Istrumentazioni Sistemi Automatici S.r.l.

VIA BERGAMO 41 - 21020 TAINO (VA) - ITALY

OFFICES TEL. +39.0331.956081 - FAX +39.0331.957091
LAB: TEL. +39.0331.956483 -
E-MAIL isa@isatest.com
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DATE: 12/12/2005 DOC.MIE11166 REV.1

APPLICATION GUIDE
FOR THE
CIRCUIT BREAKER ANALYZER
AND MICROOHMMETER
MOD. CBA1000
Doc. MIE11166 Rev. 1 Page 2 of 30

REVISIONS SUMMARY VISA

N PAGE DATE
1 All 12/12/2005 Preliminary issue Lodi.
Doc. MIE11166 Rev. 1 Page 3 of 30

SHORT FOREWORD ..................................................................................................................................................... 4

SAFETY AT WORK ........................................................................................................................................................ 5

1 INTRODUCTION ......................................................................................................................................................... 7

2 CB TIMING TEST ........................................................................................................................................................ 8

2.1 CONNECTION TO THE CIRCUIT BREAKER .................................................................................................................... 8
2.1.1 CB contacts. ...................................................................................................................................................... 8
2.1.2 Coil drivers ........................................................................................................................................................ 8
2.1.3 More than two chamber per phase................................................................................................................... 9
2.2 TEST EXECUTION ..................................................................................................................................................... 10
2.3 TEST RESULTS ANALYSIS ......................................................................................................................................... 13
3 CB MOVEMENT OR ANALOG SIGNAL TEST.................................................................................................... 15
3.1 TRAVEL TRANSDUCER CONNECTION TO THE CIRCUIT BREAKER ............................................................................... 15
3.2 PRESSURE TRANSDUCER CONNECTION TO CBA1000............................................................................................... 18
3.3 ANALOG SIGNAL CONNECTION TO CBA1000 ........................................................................................................... 19
4 AUXILIARY CONTACTS TEST .............................................................................................................................. 21

5 TWO RECORDING TEST......................................................................................................................................... 22

6 STATIC RESISTANCE TEST ................................................................................................................................... 24

7 DYNAMIC RESISTANCE TEST .............................................................................................................................. 26

8 TWO GROUNDS TEST WITH DET1000 ................................................................................................................ 29

Doc. MIE11166 Rev. 1 Page 4 of 30

SHORT FOREWORD

Dear CBA/1000 user,

I often wondered why the user’s manual is not very much used, even if it includes valuable
information. As me too I am a user of such manuals, the answer I have given myself is that valuable
information are concealed somewhere in the thick thing, and I do not have time to waste to find it.
So, either the manual is actually of help, or I ignore it.

This is why I decided to split the CBA1000 manual in three: specification, with all performance
details; introductory guide, with the device description; application manual, with instructions about
how to use it one its operation is understood. The idea is that you may read once the introductory
guide or the specification, while you need to follow application examples more than once; so, why
not to split the manual in three?

This manual deals with application examples: read through them, they will help you.

Have a good work with CBA/1000!

Primo Lodi
Q&A Manager
Doc. MIE11166 Rev. 1 Page 5 of 30

SAFETY AT WORK

The Product hereafter described is manufactured and tested according to the specifications,
and when used for normal applications and within the normal electrical and mechanical limits
will not cause hazard to health and safety, provided that the standard engineering rules are
observed and that it is used by trained personnel only.

The application guide is published by the Seller to be used together with the Product described in
the corresponding document. The Seller reserves the right to modify the guide without warning,
for any reason. This includes also but not only, the adoption of more advanced technological
solutions and modified manufacturing procedures, and also the addition of other features, not
available in the first release.

The Seller declines any difficulties arising from unknown technical problems. The Seller
declines also any responsibility in case of modification of the Product or of any intervention not
authorized by the Seller in writing.

The warranty includes the repair time and the materials necessary to restore the complete efficiency
of the Product; so, it does not include other burdens, such as the transport and customs fee. Under
no circumstances the warrantee includes any cost that the User may have suffered because of the
Product unavailability and downtime.

The Product is CE marked, and has been tested to operate according to EN 61010-1, with the
following operating conditions:
. Pollution degree 2: normally, non conductive pollution occurs;
. Measurement category 2, for measurement inputs.
Would the Product be used beyond these limits, its safety could be impaired.

