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Test Equipments for Circuit Breakers such as MCB, MCCB, ACB, VCB, RCCB & RCBO and Compliance Verification Benches for conformity assessment as per IEC 60898, IEC 60947, IEC 61008, IEC 61009 & other standards.


We design and manufacture test equipments and automation solutions for testing and production of circuit breakers such as Miniature Circuit Breakers (MCB), Molded Case Circuit Breakers (MCCB), Residual Current Operated Circuit Breakers (RCCB / RCBO), Earth Leakage Circuit Breakers (ELCB), Vacuum Circuit Breakers (VCBs), Air Circuit Breakers (ACBs) and other line protection devices.
Some of our recent solutions are listed here. These facilitate testing of breakers as per various standards such as IEC 60947, IEC 60898, IS 10322 and others. Please write to us for more details about our all test equipments for CBs.


Testing Solutions for Miniature Circuit Breakers (for testing as per IEC 60898 & others)

Thermal Calibration Test Bench for Miniature Circuit Breakers for Thermal Calibration

This is a totally Modular System for Automatic Calibration   Verification of Thermal Trip characteristics of MCBs. The system is expandable from 1 station to ‘n’ stations and handles calibration of MCBs ranging from 0.5A to 120A. Each station is provided with one MTCM CU for controlling the operation of that station. The MCB under test (its type / set of calibration parameters) at each station is essentially independent of the other stations. Consequentially, the user is free to calibrate different types of MCBs simultaneously   independent of each other. An interface module facilitates the communication between every station   the Windows based software that governs the system. Each station operates automatically as soon as the MCB is switched ON after loading. The calibration i.e. adjustment of setscrew of the MCB is done with the help of Stepper Motor. The PC in real time collects the ‘trip time’ of MCB under test and the result as Early, OK or Late. The same system can be used for verification of the calibration wherein the tripping time with limits can be checked and hence the system is also available without fixtures for verification (with manual calibration) only.
At the heart of the calibration system is the electronic DC Constant Current Source specially designed for thermal calibration of MCBs. This source is more accurate than conventional electrical source, designed for continuous duty, controlled by a dedicated micro-controller based module (that sets the correct test current instantly) and is proven to be extremely rugged and reliable. The architecture of the test system is modular and can be easily scaled up fast at a later point in time, should there be a sudden rise in production requirement; meaning – for 10 station bench, there would be 10 sources, 10 fixtures and 10 MTCMs. It is possible to add 1 or more stations as and when required, instead of directly buying another test system. This is cost-effective, guarentees zero down-time   has many other benefits. The accompanying PC based TestWare is intuitive, has secured database and exports reports easily for statistical analysis such as pareto analysis, bell-curve etc.


MAIN FEATURES AT A GLANCE:
The solution comprises of:
  1. Solid State DC Constant Current Source (with 0.2 % regulation) at each station.
  2. Display & Control Unit for each station at each station.
  3. Specially designed PC interface module.
  4. Electro-pneumatically operated mechanical fixtures (test jigs) to hold MCB with Stepper Motor for calibration of MCB at each station.
  5. PC running Windows
  6. TestWare - SCADA for control and data acquisition from the test equipment.

Models available are:
Unique Benefits of this solution over the competition
# Aspect This Solution Conventional Equipment
       
1 Line & Load Current Regulation Better than 0.3% 0.5% or 1%
2 Power Consumption Low Normal
3 Test Voltage / Operator Safety No extra guards are required as Individual
Station has its own Power Source &
maximum voltage is 7V
Higher Voltage is required for MCBs of
lower rating which calls for special safety
precautions
4 Flexibility You can spread the system to different physical locations and can test different types of MCBs simultaneously Fixed bench
5 Scalability 100%; System can have 1,2.3,...n stations as and when required No change can be made on existing
system
6 Reliability Solid state components lead to long life and less fatigue, No interruption of current as there is no need of change-over after a breaker at a station trips Interruption of current after a breaker trips
7 Maintenance /
Breakdown
Individual Station can be replaced or shut
down without affecting rest of the system;
Easy 'plug & use' possible
Failure of any one component is the failure of
complete system; skilled technician required
for repairing
8 Spares
Required
Modular system leads to lesser spares /
inventory
Different types of spares required
9 Size Compact & Portable Medium; Mounted on Castors
10 Cost No increase in cost for the last 5 years Price directly dependant on fluctuating cost of copper

This particular solution has been our star product of the decade with sizable repeat orders from small, medium and major manufacturers of Miniature Circuit Breakers including reputable clients such as Siemens, Larsen & Toubro, Legrand, Havells, Panasonic, GE, Indoasian, Wipro, Bhartia Cutler Hammer, C&S, ABB and Teknic Euchner.
Daily, more than 500,000 poles are tested with this system!

