# Patent

## Title
Method and apparatus to move an arcing fault to a different location in an electrical enclosure

## Abstract

An electrical enclosure includes a housing having a first end, an opposite second end, and a plurality of sides disposed therebetween to define an internal volume; an electrical busway having a number of electrical bus members, wherein at least one of the number of electrical bus members has a first bus member, a second bus member and a number of fusible links electrically connected between the first bus member and the second bus member, wherein the at least one of the number of electrical bus members is structured to electrically conduct a rated current, wherein the number of fusible links are structured to electrically conduct the rated current, and wherein the number of fusible links are structured to vaporize responsive to a current which is substantially greater than the rated current.

## Background
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/287,459, filed Dec. 17, 2009.


BACKGROUND
1. Field
The disclosed concept pertains generally to electrical enclosures and, more particularly, to such electrical enclosures structured to resist internal arcing faults. The disclosed concept also pertains to methods of resisting pressure caused by arcing faults.
2. Background Information
Electrical equipment such as, for example and without limitation, electrical busways, relays, circuit interrupters, electric meters and transformers, are typically housed within an electrical enclosure such as, for example, a housing, such as a box, cabinet, module or compartment, to protect the electrical equipment.
Electrical enclosures can enclose a wide range of electrical equipment, such as, for example and without limitation, medium voltage motor starter(s), low voltage switchgear, low voltage motor control center(s), low voltage switchboard(s), low voltage panelboard(s), and medium and/or low voltage transfer switches.
Switchgear typically includes a combination of an electrical busway and electrical disconnects, fuses and/or circuit breakers employed to electrically connect and disconnect electrical equipment. As one non-limiting example, switchgear includes an assembly of one or more motor starters that can also contain circuit breakers and fused switches. Example switchgear devices include, but are not limited by, a circuit interrupter, such as a circuit breaker (e.g., without limitation, low voltage; medium voltage; high voltage); a motor controller/starter; and/or any suitable device which carries or transfers current from one place to another.
Arc resistant switchgear is intended to mitigate the effects of internal arcing or arc flash outside of the electrical enclosure (e.g., without limitation, low voltage; medium voltage; high voltage). Unintended internal arcing faults can occur from a variety of causes (e.g., without limitation, accidental dropping of tools; the presence of animals; insulation failure).
Excessive pressure resulting from an unintended internal arcing fault can cause damage to the electrical enclosure resulting in hot gases, molten copper and steel escaping the electrical enclosure and creating a potential hazard. Hence, it is highly desirable to reduce internal pressures generated during an arcing fault, in order to reduce the chance of hot gases escaping from the electrical enclosure.
FIG. 1 shows a three-phase electrical busway 2 including back-connected (e.g., electrically connected to a surface facing the rear of the corresponding electrical enclosure (not shown)) power cables 4. The fault current path 6 in, for example, the bus members 12,10 provides a generally downward (with respect to FIG. 1) JxB force 14 that elongates the phase-to-phase arc 16. Similarly, another JxB force 15 elongates the other phase-to-phase arc 18 between bus members 10,8. Convective forces 20 attempt to lift (with respect to FIG. 1) the arcs 16,18 resulting in an angled downward (with respect to FIG. 1) direction 22 thereof as shown. The elongated arcs 16,18 increase the corresponding arc voltage and arc power and, thus, increase the pressure created in the corresponding electrical enclosure (not shown). Although not shown in FIG. 1, arcs (not shown) on the outer phases 24,26 attach to adjacent electrical enclosure walls (not shown).
Frequently, auxiliary equipment (e.g., without limitation, a voltage transformer; a control power transformer; a fuse truck; other electrical equipment) is employed in a location within an electrical enclosure where an unintentional arc may result that is relatively close to an outside door. This is less desirable from a safety standpoint as an arc in another controlled location of such electrical enclosure.
There is room for improvement in electrical enclosures including an electrical busway.
There is also room for improvement in methods of moving arcing faults in electrical enclosures.
SUMMARY
These needs and others are met by embodiments of the disclosed concept in which an electrical bus member is structured to electrically conduct a rated current and comprises a first bus member, a second bus member and a number of fusible links electrically connected between the first bus member and the second bus member, the number of fusible links are structured to vaporize responsive to a current which is substantially greater than the rated current; or for an arcing fault at a first location of an electrical enclosure, a first bus member, a second bus member and a number of fusible links are electrically connected between the first bus member and the second bus member, are structured to vaporize responsive to a current which is substantially greater than the rated current, and are located in a different second location of the electrical enclosure.
In accordance with one aspect of the disclosed concept, an electrical enclosure comprises: a housing comprising a first end, an opposite second end, and a plurality of sides disposed therebetween to define an internal volume; and an electrical busway comprising a number of electrical bus members, wherein at least one of the number of electrical bus members comprises a first bus member, a second bus member and a number of fusible links electrically connected between the first bus member and the second bus member, wherein the at least one of the number of electrical bus members is structured to electrically conduct a rated current, wherein the number of fusible links are structured to electrically conduct the rated current, and wherein the number of fusible links are structured to vaporize responsive to a current which is substantially greater than the rated current.
In accordance with another aspect of the disclosed concept, a method moves an arcing fault from a first location to a different second location of an electrical enclosure. The method comprises: employing an electrical busway comprising a number of electrical bus members; employing as at least one of the number of electrical bus members a first bus member, a second bus member and a number of fusible links electrically connected between the first bus member and the second bus member; structuring the at least one of the number of electrical bus members to electrically conduct a rated current; structuring the number of fusible links to electrically conduct the rated current; structuring the number of fusible links to vaporize responsive to a current which is substantially greater than the rated current; and locating the number of fusible links in the different second location of the electrical enclosure.



BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the disclosed concept can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1 is an isometric view of a three-phase electrical busway including back-connected power cables.
FIGS. 2 and 3 are isometric views of three-phase electrical busways including arc length limiter configurations in accordance with other embodiments of the disclosed concept.
FIG. 4 is an isometric view of the three-phase electrical busway and the phase-to-phase arc length limiters of FIG. 2.
FIG. 5 is a vertical elevation view of the three-phase electrical busway and the phase-to-phase arc length limiters of FIG. 2 as mounted in an electrical enclosure.
FIG. 6 is an isometric view of an electrical enclosure including the arc length limiter configuration of FIG. 3.
FIG. 7 is a cut-away isometric view of an electrical enclosure with some parts not shown to show internal structures.
FIG. 8 is a cut-away isometric view of an electrical enclosure in accordance with embodiments of the disclosed concept with some parts not shown to show internal structures.
FIGS. 9, 10 and 11 are top plan, vertical elevation and side elevation views of a three-phase electrical busway including a number of fusible links in the center phase in accordance with another embodiment of the disclosed concept.
FIG. 12 is an isometric view of a three-phase electrical busway including a number of fusible links and a phase-to-phase arc length limiter in each phase in accordance with another embodiment of the disclosed concept.
FIG. 13 is an isometric view of a three-phase electrical busway including a number of fusible links and a phase-to-phase arc length limiter in each phase and a phase-to-ground arc length limiter in accordance with another embodiment of the disclosed concept.



