Circuit Breaker Testing

Circuit breaker testing New Approach
Thomas Renaudin
SEEEI conference
Circuit Breaker Testing

>
Circuit Breakers Design and standards

Tests on Circuit Breakers
CIBANO 500
OMICRO
Page 2
Definition of Circuit Breaker

Basically a circuit breaker is an automatically
operated electrical switch designed to protect an
electrical circuit from damage caused by overload or
short circuit. Its basic function is to immediately
discontinue electrical flow.
Ideal switch:
closed
open
R=0
R =
OMICRO
Page 3
Purpose of Circuit Breakers in Power Systems

Network
Minimize losses in closed position

x
>
Open and close on command
Circuit Breaker
Busbar
Open or close a circuit to connect

the power to/from the transmission
line
(O - break, C - make)
>
Disconnector
Open a circuit for planned

maintenance (O - break)
>
>
Open a circuit at system fault to

protect the system behind the
circuit breaker (O break, O-C
reclose, O-CO, auto-reclose)
>
Isolate between poles, open

contacts and earth
>
OMICRO
Page 4
Power
Transformer
Circuit Breaker
Circuit Breaker Components
Source: ABB, [RUS07]
OMICRO
Page 5
Circuit Breaker Components
A:
B:
C:
D:
E:
F:
interrupter chamber
insulated support column
support structure
central cubical
wiring
operating mechanism
Source: Siemens
OMICRO
Page 6
Standards ANSI
> C37.04-1999
> Standard ratings defined
> C37.06-2000
> Schedule of preferred ratings
> C37.09-1999
> Type tests
> Routine tests
> C37.081, C37.082,
IEEE 693
OMICRO
Page 7
Standards IEC
> IEC 62271-100, 2001
> Type, routine & field tests
> Timing definitions
> Guide for selection and
specification
> IEC 60694, 2001
> Normal service
conditions
> Schedule of preferred
ratings
> Altitude correction
> IEC 60427, IEC 60815,
IEC 60529, IEC 61166,
IEC 61233
OMICRO
Page 8
IEC - timing definition
OMICRO
Page 9

>

CIBANO 500
OMICRO
Page 10
What is usually needed to test breakers
Timing
Analyzer
- Meter
> Rewiring for each test

> Individual -Measurement for each interrupter
> Collect data for test report
OMICRO
Page 11
CB Supply
Typical tests on circuit breakers
1.
2.
3.
Minimum pick-up test

Static resistance or contact resistance test (Ohm)
Timing of main and auxiliary contacts
a.
b.
c.
4.
5.
6.
different operations (O, C, OC, CO, OCO, COCO, OCOCO,...)

undervoltage test
coil currents
Motor current
Contact travel (motion) of main contacts
Dynamic contact resistance (DRM)
OMICRO
Page 12
1. Minimum Pick-up Test
OMICRO
Page 13
1. Minimum Pick-up Test

>
>
>
>
>
>
Indicates the lowest voltage to operate the trip or

close coil
Start at a certain voltage level
Try to operate
If not working increase voltage and try again
Ramp the voltage pulse until minimum voltage is
reached with which the circuit breaker switches
Everybody has a selfmade solution for this test
OMICRO
Page 14
2. Contact Resistance Test

Conventional Setup
OMICRO
Page 15
2. Contact Resistance Test

>
>
>
>
>
Test is performed with a Ohm-Meter

A lot of different test devices on the market (weight,
handling, output current and accuracy)
Inject a high current
Measurement of a small voltage in a noisy
environment
Use 4-wire technique to connect
OMICRO
Page 16
3a. Timing Test

>
>
>
Connect to all main contacts

Connect to trip & close coil
Voltage supply required
Conventional Setup
Time-consuming and
error-prone
OMICRO
Page 17
3a. Timing Test - Measured Values
Open Time, Close Time, Contact Spread, Phase Spread, Trip-Free Time, Reclose Time
OMICRO
Page 18
3b. Timing undervoltage condition

>
>
>
>
>
>
>
Coils are normally driven by station battery

What happens if battery condition is not the best
Perform a test with reduced supply voltage (e.g. 80
%)
Check times for under voltage
does it work anyhow
are there any delays compared to nominal voltage?
Measure the overall times and compare to

manufacturer values
OMICRO
Page 19
>
>
>
>
3c. Coil Current

Important tool in circuit breaker analysis
Detect potential problems in actuating coils
Reveal information on power supply
Comparison is best method of analysis
OMICRO
Page 20
4. Motor Current
>
>
>
Connect source
to charging motor
or use current
clamp
Check charging
times and
charging currents
Compare with
previous
measurements
OMICRO
Page 21
5. Contact Travel
Functional Breaker Model

OMICRON
Page 22 Page 22
5. Contact Travel - Travel Measurement to find out:
> Mechanical defects of the cinematic chain

> Overall mechanical performance
> Slow operation due to jammed mechanism
> Deterioration of mechanical damping
> Contact wear
> Arcing contact length (in combination with DRM)
OMICRO
Page 23
6. Dynamic Resistance Measurement (DRM)
> Recording the contact resistance during breaker

operation (resistance over time)
> Combination of contact resistance, timing and

travel measurements
1.Inject high current
2.Start recording A & V
3.Operate Circuit Breaker
4.Calculate Resistance
OMICRO
Page 24
6. Dynamic Resistance Measurement (DRM)

