MANUAL METAL-ENCLOSED SWITCHGEAR

METAL-ENCLOSED SWITCHGEAR
INDOOR AND OUTDOOR DISTRIBUTION
5kV THROUGH 38 kV

Automatic Source Transfer Manual with Metering Bay

Category B Enclosure

Metal-Enclosed Switchgear - Advantages

Around industrial plants, universities, waste water treatment facilities,
convention centers and similar other large facilities usually there is a Let-through energy (I2t) FOR 40KA RMS
need to distribute electrical power located below the ground surface at
medium voltage (5kV - 38kV) via cable circuits. Typically, these circuits are CIRCUIT BREAKER (5 cycle)
connected to a central assembly of switchgear, fed by a main circuit from
the local utility, and arranged in lineups of multiple cubicles. 133 x 106 A2 Sec
EXPULSION FUSE (1/2 x 1 cycle)
There are basically two types of Medium-Voltage (MV) Switchgear lineups:
20 x 106 A2 Sec (Average)
Metal-Clad (containing drawout circuit breakers) and Metal-Enclosed (con-
taining load-break switches and fuses). The fuses used in Metal-Enclosed
equipment can be either expulsion or current-limiting. Figure 1 represents CURRENT-LIMITING FUSE (200A)
the relative energy-limiting capabilities of MV breakers, expulsion fuses 1 x 106 A2 Sec (Typical)
and current-limiting fuses, which in the case of Metal-Enclosed Switchgear
utilizes expulsion and current-limiting fuses for protection to provide the
best energy limitation. Figure 1. The dark area under each curve represents the relative energy
limitation of damaging let-through currents provided by various protective
These two types of medium-voltage switchgear lineups of cubicles are devices. The curves illustrate that fuses allow through much less damaging let-
defined in ANSI Standards (C37.20.2 for Metal-Clad and C37.20.3 for through currents and, therefore, do a much better job of protecting cables and
Metal-Enclosed). Criteria for selecting one of these two types of switchgear transformers.
should be: security, ease of operation, the quality of protection offered,
first cost and life-cycle cost.

FEDERAL PACIFIC Section 12 - 1

MANUAL METAL-ENCLOSED SWITCHGEAR
Figure 2 below is a summary table of features favoring the selection of
Metal-Enclosed lineups with switches and fuses: Dimensions for Federal Pacific
Metal-Enclosed Switchgear 
While Metal-Enclosed Switchgear using load-interrupter switches and Width (in inches) Height Depth
Type of
fuses has many economic and protective advantages over Metal-Clad Voltage (In Inches) (In Inches)
O.C. Motor
using circuit breakers, Federal Pacific, whose predominant construction Class Manual
Protection Operated  
is Metal-Enclosed, will use a drawout circuit breaker to handle high,
continuous load-currents that exceed the fuse rating of a switch and Current 36 36 90 46
fuse combination or for automatic reclosing. Since faults on industrial Limiting
power systems are almost always "permanent", automatic reclosing is not Draw-out
desirable because subsequent reclosing will only cause further damage 5kV 36 — 90 94
VCB
to cables and equipment. Thus, Metal-Enclosed switchgear lineups are
the better choice. Expulsion 41 41 90 46
Fuse
Current 36 36 90 46
Limiting
Advantages of Metal-Enclosed over Metal-Clad
Draw-out
15kV 36 — 90 94
•Lower Initial Cost per cubicle (Metal-Enclosed = 1/3 of Metal-Clad) VCB
•Better protection for cables and transformers Expulsion
•Significantly lower let-thru currents (mechanical energy) 41 41 90 46
Fuse
• Significantly lower let-thru I2T (thermal energy)
Current — — — —
Limiting
(Breakers take 5 cycles from relay sensing to circuit interruption. 25kV
Power fuses require no more than 1 cycle for circuit interruption.) Expulsion 48 53 120 48
Fuse
•Lower installation cost (simple field assembly) Current
•No auxiliary power or VTs are needed — — — —
Limiting
•No maintenance required for fuses 35kV
•No possibility of reclosing on a fault with fuses Expulsion 60 60 130 60
•Single-phase protection: Shunt trip of three-phase switch in feeder Fuse
cubicle when a fuse operates
Dimensions are for standard production products.
Add 5.5 inches to the height for Outdoor NEMA 3R enclosures.
Figure 2. Advantages of Metal-Enclosed Switchgear compared to Metal-Clad If rear-entry compartment is needed, increase the depth of the com-
Switchgear.
partment by the following dimensions:
5 kV-add 16 inches
15 kV-add 16 inches
25 kV-add 24 inches
35 kV-add 30 inches

Section 12 - 2 FEDERAL PACIFIC

 MANUAL METAL-ENCLOSED SWITCHGEAR
Metal-Enclosed Switchgear Application
Federal Pacific Metal-Enclosed Load-Interrupter Switchgear provides a
secure, convenient method for switching and overcurrent protection of
high-voltage cable systems. The switchgear may be located indoors or
outdoors. Typical applications include:
• Service entrance switching.
• Transformer primary and secondary switching.
• Isolation and protection of feeder circuits.
• Loop circuit sectionalizing.
• Manual and automatic transfer from preferred to emergency circuits.

Federal Pacific Metal-Enclosed Switchgear has been designed to meet

the most rigid requirements for this class of equipment. High-grade
11-gauge steel panels are designed so that each switchgear bay is an
individual self-supporting unit with double walls between bays on
multiple bay lineups. • UL® Listed (5 & 15kV)
Corrosion-resistant cabinets are assured by chemical cleaning and phos- • Meets ANSI C57.12.28 enclosure security requirements
• 11-gauge steel
phatizing (or zirconization) followed by a rust-resistant baked powder • Auto-jet®II puffer-type load-interrupter switch
epoxy prime coat followed by a baked-on polyester finish coat that is UL® • Three-time duty-cycle fault-closing switch
Listed for NEMA1 and NEMA 3R installations. Powder coats are applied • No rear access required
using electrostatic deposition. Standard color is light gray, ANSI 61. • Easy inspection and maintenance
• A Portable Remote Operating Mechanism is available as a separate purchase
The Auto-Jet® II load-break switch is equipped with a quick-make, quick- to permit operating manual switches outside the arc flash hazard zone.
break stored-energy mechanism. The operating handle is mounted on
the right front of the unit at a convenient level with a maximum upward
swing of 78" above ground level. The maximum operating force is 60
pounds. The standard manual operating handle may be padlocked either
open or closed. A mechanical interlock is provided as standard to prevent
opening the door with the switch closed or closing the switch with the
door open. Optional key interlocks to replace mechanical interlocks as
well as other key-interlock systems are available. Inspection windows are
located so that the position of the switch blades may be checked with the
exterior bulkhead door closed.
Standard switchgear main bus is rated 600 amperes, 40,000 asymmetrical
rms amperes momentary. Optional main bus rating of 1200 amperes is
available to 61,000 asymmetrical amperes momentary.

