Impact of Operating Mechanism

Type on MV Vacuum Circuit

Breaker Reliability

by Juan Tobias
Jean-Marc Biasse
Philippe Picot
Denis Perrin
Marc Bonjean
Eduardo Pujadas

Executive summary
Circuit-breakers’ main duty is to interrupt short-circuit
current caused by a fault in the electrical network. As
the circuit-breaker is the ultimate electrical safety
device, reliable short-circuit current interruption in case
of network fault is paramount. The operating
mechanism is a key sub-assembly that has direct
impact on the circuit breaker reliability as well as its
cost and size. This paper describes the principle of
operation of MV VCB mechanisms, namely solenoid,
spring, and permanent magnet actuators. It provides a
synthesis of the requirements imposed by IEC and
ANSI standards for MV circuit-breakers as well as an
overview of the needs of the main MV network
998-2095-06-09-15AR0

applications regarding the mechanisms. Reliability

aspects are examined and it is argued that MV VCB
reliability in real operational conditions is not linked to
the rated number of mechanical operation that a new
VCB can do in a laboratory.
 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

Introduction Circuit-breakers are used for fast interruption of the short-circuit current to prevent damage to
the rest of the electrical installation. When the circuit-breaker is in closed position it can carry
the rated normal current indefinitely as well as the rated short-circuit current for a short time (<
3 seconds). Circuit-breakers can safely make and break several times short-circuit currents as
well as all types of load currents.

Circuit-breakers are always associated with a protection and control unit, also referred to as
Intelligent Electronic Device (IED). Current and voltage sensors supply low level signals to the
IED that will constantly monitor the current and voltage in the circuit and issue a tripping or
closing command according to how it was programmed. The circuit-breaker can also be opened
or closed for control purposes either remotely via the IED or locally via mechanical push
buttons.

Opening or closing the circuit-breaker contacts requires some form of operating mechanism
capable of storing the necessary energy to physically move the contacts. The operating
mechanism is a key sub-assembly that has direct impact on the circuit-breaker reliability. Its
design requires considerations of many factors determined by the type of interrupter technology
used and performance that has to be achieved.

MV circuit-breakers have rated voltages between 1 kV and 52 kV and are available with
maximum ratings up to 4000 A normal current and 63 kA rated short-circuit current. In the
1970’s MV current interruption technology evolved from oil to SF6 and vacuum. Over the past
20 years vacuum circuit-breakers (VCB) have dominated the market, as illustrated in Figure 1.

Figure 1
Historical evolution of MV
circuit-breaker interruption
technology

General
Standardization
aspects MV switchgear global market is ruled by two main standardization bodies: International
Electrotechnical Commission (IEC) and American National Standards Institute (ANSI).

There are significant differences in ratings and performances required by IEC and ANSI/IEEE
circuit-breaker standards. As a result global manufacturers usually have two different products.
Over the past few years IEC and IEEE standardization committees have made progress
towards convergence on type test requirements for MV circuit-breaker standards.

All standards applicable to MV circuit-breakers consider the operating mechanism as a sub-

assembly. They specify ratings and requirements for mechanical functionalities as well as the
test procedures to verify the mechanical and electrical performances. Ratings are defined in a
coherent way with the real operational needs, particularly in terms of typical switching

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 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

sequences and quantity of close-open (CO) cycles to be experienced by the circuit-breaker in

its lifetime.

Rated operating sequences are expressed as close (C) and open (O) operations followed by a
time interval (t) expressed in seconds or minutes. The requirements defined in IEC or
ANSI/IEEE standards for mechanical and switching operations, in terms of quantity of
operations and operating sequences reflect most of the needs found in the applications of
circuit-breakers.

IEC standard 62271-100

This standard defines circuit-breaker mechanical endurance ratings that impact mechanism
designs. Two types of mechanical endurance ratings are established:

 Class M1 circuit-breakers require mechanical endurance of 2,000 CO cycles;

 Class M2 circuit-breaker have an extended mechanical endurance of 10,000 CO cycles.

For switching, normal duty circuit-breakers require either O – 3 min – CO – 3 min CO or CO –

15 s – CO operating sequence. Circuit-breakers intended for rapid auto-reclosing must perform
O – 0.3 s – CO – t’ – CO where t’ can be 3 min, 1 min or 15 sec.