Mains supply characteristics are:

.. From 85 to 265 V AC; 50-60 Hz,
.. From 100 to 350 V DC.
. Power consumption: 100W maximum.

The Product includes a rechargeable NI-Cd battery. In case of replacement, dispose it in the suitable
containers. At the end of its life, the test set should be disposed in a waste dedicated to electric and
electronic equipment.

The Product deals with voltages and currents that may be lethal to the unadvertised user. Besides, in
order to avoid any danger in case of fault inside the Product, the device under test should have the
following characteristics:
. Connection sockets must be not accessible;
. Input circuits must have an isolation degree at least equal to the one of the Product.

. The symbol
! is related to dangerous output, and is located close to the coil drivers.

. The symbol is located close to the ground socket.

Doc. MIE11166 Rev. 1 Page 6 of 30

. The symbol is located close to the mains supply socket, that incorporates the protection
fuse.

The following table lists a number of situations that are potentially hazardous to the user and/or to
the Product. Please consider this list, and check the situation in case of doubt.

SITUATION CAUSE OF RISK CONTROL

TEST SET NOT GROUNDED Capacitor dividers take the case at 110 Ground connection on
BEFORE ANY CONNECTION V; the unit is not protected against the dedicated socket;
common mode noise. supply plug with
Heavy risk in case of fault during tests. ground.
CB NOT CLOSED AND When floating, main poles can be at high CB closed.
GROUNDED ON BOTH SIDES, voltage because of inductions. Main poles grounding.
BEFORE CONNECTING THE Heavy risk in case of connection error!
MAIN CONTACTS
CB NOT GROUNDED ON ONE Heavy risk in case of wrong Main poles grounding
SIDE DURING TESTS disconnector operation! on one side.
Connection sockets not isolated Contact to a live wire. If the optional cable set
is not used, use safety
connection sockets!
CB coils not disconnected from the There can be voltage from the plant CB coils disconnected.
circuit. during tests: this could damage the test
set.
Contact with the plant auxiliary The DC voltage can be higher than 50 V Connections to the DC
supply. DC, hence very dangerous. supply must be
protected.
Travel transducer does not have extra Damage of the travel transducer or joints Verify Open and Close
stroke because of extra stroke during tests positions
CB in service before disconnecting Danger of short-circuits on the test set. Disconnect CBA1000
it from CBA1000. prior to restoring. In
case, use the PARK
sockets for coil cables.
CLOSE THE CB AND CONNECT When floating, main poles can be at high CB closed.
IT TO GROUND ON BOTH voltage because of inductions. Main poles grounding.
SIDES BEFORE Heavy risk in case of connection error!
DISCONNECTING

Of these points, the first three are very hazardous, both for the user and the test set. THESE
TYPES OF FAULT ARE NOT COVERED BY THE WARRANTY.

The connection to ground is provided through the mains supply cable or, when the test set is battery
operated, it is connected to ground using the dedicated socket.

In case of doubt, please contact your Seller. The Seller, and Manufacturer, declines any and all
responsibility due to improper usage, or any usage outside the specified limits.
Doc. MIE11166 Rev. 1 Page 7 of 30

1 INTRODUCTION

The circuit breaker analyzer and micro-Ohmmeter model CBA1000 is a two-in-one test set.

When used as a circuit breaker analyzer, it allows the off-line testing of the characteristics of all
modern MV and HV circuit breakers.

When used as a micro-Ohmmeter, it allows measuring the contact resistance of the circuit breaker
contact, or also of joints or other circuit parts. It allows also to perform the dynamic test of the
contact resistance, that is to record and display how does the contact resistance change while it is
closing: this allows detecting hidden defects, that are otherwise impossible to be diagnosed.

Purpose of this manual is to guide you step by step, so that you can perform all key CB tests. It is
understood that the user knows how to perform selections, as explained in the introductory manual.
Doc. MIE11166 Rev. 1 Page 8 of 30

2 CB TIMING TEST

Purpose of the test is to verify the time delays of main contacts with respect to the coil open/close
commands, and the timing spread of contacts. Test result will tell if timings are within the limits;
the comparison with former test results will tell how much the CB has changed its timing because of
the wear induced by operation, and how uniform has been the wear on the three phases.

The test is performed connecting CBA1000 to the CB main contacts and coils, and then issuing the
test commands. During the test, CBA1000 issues the coils Open – Close commands, and measures
the corresponding contact timings. Test results are shown on the display.

