I: INTRODUCTION TO CIRCUIT BREAKERS THEORY OF CIRCUIT INTERRUPTION A circuit breaker is a device that switches on and switches off electric

circuits during normal as well as abnormal operating conditions. During the making or breaking of theswitching contacts, there is a transition stage of arcing between the contacts. The study ofthis phenomenon is of great importance for understanding the design and operational characteristicsof circuit breakers. PHYSICS OF ARC PHENOMENA Discharge in ac circuit breakers, generally in the form of an arc, occurs in the following ways: 1. When the contacts are being separated, arcing is possible even when the circuit emf is considerably below the minimum cold electrode breakdown voltage, because of thelarge local increase in voltage due to the circuit self-inductance. Note: This way of drawing arc is common to both dc and ac circuit breakers. 2. In an ac circuit breaker, the arc is extinguished every time the current passes throughzero and can restrike only if the transient recovery voltage across the electrodes alreadyseparated and continuing to separate reaches a sufficiently high value known as thebreakdown voltage. The arc phenomenon depends upon The nature and pressure P of the medium The external ionizing and deionizing agents present The voltage V across the electrodes and its variation with time The nature, shape, and separation of electrodes The nature and shape of the vessel and its position in relation to the electrodes An ideal gas is a pure dielectric because it consists of molecules which are electrically neutral. It can be made to conduct only when some means are employed to create free electronsand ions in the gas.When the gas temperature increases significantly, the molecules start to break down at the most severe collisions and dissociate into their atoms. At higher temperatures, some molecules and atoms are deprived of an electron and thehot gas called plasma becomes a conductor. Note: The free electrons which are caused by high temperature can carry an electric currentunder an electric field in roughly the same way as do the free electrons in a metal (the electricalconductivity of a metal is due to the existence within it of free conductivity electrons). ARC INTERRUPTION THEORY In circuit breakers, the modes of arc interruption are high-resistance interruption and lowresistanceor current zero interruption. High-Resistance Interruption The arc is controlled in such a way that its effective resistance increases with time, resultingin a decrease in current until it cannot be maintained. The arc resistance can be increased bylengthening, cooling, and splitting the arc. Low-Resistance or Current Zero Interruption In an alternating current, every time the current passes through zero, the arc extinguishes fora brief moment and again restrikes with the rising current. The

reestablishment or interruptionof the arc is an energy balance process.If the energy input to the arc, subsequent to the current zero, continues to increase, thearc restrikes; if not, the circuit is interrupted. II: CONVENTIONAL CIRCUIT BREAKERS Automatic Switch The simplest circuit interruption device is the knife switch shown in Fig. 1. By closingthe switch against the action of a spring, energy is stored. By applying a small force on thelatch, the stored energy is released and the contacts open within a short time. Air-Break Circuit Breakers Air-circuit breakers cool the gases to naturally deionize them, causing arc interruption. Thearc can be stretched. Its resistance can be increased by increasing its length. The increasein resistance is significant so that the current and voltage are brought into phase. If the phase difference between the system voltage and the short-circuit current isreduced, when the current is interrupted at its zero value, the recovery voltage is very lowat that instant. The application of high-resistance interruption is limited to low- and medium-power accircuit breakers. It is also used for low- and medium-power dc circuit breakers. METHODS FOR INCREASING ARC RESISTANCE The following methods increase the arc resistance: 1. Arc lengthening. The resistance is approximately proportional to the arc length. 2. Arc cooling. A decrease in temperature increases the voltage required to maintain ionization.Therefore, cooling effectively increases the resistance. PLAIN BREAK TYPE The plain break type is the simplest type of air-break circuit breaker. The contacts are madein the shape of two horns, as illustrated in Fig. 2. The arc initially strikes across theshortest distance between the horns. Then it is driven steadily upward by the convectioncurrents which are caused by heating the air during arcing. The arc extends between thehorns. This results in lengthening and cooling of the arc.The arc interruption process is relatively slow. It limits the application of these circuitbreakers to 500 V and low-power circuits. MAGNETIC BLOWOUT TYPE This type of circuit breaker extinguish the arc by means of a magnetic blast. It is limited tocircuits up to 11 kV. The arc is subjected to the action of a magnetic field set up by coils connected in series with the circuit being interrupted (Fig. 3). These coils are calledblowout coils because they help blow out the arc magnetically. The arc is magneticallyblown into arc chutes where the arc is lengthened, cooled, and extinguished. The breaking action becomes more effective with heavy currents. This results in higherbreaking capacities for these breakers.The arc chute is an efficient device for quenching the arc in air. It performs the followinginterrelated functions: 1. It confines the arc within a restricted space. 2. It provides control of the movement of the arc to ensure extinction occurs within thedevice. 3. It cools the arc gases to ensure extinction by deionization.