Product Images (Click on images to zoom):
MCB Thermal Trip Calibration Test Bench MCB 12 station Thermal Trip Calibration Bench DC Constant Current Source with Test Jig & PLC for MCB Thermal Calibration as per IEC 60898 Test jig for MCB


Thermal Trip Verification Test Bench for Miniature Circuit Breakers

The Thermal Trip Verification Test Bench is designed to perform thermal trip verification of Miniature Circuit Breakers as per clause 9.10 of the IEC 60898. The working of the test system is similar to the thermal trip calibration panel; however this system is to be used to verify the tripping characteristics simulating the actual working conditions.


MAIN FEATURES AT A GLANCE:
The test solution comprises of:
  1. Constant Current Source
  2. Display & Control Unit for each station at each station.
  3. Specially designed PC interface module.
  4. PC
  5. TestWare - SCADA for control and data acquisition from the test equipment.
Product Images (Click on images to zoom):
MCB Thermal Trip Verification Test Bench MCB Thermal trip Verification Bench as per IEC 60898


Magnetic Trip Test Bench for Miniature Circuit Breakers

The MCB magnetic characteristics verification test bench is designed to perform magnetic trip test on low voltage MCBs for short time over currents as per clause 9.10 of IEC 60898 (IS 8828). B, C, and D curve of MCBs of single pole as well as multi-pole having different magnetic characteristics can be measured on this test bench. The user can operate the entire test bench to conduct all the available tests & measurements on MCB with a PC based TestWare; All measurements are saved & reports (including current characteristics) can be generated. Decades of experience has helped us to design current source (transformer) in a special way such that good current regulation and enhanced accuracy is ensured. Our latest design has resulted in variable current output source (short time) without a single variable transformer in the system.

Main Features at a glance:

The Test Bench comprises of:

  1. Specially designed constant current source (with high current power transformer) for accurate supply of current
  2. PC to Test Bench interface card
  3. Measurement system to measure instantaneous current
  4. Test jig to load single/multi pole MCB
  5. PC running TestWare
  6. TestWareSCADA with database & reporting for test & measurement of MCB magnetic trip characteristics


Characteristics Test & Measurement System for Circuit Breakers (MCB & RCBO)

The Time Current Characteristics Test Solution for Circuit Breakers is designed to test & measure the time v/s current waveforms for B,C,D curve MCBs for both thermal as well as magnetic trip. The panel is programmed to typically follow the Table 7 of clause 8.6.1 of IEC 60898. It is suitable for RCBO (IEC 61009) also. It has an inbuilt current source to source currents equivalent to those mentioned in the above mentioned table. All MCBs with range 0.5 Amp to 63 Amp can be tested on this panel. This panel has an in-built climatic chamber to maintain temperatures of up to 45oC, which closely resembles the operating temperatures in the environment where MCBs are installed in real world situations.


MAIN FEATURES AT A GLANCE:
Product Images (Click on images to zoom):
Time-Current Characteristic Test System Time Current Characteristic Test bench for MCB and RCBO


Temperature Rise & Power Loss Test Bench for Miniature Circuit Breakers
Adjustable Constant Current Source will have:
  1. 0.5A to 100A at 30V open ckt. Voltage CT range 2A, 5A, 10A, 25A, 50A, 100A.
  2. The CT range and resistance for MCB rating to be selected through shorting links: 0.5A, 1A, 2A, 4A, 6A, 10A, 16A, 20A, 25A, 32A, 40A, 50A, 63A at 30V open current voltage.
  3. Panel shall be capable for testing three samples of same rating may SP/DP/TP/FP
  4. True RMS sensing current controller shall maintain current better than class 1.0 accuracy through out the range.
  5. Digital Temperature Indicator min 28 Channels with minimum 28 No. Thermocouple bid, Teflon insulated shall be provided with sufficient length to connect it to product.
  6. Channel selection by rotary switch.
  7. Cooling shall be provided by means of Exhaust fans distributed all over to remove the hot air generated inside the panel cabinet.
  8. Overall accuracy of the panel is better than class 1.0
  9. The entire system will be housed in sturdy M-S Cabinet (Trolley)
  10. Calibration certificate will be provided for individual meter and also for complete system.
  11. Following meter indications will be provided:
    1. Digital Temperature Indicator with 28 input for thermocouple.
    2. Digital Volt Meter with 5 ranges (200mV, 2V, 20V, 200V, 250V) to measure open circuit voltage & mV drop across MCB
    3. Digital Ammeter with CT (Indication on servo controller)