2.1 CONNECTION TO THE CIRCUIT BREAKER

2.1.1 CB contacts.

Before proceeding, apply the rules listed in the Safety at work chapter!

The first operation is to connect CBA1000 to CB contacts. To this purpose:

. Use inputs A1, B1, C1, for phases 1, 2, 3 in case of single-chamber CB.
. Use inputs A1-A2, B1-B2, C1-C2, for phases 1, 2, 3 in case of two-chamber CB.
The selection is performed as follows:

Menu > Breaker and auxiliary channel settings > Breaker contacts > A1+B1+C1 or all
RET

During the connection, CB MUST BE CLOSED AND GROUNDED ON BOTH SIDES. If the
optional cable kit has been purchased, the connection is performed using the three-conductors
cables provided, one for each phase: conductors are marked A, B, C. Once the connection is
performed, it is necessary to open the earth connection on one side, but THE OTHER SIDE
MUST BE LEFT CONNECTED TO GROUND. Which socket (red, black, blue) should be
connected to ground is not relevant.

For the test of the pre-insertion resistor there is no further connection: you have to select it.

Menu > Breaker and auxiliary channel settings > Pre-insertion resistor test > Enable
RET

If you don’t use the optional connection cables, they should be tied together, in order to minimize
the interference cause by the electric field.

2.1.2 Coil drivers

Next operation is to connect logic CBA1000 coil driver outputs to the CB coils. Before proceeding,
coils must be DISCONNECTED FROM THE PLANT CIRCUITS, so that there is no
interference during the test.

The connection is made in two steps:

Doc. MIE11166 Rev. 1 Page 9 of 30

- First step: Connect one of the two sockets of all coil drive circuits to the auxiliary DC voltage
supply of the plant; usually, the connection is performed to the positive of the auxiliary supply. Coil
driver is bidirectional, so it does not matter to which socket the auxiliary voltage is connected.
- Second step: connect the coil input to the corresponding CBA1000 sockets, considering that:
. The Close coil is always one, and is to be connected to the socked marked C;
. The Open coils command could be three phase: in this instance, connect it to THE SOCKET
MARKED O1;
. If the Open coils command is single phase, and if the four coils option is available, then connect
the Open phase 1 coil to socket O1, the Open phase 2 coil to socket O2; the Open phase 3 coil to
socket O3.

If you don’t use the optional connection cables, the cross section should be enough for the coil drive
current: at least 6 sq. mm, in order to minimize the current drop.

NOTE: sockets O2 and O3 are always present, even if the four coils option is not available.
NOTE: sockets marked PARK are not connected: prior to test, it is safer to fit the coil driving
connections in these sockets, until everything is OK.

At this moment, connections are as follows (case of: single chamber CB, with four Open coils).

2.1.3 More than two chamber per phase

If you have more than two chambers per phase, you can split the test in three, testing one phase at a
time: you can connect up to six chambers per phase.
The alternative solution is to use two (or more; up to 4) CBA1000, taking advantage of the Master-
Slave option (one Master, three Slave). The following connection refers to four chambers per phase,
but up to 8 chambers can be tested (only one pole is shown).
Doc. MIE11166 Rev. 1 Page 10 of 30

One CBA1000 is the Master: this is the one to which are connected the coils. The Slave is the one
that monitors the additional chambers: its Slave input is connected to the Master output of the
Master CBA1000; besides, on the Slave unit(s) you have to select the Slave operation, as follows:

Menu > Trigger options > External trigger RET

Only CB contacts (and auxiliary CB contacts, analog input) are connected to the slave unit: NOT
the coil drivers. At the end of tests, on the Slave unit the timings are referred to the Master’s trigger.
The total test result can be glued using the software.

2.2 TEST EXECUTION

Once connections are performed, next operation is to power-on CBA1000: the following screen is
displayed.

At the end of self-diagnostic, the following screen is displayed.

On the front panel, breaker contacts LED’s will display the contacts status: Green = Main contact
Closed, as it should be at this moment; RED = main contact Open. In case of discrepancy, correct
the connection. This is the situation with a single-chamber CB.
Doc. MIE11166 Rev. 1 Page 11 of 30

On the first test, you have to input the tests header, as follows.

Menu > Tests header RET

Once test data are input, you can proceed with the test. As you are finished with a CB, don’t forget
to input the new CB header.

The test can be executed with a number of different values for the various available choices. At
power-on, the default situation is presented: parameters selection can be read pressing the Set
pushbutton.

