10 Critical Tests for New Power Circuit Breakers

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