Switch Ratings
kV Amperes
60 HZ
Fault- Withstand
Nom. Max. Continuous
&
Momentary
RMS Closing BIL kV
Design Interrupting ASYM † RMS kV
ASYM †
4.8 5.5 600 40,000 40,000 60 19
4.8 5.5 1200 40,000 40,000 60 19
14.4 17.0 600 40,000 40,000 95 36 Applicable Industry Standards
14.4 17.0 1200 40,000 40,000 95 36 C37.20.3 – IEEE Standard for Metal-Enclosed Interrupter Switchgear
C37.20.4 – IEEE Standard for Indoor AC Switches (1kV-38kV) for use in Metal-En-
14.4 15.5 1200 61,000† 61,000† 110 36 closed Switchgear
25 27 600 40,000 40,000 125 60 ANSI C37.22 – Preferred Ratings and Related Capabilities for Indoor AC Medium-Volt-
age Switches Used in Metal-Enclosed Switchgear
25 27 1200 40,000 40,000 125 60 IEEE C37.30 – Requirements for High-Voltage Air Switches
ANSI C37.32 – High-Voltage Switches, Bus Supports, and Accessories – Schedules of
34.5 38 600 40,000 40,000 150 80
Preferred Ratings, Construction Guidelines, and Specifications
34.5 38 1200* 61,000 40,000 200 60 ANSI C37.34 – Test Code for High-Voltage Air Switches
ANSI C37.57 – Metal-Enclosed Interrupter Switchgear Assemblies – Conformance
† The Auto-jet Switch has a three-time fault-close capability at 40kA and a single-time
®

fault-close capability at 61kA per ANSI standards. Testing

ANSI C37.58 – Indoor AC Medium-Voltage Switches for use in Metal-Enclosed Switch-
* The switch has a 1200 ampere continuous current rating only. gear – Conformance Test Procedures

FEDERAL PACIFIC Section 12 - 3

MANUAL METAL-ENCLOSED SWITCHGEAR
Single-Bay Manual Metal-Enclosed Switchgear - Construction

1
Most single-bay Metal-Enclosed Switchgear is applied for the
HV Switch and Fuse protection of medium-voltage industrial
transformers either liquid filled or dry-type in the 500-5000 2
KVA range.
3
This switchgear enclosure (and Metal-Enclosed Switchgear in
general) can be constructed for indoor or outdoor applications. 4
• Indoor applications - Routinely called NEMA-1 Type
Construction* (default value)
• Outdoor applications - Routinely called NEMA-3R Type 5
Construction*
* By strict definition, these NEMA construction types apply
to applications of 1000V or less. 6
Cabinet security classifications Category A or Category B are
available for this and other Metal-Enclosed Switchgear designs.
7
• Category A - Suitable for “general public access”.
Category A covers the concept of tamper-proof.
Typically used in areas with “unsupervised access”.
• Category B - Suitable for “authorized access”. (Default)
Category B represents “standard” basic metal-enclosed
switchgear construction. 6
Typically used in areas with “supervised” or, more com-
monly, no public access.
Note - Category C (which allows exposed bushings, bus, or
terminals) is not available from Federal Pacific. 4
There are two important economic considerations for selecting 8
the design of single-bay assemblies for transformer switching
applications. First, there will be considerable savings by having
the switchgear cubicle "closely coupled" to the transformer
primary either by flange connection or throat connection.
This configuration eliminates the need for additional cable Exterior view of an outdoor, Category A, single-bay 15 kV
and stress relieving terminations in both the switchgear and metal-enclosed switchgear enclosure containing an Auto-
transformer and also eliminates the need for an additional jet®II load-interrupter switch with power fuses.
rear-entry compartment when bottom cable entry and bottom
cable exit are required from a "stand-alone" cubicle.
Second, strong consideration should be given to selecting 1. Lifting angles, at top of enclosure (shown on next page) are removable
current-limiting fuses for circuit protection inside the cubicle. with bolt holes blind-tapped.
Current-limiting fuses provide significantly better fault energy 2. Screened ventilation perforations include an internal backup plate.
limitation than expulsion fuses in terms of lower "peak let-thru
current" (mechanical energy that deforms windings) and lower 3. Weather sealant between roof and enclosure and between bus
I2T energy (thermal energy that damages insulation). The initial extension cover plate and enclosure.
cost of ME cubicles housing current-limiting fuses is about 25%
less than ME cubicles housing expulsion fuses, which during 4. Heavy-gauge steel cover plates over main and ground bus openings.
operation can leave significant residue on insulating barriers 5. Security cover (optional) over viewing window is hinged and
and cabinet walls. padlockable for Category A installations.
6. Security cover (optional) over switch operating handle can be positioned
over handle in either the open or closed position and is padlockable
in either location for Category A installations. Lower location shows
bottom position of cover when switch handle is in open position.
7. Door handle is recessed, includes penta-head bolt and is padlockable.
(Category A only).
8. Channel base of heavy-gauge steel supports enclosure of outdoor
units only.
Section 12 - 4 FEDERAL PACIFIC
 MANUAL METAL-ENCLOSED SWITCHGEAR

9
9. Stainless-steel door hinges and pins ensure easy
movement of doors throughout equipment life. 1
10
10. Windows of a polycarbonate material are
weather-sealed using gasketing and sealants
on outdoor units.
11. Three-Point high-strength door latches and door
rods.
12. Backup plate for ventilation openings on outdoor 11
units.
13. Storage box for replacement fuses.
14. Self-latching door holder keeps door fixed open.
15. Gasketing around enclosure entry on outdoor
units compresses against back of door when
closed to prevent water entry.
16. Sturdy internal screens provide a second barrier to 18
shield against accidental contact and perforated
to allow visual inspection.
17. Door interlock prevents access to fuses unless
switch is open. 17

18. Sturdy operating handle with cast-aluminum

housing includes provisions for padlocks and
key interlocks.
16

12 13 14 15

Enclosure door is open to show internal screens with openings

for viewing switch position and blown-fuse indicators.

