Circuit breaker testing – New Approach

Thomas Renaudin

SEEEI conference
*
Circuit Breaker Testing

> Circuit Breakers – Design and standards

Tests on Circuit Breakers
CIBANO 500

© OMICRON 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=0Ω R = ∞Ω

© OMICRON Page 3
Purpose of Circuit Breakers in Power Systems
Network
> Minimize losses in closed position
x Circuit Breaker
> Open and close on command
Busbar
>Open or close a circuit to connect
the power to/from the transmission
Disconnector
line
(O - break, C - make)
>Open a circuit for planned x Circuit Breaker
maintenance (O - break)
>Open a circuit at system fault to Power
protect the system behind the Transformer

circuit breaker (O break, O-C

reclose, O-CO, auto-reclose)
>Isolate between poles, open
contacts and earth
© OMICRON Page 4
Circuit Breaker Components

Source: ABB, [RUS07]

© OMICRON Page 5
Circuit Breaker Components

A: interrupter chamber
B: insulated support column
C: support structure
D: central cubical
E: wiring
F: operating mechanism

Source: Siemens

© OMICRON 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

© OMICRON 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

© OMICRON Page 8
IEC - timing definition

© OMICRON Page 9
Circuit Breaker Testing

Circuit Breakers – Design and standards

> Tests on Circuit Breakers
CIBANO 500

© OMICRON Page 10
What is usually needed to test breakers

Timing µΩ - Meter CB Supply

Analyzer

> Rewiring for each test

> Individual µΩ-Measurement for each interrupter
> Collect data for test report

© OMICRON Page 11
Typical tests on circuit breakers

1. Minimum pick-up test

2. Static resistance or contact resistance test (µOhm)
3. Timing of main and auxiliary contacts
a. different operations (O, C, OC, CO, OCO, COCO, OCOCO,...)
b. undervoltage test
c. coil currents
4. Motor current
5. Contact travel (motion) of main contacts
6. Dynamic contact resistance (DRM)

© OMICRON Page 12
1. Minimum Pick-up Test

© OMICRON 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

© OMICRON Page 14
2. Contact Resistance Test

Conventional Setup

© OMICRON Page 15
2. Contact Resistance Test

> Test is performed with a µOhm-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

© OMICRON 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

© OMICRON Page 17
3a. Timing Test - Measured Values

Open Time, Close Time, Contact Spread, Phase Spread, Trip-Free Time, Reclose Time
© OMICRON 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

© OMICRON 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

© OMICRON Page 20
4. Motor Current

> Connect source

to charging motor
or use current
clamp
> Check charging
times and
charging currents
> Compare with
previous
measurements

© OMICRON 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)

© OMICRON 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

© OMICRON Page 24
6. Dynamic Resistance Measurement (DRM)
Use DRM to find out
> Problems with contact fingers
> Lubrication problems
> The arcing contact length

© OMICRON Page 25
6. DRM Diagnosis: arcing contact length
main contact

motion

arcing contact length

dynamic resistance

coil current

ms

© OMICRON Page 26
Circuit Breaker Testing

Circuit Breakers – Design and standards

Tests on Circuit Breakers
> CIBANO 500

© OMICRON Page 27
Conventional Setup for Circuit Breaker Testing

> Rewiring between micro-

ohm 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

© OMICRON 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

© OMICRON 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)

© OMICRON Page 30
Unique connection concept

CB MC2

CIBANO 500 CB TN3

© OMICRON 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

© OMICRON Page 32
Unique connection concept

© OMICRON Page 33
Unique connection concept

© OMICRON 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

© OMICRON Page 35
Powerful software support

> Primary Test Manager software supports all tests

> One combined test report for all tests

© OMICRON 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)

© OMICRON Page 37
© OMICRON Page 38