Suggestion on How to Use

Industry Trainers are encouraged to use this material in their sessions Download both the PowerPoint file (.ppt) and script file (.pdf) Print the script file (.pdf) and read the script as you view the PowerPoint presentation in the Slide Show view. In this way you see the slides in large format and have animation (if there is any) Must have PowerPoint and Adobe Reader application software on your system.

2001 Cooper Bussmann, Inc.

Testing & Maintenance

CB Testing & Maintenance General Considerations

Circuit breakers require
Testing and maintenance
Verify proper calibration and operation Testing performed with the circuit breaker removed from the enclosure Required for all circuit breakers and may require special equipment

Operation at least once per year

Testing and maintenance are required to ensure proper protection by circuit breaker systems. Molded case and insulated case circuit breakers cannot be repaired must replace if testing shows CB is out of calibration or inoperative.

2001 Cooper Bussmann, Inc.

CB Replacement Required After High Fault Current Interruption

IEEE Std 1015-1997 (Blue Book) - Recommended Practice for Applying Low-Voltage Circuit Breakers Used in Industrial and Commercial Power Systems
3.35 Circuit Breaker Useful Life It is prudent to replace any MCCB that has interrupted, at most, two faults at rated maximum current.

UL 489
MCCBs are tested, per UL 489, to clear a fault at their three phase interrupting rating twice. First with closing the circuit on the circuit breaker (O), then a period of rest of 2-60 min (t), then closing the circuit breaker on the circuit (CO).

2001 Cooper Bussmann, Inc.

CB Maintenance & Testing Frequency

IEEE Std 902-1998 (Yellow Book) - Guide for Maintenance, Operation and Safety of Industrial and Commercial Power Systems Maintenance/Test Frequency
5.5 Inspection and Test Frequency Manufacturers service manuals should be consulted in determining an adequate frequency. A good guide for both maintenance and testing frequency is found in NFPA 70B.

NFPA 70B (1998) - Recommended Practice for Electrical Equipment Maintenance18-4 Frequency of Tests:
The optimum cycle depends on the use to which the equipment is put and the operating and environmental conditions of the equipment. In general, this cycle can range from six months to three years, depending upon the above criteria.

2001 Cooper Bussmann, Inc.

MCCB Power Panel Maintenance and Testing

NFPA 70B: 11-2 Application Considerations
Circuit Breaker nuisance tripping can result from:
High ambient temperature Poor or improper connections

Damaged plug-in connections

Other conditions that transfer heat to the breaker mechanism Continuous current (for three hours or more) in excess of 80% of the breaker continuous current rating.

2001 Cooper Bussmann, Inc.

MCCB Power Panel Maintenance and Testing

NFPA 70B: 11-7 Types of Maintenance
Mechanical
Good Housekeeping Proper mechanical mounting

Proper electrical connections

Manual Operation

Electrical
Field testing conditions as outlined in 18-10.2.4

2001 Cooper Bussmann, Inc.

MCCB Power Panel Maintenance and Testing

NFPA 70B: 11-8 Inspection and Cleaning
Circuit breakers should be kept clean of external contamination to ensure:
Proper heat dissipation

Reduced potential arcing conditions between live conductor and between live conductors and ground.

Circuit breaker case should be inspected for cracks and replaced if necessary.
Cracks could reduce structural strength needed to withstand stresses encountered during fault-current interruptions.

2001 Cooper Bussmann, Inc.

MCCB Power Panel Maintenance and Testing

NFPA 70B: 11-9 Loose Connection
Loose connections represent the most common cause of excessive heat and can cause nuisance tripping of circuit breakers and possibly an eventual failure.
Periodic maintenance checks should involve checking for loose connections or evidence of overheating.
Loose connections should be tightened as required using manufacturers recommended torque values. Circuit breakers with field installed interchangeable trip units could overheat if not properly tightened during installation.