FEDERAL PACIFIC Section 12 - 5

MANUAL METAL-ENCLOSED SWITCHGEAR

1. Main bus is rated for 600 amperes,1200-ampere

bus is also available.
2. Auto-Jet® load-interrupter switches, rated 600
and 1200 amperes, are UL® recognized and
feature an industry-leading three-time duty-
cycle fault-closing rating of 40,000 amperes
asymmetrical and a one-time duty-cycle fault-
closing rating of 61,000 amperes asymmetrical.
3. Unit can be furnished with a variety of power 2
fuses which are current-limiting or expulsion 1
fuses.
4. Ground studs on fuse terminal and provisions
on ground bus.
5. GP0-3 fiberglass barriers isolate phases and
ground plane.
6. Heater in fused circuit inside outdoor units (not
visible on sidewall of enclosure).
3

6
Door and screens open showing clear space for
terminating cables and replacing fuses.

Section 12 - 6 FEDERAL PACIFIC

 MANUAL METAL-ENCLOSED SWITCHGEAR
Features (Single-Bay & Multi-Bay)
• Standard doors are full height. Inner screen doors control access to fuses and
other energized components.
• Metering transformers may be located in switch-fuse compartment or may be
located in a separate adjacent compartment.
• Switch position can be seen through sealed, clear polycarbonate window and
perforated inner screen.
• Bulkhead doors feature 3-point latching, a captive hex-head security bolt,
padlockable flush mounted handle, self-latching doorstop and stainless steel
concealed hinges. Category A security features are available as an option.
• Switch handles have provisions for padlocking in the opened or closed positions
and can accommodate a Portable Remote Operating Mechanism (see optional
features).
• Standard ventilation louvers are included at top and bottom on front and back
of each bay. All louvers on outdoor assemblies are tamper resistant and have
internal screens with filters.
Exterior of
• Mechanical interlock prevents opening door with switch closed or closing Switch/Fuse Bay With
switch with door open. Category A Security
• Bus bars are aluminum (copper optional). Features
• Ground bus in each compartment is aluminum (copper optional).
• Hinged inner steel door guards against contact with the switch and is perforated
to allow view of switch blades.
• "Danger — High Voltage" signs are located on inside on screen doors.
• Rear access is not required except to accommodate special entrance requirements.
• Fuses may be current limiting or expulsion type with exhaust control devices.

Outdoor Units (NEMA 3R)

• Roof weather sealed to enclosure.
• Adjacent bays are sealed to keep water out from between the double walls.
• Roof caps over joints between bays are provided as an added measure to exclude
water.
• A space heater (on a fused circuit) in each unit eliminates excessive condensation.
• Externally removable filters provided with outdoor features.
• Formed steel channel base on each individual unit has an insulating coating
applied.
• Underside of all roofs have a heavy coat of anti-condensation compound.

Optional Features and Accessories

• Portable Remote Operating Mechanism - fits over manual handle and Open Door View
allows switch to be opened or closed from outside the arc-flash boundary. of Switch/Fuse Bay
• Mimic Bus Showing Internal
• Single-Phase Protection Screens
• Blown Fuse Indication
• Analog or Digital Customer Metering
• Utility Metering
• Drawout VTs or CPTs
• Undervoltage Trip
• Overvoltage Trip
• NEMA 3R Enclosure
• UL Listing (5 and 15kV)
• Station, Intermediate and Distribution Class Surge Arresters
• Key Interlocks
• Motor Operator, Auxiliary Switches, Operation Counter
• Current Transformers
• Special Paint
• Special Enclosure Material (304 or 304L Stainless Steel)
• Close Coupling to Transformers, Existing Switchgear, or Retrofit

Interior View of
Switch/Fuse Bay
FEDERAL PACIFIC Section 12 - 7
MANUAL METAL-ENCLOSED SWITCHGEAR

PORTABLE REMOTE OPERATING MECHANISM FOR MANUAL SWITCHES

MITIGATES EXPOSURE TO ARC-FLASH HAZARDS

Federal Pacific has developed a portable remote operating mechanism Features:

(PROM) that can be applied for operation of manually-operated Auto-jet® 1. Extendable 50-foot Air Hose With Fast-On Pneumatic Coupler for
switches from a location outside the critical arc-flash boundary zone. Connection to An Air Cylinder and CO2 Tank
The fittings required to accommodate the portable mechanism can be 2. Gusseted Mounting-Frame Weldment of Portable Mechanism
retrofitted onto switchgear already installed in the field. Alternately, the 3. Ring Bushing With Set Screw Secures Operating Lever to Switch-Op-
fittings can be provided as an option on new switchgear. erating Handle
Designs of the Federal Pacific PROM Portable Mechanism are available for 4. Lifting Eyes (2)
operation of Auto-jet® switches rated through 38kV on both metal-enclosed 5. Operating Lever of Portable Mechanism
switchgear and pad-mounted switchgear. The portable remote operating 6. Handle Grip for Portable Operating Station
mechanism is capable of opening and closing the switch from a distance 7. Portable Operating Station Holds Portable Mechanism and CO2
of up to 50 feet. Tank
8. Shield Isolates Chain-Drive Assembly
9. Mounting Bolts (2) Secure Portable Mechanism Onto Portable
Operating Station
10. Air Cylinder With Fast-On Pneumatic Coupler for Connection of An
Air Hose
11. Optional Two-Wheel Dolly is Permanently Secured to Portable
Operating Station
12. CO2 Tank, 15 lbs., Provides Approximately 150 Operations
13. Bottom of Portable Operating Station is Formed With a Channel
Base to Readily Accommodate a Two-Wheel Dolly When That Option
is Not Selected