DESCRIPTION OF THE PREFERRED EMBODIMENTS
As employed herein, the term “number” shall mean one or an integer greater than one (i.e., a plurality).
As employed herein, the term “electrical bus” or “electrical bus member” or “bus member” means a substantially rigid or rigid conductor or a flexible conductor or another suitable power conductor which carries or transfers voltage, current and/or power.
As employed herein, the term “electrical busway” means a plurality of electrical bus members for an electrical enclosure. The electrical bus members receive electrical power from, for example, a utility or other suitable power source.
As employed herein, the statement that two or more parts are “coupled” together shall mean that the parts are joined together either directly or joined through one or more intermediate parts.
As employed herein, the terms “fastener” and “fastening mechanism” refer to any suitable connecting or tightening mechanism or method expressly including, but not limited to, welding, screws, bolts, nuts (e.g., without limitation, lock nuts) and combinations thereof.
Directional phrases used herein, such as, for example, top, bottom, front, back, left, right, upper, lower and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.
For purposes of illustration, embodiments of the disclosed concept will be described as applied to switchgear enclosures, although it will become apparent that they could also be applied to other types of electrical enclosures (e.g., without limitation, electrical distribution centers; motor control centers; meter centers; modules or compartments of larger electrical enclosures; low, medium or high voltage enclosures; panelboards; switchboards; load centers; transfer switches).
In arc resistant equipment, a relatively greater distance between phases and between phase and ground provides higher arc voltage, arc power and arc pressure. Embodiments of the disclosed concept provide arc length limiters that reduce the distance between phases and between phase and ground in an environmentally friendly manner (e.g., without limitation, without resort to use of an insulating gas, such as sulfur hexafluoride (SF6)).
Referring to FIG. 2, an electrical busway 100 includes a plurality of electrical bus members 102,104,106. A plurality of phase-to-phase arc length limiters 108,110,112 are electrically connected to the electrical bus members 102,104,106, respectively. As best shown with the phase-to-phase arc length limiters 108,110,112 in FIG. 4, each of the phase-to-phase arc length limiters has a first edge 114 (limiter 110 has two edges 114) and a second edge 116. The first edge 114 establishes a first gap 118 to an adjacent one of the phase-to-phase arc length limiters 108,110,112. A phase-to-ground arc length limiter 120 is electrically connected to a housing 122 of an electrical enclosure 124 (as shown in FIG. 5). The phase-to-ground arc length limiter 120 includes a number of members, such as the example plates 126. Each of the example plates 126 has a number of arc attachment portions, such as an example third edge 128 establishing a second gap 130 to the second edge 116 of the phase-to-phase arc length limiters 108,110,112. Although one or more example plates 126 are shown, any number of members structured to attach an arc to ground during a phase-to-ground arcing time can be employed. For example and without limitation, other suitable number of members can be a flat grounded metal plate, a number of longitudinally oriented plates, bolts or pins (e.g., single; array), any grounded conductive or semi-conductive surface (e.g., carbon/graphite), or any surface that allows the arc to become attached and remain attached during the arcing time.
Example 1
FIG. 3 shows another electrical busway 200 including a plurality of electrical bus members 202,204,206. A plurality of phase-to-phase arc length limiters 208,210,212 are electrically connected to the electrical bus members 202,204,206, respectively. The phase-to-ground arc length limiter 120 is electrically connected to a housing 222 of an electrical enclosure 224 (as shown in FIG. 6). The phase-to-phase arc length limiters 208,210,212 are similar to the phase-to-phase arc length limiters 108,110,112 of FIG. 2, except that they have a greater length of the cable terminal pad 240 in order to accommodate a larger number of power cables, such as 226 (e.g., four example sets of openings 228 are shown in FIG. 3 (one set being hidden), while there are two example sets of openings 129 in FIG. 2 (one set being hidden).
The electrical enclosure 224 of FIG. 6 includes a housing with a first end 230, an opposite second end 232, and a plurality of sides 234,236,238,240 disposed therebetween to define an internal volume 242. The electrical enclosure 224 is further divided into a plurality of compartments or modules, such as modules 244,246,248. It will be appreciated that a portion of the side 240 and the module 248 is not shown in order to show internal structures such as the example electrical busway 200. Each of the modules 244,246,248 can be considered to be an electrical enclosure as employed herein. For example and without limitation, the front module 244 (to the left of FIG. 6) can include relays, switches, metering devices, pull fuses, and supplementary protectors; the mid module 246 (in about the center of FIG. 6) can include circuit breakers, voltage or control power transformers, fuse trucks, earthing switches, ground and test devices, and current transformers; and the rear module (to the right of FIG. 6) can include electrical busways and electrical devices, such as earthing switches, rear mounted control power transformers, and lightning arresters.
Example 2
Referring again to FIG. 2, the three electrical bus members 102,104,106 are made, for example, of copper, although any suitable conductor can be employed. Although three example electrical bus members 102,104,106 are shown, the disclosed concept is applicable to electrical busways having two or more electrical bus members. The electrical bus members 102,104,106 can be mechanically supported by three insulators 131,132,133, respectively, which are coupled to a bracket 136 (e.g., powder-coated) supported by a side wall 138 of the housing 122.
The electrical bus members 102,104,106 include example copper cable terminal pads 140, although any suitable conductor can be employed. Power cables 142 (e.g., without limitation, line; load) are electrically connected to the cable terminal pads 140. The phase-to-phase arc length limiters 108,110,112 can be made of zinc chromate plated steel and set the desired phase-to-phase gap 118 (FIG. 4) (e.g., without limitation, about 4 inches; any suitable gap while still maintaining desired Basic Impulse Lightning (BIL) requirements; a suitable minimum gap that will not jeopardize electrical tests per industry standards). The phase-to-ground arc length limiter 120 can be made of zinc chromate plated steel and is electrically connected (e.g., without limitation, bolted; welded; brazed; riveted; clamped; any suitable mechanism to provide a sufficient preload to maintain a good electrical path) to the housing 122 (e.g., side channel) of the electrical enclosure 124 (FIG. 5), which is suitably grounded.
The phase-to-phase arc length limiters 108,110,112 are suitably electrically connected to the respective electrical bus members 102,104,106. However, the placement of the phase-to-phase arc length limiters 108,110,112 is not limited to be at an electrical joint in the bus member, but can be located anywhere along such bus member. For example, these phase-to-phase arc length limiters could be welded or otherwise suitably electrically connected anywhere on a continuous piece of an electrical bus member. For placement of the phase-to-phase arc length limiters 108,110,112 at an electrical joint, there are many factors that determine a suitable electrical joint/connection (e.g., without limitation, finish; hardness; preload; surface area). The actual mechanism for electrical connection depends upon the desired makeup of the electrical joint.
The example phase-to-ground arc length limiter 120 includes four example plates 126, although any suitable number of members, such as one or more plates, can be employed. The edges 128 of each of the plates 126 are parallel to each other and are equidistant (e.g., without limitation, the second gap 130 is about 4 inches; any suitable gap) from the edges 116 of the phase-to-phase arc length limiters 108,110,112, which edges 116 are also parallel to each other.
The phase-to-phase arc length limiters 108,110,112 are employed on the respective bus members 102,104,106 and the phase-to-ground arc length limiter 120 is electrically connected to the housing 122 of the electrical enclosure 124 (FIG. 5). Placement of these arc length limiters 108,110,112,120 is done by recognizing what direction the phase-to-phase arcs 144 (shown in FIGS. 4 and 5) are anticipated to travel due to, for example, bus geometry, magnetic force and gas force. By reducing or minimizing the length of the phase-to-phase arcs 144, subject to design constraints or design considerations, this provides reduced total arc power, lower peak pressure, and a “successful pass” of an arc test, such as for example and without limitation, a 15 kV rated metal clad switchgear assembly, tested at 63 kA per IEEE Std C37.20.7TM-2007 (IEEE Guide for Testing Metal-Enclosed Switchgear Rated Up to 38 kV for Internal Arcing Faults).
Typically, the rear (e.g., in a direction out of the plane of FIG. 5) of the enclosure 124 (FIG. 5) is toward the right of FIG. 2.
As shown in FIG. 6, a suitably thin insulator 146 (e.g., a six-sided, insulative boot) can cover the terminal end of each of the power cables 226 (FIG. 3). The thickness of the insulator 146 is such that the phase-to-phase arcs (not shown in FIG. 3 or 6, but see the phase-to-phase arcs 144 of FIGS. 4 and 5) are not obstructed by the insulator 146 during the fault.
Example 3