28 Days & Temperature Rise Test Panel for MCB (Single Phase)

The 3 station 28 days and temperature rise test panel is been developed to test MCBs, MCCBs, RCCBs and RCBOs as per IEC 60898-1, IEC 61008-1, IEC 61009-1. In this test the MCB is subjected to 28 cycles, each comprising 21hrs with rated Current at an open circuit Voltage of more than 30V and 3hrs without Current. It consists of adjustable constant Current source which provides constant Currents from 0 to 200A (180 A max.) at open circuit Voltage of more than 30V. Specially designed True RMS sensing Current controller maintains Current with the help of stepper motor within+/-1 % throughout the range. Digital display is provided for Current measurement. Microcontroller based sequential timer maintains the sequence of operation and displays the test status.

Product Images (Click on images to zoom):
28 days and temperature rise test panel for mcb


Temperature Rise & Power Loss Test Bench for Miniature Circuit Breakers
Adjustable Constant Current Source will have:
  1. 0.5A to 100A at 30V open ckt. Voltage CT range 2A, 5A, 10A, 25A, 50A, 100A.
  2. The CT range and resistance for MCB rating to be selected through shorting links: 0.5A, 1A, 2A, 4A, 6A, 10A, 16A, 20A, 25A, 32A, 40A, 50A, 63A at 30V open current voltage.
  3. Panel shall be capable for testing three samples of same rating may SP/DP/TP/FP
  4. True RMS sensing current controller shall maintain current better than class 1.0 accuracy through out the range.
  5. Digital Temperature Indicator min 28 Channels with minimum 28 No. Thermocouple bid, Teflon insulated shall be provided with sufficient length to connect it to product.
  6. Channel selection by rotary switch.
  7. Cooling shall be provided by means of Exhaust fans distributed all over to remove the hot air generated inside the panel cabinet.
  8. Overall accuracy of the panel is better than class 1.0
  9. The entire system will be housed in sturdy M-S Cabinet (Trolley)
  10. Calibration certificate will be provided for individual meter and also for complete system.
  11. Following meter indications will be provided:
    1. Digital Temperature Indicator with 28 input for thermocouple.
    2. Digital Volt Meter with 5 ranges (200mV, 2V, 20V, 200V, 250V) to measure open circuit voltage & mV drop across MCB
    3. Digital Ammeter with CT (Indication on servo controller)


3 Phase MCB Endurance Test Bench
The test seup consists of 2 sub-systems:

3 Phase Inductive Load:

Inductive Load has 0.85 Power factor for Testing of MCBs of ranges 0.5, 1, 1.6, 2, 3, 4, 6, 8, 10, 13, 16, 20, 25, 32, 40, 45, 50, 63Amps, selectable with Shorting Links. The working voltage is 230V for each phase. There will be 3 Loads, which could be connected either in Single Phase or 3 Phase schemes. The resistance is ceramic tube based and insulated industrial grade.

Metering & Safety Features:
  1. Micro Controller Based Programmable timer to set ON / OFF Time 0 – 99.9sec.
  2. Digital Voltmeter with selector switch. Digital Ammeter with selector switch.
  3. Digital Power Factor Meter. Digital Frequency Meter.
  4. Electro Magnetic Counter: It will count the number of operations.
  5. Current Sensing Circuit: To detect contact weld & contact open. This will give a signal to cut off the Load, if fault persists for predefined time.
  6. Electro Pneumatic Fixture. The ON / OFF Time & Sequence will be derived from Timer Unit provided on metering panel.


Impulse Voltage Test Equipment MCB (Single Phase)

Impulse voltage tests are recommended with the object to determine effect of voltage stress on insulating due to voltage surges of short durations, even when the switch (breaker) is off. A surge is a form of over voltage, which may be defined as an exceptional voltage in excess of peak voltage to earth at line or electrical system of which line forms a part (can be caused as a result of lightning strikes as well as other overvoltage spikes in the power system level).