2001 Cooper Bussmann, Inc.

MCCB Power Panel Maintenance and Testing

NFPA 70B: 11-11 Mechanical Mechanism Exercise
Since circuit breakers may be in service for extended periods where overload or short-circuit tripping operation is not required, manual operation is needed.
Manual operation of the circuit breaker will help keep the contacts clean and exercise the breaker mechanism. Manual operation does not exercise the tripping mechanism or mechanical linkages in the tripping mechanism. Push-totrip buttons (if equipped) should be operated in order to exercise the tripping mechanism and linkages.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NFPA 70B: 18-10.2.4 Molded-Case Circuit Breaker Testing
(a) Molded Case Circuit Breakers General
Electrical testing of circuit breakers should be performed in a manner and with the type of equipment required by the type of trip unit employed. Trip unit types can be: Factory sealed, non-interchangeable trip Interchangeable trip Solid state trip

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NFPA 70B: 18-10.2.4 Molded-Case Circuit Breaker Testing
(b) Testing Thermal-Magnetic Circuit Breakers. The electrical testing of thermal-magnetic circuit breakers can be divided into three steps:
1) Overload of individual poles at 300% of trip rating 2) Verification of test procedures 3) Verification of manufacturers published data

Consult NEMA AB2 Procedures for Verifying Field Inspection and Performance Verification of MoldedCase Circuit Breakers as well as manufacturers recommended testing procedures.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NFPA 70B: 18-10.2.4 Molded-Case Circuit Breaker Testing
(c) Overload Testing Considerations Overload tests on individual poles at 300% rated current The reaction of the circuit breaker to this overload is indicative of its reaction throughout its entire overcurrent tripping range. (d) Overcurrent Trip Data (at 300%) Table 18-10.2.4(d) outlines the current and trip-time values as recommended by NEMA. Table values are indicative for most manufacturers, for more specific values, refer to the manufacturers data for the circuit breaker being tested.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NFPA 70B: 18-10.2.4 Molded-Case Circuit Breaker Testing
(e) Evaluation of Results Minimum Trip Times Table values are not considered significant unless nuisance tripping has been experienced. Table values are provided as a guideline only. If minimum tripping times are lower, the breaker should be retested. Maximum Trip Times Under normal test conditions, the breaker will trip in less than the maximum table values. Under improper test conditions, the breaker can exceed the maximum table values.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NFPA 70B: 18-10.2.4 Molded-Case Circuit Breaker Testing
(e) Evaluation of Results Maximum Tripping Times for Cable Protection If the test value exceeds the maximum tripping times from the table, but does not exceed the maximum tripping times for cable protection from the table, the circuit breaker is providing an acceptable level of protection. Coordination with other protective devices should be considered before replacing a circuit breaker that trips beyond the time-current curve.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NFPA 70B: 18-10.2.4 Molded-Case Circuit Breaker Testing
(f) Testing Instantaneous-Only Circuit Breakers. The testing of instantaneous only circuit breakers requires the use of elaborate constant rate-of-rise test equipment coupled with accurate currentmonitoring instrumentation - preferably digital readout - for accurate confirmation of manufacturers test results.

2001 Cooper Bussmann, Inc.

CB Maintenance & Testing

Is the testing and maintenance required per NFPA 70B sufficient? Are other sources available for recommended testing and maintenance of circuit breakers?
NEMA AB4 (1996) - Guidelines for Inspection and Preventive Maintenance of Molded Case Circuit Breakers Used in Commercial and Industrial Applications.

