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Test Equipment for Residual Current Circuit Breakers such as RCCB (ELCB) & RCBO; and Compliance Verification Benches for conformity assessment as per IEC 61008, IEC 61009, IEC 60898 & other standards.


We design and manufacture test equipment and automation solutions for testing and production of residual current circuit breakers with overload protection, residual current circuit breakers & earth leakage circuit breakers.
Some of our recent solutions are listed here. These facilitate testing of circuit breakers as per various standards such as IEC 61008, IEC 61009, IS 12640 and other referring standards. Please write to us for more details about our all test equipments for residual current CBs

We have the following customised test equipment for routine & type testing of RCCB, RCBO & ELCB

For Tests common to RCBO & MCB, please browse to  Testing Solutions for Miniature Circuit Breakers

 

This table shows the various test equipments for residual current devices (Refer to our operating manuals for testing procedure of residual current devices & earth leakage circuit breakers as per IEC standard reccomendation). The description of some test equipment is given further below.

LIST OF EQUIPMENT & FIXTURES  FOR TESTING OF ELCB, RCCB & RCBO AS PER IEC 61008, 61009 & IS : 12640 Part I &II (2000 & 2001)

Sr.

Name of Equipment/

Test Procedure for which to be used

IS Clause

No

Fixture / Instruments

 ref.

1

Test Bench for verification of operating characteristics. (sensitivity test bench)

Sensitivity Test

9.9.1(Annex D)

Speed of Operation Test

9.9

Push Button Test

9.9

Verification of Trip-Free Mechanism

9.11

2

28 Days Test Bench

28 Days Test

9.22

3

Temperature Rise Test Bench

Temperature Rise Test ( RCBO)

9.8

4

Electrical Endurance test bench

Mechanical & Electrical Endurance test (RCBO)

9.1

5

Glow wire Test Apparatus

Resistance to abnormal heat & fire

9.15

6

Megger

Dielectric properties

9.7.2

7

H. V. Tester

Dielectric properties

9.7.3

8

1. Rigid Finger

Protection against electric shock

9.6

2. Flexible Finger

Resistance to heat

9.6

3. Control Panel For Test  Finger Apparatus

 

9.6

9

Ball pressure test Apparatus

Resistance to heat

9.14

10

Shock test Apparatus

Resistance to mechanical shock & impact

9.13.1

11

Impact test Apparatus

Resistance to mechanical shock & impact

9.13.2

12

Heating cabinet

Resistance to heat

9.9, 9.14 & 9.22

Resistance to rusting

13

Cooling chamber

Tripping characteristic test

9.9

Resistance to rusting

14

Humidity chamber

Dielectric properties

9.7 & 9.22

Resistance to rusting

15

Torque Screw Driver

Reliability of screw, current carrying parts & connections , Reliability of terminals for external conductor

9.4  & 9.5

16

Pully & weight arrangement

Reliability of terminals for external conductor, Resistance to Mechanical shock & impact

9.5 & 9.13

 

Test Equipment for RCCB/RCBO - (Model: TB-RCB-04)

This test equipment is developed for conducting tests on RCCB/RCBO, viz. Tripping Test and Performance of Test Device Test as per IS 12640-2000 and IEC 61008 Clause 9.1.3 (Annex D) listed below:

Tripping Test:

  1. Sensitivity Test: The RCCB should trip at a value of pre decided residual current (I∆n); and should not trip at a value of 0.5 I∆n.
  2. Speed of Operation Test: During the sensitivity trip test, time of tripping is recorded and compared with the limit.

Performance of Device Test: To check the function of the push button, whether the RCCB trips when push button is pressed.