Set > Show current setup (RET)

If these values match with what you want to do, you can immediately start the test; else, you can
load a previously saved setting, or you can enter the menu, modify the desired parameters and then
save the setting, before proceeding. For instance, if you want to modify the timing setting, act as
follows:

Menu > Recording options > Open to close delay > (value) RET

And so on with other delays. At the end of timing programming, you can check your values pressing
Help diagram: the following window is displayed.

Remember that he “Recording duration” must be bigger than “Pre-trigger” + “OC delay” + “CO
delay” + the CB timings, so that no significant part of the test is lost. On the other side, it should not
be too big, as it defines the test result dimension, hence the number of test results that can be kept in
memory.
Doc. MIE11166 Rev. 1 Page 12 of 30

There are as many as 64 memory positions available for test settings; so, we suggest to prepare the
desired ones using the software, possibly before leaving the office; when you are on site, you just
load the desired setting, as follows.

Set > Load setup > File selection RET

Now, you are ready for the test. As you see, on the front panel there are two buttons in all: one
selects the type of test; the other one starts the test. You don’t have to use the Menu selection to set
the desired test. After power-on, the default selection is OCO; for instance, if you want to perform
an O-C test, press the SEL button until the OC LED turns on: the test is selected.

Now, press the START button: the buzzer warns eight times that the test is about to start, then the
test is performed. The LED above the pushbutton turns on until the test is over.

Breaker contacts LED’s turn red and green, as main contacts open and close: at the end of the test,
green LED’s should follow the selection. On the display it is shown the test result.

You can examine it, and verify current peaks and diagram, main contact timing, pre-insertion
resistor timing, by moving the two cursors (cursor selection is obtained checking on t1 or t2). If the
result is OK, you can save it, and perform other tests; else, you can repeat it, ignoring the warning
message about saving Saving the result is performed using the Res selection:

Res > Save result > File name RET

The following window is displayed:

Doc. MIE11166 Rev. 1 Page 13 of 30

It is possible to continue testing the same CB and saving results with different tests. It is also
possible to recall the former result of the same CB, so that you can check for deviations in time; this
is easily performed using the software.

When the test on the CB is finished, before going to another one, remember to select Close at the
end of test, prior to disconnect cables!

2.3 TEST RESULTS ANALYSIS

The analysis of test results allows to measure the relevant CB contacts parameters.
The first measurement is the delay between the Open (Close) coil command and the corresponding
main contact Opened (Closed) position. The following figure shows the recording with an Open –
Close command: delays are referred to coil commands.

CLOSE COIL CURRENT

OPEN COIL CURRENT

A1
B1
C1
OPEN DELAY CLOSE DELAY

Other relevant measurements are the Open coil current and Close coil current: they are metered
moving the cursors on the desired point.

The coil current shape is also providing information on what does it happen as the coil actuator
moves. At the beginning, the coil inductance is low, as there is a big gap on the actuator. At some
moment, the actuator operates the mechanical latch that keeps the contact in the Closed position:
from then, the actuator moves faster, and the inductance increases until the actuator reaches the end
Doc. MIE11166 Rev. 1 Page 14 of 30

of stroke. The inductance increase typically causes a momentary current decrease, that depends upon
the actuator characteristics of inductance and speed. From this moment on, the current increase is
defined by the R-L actuator characteristic, where L is the end-of-stroke actuator inductance, and R is
the coil DC resistance. The maximum coil current is Imax = Vaux / R.

MAXIMUM COIL CURRENT

COIL CURRENT OPENING

END OF STROKE
TRIP LATCH OPENED

When the CB contact is close to its Open position, the auxiliary contact cuts the Open coil current:
this is (almost) the end of the CB stroke. All these timings can be compared to specs or to former
test results.

Another important measurement is the contact timing spread and the pole spread: the first one
applies when there are two chambers per phase. Zooming on the contacts trip, it is possible to
examine the details.

A1
A2
B1
B2
C1
C2

CONTACTS TIME SPREAD CONTACTS TIME SPREAD

POLES TIME SPREAD
POLES TIME SPREAD

Zooming even more, it is possible to verify if there are bounces on the contact: they are detrimental
to contact life, and mean that the contact surface is worn.

