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CONTENTS

1. PURPOSE

2. SCOPE

3. REALTED DOCUMENTS

4. GENERAL INFORMATION

5. TEST PROCEDURE
5.1 Visual Inspection
5.2 Mechanical Cheks of Withdrawable units
5.3 Operational Checks

6. TESTING METHOD
6.1Secondary Injection test
6.2 Primary Injection test
6.3 High Volatge AC tests on Main Circuits
6.4 Dilelctric test on Auxiliry and Control Circuit
6.5 Ammeter/ Current Transducer test
6.6 Voltage/ Voltage Tansducer test
6.7 Verification of Corrrect Wiring
6.8 Measurement of the Resistance of the Main Circuit

7. INSPECTION & TESTING FROMS

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1. PURPOSE
Purpose of this procedure is to show routine tests on low-voltage switchgear and control gear
assemblies up to 1000 V AC or 1500 V DC and perform the way of inspection during assembly
process of switchgear and control gear.

2. SCOPE
Test procedure has application in routine tests low-voltage switchgear and control gear assemblies
carried out by Quality Inspectors.

3. REALTED DOCUMENTS
 Standards: PN-IEC 439-1:1994, CEI / IEC 60439-1:1999
 Customer order and documentation
 Assembly documentation, elementary and assembly drawings
 Routine Test Card for LV
 Form test, "Report of carried out testing"

4. GENERAL INFORMATION.
This procedure presents general rules of routine test on low-voltage switchgear and control gear
assemblies. Requirements given below are minimized and can be tighten or developed if particular
technical documentation or customer order provides additional test or other value of parameters
(for example higher test voltage)

5. TEST PROCEDURE.
Routine tests are carried out by a Quality Inspector on each assembled set

5.1. VISUAL INSPECTION

5.1.1. Overall visual inspection

- Check switchgear layout according to the technical documentation
- Check that all mounted devices have previous test stamps or other acceptance
references (for example producer attestation)
- Check doors clearance: doors must freely open and close; when closed, all sides of the
doors shall mate completely with panel frame. The door gaskets shall appear
compressed
- Check that every lock on the panels is properly working and is equipped with its own key.
- Check that the color of the panel surfaces is according to the technical documentation
- Check that the surfaces (painting and plaiting) are free of spots, scratches, marks and
other damages
- Check that the prescribed degree of protection is ensured according to the technical
documentation
- Check that clearances and creep age distances is ensured according to the technical
documentation - if it is not defined it should be used
- Clearances not less than 10 mm
- Creep age distances not less than 14 mm
- Check cleanness inside the panels (chips, pieces of insulation, etc.)

5.1.2. Electrical data labels and nameplates check

 Check data labels and nameplates according to the technical documentation
 Check that the nameplates are legible and well stuck near respective item, check meters
for full-scale value, class and zero mechanical position.

5.1.3. Devices wiring and terminal boards check

 Check the layout of devices and terminal boards according to the technical
documentation
 Check that wiring of devices are installed in order that no mechanical damage can occur
to wire as a result of movement of the covers or of the doors

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 Check that bus-bars supports distances are correct according to the technical
documentation
 Check that secondary winding of transformers (CT & VT) are connected to the ground
(if required according to the technical documentation)
5.1.4.Bus bars and wiring check
 Check that the bus-bars, power and auxiliary cables are according to the technical
documentation (size, color, insulating degree, sheath, galvanic protection)
 Check that insulation has not to be crimped inside lug body

5.1.5. Screw connections check

 Check visually that screws and nuts are according to the technical documentation
 Check that, when required by relevant drawings, screws have correct torque force and
are in place proper devices in order to assure reliability of connections (e.g.: washer,
spring washer, etc.)

