Utilization of Electric Power Laboratory‐3rd Year‐ 2013

G2: Testing & Characteristic of MCCB Used in

Commercial and Industrial Applications
 Utilization of Electric Power Laboratory‐3rd Year‐ 2013

Contents
1. Laboratory Objective ...................................................................................................4
2. MECHANICAL OPERATION TESTS ..................................................................................4
2.1 Purpose ..............................................................................................................4
2.2 Procedure .............................................................................................................4
2.3 Results ..................................................................................................................4
3. INSULATION RESISTANCE TEST .....................................................................................4
3.1 Purpose ..............................................................................................................4
3.2 Equipment ..........................................................................................................5
3.3 Procedure ...........................................................................................................5
3.4 Test.....................................................................................................................5
3.5 Results................................................................................................................5
4. INDIVIDUAL POLE RESISTANCE TEST (MILLIVOLT DROP) ..................................................6
4.1 Purpose ..............................................................................................................6
4.2 Equipment ..........................................................................................................6
4.3 Procedure ...........................................................................................................7
4.4 Test.....................................................................................................................7
4.5 Results................................................................................................................7
5. INVERSE‐TIME OVER CURRENT TRIP TEST ......................................................................7
5.1 Purpose ..............................................................................................................7
5.2 Equipment ..........................................................................................................7
5.3 Procedure ...........................................................................................................7
5.4 Test.........................................................................................................7
5.5 Results................................................................................................................8
6. INSTANTANEOUS OVER CURRENT TRIP TEST................................................................ 11
6.1 Purpose ............................................................................................................ 11
6.2 Equipment ........................................................................................................ 11
6.3 Procedure ......................................................................................................... 11
6.4 Test................................................................................................................... 11
6.4.1 Run-Up Method.......................................................................................... 11
6.4.2 Pulse Method ............................................................................................. 12
6.5 Results.............................................................................................................. 13
7. RATED HOLD‐IN TEST ................................................................................................. 13
7.1 Purpose ............................................................................................................ 13

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 Utilization of Electric Power Laboratory‐3rd Year‐ 2013
7.2 Procedure ......................................................................................................... 13
7.3 Equipment ........................................................................................................ 13
7.4 Test................................................................................................................... 13
7.5 Results.............................................................................................................. 13
8. Experiment data, recorded by student: ....................................................................... 14
9. Report...................................................................................................................... 15

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 Utilization of Electric Power Laboratory‐3rd Year‐ 2013
1. Laboratory Objective
• To be familiar with measurement and test equipments used for C.B. testing
• To know different types of tripping units of C.B.
• To understand tripping characteristic curve of C.B
• To be familiar with main non-destructive testing applied on MCCB

The following non-destructive tests may be used to verify specific operational

characteristics of molded case breakers:

A. Mechanical operation test

B. Insulation resistance test
C. Individual pole resistance test (millivolt drop test)
D. Inverse time over current trip test
E. Instantaneous over current trip test
F. Rated hold-in test.

Note‐ All Tests above are according to ANSI/NEMA AB 4‐2009 (Guidelines for
Inspection and Preventive Maintenance of Molded‐Case Circuit Breakers Used in
Commercial and Industrial Applications)

2. MECHANICAL OPERATION TESTS

2.1 Purpose
To verify that the circuit breaker mechanism is operating freely.

2.2 Procedure
• After the circuit breaker is properly isolated, operate it ON and OFF 2 or 3 times. The
breaker handle should operate smoothly without binding.
• Using an ohmmeter or other indicating device, verify that all circuit breaker contacts
are open when the handle is in the OFF position and closed when the handle is in the
ON position.
• For breakers that are provided with mechanical trip provisions (generally indicated by
a test button) operate the tripping means according to the manufacturer's instructions.
With the breaker in the tripped position, verify that the contacts are open using an
ohmmeter (or other indicating device). Reset the breaker according to the
manufacturer's instructions and operate the breaker to the ON and OFF positions.
Use an ohmmeter (or other indicating device) to verify that all the contacts are closing
and opening respectively.