Use DRM to find out
Problems with contact fingers
Lubrication problems
The arcing contact length
>
>
>
OMICRON
Page
Page 25
6. DRM Diagnosis: arcing contact length

main contact
motion
arcing contact length
dynamic resistance
coil current
ms
OMICRON
Page
Page 26

>
OMICRO
CIBANO 500
Page 27
Conventional Setup for Circuit Breaker Testing

>
>
>
>
>
Rewiring between microohm measurement and

timing tests
Lots of cables
Time-consuming and
error-prone
Mirco-ohm measurement
Long test cables create

inductive loops which
catch interferences
External supply or
station battery required
Timing Tests
OMICRO
Page 28
CIBANO 500 3-in-1 Test System

>
>
>
>
>
>
>
>
>
>
Timing analyzer
Possible operations: O, C, CO, OC, O-CO, CO-CO, O-CO-CO
Motion measurement is possible in parrallel
Micro-ohm meter
Static AND dynamic contact resistance test
Powerful coil and motor stabilized supply

Coil/motor current analysis
Undervoltage condition test
Minimum pick-up test
Tests are possible without station battery
OMICRO
Page 29
CIBANO 500 one system for all types of breakers

>
>
>
Medium-voltage circuit breakers

High-voltage circuit breakers (Live Tank)
High-voltage circuit breakers (Dead Tank)
OMICRO
Page 30
Unique connection concept

CB MC2
CIBANO 500
OMICRO
CB TN3
Page 31
Modular concept for simplified testing

Main Contact Module CB MC2
>
>
>
>
>
>
>
>
2 high-current outputs and 2 sensitive voltage

measurement channels
Keeps high-current cables as short as possible
minimizing the weight of the necessary cables
A digitized measuring signal is produced directly

at the interrupter keeping analog cables as short
as possible
very low noise interference
Only one connection cable to the main unit

fast set-up and reduced risk of wiring errors
Both sides grounded test possible
OMICRO
Page 32
OMICRO
Page 33
OMICRO
Page 34
Modular concept for simplified testing

Transducer Node CB TN3
>
>
>
Accessory for motion/contact travel test

3 analog and digital channels for data
acquisition of linear or rotational motion
sensors
Interference-free digital transmission of
results via one cable
OMICRO
Page 35
Powerful software support

>
>
Primary Test Manager software supports all tests

One combined test report for all tests
OMICRO
Page 36
Benefits of all-in-one OMICRON approach

>
>
>
>
>
>
>
>
>
3-in-1 system combines:

timing analyzer
micro-ohmmeter
powerful AC/DC supply
One wiring for all test: all-in-one / all-in-once
One system for medium- and high-voltage circuit
breakers
Immunity to interference due to short test cables
One combined report for all tests
Light-weight test system for on-site testing (20 kg / 44.1
lbs)
OMICRO
Page 37

OMICRO
Page 38

Circuit Breaker Testing - New Approach: Thomas Renaudin

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Circuit breaker testing New Approach

Circuit Breakers Design and standards

Definition of Circuit Breaker

Purpose of Circuit Breakers in Power Systems

Minimize losses in closed position

Open and close on command

Open or close a circuit to connect

Open a circuit for planned

Open a circuit at system fault to

Isolate between poles, open

Circuit Breaker Components

Source: ABB, [RUS07]

Circuit Breaker Components

IEC - timing definition

Circuit Breaker Testing

Tests on Circuit Breakers

What is usually needed to test breakers

> Rewiring for each test

Typical tests on circuit breakers

Minimum pick-up test

different operations (O, C, OC, CO, OCO, COCO, OCOCO,...)

1. Minimum Pick-up Test

1. Minimum Pick-up Test

Indicates the lowest voltage to operate the trip or

2. Contact Resistance Test

2. Contact Resistance Test

Test is performed with a Ohm-Meter

3a. Timing Test

Connect to all main contacts

3a. Timing Test - Measured Values

3b. Timing undervoltage condition

Coils are normally driven by station battery

Measure the overall times and compare to

3c. Coil Current

Functional Breaker Model

5. Contact Travel - Travel Measurement to find out:

> Mechanical defects of the cinematic chain

> Contact wear

> Arcing contact length (in combination with DRM)

6. Dynamic Resistance Measurement (DRM)

> Recording the contact resistance during breaker

> Combination of contact resistance, timing and

6. Dynamic Resistance Measurement (DRM)

6. DRM Diagnosis: arcing contact length

arcing contact length

Circuit Breaker Testing

Conventional Setup for Circuit Breaker Testing

Rewiring between microohm measurement and

Long test cables create

CIBANO 500 3-in-1 Test System

Powerful coil and motor stabilized supply

CIBANO 500 one system for all types of breakers

Medium-voltage circuit breakers

Unique connection concept

Modular concept for simplified testing

2 high-current outputs and 2 sensitive voltage

A digitized measuring signal is produced directly

Only one connection cable to the main unit

Both sides grounded test possible

Unique connection concept

Unique connection concept

Modular concept for simplified testing