Circuit Breaker Testing Complexities Removed

Joint Authors: Aditya Taneja,Ulrich Klapper (OMICRON Electronics)

Introduction
A circuit breaker is an electrical switch designed to
protect an electrical circuit from damage caused by
overload or short circuit. It is also used to isolate
part of a healthy circuit for regular maintenance. Its
operation can therefore be both automatic and
manual. Its basic function is to immediately
discontinue electrical flow. The circuit breaker
plays a significant role within the power system
where it;
> Minimizes losses in closed position
> Opens and closes on command Figure 1: Conventional wiring set-up for micro-ohm
> Opens or closes a circuit to connect the power measurement
to/from the transmission line
(O - break, C - make)
> Opens a circuit for planned maintenance (O -
break)
> Opens a circuit at system fault to protect the
system behind the circuit breaker (O break, O-
C reclose, O-CO, auto-reclose)
> Isolates between poles (TRV), open contacts
and earth
To ensure appropriate operation of the circuit
breaker it is important to test the performance of
key components including;
> kinematic chain
> timing of main and auxiliary contacts
> contact travel (motion) of main contacts Figure 2: Conventional wiring set-up for timing tests
> control circuits
> coil current analysis The wiring for the micro ohm certainly is not done
> minimum pick-up test all in parallel in the conventional set-up, however
> charging motor all the wires shown in the picture are needed.
> motor current analysis
> main contacts' wear and tear Classic Circuit Breaker Testing
> contact resistance of main contacts (static
and dynamic) Traditionally, reference to "circuit breaker testing"
excluded the static resistance measurement,
Conventional testing of circuit breakers does despite the fact that this is an absolutely necessary
test.
generally mean the disconnection of the circuit
breaker from the system. This involves an OMICRON defines "circuit breaker testing" as:
inevitable outage and brings about much the distribution of open and close commands of
paperwork and cost in order that safety the circuit breaker with nominal and under
requirements are met, often involving a number of voltage
staff to complete the work. It is imperative, analysis of coil currents
therefore, that testing of circuit breakers is done in the measurement on the main and auxiliary
the shortest possible time, utilising equipment contacts
which provides accurate results. static contact resistance test
The conventional set-up for circuit breaker testing and if necessary,
(Figures 1 and 2) involves rewiring between micro- a dynamic resistance measurement of the main
ohm measurement and timing tests. This involves contacts
many cables, is time-consuming and error-prone.
motion analysis or time travel diagram

