________
____________________________________________________________

4. ANSI design and proof testing for switchgear assembly includes many types
of tests. Seven types were mentioned. Name four.
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________

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Answer to Quiz 2:

1. Main bus conductors are sized to handle the current, while maintaining the
rated temperature rise established by standards.

2. The space between the front of the circuit breaker and the front doors of the
assembly is generally considered as the control compartment area. Door-
mounted devices are viewable with the door closed. If there is a large
volume of control equipment, it could be located in an auxiliary
compartment.

3. Three primary approaches to outdoor switchgear assembly installations are:

Outdoor aisle-less switchgear, Sheltered aisle switchgear (or common aisle
switchgear).

4. Four of seven types of ANSI proof testing are:

Short circuit, BIL, Dielectric, Continuous current, Mechanical life, Thermal
and Environmental.

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6. Acknowledgement, References and Suggested Readings:

Acknowledgement:
Special thanks to Clayton Engineering Company who allowed the use of their
graphics and education materials for inclusion in this document.

References and Suggested Readings

[1] Caylton Engineering Company
http://www.claytonengineering.com/cecoweb/pittsburgh.htm

[2] NEMA – National Elelctrical Manufacturing Association

http://www.nema.org/

[3] CSA – Canadian Standards Association

http://www.csa.ca

[4] ANSI – American National Standards Intitute

http://www.ansi.org

[5] IEEE – Institute of Electrical and Electronic Engineers

http://www.ieee.org

[6] IEC – International Electrotechnical Commission

http://www.iec.ch/

[7] Electro Federation Canada

http://www.electrofed.com/councils/EEMAC/

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