11

2
3
4

12
6

7
8

13
10

Section 12 - 8 FEDERAL PACIFIC

 MANUAL METAL-ENCLOSED SWITCHGEAR

METAL-ENCLOSED SWITCHGEAR
CHECKLIST APPLICATION GUIDELINES
This checklist is an aid to establish the desired configuration of metal-  Incoming (sometimes fused)
enclosed switchgear. This page can be used as a guide of what is to be  Feeder (almost always fused)
furnished.  Transition (main bus is redirected from a top routing to a bottom
routing or vice versa)
These pages contain information for defining the entire lineup and for  Metering (includes current and voltage transformers)
setting the contents of each bay in the lineup. Insert in the space below
each bay the cubicle number shown on “page 132”. The cubicle number Regarding cubicles with fuses, Federal Pacific recommends that current-
and the information in the "Unit Requirements" matrix (below) will allow limiting fuses be selected wherever possible for better energy limiting
a clear understanding of what is to be furnished. protection without the exhaust gases typically associated with expulsion
There are two basic metal-enclosed switchgear arrangements. One is a fuses, whose pressures are contained by the cubicle and whose arcing
single-bay transformer primary that is almost always used for a fused products are de-ionized through an exhaust control device. Cubicles
HV switch connected to a liquid-filled or dry-type transformer, or can with current-limiting fuses have a significantly lower initial cost than
add-on bay to an existing switchgear assembly. It is suggested that this expulsion fuses.
single cubicle be attached (closely coupled or throat connected) to a For Incoming Cubicles connected to circuits at 15 kV that are above 400
transformer to eliminate costly extra terminations and rear cable entry continuous load amperes, Federal Pacific offers the choice of a metal-clad
compartment needed for “bottom cable entry” and “bottom cable exit” drawout vacuum circuit breaker that contains in a single module all of the
in the same cubicle. CTs, relays, etc. necessary for operation, and which can be provided with a
The second type of switchgear arrangement is a multi-bay lineup UL listing in a standard 36”wide x 90” high cubicle or parallel arrangements
®

containing two (2) or more cubicles. Within this type of arrangement of expulsion fuses, which require bays of up to 60 inches in width. Current-
there are several basic types of cubicles: limiting fuses can be used in Incoming Cubicles at 5kV up to a continuous
ampere rating of 1100 amps.

Unit Requirements - Applies to the entire lineup

System Voltage: ___________________ Volts
Fusing:  Current Limiting  Expulsion
Enclosure:  NEMA 1 (indoor)  NEMA 3R (outdoor)
Bus:  Aluminum  Tinplate  Copper  Silver Plate  Other
Construction:  Bolted  Welded  Other
Special Seismic Requirements:  None  300%g  200%g
Category (Cabinet Security): A B C
UL Listed:
®
 Yes  No
Finish:  ANSI 61  Other (Specify)
Door:  Flush Door Handle (Available with Category A only) Grip Handle Lever
Interlocks:  Mechanical  Key Other (Specify)
Utility-Type Metering Bay:  Required  Not Required

Enter in space below each bay # at Bay #1 Bay #2 Bay #3 Bay #4 Bay #5 Bay #6 Bay #7 Bay #8 Bay #9 Bay #10 Bay #11
right applicable cubicle number
from One-Line Diagrams on next
page.
Switch (Amps) for each cubicle
Fuse (Amps) for each cubicle
Bushings between Cubicles (Y or N)
LA __________ ________
MCOV (Y or N)
 Dist.  Int.  Stat.
Power Operated (Y or N)
Automatic Transfer (Y or N)
Fast-Trip Transfer (Y or N)
Run & Trip (Y or N)
With SCADA (Y or N)
1-Phase Protection (Shunt Trip) (Y or N)

FEDERAL PACIFIC Section 12 - 9

 MANUAL METAL-ENCLOSED SWITCHGEAR
Typical One-Line Diagrams for Individual Bays of the Lineup Showing the Applicable Cubicle
Number and Cubicle Description.

VCB

Cubicle Number: 1 2 3* 4* 5* 6 7* 8* 9 10 • 11+ 12+ 13+* 14+

1. Incoming Vacuum Circuit Breaker for circuit protection at 15 kV of 9. Feeder Cubicle Fuse Only, main bus top, bottom entry (or exit).
load currents greater than 400 A. 10. Main-Bus Metering, provisions for CTs and drawout fused PTs.
2. Bus Entrance, main bus top, provision for bottom entry. 11. Main-Bus Metering, provisions for CTs and fixed fused PTs.
3. Switch Only, main bus top, bottom cable entry. 12. Bus-Entrance Metering, main bus top, provisions for CTs and
4. Switch Only, main bus bottom, top cable entrance. fused PTs, bottom entry.
5. Switch/Fuse, main bus bottom, top cable entrance. 13. Switch/Fuse Metering, main bus top, provisions for CTs and fused
6. Bus Transition. PTs bottom exit.
7. Incoming Cubicle Switch/Fuse, main bus top, bottom cable entry. 14. Bus-Transition Metering, provisions for CTs and fused PTs.
8. Feeder Cubicle Switch/Fuse, main bus top, bottom cable exit.

Typical Single Units

Cubicle Number: 15* 16* 17* 18* 19*+

15. Switch/Fuse top cable entrance, bottom cable exit. 18. Switch Only, top cable entrance, bottom cable exit.
16. Switch/Fuse, bottom cable entrance on side, bottom cable exit. 19. Switch/Fuse Metering, bottom rear cable entrance, bottom front
17. Switch/Fuse with bottom rear cable entry and with transformer cable exit.
transition.