Impulse Tester is designed to generate impulse voltage of 1.0 KV to 5 KV. The waveform generated has rise time of 1.2 micro second and 50 micro second duration as defined in IEC61180. The peak voltage can be adjusted continuously with the help of variac provided. The test sequence i.e. number of Impulse for Positive and Negative polarity, time between two subsequent impulses can be programmed through key pad with the help of dedicated PLC module. The entire sequence, for both positive and negative impulse is automatic. At the end of the test, the test results are displayed on LCD display. Output is provided for connecting an oscilloscope for displaying the Wave Form at the output Terminals.

In case any flash over occurs, it is detected by a circuit which stops the test sequence, and output PLC displays the number of cycles with polarities at which the failure has taken place.

Testing Solutions for Molded Case Circuit Breakers (for testing as per IEC 60898 & others)

Overload Trip Test Bench for Molded Case Circuit Breaker (MCCB)

The MCCB overload test bench is specifically designed for routine testing of Moulded Case Circuit Breakers. The test panel has multiple stations to test multiple MCCBs, such that all MCCBs under test can be tested simultaneously and independently from each other. The test bench features a micro-controller based controller with PC interface for data collecting and report generation.

Main Features at a glance:

The Test Bench comprises of:

  1. Specially designed constant current source
  2. PC to Test Bench interface card
  3. Test jig to load single/multi pole MCCB
  4. PC running TestWare
  5. TestWareSCADA with database & reporting for test & measurement of MCCB thermal trip characteristics


Short-circuit Trip Test Bench for Molded Case Circuit Breaker (MCCB)

The MCCB Short Circuit Current Test Bench is specifically designed for routine testing of Moulded Case Circuit Breakers for current rating up to 800A of continuous duty-cycle & up to 10kA for short-time. All poles of the MCCB are tested one by one as per IEC 60947-2. It is a completely micro-controller based system with PC interface for data collecting and report generation. Years of experience in this field have led us to design the unique current source (transformer) capable of sourcing such a high current for short time duty.

Main Features at a glance:

The Test Bench comprises of:

  1. Specially designed constant current source
  2. PC to Test Bench interface card
  3. Test jig to load single/multi pole MCCB
  4. PC running TestWare
  5. TestWareSCADA with database & reporting for test & measurement of MCCB magnetic trip characteristics


Testing Solutions for Residual Current Circuit Breakers / Earth Leakage Circuit Breakers (for testing as per IEC 61008 & others)

Automatic Routine Test System For RCCB/RCBO

SCR ELEKTRONIKS have developed Test Set up for carrying out Routine Tests namely, “Tripping Test” and “Performance of the Test Device Test” as per IS12640-2000 & IEC 61008 Clause 9.1.3 (Annexure D). The panel is designed to perform routine test for RCCB in production line, automatically once the product is loaded in Test Fixture.

The system covers following tests:

Tripping Test Performance Test

Sensitivity Test:

During Sensitivity of I∆n trip cycle the trip time is recorded and compared with limit. The number of operation for verification is settable. Optionally, the recorded time is downloaded on the PC.


Speed of Operation Test:

A residual current is passed through each pole of the RCCB in turn. First current equal to 0.5I∆n is passed (No Trip current) and verified that the RCCB does not trip. Then current equal to I∆n is passed and checked that the RCCB trips for each pole. After each trip, the pneumatic fixture will reset the RCCB for next trip operation.


Performance of the Test Device (Push button test):

This test checks the functioning of test devices (push button), whether the RCCB trips when push button is pressed. Specially designed Electro-pneumatic fixture is design in such a way that all the tests are perform automatically & results are stored in memory of the specially designed Micro Controller Based Unit. Test results are downloaded on PC through RS232C port.


Specifications:
Type Test Bench for RCCB & RCBO

SCR Elektroniks have designed this system to carryout the type test namely, Verifications of Operating Characteristic as per IS 12640 & IEC 61008 clause No. 9.9 & 9.15, 9.16. This is useful for checking the exact tripping value of current and also provides a facility to measure the tripping time at different leakage current.