2001 Cooper Bussmann, Inc.

CB Maintenance & Testing

NEMA AB 4 - Recommended Tests
Mechanical Operation Insulation Resistance Test Individual Pole Resistance Test Inverse Time Overcurrent Trip Test Instantaneous Overcurrent Trip Test Rated Hold-In Test

2001 Cooper Bussmann, Inc.

CB Maintenance & Testing

NEMA AB 4 Recommended Tests
Mechanical Operation (Section 5)
Breaker Handle should operate smoothly without binding Verify that all circuit breaker contacts are open when the handle is in the off position and closed when in the on position Verify operation of the mechanical trip provisions (push-to-trip button) if available and verify if contacts are opening and closing. Replace circuit breaker if The contacts are not open in the off or tripped position The push-to-trip button (if provided) does not trip breaker. The contacts are not closed in the on position The breaker does not reset

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NEMA AB 4 Recommended Tests
Insulation Resistance Test (Section 5)
Determines resistance of breaker by applying a direct current voltage of at least 500 volts. Between line & load terminals (breaker off)

Terminals of adjacent poles (breaker on)

Line terminals to metal baseplate (breaker on). Results should be one mega ohm or greater. Any reading less than one mega ohm may indicate contaminated, flawed, or cracked insulating material.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NEMA AB 4 Recommended Tests
Individual Pole Resistance Test (Section 5)
Tests each pole with test current equal to breaker rating and measure voltage drop and consult the manufacturer for acceptable values. If test values exceed manufacturers data, a potential overheating condition may be indicated and additional tests may be required, consult the manufacturer for more guidance.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NEMA AB 4 Recommended Tests
Inverse Time Overcurrent Trip Test (Section 5)
Test each pole separately at 300% of rated current Test with minimum of 4 feet rated copper conductor as listed in Table 5-1 or copper busbar connections for circuit breakers over 1600A, as listed in Table 5-2. Verify results with Table 5-3 which gives maximum trip time based upon breaker rated current (or consult manufacturer). Varies from Table Table 18-10.2.4(d) in NFPA 70B.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NEMA AB 4 - Recommended Tests
Instantaneous Overcurrent Trip Test (Section 5)
Use Run-up or Pulse Method (Pulse Method more accurate) Pulse Method:
Apply pulse of current for 5-10 cycles approximately 10 percent below lower tolerance trip level. Breaker should not trip. Apply pulse of current for 5-10 cycles equivalent to the high tolerance trip level. Breaker should trip. Tolerance trip level 25% for non-adjustable, -30% to +40% for adjustable trip.

2001 Cooper Bussmann, Inc.

Circuit Breaker Testing

NEMA AB 4 Recommended Tests
Rated Hold-In Test (Section 5)
Test all three poles in series with copper conductors not less than 4 feet in length.

Deliver rated current until the circuit breaker temperature stabilizes.

Typical stabilization - 1 hour 100A or less, several hours for breakers larger than 100A

2001 Cooper Bussmann, Inc.

Switchgear Assembly Testing and Maintenance

NFPA 70B: 6-2.2 Frequency of Maintenance
Frequency of maintenance depends upon environmental and operating conditions, no fixed rule can govern all applications. Follow specific manufacturers recommendations regarding inspection and maintenance.

Inspection of switchgear focuses on:

The enclosure integrity and security Moisture, condensation and ventilation Insulation and Insulator integrity

Signs of corona, tracking and thermal damage.

2001 Cooper Bussmann, Inc.

Air Circuit Breaker Testing and Maintenance

NFPA 70B: 6-4 Air Circuit Breakers
6-4.1 General
Consult manufacturers instruction manuals before performing maintenance work. Open and remove Drawout-type breaker for maintenance. De-energize all sources of power for fixed- or bolted-type circuit breakers.

6-4.2 Insulation
Remove and clean interphase barriers. Inspect for signs of corona, tracking, or thermal damage.

2001 Cooper Bussmann, Inc.

Air Circuit Breaker Testing and Maintenance

NFPA 70B: 6-4 Air Circuit Breakers
6-4.3 Contacts
Inspect main and arcing contacts to assure: Contacts are clean, smooth and in good alignment Contact pressure is normal as prescribed in the manufacturers literature.

6-4.4 Arc Interrupters

Inspect and clean arc interrupters Check for broken or cracked ceramic parts, erosion of ceramic parts and dirt in interrupters.