Component Standard Symbols

Drawout VCB
•Drawout
Potential
*Non-
Drawout
Interrupter
Switch Bottom Top
Transformer Potential Incoming
Transformer Cable

VCB
Bottom Top
Cable Lugs Fuse Current *Motor-Operated Outgoing
Transformer Switch Cable

• +* Typical units with corresponding footnote symbols can accommodate the associated components.
Section 12 - 10 FEDERAL PACIFIC
 MANUAL METAL-ENCLOSED SWITCHGEAR

STANDARD SPECIFICATIONS FOR MANUAL

METAL-ENCLOSED SWITCHGEAR
A. General b) The manufacturer shall furnish upon request certification of
ratings for the basic switch and fuse components and/or the
1. Product integrated metal-enclosed switchgear assembly consisting
of the switch and fuse components in combination with the
The metal-enclosed switchgear shall be in accordance with the enclosure(s).
applicable plans, drawings and one-line diagrams and shall
conform to these specifications. 5. Compliance with Standards and Codes
2. Assembly a) ANSI C37.20.3 and IEEE Standard 27 (Standards for Switchgear
Assemblies including Metal-Enclosed Bus).
The metal-enclosed switchgear assembly shall consist of one
or more indoor, outdoor self-supporting bays, containing inter- b) Applicable safety and health standards promulgated pursuant to
rupter switches and/or power fuses with the necessary accessory Federal Occupational Safety and Health Act of 1970.
components, all completely factory assembled and operationally c) Article 490.21(E) "Load Interrupter" in the National Electrical Code,
checked. which specifies that the interrupter switches in combination with
3. Ratings power fuses shall safely withstand the effects of closing, carrying,
a) Ratings for the integrated switchgear assembly shall be as and interrupting all possible currents up to the assigned maximum
designated below. Select appropriate column. short-circuit rating.
d) (Optional) The switchgear assembly shall be UL listed. (Available
System Voltage Class
on 5kV and 15kV switchgear only.)
5kV 15kV 25kV 25kV 35kV 35kV
kV, Nominal 4.16 14.4 24.9 24.9 34.5 34.5 B. Construction — Assembly:
kV, Maximum 5.5 17.5 27 27 38 38
Design 1. Insulators
kV, BIL 60 95 125 125 150 200
Main Bus The interrupter-switch and fuse-mounting insulators shall be a
600 1200 600 1200 600 1200 600 1200
Continuous Amp cycloaliphatic epoxy resin system with material characteristics and
Switch Load 600 1200 600 1200 600 1200 600 — restrictions as follows:
Interrupting a) Operating experience of at least twenty (20) years under similar
Short-Circuit Ratings  conditions.
Amps, RMS 25,000 38,000 25,000 38,000 25,000 25,000 25,000 38,000* b) Ablative action to ensure non-tracking properties.
Symmetrical
MVA 3-Phase
Symmetrical at c) Adequate leakage distance established by test per IEC Standard
180 275 625 950 1,000 1,000 1,500 1,500 60507.
Rated Nominal
Voltage
Fault-Closing d) Adequate strength for short-circuit stress established by test.
Amps, RMS 40,000 40,000 40,000 40,000 40,000 40,000, 40,000 —
Asym 3-Times e) Conformance with applicable ANSI and IEEE standards.
Duty-Cycle 
Fault-Closing f) Homogeneity of the cycloaliphatic epoxy resin throughout
Amps, RMS Asym — 61,000 — 61,000 — — — — each insulator to provide maximum resistance to power arcs.
1-Time Duty-Cycle Ablation due to high temperatures from power arcs shall

 These are nominal switch ratings. Integrated switchgear unit may be limited
continuously expose more material of the same composition
by fuse ratings. Use the fuse ratings charts in this publication to adjust short and properties so that no change in mechanical or electrical
circuit ratings, when applicable. characteristics takes place because of arc-induced ablation.
 The three-time duty-cycle fault-closing rating means that the switch can be Furthermore, any surface damage to insulators during
closed 3 times into rated fault amperes and remain operable and able to carry installation or maintenance of the metal-enclosed gear shall
and interrupt its rated load current.
 The one-time duty-cycle fault-closing rating means that the switch can be expose material of the same composition and properties so that
closed 1 time into rated fault amperes and remain operable and able to carry insulators with minor surface damage need not be replaced.
and interrupt its rated load current.
* The asymmetrical rating is 61,000 amperes, one-second. 2. High-Voltage Bus
a) Bus and interconnections shall consist of aluminum bar of 56%
b) For cubicles or bays in which overcurrent circuit protection IACS conductivity.
is required on circuits, where the continuous load amperes b) Bolted aluminum-to-aluminum connections (copper is optional)
exceed the maximum continuous ampere rating of a single shall be made with a suitable number of non-corrosive bolts and
fuse, a drawout circuit breaker should be specified in preference nuts, and with two Belleville spring washers per bolt, one under
to employing paralleled expulsion fuses whose arcing products the bolt head and one under the nut or with a wide, flange-head
and pressures may be substantial during the interruption of carriage bolt and one Belleville spring washer per bolt. As an
fault current. alternate, bolted aluminum-to-aluminum connections shall be
4. Certification of Ratings made with a suitable equivalent surface area, i.e. I-bolt and spring
a) The integrated metal-enclosed switchgear assembly shall be washer. Bolts shall be tightened to proper torque for the particular
designed and built by the manufacturer of the basic interrupter Belleville washer.
switch who shall be completely and solely responsible for
the performance of these basic components as well as the
complete integrated assembly as rated.

FEDERAL PACIFIC Section 12 - 11

MANUAL METAL-ENCLOSED SWITCHGEAR
3. Ground Bus tampering. Each handle shall be provided with a recessed
(select the hex or penta-head) bolt for additional security.
a) A ground bus of short-circuit rating equal to that of the
integrated assembly (or a ground connection, in the case 3. Access Control
of single-bay switchgear) shall be provided, maintaining
electrical continuity throughout the integrated assembly. a) Doors providing access to interrupter switches with power fuses
shall be mechanically or key interlocked to guard against:
b) The ground bus shall consist of aluminum bar of 56% IACS
conductivity. 1) Opening the door if the interrupter switch on the source
side of the power fuse is closed, and
c) In each bay, the ground bus (or connector) shall be bolted to a
stainless steel bracket, which shall be welded to the enclosure 2) Closing the interrupter switch if the door is open.
(copper is optional).
b. Doors providing access to interrupter switches only shall have
C. Construction - Enclosure & Finish provisions for padlocking.