As another non-limiting example, the phase-to-phase distance of the first gap 118 (FIG. 4) can be about 3.5 inches and the phase-to-ground distance of the second gap 130 (FIG. 2) could range from about 3.17 inches to about 3.78 inches. However, the actual distances can be modified depending on a particular design with one goal of keeping it as close to about 4 inches as possible, although larger or smaller distances are possible. Primarily, the BIL requirement prevents a closer spacing; otherwise, the gap 118 could have about a 1-inch separation.
For example, for 15 kV rated metal clad switchgear per IEEE C37.20.2 and IEEE C37.20.7 standards, there is an insulated bus and the bus joints are insulated with insulative boots, as one example. For 15 kV rated switchgear, the IEEE standards employ a 95 kV BIL test. The design parameters to pass this test use about 3-inch minimum phase-to-phase and phase-to-ground clearances. Slightly larger gaps as set forth in this example can be employed because sharp edges are at close proximity. The extra distance is a factor of safety to pass the 95 kV BIL test.
For example, the phase-to-phase gap 118 and the phase-to-ground gap 130 can depend upon meeting suitable design standards and/or design criteria for a particular product (e.g., without limitation, standards, such as NEC, IEEE, CSA or IEC; other suitable standards; other controlling factor(s)). Preferably, the gaps 118,130 are as small as possible, but meet the desired design standards and/or design criteria.
As another non-limiting example, the phase-to-phase gap 118 and the phase-to-ground gap 130 can vary with voltage. For example and without limitation, the gaps 118,130 can be relatively greater at relatively higher voltages (e.g., without limitation, about 7 inches to about 8 inches for 38 kV) and relatively lower for relatively lower voltages (e.g., without limitation, about 1.5 inches to about 2 inches for 5 kV; about 1 inch for 2.4 kV; less than 1 inch for 600 V).
Example 4
In the example of FIG. 3, one of the sides of the enclosure 224 (FIG. 6) supports a bracket 250 carrying a plurality of insulators 252 (shown in hidden line drawing in FIG. 6), 254 and 256. Each of these insulators supports one of the cable terminal pads 240 of the electrical bus members 202,204,206.
Example 5
Referring to FIGS. 2, 4 and 5, the plates 126 of the phase-to-ground arc length limiter 120 typically show arc attachment from at least the edge 116 of the center phase at the center phase-to-phase arc length limiter 110. The outer phases at the outer phase-to-phase arc length limiters 108,112 can arc at 148,150 to the adjacent side walls 152,154, respectively, of the electrical enclosure 124 and to the center phase as shown in FIG. 5. The arc fault can start, for example, as a phase-to-phase fault and then transition to a phase-to-ground fault as the fault current 158 and the convective force motivate, at 157, the arcs 144 upward and rearward (up and to the right with respect to FIG. 2) to the phase-to-ground arc length limiter 120 (FIG. 2). Hence, for a typical arcing fault, the arc length limiters 108,110,112,120 and the sidewalls 152,154 all show arc attachment.
As can be seen in FIGS. 2, 4 and 5, the electrical bus member 102 and the cable terminal pad 140 thereof form a first L-shape, the electrical bus member 104 and the cable terminal pad 140 thereof form a T-shape, and the electrical bus member 106 and the cable terminal pad 140 thereof form a second L-shape. The T-shape of the center phase is disposed between the first L-shape and the second L-shape of the outer phases. The cable terminal pads 140 of the outer electrical bus members 102,106 form one side of the first L-shape and the second L-shape, respectively, and are disposed proximate but separated from the edges 114 of the corresponding phase-to-phase arc length limiters 108,112.
The example phase-to-phase arc length limiters 108,110,112 prevent the length of the arcs 144 from significantly increasing since the JxB force 156 directs the arcs 144 toward the phase-to-ground arc length limiter 120. The arc current density, J, is equal to the current divided by the arc diameter. The direction of J is in the direction of current flow in the arc. The magnetic field, B, direction depends on the direction of current flow but will generally be enhanced between the gaps between the tops of the phase-to-phase arc length limiters 108,110,112, to create a force that pushes the arc outward toward the rear door (e.g., out of the plane of FIG. 5). The phase-to-phase arc length limiters 108,110,112 reduce the gap between phases. The side connected cable terminal pad 140 does not produce a magnetic field to drive the arc downward unlike the configuration of FIG. 1. The phase-to-ground arc length limiter 120 limits arc length. The configuration of FIG. 2 produces relatively shorter arcs resulting in lower arc voltage and lower pressure. The JxB force 156 (and the upward (with respect to FIG. 5) convective force 20) advantageously drive the arcs 144, at 157, toward the phase-to-ground arc length limiter 120 (FIG. 2), which is advantageously disposed somewhat above (with respect to FIG. 2) and to the rear (to the right with respect to FIG. 2) of the edges 116 of the phase-to-phase arc length limiters 108,110,112.
The JxB force 156 is produced on the arcs 144 by the cross-product of the current density (J=fault current I/cross-sectional area of the arc 144) and the self-produced magnetic field (B) due to the fault current 158 flowing in the conductors including the bus member 106 and the phase-to-phase arc length limiter 112. Unlike normal current flow, a gap (as best shown in FIG. 4) generally prevents the fault current 158 from flowing in the cable terminal pad 140. The magnetic field (B) is additive during part of the time (the current direction depends on the phase angle of the currents at that instance in time) between these conductors in the adjacent phases due to the direction of the current and the orientation of the conductors on either side of the arc 144. The cross-product is the product of the magnitudes of the J and B vectors times the sine of the angle (θ) between the vector components of the current density (J) and the magnetic field (B). In this geometry, the current and magnetic fields are mostly orthogonal, thereby maximizing the cross-product (i.e., θ=90°).
The magnetic force component on the arc is also relatively stronger than the upward (with respect to FIG. 5) convective force 20. As an example, in the left phase (with respect to FIG. 5) during an instance in time when the currents are such that the current path is flowing upward (with respect to FIG. 5) in the left bus and downward (with respect to FIG. 5) in the center bus, the fault current path 158 flows up (with respect to FIG. 5) and into the phase-to-phase arc length limiter 112 and into the arc and back into the center phase-to-phase arc length limiter 110. The net movement of the arc 144 by the JxB force 156 and the upward (with respect to FIG. 5) convective force 20 is that the arc 144 is directed, at 157, toward the phase-to-ground arc length limiter plates 126 and is subsequently lengthened significantly less than the arcs 16,18 of FIG. 1, which are moved significantly downward (with respect to FIG. 1) by the downward magnetic force component (not shown) since there is no phase-to-phase arc length limiter and since the power cables 4 are electrically connected to downwardly extending cable terminal portions as shown in FIG. 1.
As shown with the electrical bus member 106 of FIG. 4, each of the phase-to-phase arc length limiters 108,110,112 and the corresponding electrical bus members 102,104,106, respectively, direct the fault current 158 flowing therein in the arc 144 between the adjacent pair of the phase-to-phase arc length limiters 112,110.
The electrical bus members 102,104,106 include conductors (e.g., the example cable terminal pads 140) separated from (as best shown by a gap in FIG. 4) the respective phase-to-phase arc length limiters 108,110,112. Current normally flows in the corresponding one of the electrical bus members 102,104,106 and in the conductor 140 separated from the corresponding one of the phase-to-phase arc length limiters 108,110,112, but not in the corresponding one of the phase-to-phase arc length limiters 108,110,112. Each of the phase-to-phase arc length limiters 108,110,112 direct the fault current 158, as shown with electrical bus member 106 and phase-to-phase arc length limiter 112, flowing in the corresponding one of the electrical bus members in the arc 144 between an adjacent pair of the phase-to-phase arc length limiters 112,110, but not in the conductor 140.
The arcs 144 would move horizontally outward (out of the plane of FIG. 5) if it was not for the convective force 20 that tends to raise (with respect to FIG. 5) the arcs 144.
Example 6
Although the electrical enclosure 124 advantageously employs both of the plural phase-to-phase arc length limiters 108,110,112 and the phase-to-ground arc length limiter 120 (as shown in FIG. 2), the disclosed concept is applicable to configurations that employ only plural phase-to-phase arc length limiters, such as 108,110,112 (FIG. 5).
Example 7
Although the electrical enclosure 124 advantageously employs both of the plural phase-to-phase arc length limiters 108,110,112 and the phase-to-ground arc length limiter 120 (as shown in FIG. 2), the disclosed concept is applicable to configurations that employ only the phase-to-ground arc length limiter 120. This limiter 120 can be placed on the sidewalls in addition to above the arcing area and, in this example, the arcs 144 can be struck between the sides of the adjacent electrical bus members 102,104,106. However, the limiter 120 can advantageously be placed anywhere the arc is anticipated to be located.
Example 8
Table 1 compares peak power, peak pressure, time-to-ground, and test result for the disclosed concept and for prior back-connected power cables (FIG. 1) with no arc length limiters.












