Circuit breaker

A circuit breaker is an electrical switching device designed to protect electrical circuits and
equipment from damage due to over currents, short circuits, and other faults. When an
abnormal condition occurs, such as an overload or a short circuit, the circuit breaker
automatically trips and interrupts the flow of current, thereby preventing damage to the
connected equipment and the electrical system.
Types Of HV Circuit Breaker:
High-Voltage (HV) AC power circuit breakers are critical components in electrical substations
and power systems, designed to interrupt high currents and protect the network from faults
and overloads. They are commonly used in transmission and distribution systems to ensure the
safe and reliable operation of the electrical grid. Some of the main types of HV AC power circuit
breakers include:
1. Air Blast Circuit Breaker (ABCB): Air blast circuit breakers use a high-pressure air blast to
extinguish the arc when the contacts open. They are suitable for high-voltage applications and
are commonly used in power transmission substations.
2. Vacuum Circuit Breaker (VCB): Vacuum circuit breakers use vacuum as the arc-quenching
medium. They are compact, require minimal maintenance, and are widely used in medium-
voltage applications. It has minimum disadvantages.
3. Sulfur Hexafluoride (SF6) Circuit Breaker: SF6 circuit breakers use SF6 gas as the arc-
quenching medium. They have excellent dielectric properties, making them suitable for high-
voltage applications. Maintenance of SF6 is expensive.
4. Oil Circuit Breaker (OCB): OCBs use oil as the arc-quenching medium. They are suitable for
high-voltage applications and have largely been replaced by modern alternatives. Oil
maintenance is needed and oil can be flammable during arc.

Working of HV circuit breaker:

A circuit breaker consists of following main parts:
1) Tripping spring and tripping coil
2) Closing spring and closing coil
3) Spring charging motor
When tripping coil receive signal it opens the circuit breaker and for closing contact jaws of
circuit breaker. Closing spring needs to be charge through motor so when closing coil get signal
it closes the contact jaws and cycle goes on.
When fault occurs CT (current transformer) and PT (potential transformer) send signal to relay
and then it sends signal to circuit to trip and disconnect the supply.
Voltage Ranges:
In NETA voltage ranges:
1) Low voltage ranges from 0V to 1000V.
2) Medium voltage ranges from 1000V to 100kV.
3) High voltage ranges from 100kV to 230kV.
4) Extra High voltage greater than 230kV.
In Pakistan voltage ranges:
1) Low voltage ranges from 0V to 1000V.
2) Medium voltage ranges from 0V to 35kV.
3) High voltage ranges from 35kV to 132kV.
4) Extra high voltage ranges from 132kV

Types Of LV Circuit Breaker:

There are four main types of LV circuit breakers:
1) RCCB (Residual Current Circuit Breaker)
2) ELCB (Earth Leakage Circuit Breaker)
3) MCB (Miniature Circuit Breaker)
4) MCCB (Molded Case Circuit Breaker)

1. RCCB (Residual Current Circuit Breaker):

RCCB (Residual Current Circuit Breaker) is an electrical safety device that quickly disconnects
power. It is voltage operated. when it detects ground faults or current imbalances, preventing
electric shocks.
Working:

RCCB monitors the vector sum of currents through the phase wire and neutral wire, if the
current flowing through the phase wire to the load returns back to the supply through the
neutral wire, then their vector sum is zero. Hence, the RCCB does not operate.
Now, if there is any fault or a living being touches the phase wire, which results in the flow of
some leakage current from phase wire to the earth. In this case, current in the phase wire and
neutral wire becomes unequal and thus their vector sum is not equal to zero. Under this
condition, the core balancing current transformer of RCCB sends an unbalance current to the
relay’s operating coil. Therefore, the RCCB trips the circuit
Usual Facts:
1) Current operated device trips at current above 5mA.
2) No need of earth connection for sensing of fault.
 3) Nuisance tripping (Nuisance tripping, also known as 'sympathetic tripping', is the unnecessary
tripping of circuit breakers when a fault does not exist) may occur.

Protection:
1) Earth faults
2) Electric shocks

2. ELCB (Earth Leakage Circuit Breaker):

ELCB stands for Earth Leakage Circuit Breaker. It is current operated. It is an electrical safety
device that quickly disconnects the power supply when it detects leakage currents to the
ground, providing protection against electric shocks and ground faults.
Working:
An ELCB consists of a coil that is connected in series with the earth terminal. When phase wire comes in
contact with the body of the equipment, a voltage is developed in the earth conductor. This voltage
operates the ELCB to trip the circuit.

Usual Facts:
1) Voltage operated device trips at voltage above 50V.
2) Earth must be connected in series with the trip coil.
3) Nuisance tripping is very less.
Protection:
1) Earth faults

3. MCB (Miniature Circuit Breaker):

MCB stands for Miniature Circuit Breaker. It is an electrical protection device that automatically
switches off the power supply when it detects overcurrent or short circuits, preventing damage
to electrical circuits and equipment.
Working:
When the current overflow occurs through MCB – Miniature Circuit Breaker, the bimetallic strip
gets heated and deflects by bending. The deflection of the bi-metallic strip releases a latch. The
latch causes the MCB to turn off by stopping the current flow in the circuit.
Protection:
2) short circuit
3) electric shocks

4. MCCB (Molded Case Circuit Breaker):

MCCB stands for Molded Case Circuit Breaker. It is an electrical protection device used to
automatically interrupt the flow of current in the event of an overload or short circuit in low-
voltage electrical systems.