A1

CONTACT BOUNCE
Doc. MIE11166 Rev. 1 Page 15 of 30

3 CB MOVEMENT OR ANALOG SIGNAL TEST

In this instance, you want to test also the CB movement during tests, or you want to monitor some
other analog signal. It is therefore necessary to perform some more connection to the CB.

3.1 TRAVEL TRANSDUCER CONNECTION TO THE CIRCUIT BREAKER

Travel transducers are used for the purpose of having a better detail on the mechanical status of the
CB. This is accomplished as follows:
. Comparing the movement trace to CB Open and Close contacts, it is possible to verify if they act
at the desired stroke positions, including tolerances;
. Computing from the trace the corresponding speed and acceleration, it is possible to verify if CB
limits are exceeded because of plays caused by wearing.
. Also auxiliary CB contacts acting positions can be checked.

The travel transducer is a potentiometer (pulse transducers are not foreseen); the cursor position
corresponds to the pole position during the movement.

There are two types of transducers: linear, with different strokes, and angular. The linear transducer
is mechanically connected to the leverage that acts on poles by means of joints; the angular one is
connected to the motor shaft. To solve the mechanical problems, the optional linear transducers are
equipped with suitable connection hardware.

The linear transducer is usually connected to a point that does not perform the same movement of
the contact: usually, the movement is less that the one of the contact. This means that for both types
of transducers it is necessary to know not only the contact nominal stroke, but also the nominal
stroke of the transducer connection.

As both types of transducers are potentiometers, it is necessary to supply them with a DC voltage,
that is measured by CBA1000. This voltage is available on sockets (18): see the connection
diagram.
Doc. MIE11166 Rev. 1 Page 16 of 30

The programming of the test is performed as follows.

. First of all, install the transducer and connect it to CBA1000. During transducer installation, mount
it so that there is some stroke after Open and Close positions (minimum 5% of the stroke): this
is because during operation the CB shaft moves beyond the Open and Close positions at rest. If you
don’t, the movement diagram would cut the extra stroke, and the transducer could be damaged.
The following design shows the situation.

MIN. STROKE OPEN CURSOR CLOSE MAX. STROKE

TRANSDUCER

>5% >5%
100%

. If you don’t use the optional connection cables, use the connector provided and make the
connection cable using a shielded wire pair, wit the shield connected to the connector body. This
serves to minimize interference on the measurement signal.
. Enable the Analog input measurement, as follows:

Menu > Analog channel/coils setting > Analog channel > Enabled > Travel
transducer > Label > 5 V >
Doc. MIE11166 Rev. 1 Page 17 of 30

. At this moment, the following window is displayed.

. The first set of data is referred to the transducer. You can select the type of transducer: degree for
angular, mm or Inch for linear. Next you have to key in the nominal transducer stroke, that is the
nominal stroke at the connection point, and the maximum transducer stroke that is the maximum
movement of the transducer itself: it will be, for instance, 350° for an angular transducer, and 100 or
200 mm for a linear one. This information allows CBA1000 to translate the input voltage into the
transducer position.
Next, you have to inform about the supply voltage for the transducer. If it is the internal source, the
test can continue; else, you have to key in the voltage, that must be accurately measured for an
errorless test result.

. The next set of data refers to the CB contact. You can select the unit of measurement, that can be
feet, millimetres or inches; then, you have to input the nominal CB contact stroke.

. Now, select TEST: this serves to measure the actual transducer stroke, hence the actual CB
contact stroke. After checking, the following window is displayed.
Doc. MIE11166 Rev. 1 Page 18 of 30

. CBA1000 recognizes if the CB is open or closed, and displays the Close (or Open) transducer
position, in the selected U.M. and in percentage of the total transducer stroke. Now, issue a
command so that the CB goes to the opposite position, Open (or closed): the window displays the
next position, and computes the actual transducer and CB contact strokes and the stroke percent
error with respect to the nominal, that must match with the tolerance limits.

. From this moment, CBA1000 is ready to display the CB contact movement in the selected U.M.:
from these values, the software computes speed and acceleration.

The analysis of test results allows to measure other relevant CB parameters. Next figure shows a
typical movement diagram, after an Open – Close command.

OVER-TRAVEL BOUNCE

CONTACT OPENED
OPEN COIL CURRENT

STROKE
DAMPING TIME
OVER-TRAVEL
CONTACT OPENS
REBOUND
WIPE
CONTACT CLOSED
A1
B1
C1
CB reaction time
CLOSE DELAY

CBA 1000 computes the key parameters of the diagram, that are: CB reaction time (from the
command to when the contact starts to move); “wipe” movement (from Closed to when contacts
open; “damping time” (from the contact opening to the Open position); “over-travel” (the stroke
beyond the reference Open or Closed positions), “rebound” (the stroke after the over-travel).

