SMB BRIGHTEN SWITCHBOARD ENGINEERING SDN BHD
PLO 131, Kawasan Perindustrian Senai III,
81400 Senai, Johor,
Malaysia.
FACTORY TESTING PROCEDURE
This Factory Testing Procedure is specifically prepared for better
understanding of LV Switchboard testing procedure and method used to ensure a full
and proper testing is conducted in accordance with technical specification of LV
Switchboard Testing for electrical services.
The Factory Testing Procedure mentioned herein shall be read in conjunction
with approved shop drawings and project technical specification to ensure fully
compliances to the owner requirements and fulfill its high expectation on the products
quality. These also ensure smooth and proper implementation of the installation in
order for timely completion of work.
Main Switchboard / Essential Main Switchboard / AMF Board
a) Compliance with contract specifications, approved shop drawing standard &
codes and etc.
b) Quality inspection on workmanship, materials, surface defects, components,
painting, dimensions, clearance, labels, identification and etc.
Test Procedures for Physical Inspection Flow Chart
Approved Shop Drawing Standard
Check Paint of Finishing Switchboard
Check Structure of Finishing Switchboard
Check Dimension of Switchboard
Check Incoming/Outgoing Breakers Name Plate
Check Busbars Clearance & Colour Code
Check Outgoing Cables Termination
Check Bolt & Nut Tightening
Check Fiber and Plastic Partition
Check Breaker Operation ON/OFF
Check Breaker Interlock Key (if any)
Done
- Dielectric Test / Pressure Test
Dielectric Test will be carried out by applying a test voltage 2KV between
the exposed connectors and metal body of the switchboard frame for 60
seconds. All electrical equipment of the assembly shall be connected for
the test, except those apparatus, which according to the relevant
specification, are designed for a lower test voltage and current consuming
apparatus (e.g. Windings, measuring instruments) in which the application
of the test voltage would cause the flow of a current shall be disconnected.
Instrument used: 0~5KV High Voltage Test Set
(Kikusui: TOS5050)
Dielectric Test / Pressure Test Flow Chart
Dismantle all control wiring from main busbars R Y B N E
Apply 2kV to Red Phase and Earth for 60 sec. Meanwhile
Yellow Phase, Blue Phase and Neutral Phase shall be short
together. (Visually inspect, there shall not flash over occur 2kV
during the Test) Y R B N E
Apply 2kV to Yellow Phase and Earth for 60 sec.
Meanwhile Red Phase, Blue Phase and Neutral Phase shall
be short together. (Visually inspect, there shall not flash
over occur during the Test) 2kV
B R Y N E
Apply 2kV to Blue Phase and Earth for 60 sec. Meanwhile
Red Phase, Yellow Phase and Neutral Phase shall be short
together. (Visually inspect, there shall not flash over occur
during the Test)
2kV
Apply 2kV to Neutral Phase and Earth for 60 sec. N R Y B E
Meanwhile Red Phase, Yellow Phase and Blue Phase shall
be short together. (Visually inspect, there shall not flash
over occur during the Test)
Done 2kV
- Insulation Resistance Test
Insulation Resistance Test will be carried out by applying a DC500V
between the 3-phase, neutral and earth system of the switchboard.
Insulation resistance value will be recorded throughout the test.
Instrument used: 0~1KVDC Insulation Resistance Tester
(Kyoritsu: 3005A)
Insulation Resistance Test Flow Chart
Dismantle all control wiring from main busbars
Apply 500VDC to Red Phase and Earth.
Apply 500VDC to Yellow Phase and Earth.
Apply 500VDC to Blue Phase and Earth.
Apply 500VDC to Neutral Phase and Earth.
Apply 500VDC to Red Phase and Neutral Phase.
Apply 500VDC to Yellow Phase and Neutral Phase.
Apply 500VDC to Blue Phase and Neutral Phase.
Apply 500VDC to Red Phase and Yellow Phase.
Apply 500VDC to Yellow Phase and Blue Phase.
Apply 500VDC to Red Phase and Blue Phase.
Done
- Ratio and Polarity checks for Measurement Current Transformer (MCT)
and Protection Current Transformer (PCT) and accuracy of Ammeter.
o Primary Current Injection Test
This test will be carried out by injecting the actual value of current
through the current transformer to ensure proper working condition
of Overcurrent Relay and Earth Fault Relay to trigger auto tripping
function.
Instrument used: Primary & Secondary Injection Test Set
Leakage Clamp Meter (Kyoritsu: 2434)
Digital Clamp Meter (Kyoritsu: 2002)
Simple Diagram Primary Injection for Earth Fault Simulation
Outgoing
R Y B N
Current Injection
Current
Transformer
Incoming
Earth fault is creating by injecting current through one of the live phase (Red Phase,
Yellow Phase, Blue Phase). When the protection unit does not receive any feedback
from neutral phase but there is current pass through the red phase, the current pass
through the red phase will be consider as earth fault current. When the earth fault
current has reach the set point of the protection unit, a signal will be sent out to trip
breaker from the protection unit.
Simple Diagram Primary injection for Overcurrent Simulation
Outgoing
R Y B N
Current
Transformer
Incoming
Current
Injection
Overcurrent is creating by injecting current from live phase (Red Phase, Yellow
Phase, Blue Phase) and return through neutral phase. The current injected will be
double or 2x the setting current for low set (depend on system requirement) and for
high set might be 3x or higher (depend on system requirement). When the current has
flow through the live phase current transformer and return through neutral phase
current transformer reaching the setting point of the protection unit, a signal will be
sent out to trip breaker from the protection unit.