2.3 Results
The breaker should be replaced if:
A. The contacts are not open with the breaker in the tripped or OFF position
B. The contacts are not closed with the breaker in the ON position
C. The breaker does not reset
D. The mechanical trip provisions (if provided) do not trip the breaker

3. INSULATION RESISTANCE TEST

3.1 Purpose
To determine the adequacy of the insulation between line and load terminals, between poles,
and between each pole and ground.

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3.2 Equipment
This test requires an insulation resistance tester capable of applying a direct-current voltage
of at least 500 volts. It should be also noted that more accurate information can be obtained
when 1000 volt testers are used since they are more likely to detect deteriorated insulation
systems (See Figure 1).

Figure 1: Insulation Resistance Test Set-Up

3.3 Procedure
After being properly isolated, remove the breaker from the enclosure. In cases where the
circuit breaker can be safely isolated/disconnected from line and load connections as
installed, the test may be performed with the circuit breaker in its equipment.

3.4 Test
• All exposed metal parts except line, load, and accessory terminals should be
electrically connected to a metal base-plate.
• Using an insulation resistance tester, apply a direct-current voltage of at least 500
volts to determine the resistance. Voltage is to be applied as follows:
a. Between line and load terminals of each individual pole with the circuit
breaker in the OFF position and tripped position if possible.
b. Between terminals of adjacent poles with the circuit breaker in the ON
position.
c. From line terminals to the metal base-plate with the circuit breaker in the ON
position.

3.5 Results
All resistance readings should be one megohm or greater for each measurement. Any
reading less than one megohm may indicate the Circuit breaker is contaminated, flawed, or
cracked insulating material, in this case; the circuit breaker should be replaced

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 Utilization of Electric Power Laboratory‐3rd Year‐ 2013
4. INDIVIDUAL POLE RESISTANCE TEST (MILLIVOLT DROP)
See Figure 2 and Figure 3 for typical test set up.

Figure 2: Individual Pole Resistance Test Set‐Up

Figure 3: Individual Pole Resistance Test Set‐Up

4.1 Purpose
To assess the electrical integrity of internal connections and contacts in a circuit breaker. This
can be done by conducting a millivolt drop test across the line and load terminals of each pole
with the circuit breaker contacts closed. The millivolt drop (resistance) of a circuit breaker pole
can vary significantly due to inherent variability in the extremely low resistance of the
electrical contacts and connectors. Such variations do not necessarily predict unacceptable
performance and should not be used as the sole criteria for determination of acceptability
(See 4.5).

4.2 Equipment
• This test should be conducted using a 24 volt, or less, direct current power supply
capable of supplying the rated current of the circuit breaker. For circuit breakers rated

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 Utilization of Electric Power Laboratory‐3rd Year‐ 2013
higher than 500 amperes, the power supply should be capable of delivering no less
than 500 amperes.
• If the above equipment is not available for field tests, a Digital Low Resistance
Ohmmeter (DLRO), or 4-point tester, capable of 10 to 100 amperes (DC), may be
used.
.
4.3 Procedure
After being properly isolated, remove the breaker from the enclosure. In cases where the
circuit breaker can be safely isolated/disconnected as installed, the test may be performed
with the circuit breaker in its equipment.

4.4 Test

4.4.1 The test is performed as follows:

a) Apply test current across a pole equal to the breaker rating (or 500 Amperes
minimum for breakers rated in excess of 500 Amperes). Record the millivolt drop and
the test current. Do not maintain current for more than 1 minute. If this equipment is
not available, use the following test.
b) Apply test current across a pole of 10 Amperes, or the Ampere rating of the breaker,
for breakers rated less than 100 Amperes. For breakers rated more than 100
Amperes, apply a test current across a pole of 100 Amperes. Record the millivolt drop
and the test current, or resistance. Do not maintain current for more than 1 minute.
c) De-energize the test circuit. Manually operate the breaker to the OFF and then ON
positions.
d) Repeat steps (a) and (b) for a total of three readings on the pole being tested.
e) Repeat steps (a) through (c) for each of the remaining poles of the circuit breaker.

4.5 Results
The results of test will vary according to the breaker frame type, ampere rating, and
manufacturer. The manufacturer should be consulted to determine the maximum allowable
voltage drop (Please see Appendix A). If the average test values of any pole of the breaker
exceed the maximum allowable drop, the circuit breaker may have reached the end of life and
additional tests may have to be conducted.