FIGURE 1.Automatic switch.

FIGURE 2.A simple air-break breaker.

FIGURE 3.Principal scheme of a magnetic-blast breaker.

ARC SPLITTER TYPE The blowouts in these breakers consist of steel inserts in the arcing chutes. These insertsare arranged so that the magnetic field induced in them by the current in the arc helpsmove the arc upward. The steel plates divide the arc into a number of short arcs in series. APPLICATION In general, air-break circuit breakers are suitable for the control of power station auxiliariesand industrial plants. They combine a high degree of safety with minimum maintenance.They do not require any associated equipment such as compressors. Sincethey have no oil, they are recommended for locations where fire or explosion hazardsare feared. III: ACB OPERATION Never touch live terminal parts. Otherwise, electric shock may result. Do not force down the spring charging handle after completion of manual charging operation. Doing so may cause a malfunction. The permissible operating voltage of the spring charging motor is 85 to 110% of the rated ac voltage or 75 to 110% of the rated dc voltage. Be sure to supply a voltage within the above ranges to the motor. Otherwise, burnout may result. Repeated open/close operation by the motor charging mechanism without pause should not exceed 15 times. If repeated continuous open/close operation is inevitable, a pause of at least 20 minutes should be provided after the repetitions of 15 times. Otherwise, a spring charging motor may be burnt out. Do not bring your hand or face close to arc gas vent of the arc chamber while the ACB is energized. Otherwise, a burn may result from high-temperature arc gas blowing out of the arc gas vent when the ACB trips open. If the ACB trips open automatically, remove the cause of tripping operation before re-closing the ACB. Otherwise, a fire could result. If the ACB has the breaker fixing bolts, make sure the bolts on both sides are securely tightened before using the ACB. Loosened fixing bolts may cause a malfunction of the ACB, in particular when it is installed in such an area that is subject to strong vibrations. The ACBs are available in two types in terms of the closing spring charging method and the remote operation capability: a manual charging type and a motor charging type. The manual charging type requires the charging and ON-OFF (close/open) operation to be done manually while the motor charging type allows the operation to be done either manually or by using a motor. Charging operation The ACB can be closed only when the closing springs have been charged. Be sure to charge the closing springs before closing the ACB. The charging operation is permitted, regardless of whether the ACB is ON (closed) or OFF (open). The procedure for charging the closing springs is as follows: Manual charging Pump the spring charging handle until the spring charge indicator shows CHARGED. Pumping the handle with the full stroke 10 - 13 times will fully charge the closing springs.

Motor charging When the charge indicator changes to DISCHARGED, while both the specified operation and control voltages are applied, the charging motor is activated to start charging the closing springs. Upon completion of the charging operation, the charge indicator shows CHARGED and the charging motor is automatically deactivated. The time required for the motor charging operation depends on the operation voltage or the ACB types, but does not exceed 10 seconds. IV: AIR CIRCUIT BREAKER INSPECTION AND MAINTENANCE The service life of the ACB depends on the working and environmental conditions. The ACB is exposed to mechanical and electrical stresses and thus suffers gradual degradation during use, which will increase the possibility of malfunctions. Preventive maintenance and periodical inspection are very important to avoid any functional degradation, prevent malfunctions, extend the service life, and ensure safe operation. The appropriate frequency of maintenance and inspection of the ACB varies depending on the installation conditions, the number of tripping operations, the magnitude of breaking current and other factors that are to be considered empirically. As a guideline, Table 24 shows the recommended inspection frequency. Table 24 Frequency of maintenance and inspection

Normal inspection includes inspection and actions that can be done only with removing the arc chamber, contacts, front cover and the like. Normal inspection can be performed by the user. The manufacturer also provides normal inspection service. Detailed inspection includes inspection, actions, and parts replacement that will be done to prevent functional degradation caused by aging or the like when abnormality is found during normal inspection. You are recommended to use the manufacturers detailed inspection service. Thorough inspection must be left to the manufacturer. Overhaul will be done in a manufacturers factory.