Mechanism designs used in normal duty and rapid auto-reclosing duty MV circuit-breakers are
quite different. Meeting rapid auto-reclosing operating sequence is challenging as the
mechanism must be capable to perform a closing operation 0.3 seconds after opening

ANSI/IEEE standards applicable to MV circuit-breakers

ANSI/IEEE has three complementary standards that impact the mechanism design.

 ANSI/IEEE standard C37.04 – Rating structure;

 ANSI/IEEE standard C37.06 – Preferred ratings;
 ANSI/IEEE standard C37.09 – Test procedures.

Manufacturers must choose the optimized ratings to cover the target markets and carry out the
circuit-breaker type tests accordingly.

The rated operating sequence defined for normal duty circuit-breakers is O – 15 s– CO – 3 min
CO while circuit-breakers intended for rapid auto-reclosing must perform O – 0.3 s – CO- 3min
– CO.

The rated interrupting times defined by ANSI/IEEE C37.04 are expressed in terms of cycles of
the power frequency: the most commonly used values are 3 cycles (i.e. 50 ms at 60 Hz) and 5
cycles1. ANSI/IEEE C37.06 defines different values of operating mechanical endurance
capabilities for MV circuit-breakers, from 1,500 to 10,000 operations depending on ratings.

1
R. Catlett, J. Anderson, L. Chassereau, 2005, “Three-Cycle Breaker Applications”, IEEE INDUSTRY
APPLICATIONS MAGAZINE, SEPT|OCT 2005, 33-43
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 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

IEC 62271-111 and IEEE C37.60 standards for automatic circuit-

reclosers up to 38 kV
The preferred rated operating sequence for this special type of circuit-breakers is: O – 0.5 s –
CO – 2 s – CO – 5 s – CO. Longer time intervals between C-O operations may be used,
depending on the application.

This standard requires a minimum of 2,000 CO operations to be done without maintenance, of

which 1,800 have to be done using the automatic circuit recloser integral protection and control
unit. The remaining 200 operations shall be done by using the manual opening and closing
mechanisms (when provided).

VCB Mechanisms for MV VCBs have specific requirements that are related to the physical
characteristics of vacuum interrupters, which consist of a fixed and moving butt contacts kept
mechanism under high vacuum inside a ceramic envelope. The moving contact is attached to metallic
design bellows that allow it to move to the open position, leaving a short gap of typically 10 to 20 mm.
A typical MV vacuum interrupter is illustrated in Figure 2.
constraints
Butt contacts in closed position tend to be forced apart by the electromagnetic forces generated
when the short-circuit current passes through them. This phenomenon, known as “contact
popping” must be avoided as it leads to arcing, which causes contact surfaces to melt and
subsequently to weld, making it impossible to separate them again.

To avoid “contact popping” the operating mechanism has to provide a high compression force
on the contacts in closed position. In all cases this is provided by the “wipe spring” located in
the drive linkage, which is compressed as the contacts close.

Figure 2
Typical MV vacuum
interrupter

All MV circuit-breaker mechanisms must be able to achieve close-open operation on short-

circuit. This means that when the circuit-breaker closes onto a fault, the mechanism should
have sufficient energy stored to be able to immediately open the interrupter and clear the short-
circuit current. The circuit-breaker must also be able to manage two simultaneous orders close
and open (trip-free, as defined by IEV 441-16-31, and anti-pumping features).

For a class M2 circuit-breaker (10,000 CO cycles), the vacuum interrupter itself is generally
designed to achieve a mechanical endurance between 20,000 to 30,000 CO cycles. The limit
comes from the metallic bellows that eventually break under fatigue.

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 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

Mechanism Three types of operating mechanisms can be found in MV VCBs and auto-reclosers available in
the global market today. These are classed by the type of technology used to store the energy
operating needed to close and open the vacuum interrupters.
principles
Solenoid mechanism
Solenoid mechanisms use a compressed spring to open the interrupter and a solenoid to close
it as well as charging the opening spring. The energy required to operate the solenoid is
supplied by the DC or AC auxiliary supply. Solenoids take a high current surge when they are
energized, which requires a stiff auxiliary power source (DC battery or LV AC) or a large
capacitor discharge, and high rating auxiliary contacts. They are also bulkier and heavier than
spring operated mechanism. For this reason they are now rarely used in practice.

Spring mechanism
Spring mechanisms use separate charged springs to store energy for opening and closing the
interrupters. The closing spring has sufficient energy to charge the opening spring and is
recharged either manually or by a small motor supplied by the auxiliary supply. There are two
basic types of VCB spring mechanisms:

 Mechanisms for VCBs that do not require fast reclosing duty (e.g. O – 3 min – CO rated
operating sequence);
 Mechanisms for VCBs able to perform fast reclosing duty (e.g. O – 0.3s – CO – 15 s –
CO rated operating sequence), as shown in Figure 3.