5. INVERSE-TIME OVER CURRENT TRIP TEST

5.1 Purpose
To verify the operation of the inverse-time over current tripping function of a circuit breaker.
This test is not applicable to instantaneous only breakers or molded case switches.

5.2 Equipment
Variable low voltage power supply, including an RMS reading ammeter capable of delivering
the required test current for the maximum test duration as shown in Table 1. Circuit breakers
with electronic trip units are often equipped with integral test provisions for verifying the
functional operation of the trip unit. Where integral test provisions are not included, separate
test devices are frequently available from the circuit breaker manufacturer. When using either
of these alternate test means, the instructions of the manufacturer must be followed.
5.3 Procedure
After being properly isolated, remove the breaker from the enclosure. In cases where the
circuit breaker can be safely isolated/disconnected from line and load connections as
installed, the test may be performed with the circuit breaker in its equipment.

5.4 Test
NOTE 1—These tests should be conducted on individual circuit breaker poles using a test
current of 300% of the circuit breaker's rated current. This test current has been chosen
because it is relatively easy to attain and the wattage per pole is low enough that the transfer
of heat into the adjacent poles is minor and does not appreciably affect the test results.

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NOTE 2—Circuit breakers equipped with electronic trip units typically are provided with more
than one long-time trip curve. The tests in this clause should be performed with the circuit
breaker set at the longest time setting or at the end use setting, as preferred.
NOTE 3—Circuit breakers equipped with electronic trip units incorporating ground fault
protection should be tested with two poles or more in series to avoid an early trip via the
ground fault trip circuit.
NOTE 4—Plug-on or draw-out circuit breakers will require specialized connections or test
fixtures.

Conduct the test on each pole of the circuit breaker by connecting the line and load terminals
of that pole to the test equipment by copper conductors not less than 4 ft (1.2 m) in length,
sized in accordance with Table 2.A circuit breaker rated 1600 amperes or more may be tested
with copper bus bars per Table 3 instead of cable. A circuit breaker rated more than 4000
amperes should be tested with copper bus bars unless it is marked for cable connections
only.
Tests should be conducted with the circuit breaker at a room ambient of approximately 25°C
(77°F).
a) Connect one pole (two or more poles for electronic trip circuit breakers equipped with
ground fault protection) as indicated above.
b) With the test circuit breaker closed, energize the test circuit and quickly adjust the
transformer to the required 300% test current.
c) With the test current at the correct value, start timing.
d) Record trip time.
e) Repeat steps (a) through (d) on each of the other individual poles. (Where ground fault
protection [GFP] is supplied, repeat steps (a) through (d) using two additional
combinations of poles.) Tests on adjacent poles should be made at no less than five
minute intervals. For circuit breakers with thermal trip elements, wait at least 20 minutes
before repeating tests on the same pole. For circuit breakers with electronic trip elements,
consult the manufacturer’s published instructions for required intervals between tests.

If the intervals are shortened, subsequent tests may result in premature tripping. If more
accurate results are required, the between-test intervals should be extended to permit the
temperature of the circuit breaker to return to that of the surrounding ambient air.

For information regarding testing of an electronic trip circuit breaker's ground fault trip
element, consult the manufacturer's published instructions.

5.5 Results
The circuit breaker should trip within the maximum times shown in Table 1. Circuit breakers
that do not trip within these maximum time limits should not be accepted unless its tripping
curve confirms with the C.B. manual published by manufacturer (Please see Appendix B)

NOTE—If there is concern that the trip time is too low, then the hold-in test should be
conducted (See section 7).

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Utilization of Electric Power Laboratory‐3rd Year‐ 2013
Table 1
VALUES FOR INVERSE TIME TRIP TEST
(At 300% of Rated Continuous Current of Circuit Breaker)

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Utilization of Electric Power Laboratory‐3rd Year‐ 2013
Table 2
COPPER TEST CONDUCTOR SELECTION

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 Utilization of Electric Power Laboratory‐3rd Year‐ 2013
Table 3
SIZE OF COPPER BUSBAR CONNECTIONS

6. INSTANTANEOUS OVER CURRENT TRIP TEST

6.1 Purpose
To verify the operation of the instantaneous trip functions under field test conditions.
Accordingly, the tolerances given in Table 4 are necessarily broader than the manufacturer's
factory tolerances.