Service Life When an ACB performs three times of tripping operation nearly at the rated breaking current (three standard operating duty cycles), it is at the end of its safe service life even if thorough inspection is done every time it trips open. Such an ACB will be apt to suffer malfunctions and should be replaced without delay to avoid frequent inspection and parts replacement. Inspection Procedures ACB maintenance, inspection and parts replacement must be performed by competent persons. Do not touch ACB current carrying parts and ACB structural parts close to a current carrying part immediately after the ACB trips open. Remaining heat may cause a burn. Prior to commencing any work on the ACB, open an upstream circuit breaker or the like to isolate all sources of power/voltage from the main and control circuits. Otherwise, electric shock may result. Take care to avoid adhesion of dust to main and control circuit contacts. Dust on the contacts may result in a fire. Prior to commencing maintenance, inspection, or parts replacement, make sure that the closing springs are released and the ACB is open. Otherwise, unintentional open/close operation may lead to fingers or tools to be pinched by the open/close mechanism, resulting in injury. Retighten the terminal screws periodically to the specified torque. Otherwise, a fire could result. When grinding a contact tip, be careful to prevent grinding dust from entering the breaker operating mechanism. Wipe the tip clean after grinding. Otherwise, a malfunction or fire could result. Do not perform dielectric withstand/insulation resistance tests under other conditions than specified. Doing so may cause a malfunction. Be sure to reinstall the arc chamber if removed. Failure to do so or incorrect installation of the arc chamber may result in a fire or burn. When charging the closing springs or performing open/close operation of the ACB with the arc chamber, front cover and/or side covers removed during maintenance or inspection work, do not touch parts other than those required for the above operation (charging handle, ON/OFF buttons, moving core and the like). Doing so may cause fingers or tools to be pinched, resulting in injury. When replacing an auxiliary, do not damage the control wire for the auxiliary or pinch the wire between the auxiliary and the breaker body. Doing so may cause a malfunction.

Table 26 Normal inspection procedure

Check point No.
1

Check item Discoloration of conductors Parts missing

Damage to parts

2 General 3 4

Main/control circuit terminals

Dust accumulation Connections

Main/control circuit contacts

Surface condition

Arc chamber

Dust accumulation

Surface condition

Contacts

Main circuit, Arc chamber

10

Looseness of screws Insulation resistance

Operating mechanism

11

Internal mechanism

Control circuit

12

Wiring

Auxiliary switches

13 14 15 16

Operation Auxiliary contacts Looseness of screws Drawout/ insertion mechanism UVT

Description Check connection conductors, main circuit terminals, and current carrying parts for heat discoloration. If such a symptom is found, you may contact the manufacturer. Check that screws, bolts, nuts, washers, springs, retainers and the like are not missing. If any parts are missing, you may contact the manufacturer. Check for deformation, cracks, chips, or other damage of parts. If damage is found, you may contact the manufacturer. Check that no dust is accumulated in ACB. If dust is accumulated, use vacuum cleaner to remove dust and wipe off with dry, clean cloth. Check main circuit terminal screws, ground terminal screw, auxiliary switch terminal screws, control circuit terminal screws, and position switch terminal screws for looseness. If loose, tighten to specified torque. Check that receptacle terminals are inserted correctly. If incorrect, reinsert correctly. Check that contacts have no dust accumulation and discoloration. If dust is accumulated, use vacuum cleaner to remove dust and wipe off with dry, clean cloth. If surface is discolored badly, polish it with #200 sandpaper. * For main circuit contacts, apply contact grease (SS grease, No. F-5G, FUJI KAGAKU SANGYO) to contact surface after cleaning. Excessive grease may foster dust accumulation. Grease should be applied lightly. Blackening of contacts is caused by oxidation or sulfuration and has no harmful effect except in extreme cases. If heat discoloration, arc marks, roughness, or peeling of plating layer is found, contact us. Remove arc chamber and check it for foreign object or dust accumulation, deformation, cracks, chips and other damage. If foreign matter or dust is accumulated, use vacuum cleaner to remove foreign matter of dust and wipe off with dry, clean cloth. If metal spatters are adhered, use sandpaper to remove them. * If arc chamber has stubborn adherents suffers damage, replace arc chamber. Remove arc chamber and check contact circumference, contacts, and contact tips for foreign object or dust accumulation, deformation, cracks, chips and other damage. If dust is accumulated, use vacuum cleaner to remove dust and wipe off with dry, clean cloth. If contact tips are badly discolored or roughened, polish with #200 sandpaper. * If contact tip suffers damage or is less than 0.7 mm thick after polishing, replace both moving and stationary contacts. Blackening of contact tips is caused by oxidation or sulfuration and will be removed during closing operation. It has no harmful effect except in extreme causes. If heat discoloration is found, perform detailed inspection. Check moving and stationary contact mounting screws A and B for looseness. If loose, retighten. Use Megger to check that insulation resistance between main circuit terminals, between main circuit terminal group and ground, and between ends of adjacent grids exceeds 5M ohm. If resistance does not exceed 5M ohm, use sandpaper to remove carbonized portions of insulation around contacts or current carrying parts and/or spatters adhered to arc chambers and arc extinguishing grids. If problem persists, you may contact the manufacturer. With OCR removed, check internal mechanism for missing parts, deformation, cracks, chips, foreign mater or dust accumulation, breakage of springs, and rust. If foreign matter or dust is accumulated, use vacuum cleaner to remove foreign matter of dust and wipe off with dry, clean cloth. If any parts are missing or damaged or springs are broken, you may contact the manufacturer. Remove side and front covers, check that wiring is properly connected, and not disconnected nor damaged. If incorrect connection is found, connect correctly. If disconnection or damage is found, contact us. Check that auxiliary switches operate as desired. If not so, replace switches. Remove auxiliary switches and check contacts for roughness. If roughened excessively, replace contacts. Check screws of auxiliary switches for looseness. If loose, retighten. Draw out and insert breaker body to check that draw-out handle can be turned with max. Operating torque or less, position indictor provides correct indication, release button operates normally, and no abnormal sound is heard during handle operation. If abnormality is found, you may contact the manufacturer. With breaker body in ISOLATED position, charge closing springs manually and attempt closing ACB to make sure ACB cannot be closed. If ACB can be closed, perform detailed inspection. With breaker body in TEST position and control/operation circuits, SHT and UVT supplied with power, perform closing spring charging operation and manual and electrical open/close operation several times to check that charge indicator, ON-OFF indicator and ON-OFF cycle counter provide correction indication and no abnormal sound is heard. If abnormality is found, perform detailed inspection. Move the breaker body to TEST position and supply ACB with control power, and then check that system alarm LED on OCR front panel is off. If LED is on, press reset button and make sure LED turns off.