TABLE 1







Peak
Peak
Time-to-
Test



Power
Pressure
Ground
Result




















Phase-to-
219 MW
18 psig
1.1 mS
Passed


ground arc


length limiter


Back-connected
287 MW
28 psig
2.1 mS
Failed


power cables


with no arc


length limiters









Referring to FIGS. 7 and 8, a need exists to move an internal arcing fault from an example uncontrolled auxiliary location 300 of an example electrical enclosure 302 to an example different predetermined, controlled location 304 in an electrical enclosure 306. There is a more particular need to move an unintentional internal arc fault to a different location in arc resistant equipment, such as a more remote location inside switchgear in order to protect site personnel.
Although the electrical enclosures 302,306 are shown as two different vertical sections, the disclosed concept applies to moving an internal arcing fault from an uncontrolled location of an electrical enclosure, or compartment or module or vertical section thereof, to a different controlled location of the same vertical section. This will be described, below, in connection with FIGS. 9-13 and FIG. 8. For example, the electrical enclosures 302,306 can be the same as or similar to the electrical enclosure 124 of FIG. 5 or the electrical enclosure 224 of FIG. 6.
As shown in FIGS. 7 and 8, the electrical enclosures 302,306 can be, for example and without limitation, vertical sections of switchgear, in which an example of the disclosed concept is shown in FIG. 8. A mid-module 310 of the electrical enclosure 302 can include, for example and without limitation, a voltage transformer truck 312 and an empty compartment 314, which can receive another voltage transformer truck (not shown), a control power transformer truck (not shown), or a fuse truck (not shown) to a remote control power transformer (not shown). Three-phase terminals 316 of compartment 314 can receive power (e.g., without limitation, 5 kV) from a main bus (not shown, but which extends between different vertical sections, such as 302,306). Three-phase terminals 318 of compartment 314 can power a load (not shown). Three-phase terminals 320 of voltage transformer truck 312 can be electrically connected to primary windings (not shown) of a voltage transformer (not shown). The secondary windings (not shown) of such voltage transformer can power low voltage equipment (not shown) in front module 322 of vertical section 302 or remote low voltage equipment (not shown). The three-phase terminals 320 of voltage transformer truck 312 can be powered through power cables 324 (for convenience of illustration only one power cable 324 is shown) from vertical section 306.
For example and without limitation, an electrical busway 326 of FIG. 8 includes a plurality of electrical bus members 328,330,332, which can be powered by a suitable power source (not shown) electrically connected to terminals (not shown) at one end 334. The other end 336 of the electrical busway 326 can be electrically connected to the line terminals 338 (only one line terminal 338 is shown) of a circuit breaker (not shown) of mid-module 340. The load terminals 342 (only one load terminal 342 is shown) of the mid-module circuit breaker (not shown) can power a main bus (not shown, but passing through openings 344) common to various vertical sections, such as 302,306. The rear (e.g., to the right with respect to FIG. 8) module 308 of the vertical section 306 is structured to resist an arcing fault, as will be discussed below in connection with FIGS. 9-13.
Referring to FIGS. 9-11, a three-phase electrical busway 350 includes a number of fusible links 352 (two example fusible links 352 are shown in FIGS. 9 and 10; only one of the two fusible links 352 is shown in FIG. 11) in the center phase 354. Although not shown, the electrical busway 350 can be similar to the electrical busway 326 of FIG. 8 and can be housed by one of the electrical enclosures disclosed herein, such as for example and without limitation, the vertical section 306 of FIG. 8.
The example three-phase electrical busway 350 also includes a plurality of example electrical bus members 356,358,360. As best shown in hidden line drawing in FIG. 10, at least one of the electrical bus members, such as 358, includes a first bus member 362, a second bus member 364 and the number of fusible links 352 (shown in hidden line drawing) electrically connected between the first bus member 362 and the second bus member 364. Although example rigid bus members 362,364 are shown, any suitable substantially rigid conductor, flexible conductor, or another suitable power conductor which carries or transfers voltage, current and/or power can be employed, such as for example and without limitation, the power cable 324 of FIG. 8.
As is conventional, the electrical bus members 356,358,360 are structured to electrically conduct a rated current (e.g., without limitation, 30 A for auxiliary equipment 366 in a different electrical enclosure 368 as shown in FIG. 9). In accordance with aspects of the disclosed concept, the number of fusible links 352 are structured to electrically conduct such rated current, and the number of fusible links 352 are also structured to vaporize responsive to a current which is substantially greater than such rated current.
Example 9
The length and size of the number of fusible links 352 are structured to carry continuous current demand for the example auxiliary equipment 366, but small enough to vaporize under an unintentional internal arcing fault. The number of fusible links 352 vaporize and produce enough ionized gas to permit an arc to be established between phases (and optionally between phase-to-ground) in a desired location, such as at phase 354 in a controlled electrical enclosure, vertical section, module or compartment thereof. However, the length of the number of fusible links 352 is suitably short in order to not produce excessive pressure due to an extended arc length.
The example number of fusible links 352 are in series with the auxiliary equipment 366 (FIG. 9) and have a predetermined size and length, in order to easily carry rated current (e.g., without limitation, tens of amperes; normal operating current) but vaporize under a significantly greater current of an internal arcing fault (e.g., without limitation, thousands of amperes; tens of thousands of amperes). The vaporized gases from an exploding fusible link (e.g., a number of fusible conductors) create phase-to-phase (and optionally phase-to-ground faults) at the location thereof. The length (gap) of the number of fusible links 352 is selected to be long enough to quickly commutate the arc from an uncontrolled location to the location of the number of fusible links 352, but not too long so as to create an undesirable pressure wave that could damage the electrical enclosure, such as 306 of FIG. 8.
Example 10
Although FIGS. 9-11 show two fusible links 352, the disclosed concept is applicable to a single fusible conductor for one or more phases, as is shown by the single fusible link 370 of FIG. 8.
Example 11
Although the two example fusible links 352 of FIGS. 9-11 can be conductors, such as wires, the single fusible link 370 of FIG. 8 can be a single conductor, such as a wire or a foil conductor (e.g., having a suitable length and width and a relatively small cross-section).
Example 12
As best shown in FIG. 10, the two example fusible links 352 are first and second conductors (e.g., without limitation, two #14 gauge wires). The first and second bus members 362,364 have respective ends 372,374, with a width 376 defined by a first side 378 and an opposite second side 380. The first one of the two fusible links 352 is electrically connected between the ends 372,374 at about the first side 378 and the second one of the two fusible links 352 is electrically connected between the ends 372,374 at about the opposite second side 380. This configuration advantageously promotes phase-to-phase arcing to the outer phases 382,384.