5.2 MECHANICAL CHECKS OF WITHDRAWABLE UNITS

5.2.1. Power clamps and auxiliary terminal boards check

 Insert drawer units and check that these can be inserted and removed from their cells
 Check that power plugs and aux. terminal boards plugs have no damage after the
operation

5.2.2. Position DISCONNECTED, TEST, CONNECTED check

 Check the correct insertion and stops in DISCONNECTED, TEST, CONNECTED position
 Check that the cell door can be closed in the DISCONNECTED position.
 Check that the clearance is ensured in position DISCONNECTED and TEST
 Check connection of auxiliary circuits of withdraw able unit in position TEST

5.2.3 Interchangeability of withdraw able units check

 Interchange at least 3 units and check you do not need any adjustment

5.3. OPERATING CHECKS

5.3.1 Mechanical interlocks check

a) Check the following operations are prevented by mechanical interlocks
 door can’t be opened with circuit breaker closed
 unit can’t be moved from “connected” to “test” position and vice versa with circuit breaker
closed
 with unit in a middle position between "connected" and "test" circuit breaker cannot be
closed
b) Check the correct operation of the back shutter that protects bus bars with unit withdrawn.
c) Check that circuit breakers handles work correctly with door closed
d) Check that circuit breakers electrical interlocks work correctly with door closed

5.3.2 Power and auxiliary circuits

 Check power and auxiliary connections according to the wiring diagrams

5.3.3 Operation test

 Check proper operation under nominal voltage:

5.3.3.1 Withdraw able units test

a) "Test" units position:
 Open the circuit breakers of all units
 Move all units in TEST position.
 Power on auxiliary circuit
 Operate pushbuttons on unit panels, check correct operation of main contactors

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b) "Connected" units position:

 Insert all units to CONNECTED position
 Power on main circuits
 Close main circuit breaker
 Close all cell circuit breakers
Check all units are operating according to the technical documentation

5.3.3.2 Checking equipments without drawer units

 Power on main circuits
 Close main circuit breaker
 Close all units circuit breakers
Check all operations according to the technical documentation

5.3.4 Insulating resistance check

Check insulating resistance is >1000 Ω / 1 Volt using a insulation meter min. 500 V DC
Apply test voltage between:
 Main circuits and grounded equipment structure (enclosure)
 Circuits at different voltage

5.3.5 Dielectric test

Test conditions: test voltage sinusoidal; frequency 45-62 Hz; test time min. 1 sec.

Value of test voltage apply according to the following table:

Insulating nominal voltage Ui [V] Test voltage (RMS ) [V]

Ui ≤ 60 1000
60 < Ui ≤ 300 2000
300 < Ui ≤ 690 2500
690 < Ui ≤ 800 3000
800 < Ui ≤ 1000 3500
1000 < Ui ≤ 1500 *) 3500
*) only for AC

If devices passed dielectric test before the test voltage should be reduced to 85% of value given in the
above table.

Dielectric test procedure is the following:

a) Main circuits dielectric test
 connect auxiliary circuits to equipment structure
 apply test voltage between:
 connected (shorted) main circuits of all phases and equipment structure
 each phase and the other ones connected (shorted) to equipment structure
 connected (shorted) main phases of fixed portion and connected (shorted) main phases of
withdraw able unit in Test position to equipment structure
b) Auxiliary circuits dielectric test:
 Connect main circuits to equipment structure
 Apply test voltage between:
 Connected (shorted) all auxiliary circuits and equipment structure
 Parts of auxiliary circuit which should be insulated in specified work condition

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6. Testing Method

6.1 SECONDARY INJECTION TEST

Description of test

1. Connect as shown in the diagram.

2. Turn on the secondary injection set and increase current source unit protective relay operates.
3. Record the relay pick-up current.
4. Increase the current Up to the relay setting.
5. Check and record the tripping timing.
6. Perform similar test and measurement for the other remaining phase.

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6.2 PRIMARY INJECTION TEST

Description of test

1. Connect as shown in the diagram.

2. Inject full rated current between the red and neutral bus bar by using primary injection test
equipment.
3. Measure the spill current at ammeter.
4. perform similar test and measurement for the other remaining phase.
5. Record all test results on test as described.

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6.3 HIGH VOLTAGE AC TESTS ON THE MAIN CIRCUITS

Description of test

1. Check insulation before testing.

2. Connect as shown in the diagram.
3. Test at red phase, shorted yellow, blue and neutral phase to earth.
4. Apply 2KV to red phase and earth for 1 minute.
5. Test at yellow phase, shorted red, blue and neutral phase to earth.
6. Apply 2KV to yellow phase and earth for 1 minute.
7. Test at blue phase, shorted red, yellow and neutral phase to earth.
8. Apply 2KV to red phase and earth for 1 minute.
9. Test at neutral phase, shorted red, yellow and blue phase to earth.
10. Apply 2KV to red phase and earth for 1 minute.
11. Check insulation after testing.
12. Record all test results on test as described.