1. Enclosure c) Each bay or compartment thereof containing high-voltage

components shall be provided with a protective screen or
a) The enclosure of each bay shall be constructed of heavy-gauge second door, bolted closed, to guard against inadvertent entry
formed steel panels that maximize strength, minimize weight, to bays containing these components when the enclosure door
and inhibit internal corrosion. (Optional all welded construction is open.
is also available.) For Category A only: externally removable
bolted panels will not be accepted unless specified and when d) Access to the enclosure shall be from the front only, unless
specified must be installed with tamper-resistant hardware. otherwise specified (for example) for cable termination at rear.
b) The basic material for the enclosure, roof and doors shall be 4. Vents
11-gauge, hot-rolled, pickled-and-oiled steel sheet.
Ventilation openings shall be provided at the top and bottom of the
c) Each bay containing high-voltage components shall be a unit as required for proper air circulation. Vents shall have stainless
complete unit in itself, with full side sheets resulting in double- steel screened interior baffles to prevent entrance of foreign objects.
wall construction between bays. To guard against unauthorized
or inadvertent entry, side and rear sheets shall not be externally 5. Lifting Eyes
attached with removable bolts except where tamper-resistant
hardware is specified. Lifting provisions shall be removable and shall not permit entry
into the interior when removed.
d) Sufficient space shall be allowed for ease of cable pulling and
installation. Space shall be free from fixed structural members 6. Finish
or electrical devices.
a) Full coverage at joints and blind areas shall be achieved by
e) On multi-bay units when "thru-bushings" between the cubicles processing enclosure panels or welded enclosures independently
are specified, the thru-bushings should be shipped completely of components such as doors and roofs before assembly into the
assembled to the cubicle and shall not require field assembly unitized structures.
of semi-conducting grommets.
b) All surfaces shall undergo a chemical cleaning, phosphatizing
2. Doors or zirconization and sealing before any protective coatings are
applied in order to remove oils and dirt, form a chemically and
a) Doors shall be constructed of 11-gauge hot-rolled, pickled-and- anodically neutral conversion coating, improve the finish-to-
oiled steel sheet. metal bond, and retard underfilm propagation of corrosion.
b) Door edge flanges shall overlap with door opening flanges and c) The finishing system shall be applied without sags or runs for a
shall be formed to create a mechanical maze that shall guard pleasing appearance.
against water entry and discourage tampering or insertion of
foreign objects. d) After the enclosure is completely assembled and the components
(switches, bus, etc.) are installed, the finish shall be inspected for
c) Doors shall have an appropriate number of hinges based on door scuffs and scratches. Blemishes shall be carefully touched up to
height and, in no case, less than three when door height exceeds restore the protective integrity of the finish.
forty (40) inches. The hinges and hinge pins shall be stainless
steel and secured in place to guard against tampering. e) Unless otherwise specified, the color shall be ANSI 61 Light Gray.

d) In consideration of controlled access and tamper resistance, each f) To assure that the finishing system is capable of resisting corrosion,
door shall be equipped with a positive-action three-point latching the manufacturer shall provide if requested certification that
system. representative test panels,protected by the manufacturer's finish
system, have passed the following tests:
e) Doors providing access to fuses shall have provisions to store
spare fuse units or refill units. 1) Salt spray (relates to coastal environments and/or presence
of snow-melting salts or fertilizers). Scribe to bare metal
f) Each door is provided with a door holder to hold the door open and test for 2000 hours in a 5% salt spray per ASTM B-117.
against inadvertent closing. It shall be integral with the door Loss of adhesion from bare metal should not extend more
and frame and shall self-secure when the door is fully opened. than 1/8" from the scribe. Underfilm corrosion should not
extend more than 1/16" from the scribe.
For units specified with optional Category A features:
2) Crosshatch adhesion (relates to adhesion after scratching
g) Each door shall be provided with a recessed stainless-steel of the finish). Scribe to bare metal a crosshatch pattern of
door handle. The door handles shall be padlockable and 100 1/16" wide squares. Apply Scotch 710 tape and rapidly
shall incorporate a hood to protect the padlock shackle from remove. There should be 100% adhesion to the bare metal