Example 13
Although the number of fusible links 352 of FIGS. 9-11 are applied to a single phase 354 of the example three-phase electrical busway 350, the disclosed concept can be applied to two or more phases as will be discussed below in connection with FIGS. 12 and 13.
Example 14
As can be seen in FIGS. 10 and 11, the two example fusible links 352 have the same length 386.
As shown in FIG. 12, the single fusible links 370 of each phase have the same length, which can be the same as or different from the length 386 of FIGS. 10 and 11.
Example 15
As shown in FIGS. 12 and 13, the single fusible links 370 can be employed for each of the electrical bus members 388,390,392 of the example three-phase electrical busway 394.
Example 16
For example and without limitation, the length 386 of FIGS. 10 and 11 can be about 3 inches to about 5 inches, although any suitable length can be employed.
Example 17
The rated current of the example number of fusible links 352 can be about 30 amperes, although any suitable rated current can be employed.
Example 18
Referring to FIG. 12, the example three-phase electrical busway 394 includes the example single fusible links 370 for each of the electrical bus members 388,390,392 as well as the example phase-to-phase arc length limiters 396,398,400. The phase-to-phase arc length limiter 400 and the corresponding single fusible link 370 for the electrical bus member 392 are shown in hidden line drawing behind a suitable insulator (e.g., without limitation, insulative boot 402 which can function in a manner similar to the insulative boot 146 of FIG. 6). Each of the phase-to-phase arc length limiters 396,398,400 is electrically connected to a corresponding one of the electrical bus members 388,390,392, respectively, and includes a first edge 403 and a second edge 404. The first edge 403 of the phase-to-phase arc length limiter 396 establishes a first gap 406 to the adjacent phase-to-phase arc length limiter 398. The second edge 404 will be discussed, below, in connection with FIG. 13.
Each of the example phase-to-phase arc length limiters 396,398,400 is structured to provide power to another electrical enclosure location (e.g., without limitation, through one of the power cables 324 of FIGS. 8 and 12). For example and without limitation, this can provide power for auxiliary equipment, such as a voltage transformer (e.g., without limitation, 312 of FIG. 7), a control power transformer or a fuse truck (not shown).
As shown in FIG. 12, the example single fusible link 370 is electrically connected between the electrical bus member 390 and the corresponding power cable (not shown, but see the power cable 324 in connection with electrical bus member 392) by a first terminal 408 at one end and by a second terminal 410 at the opposite end. The second terminal 410 is supported by a suitable insulator 412 (e.g., without limitation, a red glass insulator), which is suitably coupled to the phase-to-phase arc length limiter 398. In this manner, when the single fusible link 370 vaporizes responsive to arc fault current, the auxiliary equipment at the other end of the power cable 324 is electrically isolated from the corresponding one of the electrical bus members 388,390,392, and the arcing fault is advantageously moved to the location of the corresponding one of the phase-to-phase arc length limiters 396,398,400 (e.g., by providing phase-to-phase arcing faults in FIG. 12; by providing phase-to-phase and phase-to-ground arcing faults in FIG. 13).
Example 19
FIG. 13 shows another example three-phase electrical busway 394′, which is similar to the three-phase electrical busway 394 of FIG. 12, except that the phase-to-ground arc length limiter 120 of FIG. 2 is also employed. The third edges 128 of the plates 126 of the phase-to-ground arc length limiter 120 establish a second gap 414 to the second edge 404 of the phase-to-phase arc length limiters 396,398,400.
Example 20
Referring again to FIGS. 9-11, one of the first bus member 362 and the second bus member 364 is normally energized. In this example, the second bus member 364 is normally energized and is electrically connected (e.g., without limitation, by a number of fasteners, such as bolts 416; by welding) to a phase-to-phase arc length limiter 418. In this manner, when the other bus member 362 is de-energized when the number of fusible links 352 vaporize responsive to current which is substantially greater than rated current, the phase-to-phase arc length limiter 418 remains electrically connected to the normally energized bus member 364.
The other example electrical bus members 356,360 are also electrically connected to respective phase-to-phase arc length limiters 420,422 by bolts 416.
Example 21
The second terminal 410 of FIG. 12 functions as a cable terminal portion.
Example 22
The cable terminal portion of Example 21 can be structured to receive a number of power cables, such as the power cable 324.
Example 23
Further to Example 9, for example and without limitation, the current which is substantially greater than the rated current can be an arcing fault current in the range from about 1,000 amperes to about 100,000 amperes symmetrical. Some non-limiting typical values of such arcing fault current can be 40,000 amperes, 50,000 amperes, and 63,000 amperes symmetrical.
Example 24
The example phase-to-phase arc length limiters 396,398,400 of FIGS. 12 and 13, and the example phase-to-phase arc length limiters 418,420,422 of FIGS. 9-11 can be made of steel.
Example 25
The first gap 406 of FIG. 12 can be about four inches or any suitable gap distance. See, for example, Example 3.
Example 26
The second gap 414 of FIG. 13 can be about four inches or any suitable gap distance. See, for example, Example 3.
Example 27
The third edge 128 of each of the plates 126 of the phase-to-ground arc length limiter 120 is parallel to the third edge 128 of each of the other plates 126 and establishes the same second gap 414 to the second edge 404 of each of the phase-to-phase arc length limiters 396,398,400 of FIG. 13.
Example 28
With reference to FIGS. 8-12, a method of moving an arcing fault from a first location (e.g., without limitation, mid-module 310 of FIG. 7; electrical enclosure 368 of FIG. 9) to a different second location (e.g., without limitation, rear (to the right with respect to FIG. 8) module 308 of FIG. 8) of the electrical enclosure 306 includes employing the example electrical busway 326 or 350 or 394 having a number of electrical bus members 328,330,332 or 356,358,360 or 388,390,392, employing as at least one of such number of electrical bus members a first bus member 362 or 408, a second bus member 364 or 410,324 and a number of fusible links 352 or 370 electrically connected between such first and second bus members, structuring such at least one of such number of electrical bus members to electrically conduct a rated current, structuring such number of fusible links to electrically conduct such rated current, structuring such number of fusible links to vaporize responsive to a current which is substantially greater than such rated current, and locating such number of fusible links in such different second location of such electrical enclosure.
Example 29
Table 2 compares peak power, peak pressure, time-to-ground, and test result for the disclosed concept and for no fusible links in the rear module (shown, but not numbered) of electrical enclosure 302 of FIG. 7.