2001 Cooper Bussmann, Inc.

Air Circuit Breaker Testing and Maintenance

NFPA 70B: 6-4 Air Circuit Breakers
6-4.5 Operating Mechanism
Inspect for loose or broken parts, missing cotter pins or retaining keepers, missing nuts or bolts, and binding or excess wear. Check closing and tripping action for quick, positive and smooth operation.

6-4.6 Breaker Auxiliary Devices

Inspect auxiliary devices (closing motor, shunt trip, auxiliary switches, and bell alarm switch) for correct operation and condition.

2001 Cooper Bussmann, Inc.

Air Circuit Breaker Testing and Maintenance

NFPA 70B: 6-4 Air Circuit Breakers
6-4.5 Operating Mechanism
Inspect for loose or broken parts, missing cotter pins or retaining keepers, missing nuts or bolts, and binding or excess wear. Check closing and tripping action for quick, positive and smooth operation.

6-4.6 Breaker Auxiliary Devices

Inspect auxiliary devices (closing motor, shunt trip, auxiliary switches, and bell alarm switch) for correct operation and condition. Inspect protective relays and trip units for correct operation.

2001 Cooper Bussmann, Inc.

Air Circuit Breaker Testing and Maintenance

NFPA 70B: 18-10.2.5 Low-Voltage Power Circuit Breakers
(a) Overcurrent Trip Device
Can be electromechanical or solid state with two or more of the following types of elements. Long Time-Delay Element Operates on overloads between its pickup setting and the pickup of a short time delay or an instantaneous element. Pickup setting is typically 80% to 160% of the trip device rating (rating does can not exceed breaker frame size rating). Short Time-Delay Element Has time delay measured in cycles and is used to delay tripping, for coordination purposes, to allow downstream molded case circuit breakers to trip first. Pickup settings is typically 250% to 1000% of the trip device rating.
2001 Cooper Bussmann, Inc.

Air Circuit Breaker Testing and Maintenance

NFPA 70B: 18-10.2.5 Low-Voltage Power Circuit Breakers
(a) Overcurrent Trip Device (Continued)
Instantaneous Element Has no intentional time delay and is used to protect against heavy fault currents and short circuits. Pickup settings typically range from 500% to 1500%. Ground-Fault Element Available only on solid-state devices and is used to protect against ground-fault currents at levels below those that would be sensed otherwise.

2001 Cooper Bussmann, Inc.

Air Circuit Breaker Testing and Maintenance

NFPA 70B: 18-10.2.5 Low-Voltage Power Circuit Breakers
(b) Testing
Primary injection method is used to test both electromechanical and solid-state devices. Testing requires use of high-current test set capable of producing sufficient current at low voltage to operate each of the trip element devices. Testing should include at least one test in the range of each element of the trip device. Long time-delay should be tested at 300% of its setting. Short time-delay should be tested at 150-200% of its setting. Instantaneous should be tested at 90-110% of its setting.
2001 Cooper Bussmann, Inc.

Fuse Maintenance & Testing

NFPA 70B: 13-1 Fuses Rated 1000 Volts or Less
13-1.1 Installing and Removing
De-energize before installing or removing fuses. If impossible to de-energize, take appropriate safety precautions (See NFPA 70E).

13-1.2 Inspection
Fuse terminals and fuse clips should be examined for discoloration caused from heat or corrosion.

Use of infrared examination can provide early detection of overheating.

Determine cause of overheating if present.

2001 Cooper Bussmann, Inc.

Fuse Maintenance & Testing

NFPA 70B: 13-1 Fuses Rated 1000 Volts or Less
13-1.3 Cleaning and Servicing
Fuseholder connections should be tightened. Check to insure proper clip pressure. Clean contact surfaces of fuse terminals and clips that have become corroded or oxidized. Wipe contact surfaces with noncorrosive cleaning agent. If signs of deterioration, such as discolored or damaged casings or loose terminals, replace.

2001 Cooper Bussmann, Inc.

Fuse Maintenance & Testing

NFPA 70B: 13-1 Fuses Rated 1000 Volts or Less
13-1.4 Replacement
Assure replacement fuses are of the proper type and rating. When replacing fuses, never alter or force fuseholders to accept fuses that do not readily fit. An adequate supply of spare fuses with proper ratings will minimize replacement problems.

