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Secondary Injection Kit

Single compact unit equipment for easy operation.
Designed to offer continuously variable & selectable output current
Built in Digital Timer for measuring tripping
Adequate fuse protection from overloads
Customization as per customers

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FEATURES: Single Kit with Three units
Two separate inputs & five outputs
Test outputs available:
Unit I : 0 to 100 A, AC, 0 to 240 volts AC
Unit I : 0 240 V DC separate 2A
Unit II: 0 to 2 A AC, 0 to 240 volts AC and aux.
0 to 240 volts DC.
Panel with clear and easy to follow legend.
Built in Timer for testing relays and circuit breakers.
Overload protection.
Independent Digital readouts of current, voltage and time.
The kit can be used for all types of relays (current and voltage relays / Low current
C.T) except 6 current differential relay & Distance relays
Weight : 25 kegs. Approx

Secondary injection tests are performed to verify the correct operation of the
protection system with regard to everything that is connected to the secondary of
the transformers. The secondary protection system may include protective relays,
auxiliary relays, protection circuits, communications and control systems, metering
devices, low-voltage devices, alarms, etc. Accordingly, the secondary injection test
covers not only the testing of protective relays and their tripping settings, but also
the checking of all associated circuits and devices involved in the proper
performance of the secondary protection system.
The secondary injection test involves disconnection of the device and/or circuits
from its normal CT/VT connection and it might include, among others, the following
Test all kind of relays: the relay testing through secondary injection test may range
from a simple check of some points of the relay characteristic to a complete
verification of the protection scheme logic, even including the response to transient
waveforms, harmonics, etc.
Test switches and connections
Check on-load wiring, trips, alarms and communications circuits, currents and
voltage wiring, phase by phase.
Check phasing and polarity up to the relay terminals.
Test current, voltage and energy meters, transducers, sensors, motor overload
units, etc.
Check low voltage circuit breakers (if solid-state trip units have accessible terminal
blocks for secondary injection test, otherwise the primary current injection is
preferred because verifies all the breaker, and not only the trip unit)

Secondary Injection Testing

What is Secondary Injection Testing?
It is a method of connecting a secondary injection test set to a trip unit (trip device, over current
module, protection device, OCR, ETU etc) on a circuit breaker and injecting a simulated current to
prove it works at different levels.

Why is it important to Secondary Injection Test Trip

Units during a breaker service?
The trip unit on a low voltage breaker (moulded case or air type) is usually an option selected by the
system or panel designer to provide protection to the site in the event of a fault or over current
occurring. The trip unit measures the amount of current and calculates its effect on the site system
against its settings (usually decided by a commissioning Engineer), and will trip or open the breaker as
required. The larger the current measured, the quicker the breaker should trip or open.

It is an important test to carry out on a trip unit during a service. By connecting one of our many
different manufacturers secondary injection test sets we can ensure that the trip unit, its settings or
factory parameters, and associated components are working as they should do. It is also a key test for
a circuit breaker after a mechanical service and inspection, as the breaker is repeatedly charged,
closed and opened. These sequences help ensure key lubrication has worked into the mechanisms
that are often found dry and un-serviced. The test equipment types, and designs, vary greatly but all
are designed to prove the breaker protection from very simple to complex methods. Tests normally
carried out, dependant on the specification of trip unit and tester are:

Long Time
Short Time
Ground Fault
Earth Leakage

Each of these tests are repeated several times, to ensure reliable, repeatable, operation and trip times.
Any inconsistence could imply the trip unit is not working correctly hence not protecting the site
Switchserve are continually assessing customer and site requirements and invest in old and new
secondary injection test equipment every year. We pride ourselves on having a substantial range of
key current, and obsolete, manufacturer test equipment that is maintained and calibrated for our use
on site and in our workshop. On occasion where the breaker is obsolete and equipment is not
available we use, where possible, our Sverker secondary injection tester to test breaker protection.

What is Primary Injection Testing?

Primary Injection Testing is where an actual current is applied to a breaker to check its protection. This
test is usually done, on low voltage switchgear, in the manufacturers facility only. This testing can be
done on site but requires further heavy test equipment to generate the currents required to test
protection; hence the importance and availability of secondary injection testing. If you require primary
injection testing please contact us for further details.
Please contact us for you specific requirements or if you have any questions we can help with.
Switchserve has a vast range of secondary injection test equipment being able to support customers
with Air Circuit Breakers and Moulded Case Circuit Breakers from Manufacturers such as:



Switchserves Mitsubishi SW Demo ACB. Here we are conducting a number of tests: Contact
Resistance, individual component testing and secondary injection testing using the Mitsubishi Y2005
set. All of these tests can be carried out on site, or alternatively in our workshop. These tests are an
integral part of Switchserves Air Circuit Breaker maintenance.

Mitsubishi SW Air Circuit Breaker being Secondary Injection Tested


SACE ABB Classic Emax


For use on certain ABB trip units is the BT030 Bluetooth diagnostic tool. This allows Switchserve to
diagnose accurately any hardware faults and view the entire trip history since commission! The
advantage of this piece of equipment is its ability to be used whilst the breaker is in operation giving
us a live readout directly to our laptop.

Here is an ABB Classic Emax ACB being secondary injection tested using Switchserves ABB PR010/T
Test Kit.


Merlin Gerin / Schneider

Masterpact NW
NT (compact)

Here is a Merlin Gerin Masterpact Air Circuit Breaker with an STR trip unit being secondary injection
tested with the full function test kit, proving all trip curves including ground fault are functioning


AT series
AR series

Terasaki AT series Air Circuit Breakers are secondary injection tested by Switchserve with our Megger
Sverker 650 test set. The Sverker is a versatile piece of equipment with a 0-100 amp injection range
which also enables us to test an array of components of varying voltage and current.


M-Pact Classic

GE M-Pact Air Circuit Breakers with M-Pro trip units are secondary injection tested using the GE test
box. Switchserve can also test the older GE M-Pact Classic ACBs that are fitted with the rarely seen
CTZ trip units, as well as the current range of Entelliguard equipped breakers. Please contact us for
further information.

WL series (awaiting image)


Eaton/Cutler Hammer

Displayed here is the full function secondary injection test kit from Eaton. This is for use on a variety of
breakers and trip units. Predominantly we use it on the digitrip units which are found on Magnum and
NRX Air Circuit Breakers. These are not always labelled as Eaton and are commonly re-badged as
Moeller or Cutler Hammer.