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Testing System Plan
OMICRON's new CIBANO 500 test system
combines, in a single device, the three devices
which are typically required for circuit breaker
testing, including;
Circuit breaker testing
Micro ohm measurement
Breaker supply
Figure 3: CIBANO 500's 3-in-1 solution
The measurements possible with this combination
of equipment enable the user to draw numerous
conclusions regarding the condition of the circuit
breaker.
Through the analysis of coil circuits from the
different open and closed coils, it can be
determined whether an operating characteristic of
any nature or manner is sluggish, and compare the
chronological sequence with nominal values.
Timing analysis gives information on whether the
different main and auxiliary contacts are switching
within the correct time, according to the
manufacturer's specified nominal behaviors.
Synchronization of individual main contacts within
a phase is therefore particularly important, but also
between the phases of the maximal permissible
deviations indicated by the manufacturer.
The dynamic resistance measurement allows the
recording of resistance during the opening of the
main contacts. The point in time the current line
passed from the main to the arcing contact can be
read from the curve. This time is decreased in
comparison to earlier measurements so that the
arcing contact becomes shorter. In combination
with a travel analysis even the length of the arcing
contact in millimeter can be determined.
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Opening of the
arcing contact
Transfer from main
contact to arcing
contact
Figure 4: Dynamic resistance measurement (time in ms)
The motion analysis gives information on the
mechanical position of components of the circuit
breaker over time. The aim, if possible, is to
determine the position of the main contacts. As
they are not directly accessible, motion sensors
are affixed to the closest possible points of the
main contacts.
Statements that can be made from this
measurement include whether the motion runs
within the specified boundary conditions. Also it
can show whether, for example, the damping of the
motion towards the end of the switching process
occurs in the desired nature and manner.
The combination of dynamic resistance
measurement and time travel analysis also allows
the lengths of the arcing contacts to be added in
millimeters.
Static Resistance Measurement
The micro ohm measurement or static contact
resistance measurement on the closed main
contacts is a further measurement that should
typically be undertaken.
It leads to a larger direct current via the main
contact and the voltage can be picked up with
separate cables as close as possible to the main
contact.
This measurement is particularly easy if it is
undertaken with Kelvin clamps. A Kelvin clamp has
two separately isolated terminal jaws. The current
feeds to one side of the clamps and the voltage is
measured on the other side. The clamps are
perfectly suitable for massive lines like busbars or
conductor cables with large diameters.
Measuring on contact fingers, for example on Static contact resistance test (micro ohm
medium voltage circuit breakers, is more functional measurement)
when working with two separate clamps, whereby Test of the response threshold of trip and close
the voltage clamps must then be nearer the main coils
contact. Classic switching time tests
Recording of coil and motor current analyses
Breaker Supply Under-voltage tests
To test the circuit breaker the voltage must be lead Thus, the device offers all of the functions of a
to the trip and closing coils, but also the motor simple circuit breaker testing device, a source and
tightening of the springs or the compression of a micro-ohmmeter combined in one device.
gases with which the circuit breaker operates, must For high-voltage circuit breakers in particular, a
be supplied. simple circuit breaker testing device is not
To supply the circuit breaker during the test either sufficient. Several interrupting units should be
the previously used station battery or an external measured per phase simultaneously. In addition to
supply can be used. Using the station battery has pure time analysis, a dynamic resistance
many disadvantages: measurement must also be performed. It is also
the connection to the station battery can be necessary in high-voltage applications to leave the
very dangerous depending on the system circuit breaker grounded on both sides during the
the voltage of the station battery cannot be entire test.
controlled. It can fluctuate within a certain range The main contact modules CB MC2 (seen in small
and thus the test undertaken is only picture 4 between the interruption units) fulfill these
conditionally reproducible. requirements and offer additional advantages.
An external supply does not have these
disadvantages if it is electronically stabilized,
although unfortunately this is often not the case. It
also creates the need for an additional device.
With the CIBANO 500 the supply from coils and
motors is "on board". Thus you have more safety
from the independence of the station battery and
perfect reproducibility due to the stable voltage.
Additionally the setting of sources is automatically
realized in the protocol of the test.
Under-voltage tests through which the trip coils are
triggered with a voltage of 20% within the nominal
voltage for example, were previously very
complicated. With the CIBANO 500 they only
require a few mouse clicks.
Separate tests on the motor and recording of the
motor current over time are also easy with the built
in supply.
Figure 6: CIBANO 500 with main contact modules CB
MC2

CIBANO 500
The CIBANO 500 main device offers all essential
functions that are required for testing all types of
circuit breakers without the need for any peripheral
devices.

Figure 5:Medium-voltage, high-voltage and dead tank

breakers can be tested with CIBANO 500

It is therefore possible to undertake the following

five standard tests on the circuit breaker:

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The use of the main contact module offers the About the Authors
following advantages:
Measurement of dynamic contact resistance Aditya Taneja holds a
during the opening and closing of the circuit Bachelors degree in Power
breaker Engineering (Electrical) from
Measurement of several interrupting units at the National Power Training
same time Institute (India). He has
Both sides grounding of circuit breaker for
been working as Application
safety reasons during the entire measurement
Really simple cabling: The entire wiring is done Engineer for Primary and
directly on top of the circuit breaker and the Secondary assets since
cable only leads to the main device 2009. He is currently
Short cables: The digitalization is done directly working as Regional
on top of the circuit breaker. Thus the Application Specialist for Circuit Breakers and
measurement errors through interference are Switchgears in Middle East & South Asia Region.
minimized and the high-current cables are only
short and light
Ulrich Klapper studied electrical engineering at
The external modules are connected via an the FernUniversitt (Distance University) Hagen

EtherCAT Bus with the main device. Data is sent and worked in different companies as a hardware
from and to the modules via the same cable that and software developer.
also supplies power to the module. The CB MC2
modules temporarily require particular high power He has been working for OMICRON since 1998.
in order to deliver up to 2 times 100 A for micro Initially as a HardwareDeveloper and then later as
ohm measurements. They therefore have a built-in Product Manager. Today he is Innovation Manager
temporary power storage, however the current is (Development Manager) in the Business Unit for
electronically stabilized. Testing and Diagnostic Solutions for Primary
Assets.
The CB TN3 module can likewise be connected via

the EtherCAT Bus. Up to three analog or three
digital transducers can be optionally connected to
the module.

Figure 7:Module CB TN3 for recording of path/time

diagrams

The travel or motion analysis provides further

insights into the condition of the circuit breaker.

The EtherCAT Bus, which can supply the module
and synchronously deliver and collect
measurement data from different positions of the
circuit breaker, offers even more expansion
possibilities of the circuit breaker measurement
system in the future.

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