Salient Features and Specifications:

Product Images (Click on images to zoom):
Automatic Routine Test Equipment for RCCB/RCBO


Portable Tester (Demonstration Kit) for RCD/RCCB - (Model: TB-RCB-01)

SCR ELEKTRONIKS have designed a Portable Tester (Demonstration Kit) for testing of residual current devices such as RCCB. This is handy tool for dealers or marketing personnel to give live demonstration as well as for field testing of RCD. This RCD tester can conduct the following tests:

Product Images (Click on images to zoom):
 Portable Tester for Earth Leakage Circuit Breaker


Automatic Test Equipment for RCCB/RCBO for carrying out Performance + Di-Electric Strength Test

The Test Bench is designed to carry out Routine Test of RCBO/RCCB/AOB + MCB as per Annexure D of IS 12640 (Part 2) 2008, Annexure D of IEC 61009-1:1996 Edition 2.2-2006 and Annex D of IEC 61008 Edition 2.1-2002-10.
The Test Equipment has PLC & SCADA with Touch Screen for monitoring and controlling the sequence. Optionally PC with specially designed TestWareTM can be provided for data-logging, user access control & report generation. It is designed for 2 Stations - simultaneous & independant.

    Test Sequence:
  1. Tripping Test as per your specifications for Ian – 30mA, 100mA, 300mA (User may specify the exact value). (Test D.1 in Annexure D)
  2. Electrical Strength Test (High Voltage) of Voltage 2.5 kV as per different combination of live and neutral poles for 4 pole or 2 pole products
    1. Test Upstream / Downstream (Conventional Di-electric testing with shorting of all live poles & all neutral poles and HV test between live pole and neutral pole) (test b in Annexure D.2)
    2. Test between each pair of terminal on either side: Live and Neutral (test a and c in Annexure D.2)
  3. Performance of Test Device (Push Button Test) (Test D.3 in Annexure D)

Special Fixture: In order to carry out the above test in a glass enclosed cabinet, special pneumatic-based fixture are designed and built as per the profile of RCCB. This fixture will be able to accommodate two RCCBs in 2 different test stations. These will be operated automatically (for the above test sequence) with the help of SCADA or TestWareTM.

The Test sequence will be as per the previous description. A pair of RCCBs will be tested in less than 25 seconds.

Product Images (Click on images to zoom):
 Test Equipment for RCCB/RCBO


Test Equipment for type-test of Residual current devices (Residual current circuit breaker & residual current circuit breaker with overload protection) for circuit breaker testing as per IEC 61008 or IS 12640

The device under test (RCCB) is also known as ground fault circuit interrupter (GFCI) or ground fault interrupter (GFI) or appliance leakage current interrupter (ALCI). This tests are also applicable to RCBO.

This test equipment for type testing of residual current circuit breakers incorporate 2 modules:
Module A: Test system to carry out the verification of operating characteristics. Test procedure as per IEC 61008–1 clauses 9.9.2.1, 9.9.2.2, 9.9.2.3, 9.15, 9.16 of RCBO / RCCB.
Module B: Test system to carry out the verification of correct operation at residual current with DC component. Test procedure as per IEC 61008 – 1, clauses 9.21.1.1, 9.21.1.2, 9.21.1.4 of RCBO / RCCB.

Description of Module A: Test system to carry out the verification of operating characteristics as per IEC 61008–1 clauses 9.9.2.1, 9.9.2.2, 9.9.2.3, 9.15, 9.16 of RCBO / RCCB:
Test 1: Verification of the correct operation in case of a steady increase of the residual current as per IEC 61008-1 clause 9.9.2.1. The circuit is arranged as shown in figure 4a of IEC 61008-1. The residual current is steadily increased with the help of variable resistance and current is displayed on meter. The tripping current of the RCCB is noted.
Test 2: Verification of the correct operation at closing on residual current as per IEC 61008-1 clause 9.9.2.2 (Commonly called as speed of operation test). The RCCB is closed with residual operating current set equal to I∆n, 2*I∆n & 5*I∆n in each pole one by one and the break time is measured (five times) and compared with the limiting value specified for corresponding I∆n in table 1 of IEC 61008-1.
Test 3: Verification of the correct operation in case of sudden appearance of residual current as per IEC 61008-1 clause 9.9.2.3. With the RCCB in closed position, the residual current (which is pre-adjusted) is suddenly established, as specified in table 1 of IEC 61008-1, by a switch and break time is measured and compared with the corresponding limiting values as specified in the table.
Test 4: Verification of the correct operation in case of sudden appearance of residual currents of values between 5*I∆n and 500A as per IEC 61008-1 clause 9.9.2.4. Test 2 & Test 3 are carried out with residual current of 500A at lower voltage and break time is compared with limit values specified in table 1 of IEC 61008-1.
Test 5: Verification of the trip-free mechanism as per IEC 61008-1 clause 9.15. A residual current equal to 1.5*I∆n is passed with RCCB in closed position and operating means (popularly termed as dolly) being held in closed position. It is verified that the RCCB trips. This is repeated by moving the dolly slowly over a period of approximately 1second to a position where the current starts to flow. It is verified that tripping occurs without further movement of the dolly.
Test 6: Verification of the operation of the test device at the limits of rated voltage as per IEC 61008-1 clause 9.16. The RCCB is supplied with a voltage equal to 0.85 times the rated voltage and the test device is momentarily actuated 25 times at 5s intervals, the RCCB being re-closed before each operation.