3.2 PRESSURE TRANSDUCER CONNECTION TO CBA1000

Pressure transducers measure the gas pressure as the CB is operated: watching this signal is useful
as hidden problems could be revealed. Usually the transducer is mounted on the CB, and outputs a
low voltage.

The selection is performed as follows.

. If you don’t use the optional connection cables, use the connector provided and make the
connection cable using a shielded wire pair, wit the shield connected to the connector body. This
serves to minimize interference on the measurement signal.
. Enable the Analog input measurement, as follows:

Menu > Analog channel/coils setting > Analog channel > Enabled > Pressure
transducer >

. At this moment, the following window is displayed.

Doc. MIE11166 Rev. 1 Page 19 of 30

. First of all, introduce the reference Label.

. Then, you can select the type Unit of Measurement of the transducer.
. Next, you have to key in the pressure when the voltage is 0 V (because usually it is not zero), and
the pressure transducer constant, in V/U.M.: it will be, for instance, 0,1 V/Bar. This information
allows CBA1000 to translate the input voltage into pressure.
. From this moment, CBA1000 is ready to display the pressure, in the selected U.M..

The test execution is the same as for CB contacts test; in the result window, the CB pressure is
displayed.

3.3 ANALOG SIGNAL CONNECTION TO CBA1000

The monitoring of other analog voltage can be executed; for instance, it could be interesting to
watch:
. Motors current or voltage;
. Auxiliary DC-AC supply voltage.

In this instance, the connection is performed to either of the voltage inputs, as CBA1000 monitors
only the selected one.

If you want to connect to the 5 V input, and don’t use the optional connection cables, use the
connector provided and make the connection cable using a shielded wire pair, wit the shield
connected to the connector body. This serves to minimize interference on the measurement signal.

If you want to measure the motor current, and you don’t have the optional cable set, you should use
a current to voltage clip-on meter, with a conversion constant of 1 V – 10 A.

The selection is performed as follows.

. Enable the Analog input measurement, as follows:

Menu > Analog channel/coils setting > Analog input > Label > Voltage input range
RET

The test execution is the same as for CB contacts test; in the result window, the selected analog
input is displayed.
Doc. MIE11166 Rev. 1 Page 20 of 30

The following figure shows the test of the auxiliary supply. NOTE: Do not exceed the input voltage
limit of 350 V AC or 500 V DC.
Doc. MIE11166 Rev. 1 Page 21 of 30

4 AUXILIARY CONTACTS TEST

In this instance, you need to test also some auxiliary contacts during tests. It is therefore necessary
to perform some more connection to the CB. For instance, it can be useful to connect the CB Open
and CB closed auxiliary contacts, and to verify at which point of the stroke they operate: this allows
to know if mechanical tolerances are met.

During this connection, please consider the following:

. CBA1000 has two ISOLATED groups of two inputs each; so, it is possible to watch two types of
contacts, for instance one polarized, and the other one voltage free.
. If inputs are with voltage, the zero of the voltage must be connected to the black C socket. If
contacts are more than two, connect both C sockets.
. If inputs are without voltage, connect the contacts common to the black C socket. If contacts are
more than two, connect both C sockets.

The following figure shows the connection to one polarized contact.

After powering-on CBA1000, first of all select the type of input (dry or with voltage); then, check
that the contact status displayed by LED’s on the front matches with the nominal one (light ON =
Closed or With voltage), and correct if something is wrong. The selection is performed as follows.

Menu > Auxiliary inputs

The following window is opened.

Doc. MIE11166 Rev. 1 Page 22 of 30

Select auxiliary inputs as desired.

5 TWO RECORDING TEST

This is a special test, that solves the problem of testing disconnectors, or any device that takes a
long time to switch, after the command has been issued, or to test the “Pole discrepancy” protection,
for single phase CB. The selection avoids to waste time recording all this delay while the contact is
not yet closed (opened), as follows.

Menu > Recording options > check “two recordings”

The following window is displayed:

The test is split in three parts:

. The first part, when the Open (Close) command is issued: of this part it is possible to select the
duration, so that it is possible to record the coil current and the first reaction;
. The second part, that can be any duration, during which CBA1000 does not record anything;
. The third part, when the second action is occurring, and its duration.