Figure 3
MV CB spring mechanism
designed for fast reclosing
duty

Two main principles are used in fast reclosing spring mechanism designs: cam follower and
four-bar linkage2. Trip-free feature can be provided either by the intrinsic design of cam follower
mechanism or by toggle linkage systems3.

Permanent Magnet Actuator (PMA) mechanism

Permanent magnet actuator
Permanent magnet actuator (PMA) mechanisms use energy stored in electrolytic capacitor for
closing operation and permanent magnets to latch in closed position. PMA mechanisms were

2
A. Greenwood, 1994, Vacuum Switchgear, IEE, London, UK, 152-162.
3
R.D. Garzon, 1997, High Voltage Circuit-breakers – Design and Applications, Marcel Dekker, Inc.,
NewYork, USA, 214-219.
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 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

developed specifically to be used with MV VCBs4. First commercial models were introduced in
the market in the late 90’s5,6 but uptake has been poor. There are two families of PMA
mechanisms: mono-stable (single magnetic latch) and bi-stable (double magnetic latch).

The principle of mono-stable PMA mechanism is similar to the solenoid one except that in
closed position the mechanical latch is replaced by a permanent magnet latch (see Figure 4).
The closing force is designed to keep the vacuum interrupter closed with the correct contact
pressure while charging the opening spring.

In the bi-stable PMA mechanisms, permanent magnets latch the armature in both closed and
open position. To move the armature from one position to the other a high magnetic flux is
created by a DC current in the opening or closing coil. This reduces the magnetic latch strength
and generates an opposing force in the other air gap. Energy for open and close operations is
derived from two separate electrolytic capacitors that are discharged into the opening and
closing coils. Manual trip in case of loss of DC supply is complex because it requires the
application of a high force using a lever to “unstick” the armature from the permanent magnet
latch and to provide the opening energy.

Mono-stable PMA is often preferred to bi-stable for the following reasons:

 Eliminates risk of incomplete opening (tripping energy is stored by charging the opening
spring);
 Simpler manual and electrical tripping (only requires cancelling the permanent magnet
flux to open the VCB).

Figure 4
Single magnetic latch
PMA mechanism

Electronic Control System

PMA mechanisms require an electronic control system that receives either DC or AC auxiliary
power, provides DC power to charge the electrolytic capacitors, discharges the stored energy in
the opening or closing coils and disconnects the energy source once the VCB has reached the
open or closed position. In most designs the electronic control system is used to monitor the
condition of the capacitors and operating coils, giving alarms in case of anomalies.

The electrolytic capacitor is a key component as it stores the necessary electrical energy that
will generate the current pulse needed to operate the PMA. Typical capacitance of 100,000 µF
charged at 80 V DC gives a stored energy of 320 Joules, sufficient to carry out a VCB fast
reclosing sequence, including short intervals between CO operations.

4
B.A.R. Mckean, C. Reuber, 1998, “Magnets & Vacuum – The Perfect Match”, Trends in Distribution
Switchgear, Conference Publication No. 459, IEE
5
E. Dullni, H. Fink, C. Reuber, 1999, “A Vacuum Circuit-Breaker with Permanent Magnetic Actuator and
Electronic Control”, Proceedings CIRED conference
6
A.J.W. Lammers, P.P. Leufkens, G.C. Schoonenberg, 1998, “MV Vacuum Switchgear Based on Magnetic
Actuators”, Trends in Distribution Switchgear, Conference Publication No. 459, IEE
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 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

MV VCB MV circuit-breaker mechanism performance requirements are dependent on the function they
are intended to perform in the MV electrical distribution network. There are four main types of
network MV networks:
applications  Electrical utility MV distribution networks;
 Electro-intensive industrial sites;
 Data centres and hospitals;
 Buildings, infrastructure and light industry sites.

Utility MV distribution networks are specific to each country, but they can be classified into
urban underground cable network and rural overhead line networks. Utility MV underground
cable networks use VCBs in MV transformer incomer, MV cable feeder or MV/LV transformer
feeder applications. Faults in MV cables and MV/LV transformers are rare, consequently these
VCBs remain in closed position for months or even years, just carrying load current. In case of
fault, the VCB will trip and remain open as all faults are permanent.