2001 Cooper Bussmann, Inc.

Fuse Testing & Maintenance

NFPA 70B: 18-10 Protective Device Testing
18-10.1 Fuses Test with a continuity Tester to verify the fuse is not open Resistance readings can be taken and should be compared against values recommended by the manufacturer Where manufacturers data is not readily available, resistance deviations of more than 50% for identical fuses should be investigated.

2001 Cooper Bussmann, Inc.

Fusible Disconnect Switch Testing and Maintenance

Disconnect Switches in Panelboards
NEMA PB 1.1 (1996) General Instructions for Proper Installation, Operation, and Maintenance of Panelboards rated 600 Volts or less

Bolted Pressure Switches in Switchboards

Refer to manufacturers instructions Refer to PB 2.1 (1996) General Instructions for Proper Handling, Installation, Operation, and Maintenance of Deadfront Distribution Switchboards Rated 600 Volts or Less. Similar requirements as PB 1.1
2001 Cooper Bussmann, Inc.

Fusible Disconnect Testing and Maintenance

NEMA PB 1.1 - Section 8 Maintenance
8.2 Remove all power to panelboard and check for signs of overheating. 8.3 - Inspect the panelboard once per year or after any severe short circuit.
Look for any moisture or signs of previous wetness or dripping inside enclosure and conduit entering enclosure. Remove any dust and dirt from panelboard. Examine electrical connections in the bus, terminals and wiring system for tightness and signs of overheating. Examine fuse clip contact pressure and contact means for signs of overheating or looseness, check spring pressure and tightness of fastening means. Replace as needed. Check the operation of all mechanical components. Examine all devices and bus supports for cracks or breakage and replace components as required.
2001 Cooper Bussmann, Inc.

Fusible Disconnect Testing and Maintenance

NEMA PB 1.1 - Section 8 Maintenance
8.4 Clean and dress readily accessible copper electrical contacts, blades, and jaws according to manufacturers instructions. 8.5 Lubricate switches and operating mechanisms according to the manufacturers instructions which are usually printed on diagrams or labels.
Operate each switch or circuit breaker several times to assure mechanisms are free and in proper working order. Replace as needed. Check circuit breaker and fuses to ensure proper ampere, voltage, and interrupting ratings. Ensure non-current-limiting devices are not used as replacements for current-limiting devices. Do not attempt to defeat rejection mechanisms which are provided to prevent the installation of incorrect fuse classes. Check insulation resistance after short-circuit, replacement or cleaning of parts or if exposed to high humidity, condensation, or dripping moisture.

2001 Cooper Bussmann, Inc.

Ground-Fault Protection Testing and Maintenance

NFPA 70B: 12-2 Ground-Fault Circuit Interrupters (GFCIs)
12-2.2 Maintenance
Test button on the unit should be used for tripping tests in accordance with the frequency recommended by the manufacturer. Use of separate listed test instruments are available and recommended for testing and troubleshooting of GFCIs. When using separate GFCI test instrument which indicates No Trip, but the GFCI integral test button indicates Trip, investigate the circuit for mis-wiring such as: Line and load wires transposed, Reverse polarity, Open ground If GFCI is properly wired but fails test, the test result is indicative of an improperly functioning GFCI.

2001 Cooper Bussmann, Inc.

Ground-Fault Protection Testing and Maintenance

NFPA 70B: 12-3 Ground-Fault Protectors (GFPs)
12-3.5 Maintenance
Inspect sensors for tight terminal connections and cleanliness Interconnections between components should be marked and replaced to maintain proper phasing and circuitry if disconnected. If equipped with a test panel, a formal program of periodic testing should be established. If not equipped with a test panel, the manufacturer should be consulted for test instructions. Repairs should be performed by the manufacturer.

2001 Cooper Bussmann, Inc.