Section 12 - 12 FEDERAL PACIFIC

 MANUAL METAL-ENCLOSED SWITCHGEAR
and between layers. and interrupters for circuit closing, including fault-closing,
continuous current carrying, and circuit interrupting. Interrupter
3) Humidity (relates to environments with high humidity). switches with auxiliary blades shall not be permitted.
Test for 1000 hours subject to 100% humidity at 45-50°C
per ASTM 2247. There should be no blisters. d) Interrupter switches shall be positively and inherently
sequenced with the blade position. It shall not be possible
4) Impact (relates to transit and handling damage and for the blade and interrupter to get out of sequence.
abuse by public). Impact the test panel with a 160 in.-
lb., falling dart per ASTM D-2794. There should be no e) Interrupter switches shall have a readily visible open gap
cracking or chipping of the paint on the impact side of when in the open position to allow positive verification of
the test panel. correct switch position.
5) Oil Resistance (relates to probable contact with mineral f) Each interrupter switch shall be provided with a switch
oil). Immerse two test panels in mineral oil for 3 days, operating handle. The handle shall be non-removable, and
one at room temperature and one at 100°C (212°F). provisions shall be provided for padlocking in open or closed
There should be no apparent changes, such as color position.
shift, blisters, loss of hardness or streaking.
g) Interrupter switches shall utilize a quick-make, quick-break
6) Ultraviolet Accelerated Weathering Test (Relates to mechanism installed by the switch manufacturer. The quick-
exposure to sunlight and rainfall, loss of gloss, color make, quick-break mechanism shall be integrally mounted
fading, and chalking). Continuous exposure to ultraviolet on the switch frame, and shall swiftly and positively open
light for 500 hours per ASTM G-53 with a cycle of 4 hours and close the interrupter switch independent of the speed
ultraviolet followed by 4 hours of condensation. Loss of of the switch operating handle.
gloss should not exceed 50% of original gloss per ASTM
D-523. 2. Fuses
7) Water Resistance (relates to rainfall or dew). Immerse a) Fuses shall be solid-material power fuses or current-limiting
a test panel in distilled water for 3 days at room fuses as specified by the equipment purchaser.
temperature. There should be no apparent changes, such
as blistering, color shift, loss of hardness or streaking. b) Each bay containing fuses shall be equipped with grounding
provisions on the load side of the fuses and on the ground
8) Adhesion — Fed Spec. 141A, Method 6301.1 (relates bus.
to adhesion after scratching the finish). Immerse test
panel in distilled water for 24 hours. Make two parallel 3. Metering
scratches 1" apart. Apply Scotch 710 tape and rapidly a) Primary-metering compartment shall be provided as required.
remove. There should be 100% adhesion to the bare b) Access to metering compartment shall be provided with a
metal and between layers. protective screen or second door, bolted closed to guard
9) Abrasion Test — Taber Abrader (relates to wear against inadvertent contact with energized parts when the
encountered during installation). Prepare a panel coated main enclosure door is open.
with the component of the finish intended to provide c) Metering transformers shall be mounted such that established
abrasion resistance. Test using a CS-10 wheel, 1000 gram electrical clearances are maintained.
weight, 3000 cycles, per Fed. Spec. 141, Method 6192.
This provides a comparative test between samples. d) All low-voltage wiring shall be located as required to minimize
exposure to high voltage.
g. To guard against corrosion, all hardware (including door E. Labeling
fittings, fasteners, etc.), all operating-mechanism parts, and
other parts subject to abrasive action from mechanical motion 1. Hazard-Alerting Signs & Labels
shall be of nonferrous materials, galvanized, or zinc chromate
plated ferrous materials. Cadmium plated ferrous parts shall a) All external doors and hinged bolted panels providing access
not be used. to high voltage shall be provided with suitable hazard-alerting
signs.
D. Basic Components:
b) All internal screens or doors providing access to high voltage
1. Interrupter Switches shall be provided with "Danger" signs.
a) Interrupter switches shall have a three-time duty-cycle fault- c) All internal screens or doors providing access to interrupter
closing rating equal to or exceeding the short-circuit rating of switches shall be provided with danger signs indicating
the integrated switchgear assembly. These ratings define the "Switch Blades May Be Energized in Any Position".
ability to close the interrupter switch either alone (un-fused) or
in combination with the appropriate fuses three times against a
three-phase fault with asymmetrical current in at least one phase
equal to the rated value, with the switch remaining operable
and able to carry and interrupt rated current.Tests substantiating
these ratings shall be performed at maximum design voltage
with current applied for at least 10 cycles. Certified test abstracts
establishing such ratings shall be furnished upon request.
b) Interrupter switches shall be completely assembled and
adjusted by the switch manufacturer on a single rigid mounting
frame.
c) Interrupter switches shall be provided with contact blades

FEDERAL PACIFIC Section 12 - 13

MANUAL METAL-ENCLOSED SWITCHGEAR
d) All internal screens or doors providing access to fuses shall be 2. Dielectric Tests
provided with danger signs indicating "Fuses May Be Energized
in Any Position". Insulation withstand tests are made of the completely assembled
unit to determine the ability of the insulating materials and
2. Nameplate, Ratings Labels, & Connection Diagrams spacing to withstand overvoltages for a specified time without
flashover or puncture.
a) The outside of a single or multi-compartment switchgear 3. Operating Assurance Tests
assembly shall be provided with a nameplate indicating the
manufacturer's name, catalog number, date of manufacture, Each switch shall be operated mechanically and tested to verify:
and serial number. a) That the switch position indicators and contacts are in correct
position for both open and closed positions.
b) The inside of each door shall be provided with a ratings label
indicating the following: voltage ratings; main bus continuous b) That the unit circuit configuration is shown correctly.
rating; short-circuit ratings (amperes rms symmetrical and
MVA three-phase symmetrical at rated nominal voltage); the
type of fuse and its ratings including duty-cycle fault-closing
capability; and interrupter switch ratings including duty- H. Outdoor Units
cycle fault-closing and short-time (momentary, amperes rms In addition to the above requirements, outdoor units shall be
asymmetrical and one-second, amperes rms symmetrical).
provided with space heaters in each bay. The space heaters shall
c) A one-line connection diagram showing interrupter switches, be enclosed within a perforated guard. Heater shall be fused and
fuses, bus, and auxiliary equipment shall be provided as a wired to a terminal block.
drawing with each switchgear assembly.
The edges of the top and sides of adjacent bays shall be covered to
F. Accessories prevent water entry. Roof and bay interface shall be covered between
each bay to prevent water entry.
1. Fuse units or refill units, and voltage-transformer fuses for original
installation and for spares shall be furnished as specified by the For multi-bay units the roof construction shall be made with a roof
equipment purchaser. cap channel where the cubicles are joined as shown in the drawing
2. A fuse handling tool as recommended by the fuse manufacturer entitled Outdoor Roof Construction. (See Figure 8.)
shall be furnished as specified by the equipment purchaser.
G. Routine Production Tests Louvers on outdoor units shall include backup plates with stainless
steel screens.
Production tests are those tests made to check the quality and uni-
formity of the workmanship and materials used in the manufacture
of the switchgear. The unit shall meet the production tests described Power Frequency Withstand Test
below, 1 through 3 inclusive.
Rated Max. Rated Withstand Im- Production Test, kV,
1. Circuit Resistance Test Voltage, kV pulse Voltage, kV RMS 60 Hz

The purpose of this test is to verify that all load-interrupter switch 5.5 60 19
contacts have been properly aligned and current transfer points 17 95 36
have been properly assembled.
The DC resistance of the current carrying circuit of each switch 27 125 60
phase from terminal to terminal of each pole in the closed
position shall be measured with current of at least 10 amperes 38 150 80
flowing. The resistance shall not exceed a limit specified by the
manufacturer. 38 200 80