TABLE 2







Peak
Peak
Time-to-




Power
Pressure
Ground
Test






















Fusible links
229 MW
13 psig
1.9 mS
Passed



as shown in



FIG. 8



No fusible
387 MW
31 psig
1.1 mS
Failed



links










Example 30
Table 3 compares peak power, peak pressure, time-to-ground, and test result for the disclosed concept and for fusible links, which are too long (e.g., about 10 inches, about 15 to about 20 inches, and about 25 to about 30 inches) (not shown) in each phase in the rear module (shown, but not numbered) of electrical enclosure 302 of FIG. 7.












TABLE 3







Peak
Peak
Time-to-




Power
Pressure
Ground
Test




















Fusible links
229 MW
13 psig
1.8 mS
Passed


as shown in


FIG. 8


Three different
259 MW
not available
4.1 mS
Failed


lengths of


fusible links









Example 31
With the disclosed concept, an internal arcing fault can be commutated from an uncontrolled location (e.g., without limitation, a voltage transformer drawer; an auxiliary equipment compartment) to a controlled location (e.g., without limitation, in the rear (e.g., to the right with respect to FIG. 8) module 308 of FIG. 8) before excessive pressure builds in the uncontrolled location.
Example 32
The example electrical bus members 328,330,332 of FIG. 8 are three copper busses.
It will be appreciated that although the disclosed concept illustrates application of the phase-to-ground arc length limiter 120 together with the phase-to-phase arc length limiters 108,110,112 or 208,210,212, each of these arc length limiters can be independently employed.
The phase-to-ground arc length limiter 120 advantageously limits the upward (with respect to FIGS. 2 and 6) path of the arcs 144 (FIGS. 4 and 5) and, thus, limits the arc length.
The phase-to-phase arc length limiters 108,110,112 or 208,210,212 use the direction of the fault current 158 to provide a corresponding JxB force 156, which in combination with the convective force, advantageously drives the arcs 144 toward the phase-to-ground arc length limiter 120 (FIG. 2).
The time for the arcs 144 to attach to a ground return is also greatly reduced by the phase-to-ground arc length limiter 120, thereby resulting in relatively lower arc power and arc pressure. Hence, the disclosed concept provides enhanced protection for electrical enclosures, such as for example and without limitation, switchgear enclosures.
The disclosed concept can be applied to single or multi-phase systems and can be extended to include a number of fusible links in one or more phases. For example and without limitation, this can provide redundancy and/or a high or potentially the highest level of protection (e.g., if the initial arcing fault is a single phase-to-ground arcing fault, then by employing a number of fusible links in all of the phases, it is guaranteed that a corresponding number of fusible links will vaporize).
The disclosed concept provides enhanced protection by causing an arcing fault in a controlled location of an electrical enclosure that is structured to handle the greatest pressure from an arcing fault.
It will be appreciated that any phase-to-phase arc length limiter or any phase-to-ground arc length limiter as disclosed herein can be suitably formed and/or electrically connected to a corresponding electrical bus member or an electrical enclosure housing, respectively, by any known or suitable mechanism or method, including, but not limited to, welding.
While specific embodiments of the disclosed concept have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof.