The following diagram shows the case of “Pole discrepancy”. At first, and Open command is
issued; only one pole is opened; we monitor the Open coil current and the pole opening. Next, we
program a pause, that is equal to the minimum Pole discrepancy intervention time, considering the
Doc. MIE11166 Rev. 1 Page 23 of 30

time tolerance. Next, we program the second time, that will be equal to two times the Pole
discrepancy intervention time tolerance, so that we are sure to record the final CB opening.

OPEN 1

CONTACT 1

CONTACTS 2, 3
MONITORED T1 PAUSE MONITORED T2

Example: the nominal Pole discrepancy intervention time is 30 s; tolerance is ± 1 s. We will

program: T1 = 0,5 s; Pause = 30 – 1 = 29 s; T2 = 2 s.
Doc. MIE11166 Rev. 1 Page 24 of 30

6 STATIC RESISTANCE TEST

This test serves to measure the contact resistance of the CB main contact, and also the resistance of
any connection, joint or so.

The test is performed applying an high current to the test object (if it is a CB contact it must be
Closed), and measuring the voltage drop across it.

The high current cables are connected to the high current sockets (19): they should have a cross
section of 25 sq. mm, in order to minimize the voltage drop; besides, they should be twisted for
the maximum possible length, in order to minimize the inductance.

The measurement cable is connected to connector (16): if the optional cable set was not purchased,
the cable should be two-wires, shielded: the shield is connected to the male connector provided. The
measurement cable will be connected as close as possible to the joint or CB contact, after the
current connections, so that the contact voltage drop is not affecting the measurement. Don’t
connect to CBA1000 sockets, else we would measure the conductors resistance, that is much
bigger than the contact or joint resistance. Also, don’t connect to the high current clips, as
otherwise we would measure the clips contact resistance, that is also much bigger than the contact
resistance.
Doc. MIE11166 Rev. 1 Page 25 of 30

The figure above shows the connection, with one pole grounded. However, during this test both
ends can be grounded: the paralleling resistance of ground connections is in the range of 10 mOhm
up, and it does not affect very much the measurement, that is in the range of 100 uOhm or less: if it
is more than this, the CB contact is damaged and needs an intervention. In fact, with a nominal
current is 1000 A, the contact resistance power dissipation is 1 W per uOhm: 1 mOhm means an 1
kW power dissipation.

To execute the test, select:

Menu > Static contact resistance

The following window is opened:

. First of all, select the test current: for CB contact, it is 200 A.

. Next, select the test mode. If the test is for CB contacts, select “Test on breaker phase” then
specify the CB phase and contact under test.
. Press START: the current is injected, the voltage drop measured, the corresponding resistance
measured. Test current, voltage drop and resistance are displayed to the right. If the measurement is
good, pressing on SAVE, the resistance is added to the summary table.
. If the measurement is doubtful and the measurement is to be repeated, you should wait for about 1
minute, so that the capacitor is charged, and then press START again and repeat the test.
. If the measurement is OK, select another phase or contact, move connections and continue until all
contacts have been tested.

Note that if you operate with the battery, as this test is power consuming, the maximum battery
duration drops to one hour, with respect to the four hours when timing tests are performed.
Doc. MIE11166 Rev. 1 Page 26 of 30

7 DYNAMIC RESISTANCE TEST

This test serves to verify CB main contact resistance change during actual operation: it is possible
that contact resistance is good as the contact closes, but during the closing stroke some mechanical
damage causes sudden openings or resistance changes that are detrimental to the CB contact.

The test is performed connecting CBA1000 to the contact while it is open, then issuing a Close
command: as soon as the contact closes, an high current flows through it, and the resistance profile
change is displayed. Test result is the resistance profile during close: the contact resistance value is
less accurate than the static measurement, but the additional information is the actual behaviour of
the contact as it closes.

The high current cables are connected to the high current sockets (19): they should have a cross
section of 25 sq. mm, in order to minimize the voltage drop; besides, they should be twisted for
the maximum possible length, in order to minimize the inductance, and should be as short as
possible. This is very important, because cables inductance alters the first part of the recording.

