Cairo University

Faculty of Engineering Year: Fall 2015

Electrical Power & Machines Dept.
EEE Program
Protection

Circuit breaker testing with micro-logic trip unit

5.2 E MCCB, frame 160 A

Objectives:
1. To introduce basic functions of CB.
2. To be familiar with CB testing.
3. To understand the art of backup protection.
4. To study the CB characteristic.
5. To be familiar with the usage of some experimental equipment (Current injector, MCCB
with micro logic, Megger device).

Pre-Experimental Quiz:
1. What is the difference between Miniature Circuit Breaker (MCB) and Molded Case
Circuit Breaker (MCCB)?
2. What is meant by Discrimination?
3. State the CB tests.
Theoretical Background:
1- Usage:- Distribution feeder protection

2- Fundamental characteristic of a circuit breaker:

In: Rated current
Ir or Irth: Overload trip-current setting
Ue: Rated operational voltage
Ui: Rated insulation voltage
Uimp: Rated impulse withstand
Icu: Rated ultimate short circuit breaking capacity
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

3- Discrimination (selectivity):
Discrimination may be based on the principles of current levels, or time-delays, or a
combination of both. A more recent development is based on the logic techniques.
Discrimination (selectivity) is achieved by automatic protective devices if a fault condition,
occurring at any point in the installation, is cleared by the protective device located
immediately upstream of the fault, while all other protective devices remain unaffected.
Consider the following figure.

Fig. 1: Short circuit at feeder B

 Discrimination based on current levels

This method is achieved by setting successive tripping thresholds at stepped levels, from
downstream relays (lower settings) towards the source (higher settings).

Fig. 2: Discrimination based on current level

 Discrimination based on stepped time delays

This method is implemented by adjusting the time-delayed tripping units, such that
downstream relays have the shortest operating times, with progressively longer delays towards
the source.
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

Fig. 3: Discrimination based on stepped time delay

4- Protection function:-
Long time protection
Short time protection
Instantaneous time protection

i- Long Time Protection

Long time protection on Micro-logic 5.2E trip units is adapted to protecting all types of electrical
distribution application against overload currents.

Operating Principle
Long time protection is I2t IDMT (Inverse Definite Minimum Time):
 It incorporates the thermal image function.
 It can be configured as the Ir pick-up and as the tr trip time delay.
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

Fig. 4: Tripping curve of long time protection

Setting the Long Time Protection

The Ir pick-up can be set as follows:
 On the Micro-logic trip unit, preset by the Ir dial and fine-tuned on the keypad.
 Via the communication option using the RSU software, preset by the Ir dial on the
Micro-logic trip unit and fine-tuned via the RSU software.
The time delay tr can be set as follows:
 On the Micro-logic trip unit, set on the keypad.
 Via the communication option using the RSU software.

Notes
 Ir :-is set from (0.35 to 1)In or from 56 A. to 160A. where In (frame current)=160A.
 We can set Ir=56 A. by setting the dial to 63 A, then using the fine-tuned keypad to reduce it
to 56 A.
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

With accuracy range (5-20)% from the manual.

 tr: the time at I=6Ir (e.g. if Ir=60A and tr=2sec means that at 6×60=360 A the breaker will trip
in 2sec)

With accuracy range (-20-0) % from the manual.

 The measuring is made with 20 Min separation due to thermal memory phenomenon in long
time protection curve.

ii- Short time protection

Short time protection on Micro-logic 5.2E trip units is adapted to protecting all types of electrical
distribution application against short-circuit currents.
Operating Principle
Short time protection is definite time:
 It incorporates the possibility of an I2t inverse time curve function.
 It can be configured as the Isd pick-up and the tsd trip time delay.
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

Fig. 5: Tripping curve of short time protection

Setting of the Short Time Protection

The Isd pick-up can be set as follows:
 On the Micro-logic trip unit, preset by the Isd dial and fine-tuned on the keypad.
 Via the communication option using the RSU software, preset by the Isd dial on the Micro-
logic trip unit and fine-tuned via the RSU software.
The tsd time delay can be set as follows:
 On the Micro-logic trip unit, set on the keypad.
 Via the communication option using the RSU software.
The tsd time delay setting incorporates activation/deactivation of the I2t option.

Notes

 Isd is set from (1.5-10) Ir with accuracy range ±10% from manual.
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

 tsd is set from (0-0.4)sec from manual.

 The end of long time protection is determined by the short time settings.

iii- Instantaneous Protection

Instantaneous protection on Micro-logic 5.2E trip units is adapted to protecting all types of
electrical distribution application against very high intensity short-circuit currents.

Operating Principle
Instantaneous protection is definite time. It can be configured as Ii pick-up and without a time
delay.

Fig. 6: Tripping curve of instantaneous protection

 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

Setting of the instantaneous Protection

The Ii pick-up can be set as follows:
 On the Micro-logic trip unit, set on the keypad.
 Via the communication option using the RSU software.

Ii is set from (1.5-15)In or from 240A-2400A for In=160A from manual.

The accuracy range ±10%.

The maximum tripping time is 50 msec.