6.2 Equipment
The same equipment as utilized in section 5 is required with the following exceptions:
a. For the run-up method of testing a pointer-stop ammeter or other types of meters
(digital) capable of reading and recording, the maximum current reached prior to
tripping may be used.
b. For the pulse method of testing, a calibrated image-retaining oscilloscope, or a high
speed sampling rate digital ammeter (capable of accurately measuring a half-cycle
pulse) is required instead of an ammeter

6.3 Procedure
After being properly isolated, remove the breaker from the enclosure. In cases where the
circuit breaker can be safely isolated/disconnected from line and load connections as
installed, the test may be performed with the circuit breaker in its equipment.

6.4 Test
Since the instantaneous trip characteristics of the circuit breaker can be influenced by stray
magnetic fields, the test setup must be made in such a way that the fields caused by the test
equipment itself, by steel enclosures, mounting plates, or by the conductors to the circuit
breaker, do not affect the test results. Results can also be influenced by the wave shape of
the current and, therefore, it is desirable to have sinusoidal output from the supply equipment.
Manufacturers may be consulted for individual recommendations on mounting and wire
routing if desired. The two methods which may be used for testing the instantaneous trip
function are the "run-up" and the "pulse" methods.

6.4.1 Run-Up Method

a. Connect one pole of the test breaker to the test equipment as indicated in section 5,
adjust the trip setting to the desired position, and operate the breaker to the ON
position.
b. Set the current control to a point where approximately 60% of the current setting will
flow when the circuit is energized.
c. Turn the power ON and increase the current until the circuit breaker trips. The
recommended time for increasing the current is between two and five seconds. If the
circuit breaker does not open within five seconds, the supply circuit should be turned

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OFF to prevent damage to the test equipment and overheating of the circuit breaker
thermal elements.
This method requires operator skill in recognizing the relationships between actual current
and the meter indication. If the current is increased too slowly, tripping may be caused by the
time delay element, especially if more than one test is run. If the current is increased too
rapidly, an erroneous current reading may be obtained because the meter lags behind the
actual current value due to meter damping. This problem can be overcome and the accuracy
of this method may be improved by the use of a calibrated oscilloscope to read the current
level at the time the breaker trips.

6.4.2 Pulse Method

This method is more accurate than the run-up method, if done properly. However, it is subject
to an error introduced by a distortion of the pulse current, commonly called offset or
asymmetrical waveform, as depicted in Figure 4. This current offset can be minimized by
controlling the closing of the circuit such that the circuit is closed at approximately the 90°
point on the supply circuit voltage waveform. The pulse method involves the following steps:
a. Connect one pole of the test breaker to the test equipment as indicated in 6.5, adjust
the trip setting to the desired position, and operate the breaker to the ON position.
b. Apply a pulse of current, approximately 5 to 10 cycles in duration, and at a level
approximately 5% below the lower tolerance limit specified in Table 4 for the breaker
setting. The breaker should not trip.
c. Apply a pulse of current, approximately 5 to 10 cycles in duration and at a level
equivalent to the high tolerance limit specified in Table 4. The breaker should trip.

Figure 4: Current Wave Shapes

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 Utilization of Electric Power Laboratory‐3rd Year‐ 2013
6.5 Results
Test results should be in accordance with the values shown in Table 4.
If the results differ significantly from those values, reexamine the test circuit and circuit
breaker mounting arrangements (See 6.4). If there are no apparent problems with the test
circuit or mounting arrangements, the circuit breaker should be replaced.

7. RATED HOLD-IN TEST

7.1 Purpose
To verify the capability of a molded case circuit breaker to carry its rated current.

7.2 Procedure
Remove the breaker from the enclosure. In cases where the circuit breaker can be safely
isolated or disconnected as installed, the test may be performed with the circuit breaker in its
equipment.