  1. The above test is then repeated at 1.1 times the rated voltage.
  2. The above test is then once repeated with the dolly held in the closed position for 30s.

Description of Module B: Test system for to carry out the verification of correct operation at residual current with DC component as per IEC 61008 – 1, clauses 9.21.1.1, 9.21.1.2, 9.21.1.4 of RCBO / RCCB:
Test 1: Verification of the correct operation in case of a continuous rise of the residual pulsating direct current as per IEC 61008-1 clause 9.21.1.1. This test is carried out with the current having delay angle a of 0-degree, 90-degree, 135-degree. The supply current is steadily increased and checked with limiting values as per table 17 of IEC 61008-1. The Verification at the reference temperature of the correct operation with load suggested in IEC 61008-1 clause 9.21.1.3 is possible with addition of special load and temperature oven.
Test 2: Verification of the correct operation in case of suddenly appearing residual pulsating direct currents as per IEC 61008-1 clause 9.21.1.2. With the RCCB in closed position and the pulsating current already set to test value, circuit is established with external switch and the break time is measured and verified with limiting value as per table 1 of IEC 61008-1. This test is carried out with both the polarities.
Test 3: Verification of the correct operation in case of residual pulsating direct currents superimposed by smooth direct current of 6mA as per IEC 61008-1 clause 9.21.1.4. The RCCB is subjected to half wave rectified residual current superimposed by smooth direct current of 6mA. The half wave current is steadily increased and checked that the RCCB of I∆n>10mA shall trip by current not exceeding 1.4I∆n + 6mA or for I<=10mA not exceeding 2*I∆n+6mA. The test is carried out for both the polarities.

Specifications:
  1. Input: Default is 230 V AC +\- 10%;  specify while ordering.
  2. Leakage Current Ranges: 5mA, 10mA, 30mA, 50mA, 100mA ,300mA & 500mA.
  3. Current Adjustment:
    1. Between 10mA to 2500mA at 230V AC, Coarse with Switching and Fine with Toropot
    2.  500A at low voltage
    3. Delay angle adjustment of 0-degree, 90-degree, 135-degree.
  4. Current Measurement: Digital mAmps Meter, 3 ½ Digit, 2 ranges.
  5. Transient Signal Recording Meter
  6. Time Measurement: 5 Digit 0 to 99.999 Sec.
  7. Protection: Through MCB.
  8. Fully automatic testing with TestwareTM - Custom-designed software for Control, Test Sequence, Data-logging, Report generation & User management.
  9. Other specifications as per customizations / user dependant test parameters or standards.
Product Images (Click on images to zoom):
type-test of Residual current devices
Virtual Instrument for Testware  SCADA IEC 61008



(For technical information on 28 days test and Endurance test of RCCB/RCBO, please refer MCB Test equipment page)

RCCB/RCBO Mini Test Set Up for Production Testing as per IEC 61008

The RCCB/RCBO leakage trip verification test set up is a table mounted set up for testing the operational characteristics of a residual current device (RCCB / RCD / RCBO) as per IEC 61008 and IEC 61009. The unit is designed mainly to perform the trip and no trip test (Clause 5.3.4, IEC 61008) and the push button test.