Experiment installation
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

Experiment procedure

1. Enter the CB protection setting using keypad or computer settings (Ir, tr, Isd, tsd, Ii).
2. Inject the current through the CB using the current injector (inject up to 4kA and has built
in timer) considering the range of the three protection regions based on the protection
settings.
3. Measure the injected current and the tripping time and notice the indication port (indicate
the fault type) at each trip.
4. Record the measured values in this table.
Write C.B Protecting Setting
Ir= , Tr= ,Isd= ,Tsd= ,Iinst=
Injected Tripping
% From Fault
Current Time Comments
Ir Type
Value Value

Note that
Verify the measured values by comparing them with the manual tables and curves and ensure that
the measured values within the acceptable range (from manual).
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

The time-current characteristics of micro-logic 5.2E 160A

 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

Insulation Resistance Test

 Purpose
To determine the adequacy of the insulation between line and load terminals, between poles,
and between each pole and ground.
 Equipment
This test requires an insulation resistance tester capable of applying a direct-current voltage of
at least 500 volts. It should be also noted that more accurate information can be obtained when
1000 volt testers are used since they are more likely to detect deteriorated insulation systems.

 Test procedure
1- All exposed metal parts except line, load, and accessory terminals should be electrically
connected to a metal base-plate.
2- Using an insulation resistance tester, apply a direct-current voltage of at least 500 volts to
determine the resistance. Voltage is to be applied as follows:-
3- Between line and load terminals of each individual pole with the circuit
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

breaker in the OFF position and tripped position if possible.

4- Between terminals of adjacent poles with the circuit breaker in the ON position.
5- From line terminals to the metal base-plate with the circuit breaker in the ON position.
 Note that
All resistance readings should be one mega-ohm or greater for each measurement.
Any reading is less than one mega-ohm may indicate that the circuit breaker is contaminated,
flawed, or cracked insulating material, in this case; the circuit breaker should be replaced.

Measuring values in MΩ
C.B. is in OFF position C.B. is in Tripped position
Line 1 and load terminal 1 Line 1 and load terminal 1
Line 2 and load terminal 2 Line 2 and load terminal 2
Line 3 and load terminal 3 Line 3 and load terminal 3
C.B. is in ON position
Line 1 to line 2 Line 1 to metal base-plate (Earth)
Line 2 to line 3 Line 2 to metal base-plate (Earth)
Line 3 to line 1 Line 3 to metal base-plate (Earth)

Individual Pole Resistance Test (Millivolt Drop)

 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

 Purpose
To assess the electrical integrity of internal connections and contacts in a
circuit breaker. This can be done by conducting a millivolt drop test across
the line and load terminals of each pole with the circuit breaker contacts
closed. The millivolt drop (resistance) of a circuit breaker pole can vary
significantly due to inherent variability in the extremely low resistance of
the electrical contacts and connectors. Such variations do not necessarily
predict unacceptable.

 Equipment
-The test should be conducted using a 24 volt, or less, direct current
power supply capable of supplying the rated current of the circuit breaker.
For circuit breakers rated higher than 500 amperes, the power supply
should be capable of delivering no less than 500 amperes.
-If the above equipment is not available for field tests, a Digital Low
Resistance Ohmmeter (DLRO), or 4-point tester, capable of 10 to 100
amperes (DC), may be-used.

 Test procedure
a) Apply test current across a pole equal to the breaker rating (or 500 Amperes minimum for
breakers rated in excess of 500 Amperes). Record the millivolt drop and the test current.
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

Do not maintain current for more than 1 minute. If this equipment is not available, use the
following test.
b) Apply test current across a pole of 10 Amperes, or the Ampere rating of the breaker, for
breakers rated less than 100 Amperes. For breakers rated more than 100 Amperes, apply a
test current across a pole of 100 Amperes. Record the millivolt drop and the test current,
or resistance. Do not maintain current for more than 1 minute
c) De-energize the test circuit. Manually operate the breaker to the OFF and then ON position.
d) Repeat steps (a) and (b) for a total of three readings on the pole being tested.
e) Repeat steps (a) through (c) for each of the remaining poles of the circuit breaker.

 Note that
The results of test will vary according to the breaker frame type, ampere rating, and
manufacturer. The manufacturer should be consulted to determine the maximum allowable
voltage drop If the average test values of any pole of the breaker
exceed the maximum allowable drop, the circuit breaker may have reached the end of
life and additional tests may have to be conducted.

The following table shows the power loss and resistance per pole for CB with electronic trip
unit.

Measuring values:
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

Millivolt
Current
Line 1
R (average value) =

Millivolt
Current
Line 2
R (average value) =

Millivolt
Current
Line3
R (average value) =

Report:
a. Completing all required measurements in the three tables.
b. Discussion and comments on the three tables’ results.
c. Sketching the CB characteristic.
d. Comparing the obtained characteristic with the CB one’s.

Post-Experimental Quiz:
Q1: write short notes about “discrimination”
Q2: in the long duration protection, Is it preferred to take readings consecutively and without
leaving a space of time between the measurements? Why or why not?
Q2: state a difference between
a. MCB and MCCB
b. Fuse and circuit breaker
Q3: True of False
a. It is preferred to use 500 v. or lower in insulation measuring test with the megger
device ( )
b. It is preferred to use 24 v. or lower in contact resistance measuring test ( )
c. There is a physical thermal element exist in the tested CB ( )
 Cairo University
Faculty of Engineering Year: Fall 2015
Electrical Power & Machines Dept.
EEE Program
Protection

d. If Ir = 60 A. and tr = 4 sec. it means that at a current of 60 A the CB will trip after 4

sec. ( )
Q4: Choose the correct answer:
a. The tested circuit breaker was (ACB – MCCB – MCB)
b. The insulation resistances of the tested CB were in range of ( milli ohm – ohm –kilo
ohm - Mega ohm - Giga ohm)
c. The contact resistances of the tested CB were in range of ( milli ohm – ohm –kilo
ohm - Mega ohm - Giga ohm)