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10 Critical Tests for New Power Circuit

Breakers

6-7 minutes

There are many things can happen to a circuit breaker on its

journey from the factory to facility, and while they are always
tested by a manufacturer prior to shipping, the following
checks and tests should be performed at a minimum to ensure
that a new low voltage circuit breaker is ready to be placed
into service.

Warning: Failure to perform these tests before energizing

equipment may result in a serious hazard to equipment and/or
personnel.

Testing should always be performed by qualified workers using

test instruments that have been calibrated within the past 12
months.

Visual and Mechanical Inspection

1.) Compare all nameplate data with jobsite drawings
and specifications

Pay special attention to the circuit breaker frame size,

ampacity and interrupting ratings.

Verify that the correct catalog number to be sure that the

proper accessories are installed and that the control voltage is
correct.

Ensure that all of the manufacturer supplied maintenance

devices for the circuit breaker are available, including
charging/racking handles and lifts.

Note: Some circuit breakers may require special interlock keys

or secondary blocks for testing outside of its cell. Consult
manufacturers literature.

2.) Inspect the physical and mechanical condition of

the circuit breaker

The breaker should be clean and arc chutes intact. Inspect the
main contacts and finger clusters for abnormalities. Check that
lubrication is in accordance with manufacturers specifications
and mechanically charge, close and trip the circuit breaker
multiple times.

3.) Verify that the circuit breaker fits inside of its cell
and is properly aligned.

Look inside the cell for any obvious signs of bent guides or
other components. Check that the circuit breaker racking
mechanism operates smoothly. Do not rack the circuit breaker
onto live bus until all other testing is completed!
Verify that the circuit breaker fits inside of its cell and is
properly aligned. PHOTO: EATON.

4.) Record as found and as left operations counter

readings

The operations counter should advance one digit per close-

open cycle operation. Verify settings comply with coordination
study recommendations and document as found protective
device settings. Make sure the trip unit battery is in good
working condition.

Electrical Tests
5.) Inspect bolted connections, fuses, and
contact/pole resistance using a low-resistance ohm
meter

Microhm or dc millivolt drop values should not exceed levels of

the normal range as indicated in the manufacturer's published
data.
If no manufacturer's literature can be found, investigate values
that deviate from adjacent poles or similar breakers by more
than 50 percent of the lowest value.

6.) Insulation Resistance

Perform insulation resistance tests on each pole, phase-to-

phase, and phase-to-ground with the circuit breaker closed, and
across each open pole. Test duration should be one minute
using a voltage in accordance with manufacturers published
data. If no literature is available, apply 1000 volts DC for
equipment with a nominal rating of 600 volts.

Apply 500 volts DC for equipment with a nominal rating of 250

volts. Values should typically be no less than 100 Megohms for
equipment with a rating of 600V, and 25 Megohms for
equipment rated 250 volts or less.

Important: Units with solid-state components could be

damaged if not properly isolated (via removal of plugs and/or
fuses) before applying test voltage. Be sure to follow all
manufacturers' recommendations when performing dielectric
tests on solid state components.
Solid-state components could be damaged if not properly
isolated before applying test voltage. PHOTO: SQUARE D.

7.) Control Wiring Tests

Perform insulation-resistance tests on all control wiring with

respect to ground. Apply 500 volts DC for 300-volt rated cable
and 1000 volts DC for 600-volt rated cable for the duration of
one minute. Insulation-resistance values of control wiring
should not be less than two Megohms.

8.) Test all basic trip unit functions via primary

injection testing

Verify and document the long time pickup, long time delay,
short time pickup, short time delay, instantaneous pickup,
ground fault pickup and ground fault delay using a high current
test set.

Primary injection should always be performed on new

breakers prior to being placed into service to ensure proper
CT ratio and polarity. Secondary injection may only be used
after primary injection testing has first been completed.

Note: Ground fault protection will most likely need to be

disabled by either rewiring or using the manufacturers
recommended device. Saving ground fault tests for last will
ensure the function is working properly before placing the circuit
breaker into service.
High current test sets verify that the circuit breaker ratio and
polarity is correct. PHOTO: ETI.

9.) Verify the correct operation of any auxiliary

features

Check trip and pickup indicators, zone interlocking, electrical

close, shunt trip, trip-free, and anti-pump functions. Perform
each test multiple times to ensure consistency.

Most of these tests, such as electrical charge and close

operations can be performed while primary injection testing
using the proper voltage listed on the circuit breaker
nameplate. Other devices may require special equipment and
procedures.

10.) Reset all trip logs and indicators after testing is

completed

Verify the breaker is discharged, racked out, and that any

auxiliary plugs removed for testing have been re-installed.

References

ANSI/NETA Acceptance Testing Standards

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