Section 12 - 14 FEDERAL PACIFIC

 MANUAL METAL-ENCLOSED SWITCHGEAR
The Metal-Enclosed Switchgear must comply with the Dimensions for Federal Pacific Metal-Enclosed Switchgear 
applicable sections in the following ANSI Standards: Type of Width (in inches) Depth 
Voltage Height 
IEEE C37.20.3 O.C. Motor (In
– IEEE Standard for metal-enclosed interrupter switchgear Class Manual (In Inches)
Protection Operated Inches)
IEEE C37.20.4 – IEEE Standard for indoor AC Switches (1kV - 38kV) for use in metal-en-
closed switchgear Current Limiting  36 46 90 46
ANSI C37.22 – Preferred Ratings and Related Capabilities for Indoor AC Medium-Volt-
age Switches Used in Metal-Enclosed Switchgear 5kV Draw-out VCB 36 — 90 94
IEEE C37.30 – Requirements for High-Voltage Air Switches
ANSI C37.72 – High-Voltage Switches, Bus Supports, and Accessories – Schedules of Expulsion Fuse 41 46 90 46
Preferred Ratings, Construction Guidelines, and Specifications
ANSI C37.34 – Test Code for High-Voltage Air Switches Current Limiting  36 46 90 46
ANSI C37.57 – Metal-Enclosed Interrupter Switchgear Assemblies – Conformance
Testing 15kV Draw-out VCB 36 — 90 94
ANSI C37.58 – Indoor AC Medium-Voltage Switches for use in Metal-Enclosed
Expulsion Fuse 41 46 90 46
Switchgear – Conformance Test Procedures
Current Limiting  — — — —
25kV
Draw-out VCB 48 53 120 48

Current Limiting  — — — —
35kV
Draw-out VCB 60 — 130 60

Notes for Dimensions Table:

Dimensions are for standard production products.
Add 5 inches to the height for Outdoor NEMA 3R
G&W Commutating Current-Limiting fuses are available for all voltages
5-38kV. Contact factory for dimensions.
If Rear-Entry Compartment is needed, increase the depth of the com-
partment by the following dimensions:
5kV-add 16 inches
15kV-add 16 inches
25kV-add 24 inches
35kV-add 30 inches

FEDERAL PACIFIC Section 12 - 15

MANUAL METAL-ENCLOSED SWITCHGEAR
Circuit Protection Devices Available From Federal Pacific
Power Fuses Ratings - Expulsion Type Drawout Vacuum Circuit Breaker
Circuit Max.
Max. Circuit
Max. Nominal Fault-Cur- Three-
Nom. Available Three- Max. Max.
Max. Expulsion Fault- Voltage rent in Phase
Voltage Cont. Fault- Phase Cont. Manufacturer Available
Fuse Manufacturer Current in Amps MVA
in Current MVA Amps Fault-Current in Asym.
Amps. Type in Amps kV (1.6x Sym.
kV in Sym. Amps. Sym.
Asym. sym.)
Amps
Sym. 14.4 2000 Cutler-Hammer 40,000 64,000 500
4.16 200 DBU Cutler-Hammer 22,400 14,000 200 Mini-Vac
4.16 200 RBA-200 Cutler-Hammer 19,000 30,000 237
14.4 1200 Siemens GMI 23,000 37,000 500
4.16 200 SM-4 S&C 17,200 27,500 125
4.16 200 SM-5 S&C 37,500 60,000 200
4.16 400 RBA-400 Cutler-Hammer 37,500 60,000 270
14.4 200 DBU Cutler-Hammer 14,000 22,400 350
14.4 200 RBA-200 Cutler-Hammer 14,400 23,000 350
14.4 200 SM-4 S&C 12,000 20,000 310
14.4 200 SMU-20 S&C 14,000 22,400 350
14.4 400 RBA-400 Cutler-Hammer 29,400 47,000 730
14.4 400 SM-5 S&C 25,000 40,000 620
24.9 200 DBU Cutler-Hammer 12,500 20,000 500
24.9 200 RBA-200 Cutler-Hammer 6,900 11,100 410
24.9 200 SM-4 S&C 9,400 15,000 410
24.9 200 SMU-20 S&C 12,500 20,000 540
24.9 400 RBA-400 Cutler-Hammer 21,000 33,500 840
24.9 400 SM-5 S&C 20,000 32,000 860
34.5 200 DBU Cutler-Hammer 10,000 16,000 800
34.5 200 RBA-200 Cutler-Hammer 6,900 11,100 410
34.5 200 SM-4 S&C 6,250 10,000 370
34.5 200 SMU-20 S&C 8,450 13,500 500
34.5 400 RBA-400 Cutler-Hammer 16,800 26,800 1,000
Cutler-Hammer MiniVac® Circuit-Breaker Module With
34.5 400 SM-5 S&C 17,500 28,000 1,045 Integral CTs and Relay

Power Fuse Ratings - Current Limiting

Nom. Max. Circuit Max. Available Peak Let-Thru Current in
Voltage Current-Limiting Three-Phase
Cont. Manufacturer Fault-Current in Amps on Max. Available
in Fuse Type MVA Sym.
Amps. Amps Sym. Fault-Current Circuit
kV
4.16 450 CLE/HLE  Cutler-Hammer 63,000 47,000 450
4.16 450 EJO-1 General Electric 50,000 40,000 350
4.16 600 CL-14 Ferraz-Shawmut 63,000 — 450
4.16 600 PAF  G&W 40,000 20,000 275
4.16 750 CLE Cutler-Hammer 40,000 75,000 275
4.16 900 BOLT-AZ055B1DARO Ferraz-Shawmut 63,000 — 450
4.16 900 EJO-1 General Electric 50,000 80,000 360
4.16 1100 151D870G01 Cutler-Hammer 70,000 85,000 640
4.16 1350 141D870G02 Cutler-Hammer 90,000 85,000 650
14.4 200 CS-3 Ferraz-Shawmut 50,000 14,000 1350
14.4 200 EJO-1 General Electric 50,000 30,000 1350
14.4 600 CL-14 Ferraz-Shawmut 50,000 15,000 1350
14.4 300 CLE/HLE  Cutler-Hammer 63,000 35,000 1500
14.4 300 EJO-1 General Electric 50,000 37,000 1342
14.4 600 PAF  G&W 60,000 60,000 1492
24.9 600 PAF  G&W 40,000 40,000 1700
34.5 600 PAF  G&W 40,000 40,000 22400
 Includes CLE, HLE, BHLE, and HCL medium voltage current-limiting fuses.
 PAF ® is a commutating current-limiting fuse, per ANSI C37.48.1, suitable for higher current applications, through 630A.

Section 12 - 16 FEDERAL PACIFIC