Working:
MCCBs use a bimetallic strip in their trip unit, where the heat generated by the current
imbalance causes the bimetallic strip to bend, tripping a mechanical latch that opens the
breaker contacts, interrupting the circuit.
Protection:
1) short circuit
2) electric shocks

5. RCBO
RCBO stands for 'Residual Current Breaker with Over-Current'. As the name suggests it protects
against two types of faults and in essence combines the functionality of an MCB and RCD.
Working:
RCBO consist of two compartment one is MCB and other is RCCB. MCB protects against over
flow and short circuit and RCCB part protects earth faults.
Protection:
1) short circuit
2) electric shocks
3) Earth faults

Testing of HV Circuit Breaker:

To ensure the condition of circuit breaker we need to perform several tests:
1) Closing/Opening time
2) Spring charging motor
3) Contact resistance
4) Insulation resistance
5) Minimum pick-up time
6) Primary injection (ETU (electronic terminal unit) circuit breaker) e.g., LV circuit breaker
7) Secondary injection (CT PT based circuit breaker) e.g., HV circuit breaker
8) VIDAR
1. Opening/Closing time test:
Purpose:
The purpose of the opening and closing time test of HV circuit breakers is to measure the time
it takes for the breaker to open and close, ensuring its responsiveness and efficiency in
interrupting or restoring electrical connections during fault conditions or switching operations.

Test procedure:
1. Preparation: Ensure the circuit breaker is properly isolated and all safety measures are in
place. Connect suitable test equipment to monitor the breaker's performance.
2. Opening Time Test:
1) Initiate an electrical command to open the circuit breaker.
2) Measure the time taken for the breaker's contacts to fully open and the arc to be
extinguished.
3. Closing Time Test:
1) Initiate an electrical command to close the circuit breaker.
2) Measure the time taken for the breaker's contacts to fully close and establish electrical
continuity
4. Repeat and Record: The opening and closing time tests help verify the breaker's response
and coordination with the protective system, ensuring safe and reliable operation in high-
voltage applications.
Expected Results:
The expected results of three-phase circuit breaker closing time testing include:
1. The measured closing time should be within the specified operating time limits set by the
manufacturer or relevant standards.
2. The breaker should exhibit quick and reliable responsiveness in establishing electrical
connections.
3. The closing time test confirms the breaker's safety and efficiency in restoring power during
controlled switching operations or fault conditions.

Standard values to check results:

Close time 80 mS, Open time 50 mS and Close open Time 35 mS
IEC 62271-100

Equipment:
CIBANO 500 and CB MC2 contact module

2. charging motor current test:

Trend of motor current shows you the power needed by the motor.
Main purpose:
Motor performance assessment, coil charging efficiency, charging time evaluation.

Test procedure:
1) Connect source to charging motor or use current clamp.
2) Check charging times and charging currents
3) Compare with previous measurements
4) Analyze undervoltage conditions
Expected results:
1) Motor should not be overloaded.
2) Charging time of coil by motor should be in range mentioned by manufacturer.

Instrument for testing:

SGS uses CIBANO 500 for testing of charging motor of circuit breaker.

3. Contact Resistance Test:

Focus:
The contact resistance test is conducted to evaluate the condition of the contacts inside a
circuit breaker. It aims to identify any abnormalities in the contact resistance that could lead to
issues such as excessive heating, voltage drop, or damage to the circuit breaker.

Procedure:
1. Isolate circuit breaker from power and equipment.
2. Inspect contacts for cleanliness and damage.
3. Clean contacts if needed.
4. Connect micro-ohmmeter using Kelvin test leads (kelvin test leads work on kelvin’s 4 wire
measurement principle).
5. Test contact resistance with closed contacts.
6. Record results and check for acceptable limits.

Expected Results:
1. If the measured contact resistance is within the manufacturer's specified limits or falls within
standard values, the circuit breaker contacts are considered to be in good condition.
2. A low and consistent contact resistance indicates proper contact functionality and minimal
energy losses.
3. If the measured contact resistance is unusually high, it may indicate possible issues with the
contacts, such as corrosion or degradation, requiring further investigation and maintenance.
4. Deviations from expected results may prompt additional analysis and corrective actions to
maintain the circuit breaker's safe and reliable operation.

Standard values to check results:

According to ANSI/NETA, contact resistance should not have greater than a 50% difference
between the lowest and highest reading across all three phases.
Percentage=((highest-lowest)/lowest) *100
Percentage <=50% good contact resistance or 1.5*lowest value means 50% value of lowest
resistance phase is maximum deviation allowed all phase contacts of breaker.