MV cables and MV/LV transformers are protected by time delayed overcurrent relays with
operating time > 200 ms. Consequently, VCBs with rated operating sequence O – 3 min – CO
and opening times < 100 ms are perfectly fit for purpose.

MV utility networks supplying rural areas use overhead lines that are exposed to lightning
strikes, birds, and fallen trees. Auto-reclosing duty is used in the overhead line feeder VCB to
minimize the impact of transient faults due to lightning strikes. The VCB is used to disconnect
the MV supply and reenergize the line after a few hundred milliseconds as it is very likely that
the fault disappears during the time that is de-energized. Utilities in certain countries like US,
Australia and Brazil also install pole mounted automatic reclosers along long MV overhead lines
to minimize the number of customers affected by transient faults. Reclosers are special circuit-
breakers designed to perform several CO operations with short delay (< 5 sec) between them.

MV electrical distribution networks used in oil and gas, mining, steel, cement and paper
industrial sites have very large MV motors (> 3 MW). These installations are very dynamic. MV
circuit-breakers perform many load switching operations per day to change network
configurations, shed loads, and connect local generation. MV capacitor banks are often used to
compensate lagging power factor caused by the motor inductive loads. Circuit-breakers used to
control them also need to operate several times a day. The most demanding application for an
MV circuit-breaker is electric arc furnace (EAF) control in steel plants as the process requires
several CO operations per day switching high load current. To ensure high reliability these
special VCBs are subject to regular maintenance.

MV electrical distribution networks for data centres and hospitals are designed for high supply
availability. In case of a utility supply failure, critical loads (e.g. server rooms, operating
theatres) are supplied by LV UPS for up to 10 min, giving enough time to start back-up diesel
generators usually connected to the MV network via circuit-breakers. Utility failures are indeed
very rare, but the back-up generation needs to be tested regularly, which requires MV circuit-
breaker to perform regular CO operations with light load currents. Some data centres use diesel
rotary UPS (DRUPS), which consist of an MV generator driven by a flywheel and a diesel
engine. In case of utility failure the critical load will be supplied by kinetic energy stored in the
flywheel until the diesel generator gets up to right speed to take over the load. The MV circuit-
breaker connecting the DRUPS system to the utility supply could perform many CO operations
with light load current if the utility supply is poor.

MV networks in commercial buildings, large infrastructure and light industry sites consist mainly
of MV cable feeders and MV/LV transformer feeders. These are static, very reliable MV cable

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 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

network that do not require MV switchgear to operate for months or even years. Most
operations are required to carry out planned maintenance.

Operating Selecting the VCB mechanism type for a particular MV network application requires
understanding of environmental constraints and switching duties in order to define rated
mechanism mechanical and electrical endurance and operating sequence. The VCB expected operating
performance life, maintenance frequency, and procedure are also important. The selection criteria are
summarized in Table 1.
requirement
by application For the vast majority of applications the performances of VCBs with spring mechanisms are
perfectly adequate. PMA mechanisms are recommended in special applications where the VCB
has to perform a very high number of operations (e.g. arc furnace) or several consecutive fast
reclosing cycles (e.g. pole mounted recloser).

This selection criterion is reflected in the MV VCB global market data:

 Spring mechanism is the main technology for MV VCBs (> 90% market share);
 PMA is the dominant mechanism technology for pole mounted reclosers (> 90% market
share);
 PMA mechanisms are better adapted for niche applications requiring very precise “point
7
on wave” single pole switching .

Appli Expected Rated Rated Expected Best

VCB type catio operations operating mechanical operating adapted
n per year sequence endurance life VCB
mechanism
Cable /
General O - 3 min -
transformer <30 M1 2,000 ops Spring
purpose CO
feeder / incomer
Table 1
Mechanism requirements Capacitors, 30 years
motors,
O - 0.3 s - CO Routine Spring (preferred
generators,
- 15 s - CO maintenance or PMA)
DRUPS,
Frequent overhead feeder <300 M2 10,000 ops every 3 years
switching
O - 0.3 s - CO
Pole mounted
- 2 s - CO - 5s PMA
recloser
- CO

10 years
O - 0.3 s - CO Special 30,000 Full
Heavy Arc furnace <3,000 PMA
- 15 s - CO ops maintenance
duty required
every year

The VCB rated mechanical endurance is generally verified using a new device in a laboratory
VCB reliability by performing repetitive uninterrupted sequence of CO operations that stops when the VCB fails
to open or close. This conventional test cannot represent all the situations and the real duties
that the VCB will see in the field. However, many consulting engineers and end users take the

7
C. Cereda, C. Gemme, C. Reuber, 1999, “Synchronous Medium Voltage Circuit-breakers: ABB Solution
Based on Magnetic Drive and Electronic Control”, Proceedings CIRED conference
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 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

VCB rated mechanical endurance as an indicator of operational reliability based on the belief
that higher the mechanical endurance gives higher reliability.