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6.4 Dielectric tests on auxiliary and control circuits

Description of test

1. Ensure all fuses and MCBs are switch off.

2. Select Megger tester to 500V.
3. Test on each phase in the accordance to the attached test form.
4. Record the resistance reading.

6.5 Ammeter /Current Transducer Test

Description of test

1. Connect as shown in the diagram.

2. Inject 25% rated current pass through the red phase current transformer (CT) by using
primary injection test equipment.
3. Measure the transducer output and read the ammeter reading.
4. Repeat the above test procedures for 50%, 75% & 100% rated current.
5. Perform similar test and measurement for the other remaining phase.
6. Record all test results on test as described.

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6.6 Voltmeter / Voltage Transducer Test

Description of test

1. Connect as shown in the diagram.

2. Apply 25% rated voltage at terminals by using 3 phase variour transformer..
3. Measure the transducer output and read the voltmeter reading.
4. Repeat the above test procedures for 50%, 75% & 100% rated voltage.
5. Record all test results on test as described.

6.7 Verification of correct wiring

Description of test

The test shall be carried with reference to the schematic diagram to verify the functions.

 Starter Control Test

 Functional check of the normal operation
 Simulated remote operations and status checks

 Protection device test

 Secondary injection or primary injection checks where applicable
 Tripping path to the isolating devices to be checked

 Current Transformer Ratio Test

 Primary injection to be carried out and ratio check
 Associated meter will also be checked.
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6.8 Measurement of the resistance of the main circuit

Description of test

1. Connect as shown in the diagram.

2. Set the current to 100A and pass through the red phase of the circuit under test.
3. Press the resistance pushbutton at micrometer.
4. Read the result.
5. Perform similar test and measurement for the other remaining phase.
6. Record all test results on test as described.

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4.0 QUALITY ASSURANCE PLAN FOR LV SWITCHBOARD

No. Item To Be Inspected Type of Inspection

1. Delivery Inspection For Correct Type of Materials, and damage in Transmit A

2. Check the general appearance of Panel that assembly is satisfactory completed B-A-C
o Correct layout of compartment as per accepted drawings
o Door stay clear away of internal fitting.
o Doors interlock mechanism and door lock.
o Proper enclosure assembly.
o All hook bolts, Bus bar support blocks, lifting brackets, door stay, Standard fixing bracket &
rail are properly tighten.
o Doors open and close satisfactory.
o All starter are properly labeled on the front door with their
o Equipment name and ratings.
o General cleanliness of MCC.

3. Check and ensure the copper bus bar section is satisfactorily B-A-C
o Correct bus bar size & color coded.
o Bus bar are properly secured and supported.
o Sufficient clearance between phase to phase and metal parts.
o Correct insulation cover thickness.
o “Danger” sign sticker.

4. Check and ensure the internal control cables are B-A-C

properly tagged and arranged.

5. Check and ensure the internal power cables are correctly size, B-A-C
tagged and color coded.

6. Current Transformer polarity and position are correctly installed and labeled B-A-C

7. Check and ensure the Current Transformer accuracy class & burden (VA) B-A-C

8. All components are properly installed and labeled. B-A-C

9. All components mounted on doors are properly secured B-A-C

10. Doors are properly earthed. B-A-C

11. All protective devices setting are labeled. B-A-C

12. Check that the installation properly recorded for the AS-BUILT drawing B-A-C

7. INSPECTION & TESTING FORMS

7.1 OVERCURRENT / EARTH FAULT RELAY OPERATION TEST

7.2 PRIMARY CURRENT INJECTION TEST
7.3 AMMETER / CURRENT TRANSDUCER TEST
7.4 VOLTMETER / VOLTAGE TRANSDUCER TEST
7.5 INSULATION TEST REPORT
7.6 DI-ELECTRIC AND INSULATION TEST REPORT

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