PANEL TESTING PROCEDURE

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VISUAL CHECK:

 To check the Fabrication Enclosure (As per approved drawing)

 Height

 Width

 Depth

 To check the Panel Main Name plate

 To check the panel rating plate with serial number provided.

 To check the Paint shade is as per approved drawing.

 To check the make and type of the components to be check as per BOM.

 To check the Bus bar Material, Size, Color Code, Support & clearance between the

Phase to Phase (Φ-Φ) and Phase to Neutral (Φ-N) as per the drawing.

 To check the Mechanical lock Rack in /out operation by the handle for the easiest

movement of the breaker.

 To check VCB test position & service position control circuit and legends.

 To check the breaker rating sticker with serial number as per approved drawing.

 To check the spring charge motor & shunt coil rating sticker.

 To check the VCB shutter operation.

 To check the spring charging by using the proper handle.

 To check the make, size, color code followed, ferrule & loose connection for the wires

& cables.

 Component specification should be checked as per drawing.

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 TESTS TO CHECK THE CONTROL CIRCUIT:

Check continuity for all the control wires and ensure it was done as per the drawing.

Control voltage is given to the control circuit by using the POWER PACK 110VDC.

Switch on the control supply by using the Battery based power pack

The operation of the breaker is checked along the indicating lamp.

 Red indication lamp : To check the ON condition of the circuit breaker.

 Green indication lamp: To check the OFF condition of the circuit breaker.

 Blue indication lamp : To check the spring charge condition of the

breaker.

 Amber indication lamp: To check the trip condition of the breaker.

 White indication lamp : To check the healthy condition of the trip circuit.

 Push to close manual : Manually check the breaker close operation.

 Push to trip manual : Manually check the breaker open operation.

AUTO TRIP:

The breaker will trip automatically when the fault arise. For test purpose,

short the terminals in the terminal block. The trip indication lamp will glow.

HEALTHY TRIP INDICATION:

When the trip circuit healthy push button is pressed, the indication lamp will

glow to show the healthy condition of the trip circuit.

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CUBICLE LAMP:

The lamp which is connected with the door limit switch inside the panel is

automatically on/off when the panel door is open/close respectively. This can be change

depends upon the customer requirements.

ANTI PUMPING:

Anti-Pumping relay should be checked when the circuit breaker is closed by

holding the TNC(Trip Neutral Close Switch) at close position, in the mean while the breaker

should be tripped manually using the push button at the breaker. It means the breaker should

not get closed while the TNC was at close position. This ensures us the antipumping relay

was working well.

TRUCK INTERLOCK:

When the breaker is in ON position, the truck cannot be moved. The breaker

cannot be turned on when the truck is in between the test and service position.

SPACE HEATERS:

Space Heaters should be checked by adjusting the temperature range in

thermostat and set it for room temperature.

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MINIMUM VOLTAGE TEST

Tripping and closing coil operation should be checked with the various

percentage of control voltage.

70% of 110V DC (Tripping alone operation) 77V.

85% of 110V DC (Tripping and Closing operation) 93.5V.

100% of 110V DC (Tripping and Closing operation) 110V.

110% of 110V DC (Tripping and Closing operation) 121V.

CURRENT INJECTION TEST:

RY- OVER CURRENT FAULT:

 Short the R & Y bus bar in the outgoing terminals. The current is injected in

R /Y terminal by the suitable current injection kit.

 The injected current is checked by the ammeter.

 In the case of over current low set, the current was injected above the

programmed value the breaker will trip at specific time.

 In the case of over current high set, the breaker will trip without delay.

YB – OVER CURRENT FAULT:

 Same RY – over current fault procedure is followed in YB – over current fault.

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 EARTH FAULT:

 In this the phase current is injected between any one of the phase.

 When the current was injected above the programmed value, the breaker will

trip at specific time.

 In case of Earth fault high set, the breaker will trip immediately.

 The Ammeter should be checked comparing with the injected switch at each

phase using Ammeter selector switch

 Energy Meter can be checked by observing the blinking indication of the

pulse when the panel was subjected to current injection test.

CONTACT RESISTANCE TESTING

 This is to measure the resistance of the breaker contacts in the panel.

 Current of 100A DC is given to the R – phase breaker contact and the resistance

shown in the contact resistance kit.

 This procedure is repeated for remaining Y & B phase.

 The resistance will achieve in the units of Micro ohm.

As per ohms law,

V=IR

7.0*(10^-3) = 100 * R

R = 70μohms

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 phase Milli volt drop (mV) Resistance (Micro ohms)
R
Y
B
Tabulation for contact resistance test: (Limit <30µΩ)

INSULATION RESISTANCE TEST:

Breaker condition: ON

 To check the Insulation resistance between R to Earth, Y to Earth & B to Earth.

 To check the Insulation resistance between R to Y, Y to B & B to R.

Breaker condition: OFF

 To check the Insulation resistance between R to r, Y to y & B to b phases.

 The above tests to be conducted before and after high voltage test.

HIGH VOLTAGE TEST:

Breaker condition: ON

Precaution:

 Ensure that the breaker was in service position.

 Check the breaker in ON condition.

 Ensure that the panel and high voltage kit should be properly earthed.

Procedure:

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  Short the Y & B phases and connected to the earth.

 Before giving the supply, check the earth is connected properly by short the earth rod

and the phase of the kit. If the earth was connected properly the kit will trip.

 Then 50kV supply is given to the R – phase for 1 Minute by the suitable kit.

 Observe that there is any flash over or puncture.

 The leakage current will be displayed in the high voltage kit. (Limit <4mA)

 If the leakage current is exceeds the limit, check the clearance between phases &

earth.

 The same procedure is repeated for the remaining phases.

Breaker Condition: OFF

Precaution:

 Ensure that the breaker was in service position.

 Check the breaker in OFF condition.

 Ensure that the panel should be properly earthed.

Procedure:

 The two ends of the bars are shorted. And the one end is connected to the earth.

 The 50kV supply is given to the opposite end of the bus bar for 1 minute.

 The leakage current will be noted. If the leakage current is exceeds the limit the

clearance is to be check.

 The high voltage test in OFF condition is to conduct for check the breaker was exactly

open and the interrupter is withstanding the high voltage.

PT RATIO TEST:

 To apply 415V on Primary of the PT

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 To measure the voltage on secondary side of the PT as per the ratio

11kV/RT3/110V/RT3.