Overcurrent = load current (current injection) – breaker ampere trip (design current)
o Secondary Current Injection Test
This test will be carried out by injecting current directly to the
Protection Relay without going through the current transformer to
test Protection Relay accuracy.
Instrument used: Primary & Secondary Injection Test Set
Leakage Clamp Meter (Kyoritsu: 2434)
Simple Diagram Secondary Injection for Earth Fault Simulation
Outgoing
R Y B N
Current Current
Injection Transformer
Incoming
Earth fault is creating by injecting current through one of the live phase current
transformer (Red Phase, Yellow Phase, Blue Phase). When the protection unit does
not receive any feedback from neutral current transformer but there is current pass
through the red phase current transformer, the current pass through the red phase
current transformer will be consider as earth fault current. When the earth fault
current has reach the set point of the protection unit, a signal will be sent out to trip
breaker from the protection unit.
Simple Diagram Secondary Injection for Overcurrent Simulation
Outgoing
R Y B N
Current
Transformer
Incoming
Current
Injection
Overcurrent is creating by injecting current from live phase current transformer (Red
Phase, Yellow Phase, Blue Phase) and return through neutral current transformer. The
current injected will be double or 2x the setting current for low set (depend on system
requirement) and for high set might be 3x or higher (depend on system requirement).
When the current has flowing through the live phase current transformer and return
through neutral phase current transformer reaching the setting point of the protection
unit, a signal will be sent out to trip breaker from the protection unit.
Overcurrent = load current (current injection) – breaker ampere trip (design current)
Power Factor Regulator Simulation Test Flow Chart
Manual Operation Mode
Set PFC to Manual
Manual step by step In from C1 to C12
Manual step by step Out from C1 to C12
Auto Operation Mode
Set PFC to Auto
PFC will step by step In & Out from C1 to C12
Done
Auto ATS Control System Simulation Test Flow Chart
Auto Mode Selection
3Ø 400V to Main Source Breaker Busbars
3Ø 400V to Essential Source Breaker Busbars
The Main Source is always first choice
Cut Off power Main Source, ensure failure
ATS will transfer power from Main to Essential
On back power Main Source, ensure resume
ATS will transfer power from Essential to Main
Done
Manual ATS Control System Simulation Test Flow Chart
3Ø 400V to Main Source Breaker Busbars
3Ø 400V to Essential Source Breaker Busbars
Main Mode Selection
Main Source to supply outgoing only
ATS will not action taken, if failure or resume
Essential Mode Selection
Essential Source to supply outgoing only
ATS will not action taken, if power failure
Done
Off ATS Control System Simulation Test Flow Chart
3Ø 400V to Main Source Breaker Busbars
3Ø 400V to Essential Source Breaker Busbars
Off Mode Selection
Both Sources will not supply to outgoing
ATS will not action taken, if power failure
Done
Voltmeter Test Flow Chart
3Ø 400V to Main Source Breaker Busbars
Check Voltmeter in 3 Phases L-L (400V)
Check Voltmeter in 1 Phase L-N (230V)
Done
Ammeter Test Flow Chart
Secondary Injection directly apply to phase CT
Check each phase current is equal measurement
Done
Hz Meter Test Flow Chart
3Ø 400V to Main Source Breaker Busbars
Check frequency in line is 50Hz
Done
PF Meter Test Flow Chart
3Ø 400V to Main Source Breaker Busbars
Check PF is 1 in No Load Condition
Done
DPM Meter Test Flow Chart
3Ø 400V to Main Source Breaker Busbars
Check Voltmeter in 3 Phases L-L (400V)
Check Voltmeter in 1 Phase L-N (230V)
Check frequency in line is 50Hz
Check PF is 1 in no load condition
Check Power (KW), if loaded
Check Current (Amp), if loaded
Done
DC Ammeter Test Flow Chart
1Ø 230V to 30VDC Battery Charger Breaker
Check Battery Charger Current, if loaded
Done
DC Voltmeter Test Flow Chart
1Ø 230V to 30VDC Battery Charger Breaker
Check 30VDC Battery Charger Output is approximately 27VDC
Done
AMF Functional Simulation Test Flow Chart
DC24V to AMF control system
Manual Start Mode
Generator operated in Manual Start
Generator Run Lamp On
Turn On 3Ø 415V to Main Breaker Busbars
To conduct generator each one fault signal to control
(1)HWT, (2) OS, (3) LOP, (4) FLL, (5) OC/EFR
Each one fault will trigger Alarm Bell & Fault Lamp up
To mute Alarm Bell & Reset Fault Lamp
To repeat Manual Start for each fault test
Done
AMF Functional Simulation Test Flow Chart
DC24V to AMF control system
Auto Start Mode
Generator operated in Auto Start
Failure signal from EMSB to trigger Generator Start
Generator Run Lamp On
Turn On 3Ø 415V to Main Breaker Busbars
Generator will continuously start attempt 6 times, as set
more than that consider fail to start fault
Fail to start fault signal will trigger Alarm Bell & Fault Lamp up
To mute Alarm Bell & Reset Fault Lamp
Done
c) All the instruments used for the above testing are SIRIM calibrated.
d) All the results of testing will be recorded in the Factory Inspection Test Forms
under the ELE-TRMSB in our ISO 9001 Quality Control System.