The measurement cable is connected to connector (16): if the optional cable set was not purchased,
the cable should be two-wires, shielded; the shield is connected to the male connector provided. The
measurement cable will be connected as close as possible to the joint or CB contact, after the
current connections, so that the contact voltage drop is not affecting the measurement. Don’t
connect to CBA1000 sockets, else we would measure the conductors resistance, that is much
bigger than the contact or joint resistance. Also, don’t connect to the high current clips, as
otherwise we would measure the clips contact resistance, that is also much bigger than the contact
resistance.
Doc. MIE11166 Rev. 1 Page 27 of 30

The figure above shows the connection, with one pole grounded. However, during this test both
ends can be grounded: the paralleling resistance of ground connections is in the range of 10 mOhm
up, and it does not affect very much the measurement, that is in the range of 100 uOhm or less: if it
is more than this, the CB contact is damaged and needs an intervention. In fact, with a nominal
current is 1000 A, the contact resistance power dissipation is 1 W per uOhm: 1 mOhm means an 1
kW power dissipation.

To execute the test, select:

Menu > Dynamic contact resistance

The following window is opened:

Doc. MIE11166 Rev. 1 Page 28 of 30

. First of all, select the test current: for CB contact, it is 200 A.

. Next, select the test mode. If you want to test all CB contacts, select “Test on breaker phase” then
specify the CB phase and contact under test.
. Press START: the contact is closed, and this causes the current to be injected; current and voltage
variations are recorded, and the corresponding resistance is measured point per point. The steady-
state test current, voltage drop and resistance are displayed to the right; selecting “SHOW
DIAGRAM”, the following window is displayed.

. If the measurement is good, pressing on SAVE, the resistance is added to the summary table.
. If the measurement is doubtful and the measurement is to be repeated, you should wait for about 1
minute, so that the capacitor is charged, and then press START again and repeat the test.
. If the measurement is OK, select another phase or contact, move connections and continue until all
contacts have been tested.

Note that if you operate with the battery, as this test is power consuming, the maximum battery
duration drops to one hour, with respect to the four hours when timing tests are performed.
Doc. MIE11166 Rev. 1 Page 29 of 30

8 TWO GROUNDS TEST WITH DET1000

As explained in the previous chapters, during the CBA1000 connection to main CB poles, CB must
be closed, and grounded on both sides. Once the connection is preformed, one of the two ground
connections must be removed, because otherwise the ground connection would shunt the CB
contact test current, and the CB would appear always closed.

There is a drawback about removing a grounding: it is that the operator IS NO MORE

PROTECTED AGAINST AN HV BEING APPLIED TO THE OPEN SIDE: when the CB
contact is open, that side is not grounded at all.

DET1000 has been developed to allow to perform the test EVEN IF BOTH GROUNDS ARE
CLOSED. The operating principle takes advantage of the fact that the ground connection has a
resistance in the range of 10 – 20 mOhm, that is at minimum 50 times the CB contact resistance.
DET1000 generates an higher current (10 A) than CBA1000 (50 mA or less) to detect the closed
contact: the higher current allows to generate a voltage drop that is 100 mV up for the ground
connection, and 50 times less for the closed CB contact.

VOLTAGE MEASUREMENT
V IN 10 A

DET1000

GROUND
CONNECTION
RESISTANCES

To perform the test, you have to:

. Connect CBA1000 to DET1000;
. Connect DET1000 current outputs to CB main contacts, using the 10 m three-way cables;
. Connect DET1000 measurement inputs to CB main contacts, using the 10 m 2-way shielded
cables. Take care to connect these cables closer to the CB contact than the current ones;
. Connect CBA 1000 to coils, auxiliary contacts, transducer;
. Instruct CBA1000 that the option is present;
. Issue an Open CB command: LED’s on the CBA front panel should show it OPEN. If not (LED’s
show CB Closed), go to the threshold selection, and increase the threshold until contacts are sensed
Open;
. Now, issue a Close CB command: LED’s on the CBA front panel should show it CLOSED. If not
(LED’s show CB Open), go to the threshold selection, and increase it until contacts are sensed
Open.
The possible cases for the threshold settings are summarized in the following table.
Doc. MIE11166 Rev. 1 Page 30 of 30

THRESHOLD LED CORRECTION

HIGHER THAN ALWAYS CLOSED REDUCE
OPEN LEVEL THRESHOLD
BETWEEN OPEN FOLLOW CB NONE
AND CLOSED POSITION
LEVELS
LOWER THAN ALWAYS OPEN INCREASE
CLOSED LEVEL THRESHOLD

Now it is possible to perform tests as usual, operating on CBA1000.