7.3 Equipment
A low voltage power supply such as that described in section 5.2 is required to conduct this
test.

7.4 Test
The circuit breaker should be tested with the operating mechanism set to the ON position, in
open air, with all poles connected in series by copper conductors not less than 4 ft (1.2 m) in
length, selected in accordance with Table 2.
The test should be performed at room ambient temperature approximately 25°C (77°F). The
power supply should be adjusted to deliver rated current until the circuit breaker temperature
stabilizes. Temperature stabilization usually occurs within one hour for breakers rated 100
amperes or less, but will take several hours for breakers of higher rating. Stabilization may be
verified by taking three successive temperature measurements at intervals of 10 to 20
minutes between measurements at the same location on one or more of the circuit breaker
connectors utilizing a temperature probe or thermocouple instrument.

7.5 Results
The circuit breaker should not trip during the test. If it does trip, reset the breaker and turn it
ON again while continuing to monitor connector temperatures for an indication of temperature
stabilization. If the breaker continues to trip or if any of its terminals reach temperatures
higher than 80ºC above ambient, it should not be accepted.

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8. Experiment data, recorded by student:
Student Name: Sec.: B.N.:

1.Mechanical operation test

A. The contacts are not open with the breaker in the tripped or OFF position
B. The contacts are not closed with the breaker in the ON position
C. The breaker does not reset
D. The mechanical trip provisions (if provided) do not trip the breaker
E. C. B is working
2. Insulation resistance test
The C.B in OFF Position Value
The resistance Between pole 1 "Line" and 1 "Load" ≥
The resistance Between pole 2 "Line" and 2 "Load" ≥
The resistance Between pole 3 "Line" and 3 "Load" ≥
The C.B in TRIP Position
The resistance Between pole 1 "Line" and 1 "Load" ≥
The resistance Between pole 2 "Line" and 2 "Load" ≥
The resistance Between pole 3 "Line" and 3 "Load" ≥
The C.B in ON Position
The resistance Between pole 1 and 2 ≥
The resistance Between pole 2 and 3 ≥
The resistance Between pole 1 and 3 ≥
3.Individual pole resistance test (millivolt drop test)
The C.B in ON Position
The resistance Between pole 1 "Line" and 1 "Load"
The resistance Between pole 2 "Line" and 2 "Load"
The resistance Between pole 3 "Line" and 3 "Load"
4. Tripping Curve Test
Write C.B Protecting Setting
Ir = , Tr= ,Isd= ,Tsd= ,Iinst=
% From Ir Injected Tripping Fault Comments
Current Time Type
Value Value

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 Utilization of Electric Power Laboratory‐3rd Year‐ 2013

9. Report
a) Compare between the true RMS multi‐meter and general digital multi‐meter.
b) What is the Circuit that may be used in the electronic MEGGER which can
generate 5000 VDC from 6 VDC? Mention Circuit name, draw a figure for the
circuit, and illustrate its operation
c) Fill up a table of all devices used in the experiment and mention the function
of each device
d) Fill up a table for all readings recorded in the experiment
e) What is the Hall Effect phenomena "brief description"?

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APPENDIX A

16
 Installation Power loss/ Resistance
recommendations Compact NSX equipped with thermal-magnetic
trip units

Compact NSX thermal power loss values The values indicated in the tables below are typical values for a device at full rated
are used to calculate total temperature rise load and 50/60 Hz.

in the switchboard in which the circuit Power loss per pole (P/pole) in Watts (W)
The value indicated is the power loss at IN, 50/60 Hz, for a three-pole or four-pole
breakers are installed. circuit breaker. Measurement and calculation of power loss are carried out in
compliance with the recommendations of Annex G of standard IEC 60947-2.
Resistance per pole (R/pole) in milliohms (mΩ)
N L1 L2 L3
DB115052

The value of the resistance per pole is provided as a general indication for a new
device.
The value of the contact resistance must be determined on the basis of the
measured voltage drop, in accordance with the manufacturer's test procedure (ABT
instruction document no. 1 - BEE - 02.2 -A).
Note: this measurement is not sufficient to determine the quality of the contacts, i.e. the capacity
of the circuit breaker to carry its rated current.
Additional power loss
With a Vigi module, the deviation of the N and L3 bars required Additional power loss is equal to the sum of the power dissipated by the following:
to pass through the toroid results in higher power losses b Vigi module: note that the deviation of the N and L3 bars required to pass through
compared to those of the L1 and L2 bars. the toroid results in higher power losses compared to those of the L1 and L2 bars
(diagram opposite). When calculating total power loss, use L1, L2, L3 for a 3P device
and N, L1, L2, L3 for a 4P device
b disconnecting contacts (plug-in and withdrawable devices)
b ammeter module
b transformer module.
Calculation of total power loss
Total power loss at full rated load and 50/60 Hz is equal to the sum of the device and
additional power losses per pole multiplied by the number of poles (2, 3 or 4).
If a Vigi module is installed, it is necessary to differentiate between N and L3 on one
hand and L1 and L2 on the other.