Operation related mechanism

17

18

Operation mechanism, LRC, SHT and UVT System alarm

OCR and TC

19

Maintenance Procedures Insulation Remove and clean interphase barriers. Clean all insulating materials with vacuum and/or clean lint free rags. If it is necessary to use cleaning solvents, use only solvents recommended by the manufacturer. Inspect for signs of corona, tracking, arcing, or thermal or physical damage. Ensure that insulation is left clean and dry. Contacts Ensure that all contacts are clean, smooth, and in proper alignment. Ensure that spring pressures are maintained according to manufacturers specifications. On silver contacts, discoloration is not usually harmful unless caused by insulating deposits. Clean silver contacts with alcohol or silver cleaner using non-abrasive cloths. Manually close breaker to check for proper wipe, contact pressure, contact alignment, and to ensure that all contacts make at approximately the same time. If possible, a contact resistance test should be performed to determine the quality of the contacts. Older breakers equipped with carbon contactors generally require very little maintenance. Examine for proper pressure, deterioration, or excessive dressing which may interfere with their proper operation. Draw-out contacts on the circuit breaker and the stationary contacts in the cubicle should be cleaned and inspected for overheating, alignment, and broken or weak springs. Coat contact surfaces with contact lubricant to ease mating (see manufacturers recommendations). Arc Interrupters Clean all ceramic materials of loose dirt and examine for signs of moisture, make sure the assemblies are clean and dry. Examine for cracked or broken pieces. Dirt and arcing deposits may be removed by light sanding do not use emery cloth or wire brushes which may leave conductive residue behind. Repair or replace as necessary. Examine arc chutes for dirt and/or dust accumulations and clean as necessary. Dielectric testing of arc shields may be recommended by the manufacturer. Check air puffer for proper operation. Operating Mechanism Inspect for loose, broken, worn, or missing parts (consult manufacturers schematics for required parts). Examine for excessive wear of moving parts. Observe that operating mechanisms function properly without binding, hanging, or without delayed action. Ensure any lubrication is done according to the manufacturers specifications. Ensure mechanisms are clean, properly lubricated, and all bolts and screws are properly secured. Repair or replace as necessary. Auxiliary Devices Inspect operating devices for proper operation and general condition. Ensure all indicating devices are fully functional and properly set. Protective relays and circuit breaker trip devices should be inspected and tested according to manufacturers specifications and applicable industry standards such as those issued by the Institute of Electrical and Electronics Engineers (IEEE) and the National Fire Protection Association (NFPA).

Republic of the Philippines Tarlac State University College of Engineering Tarlac City

PREVENTIVE MAINTENANCE FOR AIR CIRCUIT BREAKER

a written report in partial fulfillment of the course EE 563: Electrical Equipment Preventive Maintenance

Submitted by: Cadelinia, Mark Joseph D. Cajigal, Roman C. Ching, Darryll L. Cunanan, Royce M.

January 2013