In fact, VCB reliability is more appropriately measured by its operational MTBF (Mean Time
Between Failures). In practice, operational MTBF of a new VCB operating mechanism design it
is very difficult to estimate. Calculations must take into account the reliability of each
component that takes part in the opening or closing of the VCB, as well as the stress factors
and operating conditions (often referred to as “the mission profile”). Two simple reliability block
diagrams (see Figure 5) show how component reliability contributes to the overall reliability of
spring and PMA VCB mechanisms.

Figure 5
Basic reliability model of
spring and PMA mechanisms
used for MTBF estimation

A quantitative comparison between both systems was made using the following assumptions:

Failure rate of the mechanical parts (trip coil, motorized spring, and PMA) is low at the
beginning but increases with the number of operations due to wear. Periodic maintenance can
partially restore the condition of the mechanism; Failure rate of the electronic parts (control
board and electrolytic capacitors) is constant throughout the expected service life of the
operating mechanism but considerably higher than that of the mechanical parts at early life
stages;

Typical operational MTBF for mechanical systems was assumed to be > 1,000 years. This is
based on field failure data of spring-operated LV and MV CBs in operation for over 15 years;

Typical operational MTBF for PMA control board and electrolytic capacitor was assumed to be
< 350 years. This is based on operational reliability of Schneider Electric IEDs, which are
considered to contain similar technology. Actual reliability could be worse (< 100 years)5;
Life expectancy of the electrolytic capacitor can decrease dramatically at high operating
temperatures. Life expectancy for electromechanical systems (spring mechanism and PMA) is
> 30 years and does not significantly depend on operating temperature.

Another aspect to be considered for the comparison is the result of a Failure Mode, Effects, and
Criticality Analysis (FMECA) of each mechanism design. A summary of the main differences
observed is provided in Table 2.

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 Impact of Operating Mechanism Type on MV Vacuum Circuit Breaker Reliability

VCB failure mode and estimated risk

VCB mechanism type Inability to Slow open on trip
Incomplete open
open order after long
Table 2 operation
manually inactivity
VCB failure mode estimated
risk Motorized spring Low Negligible Medium

Mono-stable Low Negligible Medium

PMA
Bi-stable Medium Medium Low

The bi-stable PMA has a non negligible risk of ending up in an intermediate position between
open and close as there is a natural position provided by the contact pressure springs if they
cannot be compressed up to the final magnetic latch position.

In case that VCB has been inactive for many years (normal situation in static MV networks), the
spring and mono-stable PMA mechanisms have a risk of opening with lower VI contact
separation speed than required to interrupt the fault current. This misoperation can be due to
increased friction between moving parts resulting from ageing. This undesirable condition will
disappear after the mechanism operates once8. This risk can be reduced by performing a single
CO operation every 3 years or less.

Conclusion Although spring mechanisms and PMA mechanisms are based on different technologies, it is
however seen that both of them are suitable for most of MV VCB applications. VCB reliability is
not linked to the maximum number of operations that a new device can perform in a laboratory.
The real parameter to consider is operational MTBF. Spring mechanism reliability is determined
by mechanical system failure rates only while PMA mechanism reliability is determined by the
combination of mechanical and electronic failure rates. Although spring mechanisms have a risk
of performing a “slow open” operation after long periods of inactivity, the risk can be reduced by
carrying out periodical VCB operation test.

In summary, the author’s logical arguments challenge the idea that VCBs with PMA mechanism
with higher mechanical endurance are more reliable than VCBs with motorized spring
operation. This qualitative analysis highlights just some aspects of the impact of operating
mechanism on VCB reliability, thus opening debate among the MV switchgear experts.
Further work is required to achieve accurate VCB reliability models.

This white paper was originally published in June 2015, CIRED 2015, Lyon, France
Copyright Material CIRED Paper No. 0777
© 2015 Schneider Electric. All rights reserved.

8
V. Kraynov, F. Pitis, V. Tchekhov, 2013, “Ageing of Mechanisms of Circuit-breakers”, Proceedings CIRED
conference
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