Compact NSX100 to 250 equipped with TM-D and TM-G trip

units
Type of device Fixed device Additional power / pole
3/4 poles Rat. R/pole P/pole Vigi Vigi Plug-in / Ammeter Transfo.
(A) (N, L3) (L1, L2) withdr. module module
NSX100 16 11.42 2.92 0 0 0 0 0
25 6.42 4.01 0 0 0.1 0 0
32 3.94 4.03 0.06 0.03 0.15 0.1 0.1
40 3.42 5.47 0.10 0.05 0.2 0.1 0.1
50 1.64 4.11 0.15 0.08 0.3 0.1 0.1
63 2.17 8.61 0.3 0.15 0.4 0.1 0.1
80 1.37 8.77 0.4 0.2 0.6 0.1 0.1
100 0.88 8.8 0.7 0.35 1 0.2 0.2
NSX160 80 1.26 8.06 0.4 0.2 0.6 0.1 0.1
100 0.77 7.7 0.7 0.35 1 0.2 0.2
125 0.69 10.78 1.1 0.55 1.6 0.3 0.3
160 0.55 13.95 1.8 0.9 2.6 0.5 0.5
NSX250 125 0.61 9.45 1.1 0.55 1.6 0.3 0.3
160 0.46 11.78 1.8 0.9 2.6 0.5 0.5
200 0.39 15.4 2.8 1.4 4 0.8 0.8
250 0.3 18.75 4.4 2.2 6.3 1.3 1.3

Compact NSX100 to 630 equipped with MA/1.3-M trip units

Type of device Fixed device Additional power / pole
3 poles Rat. R/pole P/pole Vigi Vigi Plug-in / Ammeter Transfo.
(A) (N, L3) (L1, L2) withdr. module module
NSX100 2.5 148.42 0.93 0 0 0 0 0
6.3 99.02 3.93 0 0 0 0 0
12.5 4.05 0.63 0 0 0 0 0
25 1.66 1.04 0 0 0.1 0 0
50 0.67 1.66 0.2 0.1 0.3 0.1 0.1
100 0.52 5.2 0.7 0.35 1 0.2 0.2
NSX160 150 0.38 8.55 1.35 0.68 2.6 0.45 0.45
NSX250 220 0.3 14.52 2.9 1.45 4.89 0.97 0.97
NSX400 320 0.12 12.29 3.2 1.6 6.14 1.54 1.54
NSX630 500 0.1 25 13.99 7 15 3.75 3.75

B-10
Compact NSX equipped with electronic trip units

The values indicated in the table below are typical values for a device at full rated
load and 50/60 Hz. The definitions and information are the same as that for circuit
breakers equipped with thermal-magnetic trip units.

Compact NSX100 to 630 equipped with Micrologic trip units

Type of device Fixed device Additional power / pole
3/4 poles Rat. R/pole P/pole Vigi Vigi Plug-in / Ammeter Transfo.
(A) (N, L3) (L1, L2) withdr. module module
NSX100 40 0.84 1.34 0.1 0.05 0.2 0.1 0.1
100 0.468 4.68 0.7 0.35 1 0.2 0.2
NSX160 40 0.73 1.17 0.4 0.2 0.6 0.1 0.1
100 0.36 3.58 0.7 0.35 1 0.2 0.2
160 0.36 9.16 1.8 0.9 2.6 0.5 0.5
NSX250 100 0.27 2.73 1.1 0.55 1.6 0.2 0.2
250 0.28 17.56 4.4 2.2 6.3 1.3 1.3
NSX400 400 0.12 19.2 3.2 1.6 9.6 2.4 2.4
NSX630 630 (1) 0.1 39.69 6.5 3.25 19.49 5.95 5.95
(1) The power loss values for the Vigi modules and withdrawable circuit breakers are given for
570 A.

B-11
APPENDIX B