Equipment:
CIBANO 500 and CB MC2 contact module
4. Insulation Resistance Test:
Purpose:
The purpose of the insulation resistance test of a circuit breaker is to verify the integrity and
effectiveness of the insulation materials, ensuring there are no leakage paths that could
compromise the breaker's electrical isolation.

Procedure:
 Keep circuit breaker open
 Connect Megger leads to top connecting plate and bottom connecting plate and
measure insulation IR value in between the both plates.
 Connect megger leads to bottom connecting plate and earth and measure insulation
resistance in between the both plates.
 Connect megger leads to top connecting plate and earth.
 Make the circuit breaker close
 Measure IR between both plate and earth.

Test Mode:
1) IR between top plate and bottom plate
2) IR between bottom plate and ground

3) IR between top plate and ground

Expected Result:
The expected result of the insulation resistance (IR) test of a circuit breaker is typically a
high resistance value measured in megaohms (MΩ) or giga ohms (GΩ). A high IR reading
indicates that the insulation between the live parts and the ground is in good condition,
ensuring effective electrical isolation and minimal leakage current.

for vacuum bottle leakage current should not be greater than 0.3 milli amperes.
 5. Minimum Pick-up time:
Purpose:
Indicates the lowest voltage to operate the trip or close coil.

Procedure:
1) start at a certain voltage level.
2) Try to operate.
3) If not working, increase voltage and try again.
4) Ramp the voltage pulse until minimum voltage is reached with which the circuit breaker
switches (open).

CIBANO 500: Automatic testing after setting pass/fail level to certain percentage of nominal value.
We don’t have to increase voltage ramp step by step manually, CIBANO itself does this.

Instrument:
CIBANO 500 is used.

6. Primary Injection:
Purpose:
Assess the circuit breaker's tripping and clearing time by simulating a fault with a high current
injection to verify that it operates within acceptable time limits.
Procedure:
1) Primary injection is used in LV and some MV circuit breaker.
2) LV circuit breaker has built-in relays which detect signals and trips the breaker so we
inject rated value current on phases of circuit breaker. It senses and trips circuit breaker.
3) Check the tripping time is correct.
Four tests can be carried out:
Long-time delay and pickup: The long-time delay characteristic provides overload protection.
The pickup is typically set equal to the overcurrent protection device’s continuous current
rating. The test current injected is typically three times the long-time pickup. The test current is
injected through each pole, and the trip time is recorded each time.
Short-time delay and pickup: The short-time delay characteristic provides protection against
short-circuit or fault conditions. An intentional delay is provided for coordination or selectivity
with other protection devices. The short-time pickup is a multiple of the long-time pickup. The
test current typically used is 1.5–2.5 times the short-time pickup. The test current is injected
through each pole of the breaker and the trip time is recorded each time.
Instantaneous pickup: The instantaneous trip characteristic provides protection against short-
circuit or fault conditions but doesn’t include any time delay. In this test, pulses of current
(pulse duration between 5 and 10 cycles) with steadily incrementing magnitudes are injected
through each pole until the circuit breaker trips. The starting pulse is set at around 70% of the
expected pickup. The value of the pickup at which the breaker trips is recorded.
Ground-fault delay and pickup: The ground-fault trip characteristic provides protection against
ground faults. The ground-fault pickup is typically a fraction (20%–60%) of the continuous
current rating of the overcurrent protection device. The test current injected is typically 1.5–2.5
times the pickup.
Expected result:
Results should be according to manufacturer.
Instrument:
CPC 100 with CP CB2

7. Secondary Injection:
Normally we use this test on HV and MV circuit breaker to check if their tripping is happening
according to settings done by user.
Procedure:
In this test we inject voltage and current on relays which is used to send signals to Circuit
breaker.
In circuit breaker there is a mechanism to check the overload current, short circuit current and
earth fault current.
Expected result:
Results should be according to manufacturer.
Instrument:
CIBANO 500

8. Vacuum Interrupter testing (IR test of vacuum circuit breaker):

Purpose:
To check the dielectric, withstand voltage of vacuum bottle.
Procedure:
1) Keep the vacuum circuit breaker in open condition.
2) Connect all probe to ground.
a. Ground probe to ground.
b. Red probe to incoming vacuum interrupter.
c. Black probe to outgoing vacuum interrupter.
3) Select the voltage according to breaker rating.
4) Red light blinking means defective vacuum interrupter.
5) Green light blinking means acceptable vacuum interrupter. Normally (leakage current
<0.3mA).
Equipment:
VIDAR megger tester

SF6 gas impurity testing:

purpose:
To check the impurities (gaseous making SF6 impure) in SF6 gas caused by arc quenching.
Impure gaseous like: SO2
Procedure:
1) Connect the test equipment with the SF6 gas chamber.
2) Test kit takes all gas in its chamber and check for impurities.
3) Then fill that gas again to circuit breaker tank.
Expected Result:

Equipment:
DILO SF6 Multi-Analyzer.

Factors for selecting circuit breaker:

1) Voltage rating.
2) Overload current bearing capacity.
3) Short circuit current bearing capacity.