The unit comes with a custom built test jig designed to clamp & test the RCCB/RCBO.

The settings for the above tests are done with the help of a micro-controller based digital user interface. The user friendly micro-controller based interface module has an inbuilt digital timer to indicate trip time. There is a variable transformer based current source and relevant metering (ammeter and voltmeter) on the front panel. Other test settings can be done on a front panel with the help of a unique combination of selector switches in a simple manner even by a semi skilled operator. LED lamps complete the rest of the front panel interface.

The unit comes with a custom built test jig designed to test & clamp the RCCB/RCBO of a particular manufacturer. The test jig is expertly designed and the pole by pole supply is internal. It also accommodates the push button test where the user can push the push button on the RCCB with the help of the fixture.

The following tests can be carried out at rated voltage:

Specifications:

  1. Variable/ Current Source with resistive load of 0 to 500mA at rated voltage (mention rated voltage such as 240V while ordering).
  2. Selection of RCCB/RCBO rating with Rotary Selector Switch.
  3. Selection of No Trip and Trip Test with contactor and Push Buttons.
  4. Selection of Pole under test with Contactors and Push Buttons.
  5. Separate facility to set the current for No Trip & Trip without putting the RCCB/RCBO in circuit.
  6. Toggle clamp operated fixture with protective cover to test the RCCB/RCBO.
  7. Protection with MCB for input supply and for output.
  8. Indications:
    1. Digital Ammeter (True RMS) to indicate the set and test current. Having ranges of 0 to 199.99mA & 500.0mA AC.
    2. Digital Timer to indicate the trip time and to give the test results. Pass or Fail. Having range 0 to 99.999 sec.
    3. Digital Voltmeter to indicate the test voltage.
    4. LED Lamps to indicate pole under test, No Trip Test, Trip Test, Test ON, PASS, FAIL set mode.

Test Procedure: First user has to select the rating of the RCCB / RCBO and No Trip test with switch. Then the current can be adjusted with variac and by putting on the set mode. After current is set, put RCCB/RCBO into the fixture and then select pole with the help of Push Buttons and then push test ON. The NO Trip test will be carried out, if the RCCB/RCBO trips, then it will be declared as Fail. If it doesn't trip then, push OFF pole 1 and then check pole 2. In this way NO Trip test can be carried out on 1 to 4 pole. For Trip Test do not change any setting, only select Trip Test, the current will be automatically adjusted to trip value (i.e. IAN). Here user has to only follow the test sequence of NO Trip Test. If the RCCB/RCBO trips it will be declared as PASS and if it doesn't trip, then declared as FAIL. For Push Button Test, first put Test ON and then Press the Test Push Button of RCCB/RCBO.

Product Images (Click on images to zoom):
Test Kit for RCCB & RCBO      


Impulse Voltage With-stand Test Equipment (with automatic sequencing & polarity)

The Impulse Voltage Test Equipment is designed to generate impulse voltage (both polarity) of 1.0 KV to 20 KV depending on the model chosen. The waveform generated has a rise time of 1.2 micro second and 50 micro second duration. This instrument (suitable model based on peak voltage) incorporates testing as per the procedure described in IEC 61180, IEC 61010, IEC 60950, IEC 60065, IEC 60335-1, IEC 60230.

(Please write to us to check if specifications meet the standard requirements of those not listed here.)

The peak voltage can be adjusted from the front panel. The test sequence i.e. number of Impulse for Positive and Negative polarity, time between two subsequent impulses & so on can be programmed with the help of a dedicated controller 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 controller displays the number of cycles with polarities at which the failure has taken place.

Applications:
Impulse voltage tests are recommended with the object to determine effect of voltage stress on insulating due to voltage surges of short durations. 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).

 

Product Images (Click on images to zoom):
Impulse Voltage Tester Impulse Voltage Tester 20kV