## Claims

1. An electrical enclosure comprising:
a housing comprising a first end, an opposite second end, and a plurality of sides disposed therebetween to define an internal volume; and
an electrical busway comprising a number of electrical bus members,
wherein at least one of the number of electrical bus members comprises a first bus member, a second bus member and a number of fusible links electrically connected between the first bus member and the second bus member,
wherein said at least one of the number of electrical bus members is structured to electrically conduct a rated current,
wherein the number of fusible links are structured to electrically conduct the rated current, and
wherein the number of fusible links are structured to vaporize responsive to a current which is substantially greater than the rated current.

2. The electrical enclosure of claim 1 wherein the number of electrical bus members are three copper busses.

3. The electrical enclosure of claim 1 wherein the number of fusible links is a foil conductor.

4. The electrical enclosure of claim 1 wherein the number of fusible links is a single conductor.

5. The electrical enclosure of claim 1 wherein the number of fusible links is a first conductor and a second conductor; wherein the first bus member and the second bus member have an end with a width defined by a first side and an opposite second side; wherein the first conductor is electrically connected between the ends of the first and second bus members at about the first side; and wherein the second conductor is electrically connected between the ends of the first and second bus members at about the opposite second side.

6. The electrical enclosure of claim 1 wherein said at least one of the number of electrical bus members is a plurality of a plurality of electrical bus members.

7. The electrical enclosure of claim 6 wherein the number of fusible links have a length; and wherein the length of the number of fusible links for each of said plurality of said plurality of electrical bus members is the same length.

8. The electrical enclosure of claim 1 wherein said at least one of the number of electrical bus members is all of a plurality of electrical bus members.

9. The electrical enclosure of claim 1 wherein each of the number of fusible links has a length of about 3 inches to about 5 inches.

10. The electrical enclosure of claim 1 wherein the rated current is about 30 amperes.

11. The electrical enclosure of claim 1 wherein the number of fusible links are covered by an insulative structure.

12. The electrical enclosure of claim 1 wherein the number of electrical bus members is a plurality of electrical bus members; wherein the electrical busway further comprises a plurality of phase-to-phase arc length limiters, each of the phase-to-phase arc length limiters being electrically connected to a corresponding one of the plurality of electrical bus members, each of the phase-to-phase arc length limiters having a first edge establishing a first gap to an adjacent one of said phase-to-phase arc length limiters.

13. The electrical enclosure of claim 12 wherein each of the phase-to-phase arc length limiters further has a second edge; wherein said housing further comprises a phase-to-ground arc length limiter electrically connected to said housing, said phase-to-ground arc length limiter comprising a number of members structured to attach an arc, each of the number of members having a number of arc attachment portions establishing a second gap to the second edge of the phase-to-phase arc length limiters.

14. The electrical enclosure of claim 12 wherein one of the first bus member and the second bus member is normally energized; wherein the other one of the first bus member and the second bus member is de-energized when the number of fusible links vaporize responsive to the current which is substantially greater than the rated current; and wherein a corresponding one of the phase-to-phase arc length limiters is electrically connected to said one of the first bus member and the second bus member which is normally energized.

15. The electrical enclosure of claim 1 wherein each of the number of electrical bus members includes a cable terminal portion.

16. The electrical enclosure of claim 15 wherein the cable terminal portion is structured to receive a number of power cables.

17. The electrical enclosure of claim 1 wherein the current which is substantially greater than the rated current is an arcing fault current in the range from about 1,000 amperes to about 100,000 amperes.

18. The electrical enclosure of claim 13 wherein said phase-to-phase arc length limiters and said phase-to-ground arc length limiter are made of steel.

19. The electrical enclosure of claim 12 wherein said first gap is about four inches.

20. The electrical enclosure of claim 13 wherein said second gap is about four inches.

21. The electrical enclosure of claim 13 wherein one of the sides of said housing comprises a side channel; and wherein said phase-to-ground arc length limiter is electrically connected to the side channel.

22. The electrical enclosure of claim 13 wherein the number of members is a plurality of plates, each of the plates having a third edge establishing the second gap to the second edge of the phase-to-phase arc length limiters; and wherein the third edge of each of the plates of said phase-to-ground arc length limiter is parallel to the third edge of each of the other plates and establishes the same second gap to the second edge of each of the phase-to-phase arc length limiters.

23. The electrical enclosure of claim 22 wherein the same second gap is about four inches.

24. The electrical enclosure of claim 1 wherein the current which is substantially greater than the rated current is an arcing fault current.

25. The electrical enclosure of claim 1 wherein the number of electrical bus members is one conductive bus member; and wherein said at least one of the number of electrical bus members is said one conductive bus member.

26. A method of moving an arcing fault from a first location to a different second location of an electrical enclosure, said method comprising:
employing an electrical busway comprising a number of electrical bus members;
employing as at least one of the number of electrical bus members a first bus member, a second bus member and a number of fusible links electrically connected between the first bus member and the second bus member;
structuring said at least one of the number of electrical bus members to electrically conduct a rated current;
structuring the number of fusible links to electrically conduct the rated current;
structuring the number of fusible links to vaporize responsive to a current which is substantially greater than the rated current; and
locating the number of fusible links in the different second location of the electrical enclosure.