The equipment covers:
Verification of the correct operation in case of a steady increase of the Residual current (Clause 9.9.2.1)
Verification of the correct operation at closing on residual current (Clause 9.9.2.2)
Verification of the correct operation in case of sudden appearance of Residual current (Clause 9.9.2.3)
Verification of the correct operation in case of sudden appearance of Residual currents of values between 5 * l∆n and 500A (Clause 9.9.2.4)
Verification of the trip-free mechanism (Clause 9.15) Verification of the operation of the test device at the limits of rated voltage (Clause 9.16)

The system comprises of:
Variable Current Source:
There are two current sources namely,
    Adjustable between 15 mA to 2500 mA through steps & fine control at 230 VAC input.
    Adjustable between 5 Amp. to 500Amp at 4 volt AC (Short Time) Programmable

Micro Controller based unit:
This is with auto ranging from 00.001 sec. to 99.999 sec.( +/- 0.5% Accuracy)
The unit is used
1. For Measurement of the Trip Time in millisecond.
2. Setting Low & High time limits.
3. Indication of Test Results: OK, EARLY TRIP, LATE TRIP

Digital Transient Signal Recording Meter : This will have following full scale ranges : 10mA, 50mA, 100mA, 250 mA, 500mA, 1A, 2.5A. Full scale.

Digital Ammeter with CT ranges: 200mA, 2A, 20A.

Adjustment Of current from 2mA to 2500mA at 230 Volts and 5 to 500A at 4 volts Max.( short time) through steps and fine control.

Facility to covers I∆n 10mA, 30, 50, 100, 300, 500, mA between 0.2 IΔn to 5 IΔn.


SPECIFICATIONS:

Leakage Current Ranges IΔn : 10mA, 30mA, 50mA, 100mA, 300mA & 500mA.
Current Adjustment: Between 10mA to 2500mA at 230V AC, Coarse with Switching and Fine with Toro pot to cover 0.2 IΔn to 5 IΔn. 500A at 4 volt maximum.
Current Measurement: Digital mA Meter, 3 ½ Digit, 3 ranges with 0.5 % accuracy.
Transient Signal Recording Meter with 1.0 % accuracy.
Test Results: On digital display with Early / OK / Late Trip.
Time Measurement: 5 Digits a) 0 to 99.999 Sec. & b) 1 mSec Mains Supply : 230 V AC, 50Hz
Single Phase Protection: Through MCB
Cabinet : Table Top enclosed in elegant Alluminium Profile section with Powder Coating.
Other specifications as per customizations / user dependant test parameters or standards.
Size : 850mm X 650mm X 500mm


High Voltage Test Set Up For RCCB/RCBO Model : TB-RCB-50

SCR ELEKTRONIKS have developed a simple but speedy tool for carrying out Routine High Voltage Test (Electric Strength Test) in Production line as per IS:12640 & IEC: 61008 Clause No. 9.1.3, Annexure D-2.

 

*  There will be conventional High Voltage Breakdown Tester incorporated in the set up. Specially designed electropneumatic fixture is fully enclosed with safety features. Loading & Unloading is manual.

The fixture will be suitable for RCCB/RCBO

    a) 1 number of Four Pole  b)  2 numbers of Two pole. 

*  Selection of poles, and  making On/Off  operations is automatic.

*  Product is loaded in fixture in On condition Selection of 2 pole/ 4 pole is provided with switch.

*  Test is sequenced through Programmable Timer.  Duration of  test at  each step is Programmable (default – 1sec.)

 

*  The Test sequence is

 a) Between input and output terminals of the RCCB/RCBO (in “Off” position).

 b) Between each pole in turn and other poles connected together.

 *  Fixture is suitably mounted on the test bench & its functioning is integrated with the Program of the test bench.

SPECIFICATIONS:

 Test Voltage   : 0- 5 kV variable

Leakage Current: 10, 20, 50, 100, 200mA in steps.

Sequential Testing Facility:  For Four Pole One number OR Double pole two numbers RCCBs at a time.

Controls: Programmable timer to perform tests as per the requirement of the standard.

Indications:

  1. Lamp:  Mains, HT On, ‘PASS’ ‘FAIL’.

  2. Meters: Digital Voltmeter for High Voltage , Digital Ammeter for leakage Current and  Digital  Timer for Time.

 Mains Supply: 230 V AC, 50Hz

 Cabinet: In elegant Alluminum Profile section.

 Overall accuracy of the panel is better than class 2.0