Test Equipment 101 - The Basics of Electrical Testing

10/20/2020 Test Equipment 101: The Basics of Electrical Testing
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Test Equipment 101: The Follow TestGuy
Basics of Electrical Testing

It is the job of a test technician to know which
piece of test equipment to use for the task at
hand and also understand the limitations of the Popular topics right now
test equipment they are using.
What are the magnitude
and direction?
Percentage Differential
Electrical testing in its most basic form is the act of
Mismatch
applying a voltage or current to a circuit and comparing the
Shorting transformer
measured value to an expected result. Electrical test windings for PI, why is it
done?
equipment verifies the math behind a circuit and each
VCB with high DLRO
piece of test equipment is designed for a specific reading
application.
Outdoor Substation Rain
Safety
It is the job of a test technician to know which piece of test Transformer Testing
equipment to use for the task at hand and also understand Equipment- TTR
the limitations of the test equipment they are using. In this 15kv rated vacuum
breaker hipot test voltage!
article, we take a look at the most common pieces of test
equipment used in the field.
Test Your
Electrical test equipment should be considered a
source of lethal electrical energy. Technicians must
Knowledge
observe all safety warnings and follow all practical Sharpen your skills
safety precautions to prevent contact with energized with our collection of
quizzes on electrical
parts of the equipment and related circuits, including
https://testguy.net/content/296-Test-Equipment-101-The-Basics-of-Electrical-Testing 1/31
the use of appropriate Personal Protective safety, maintenance &

testing of electrical
Equipment.
equipment and
industry standards.
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Test Equipment 101: The Basics of

Electrical Testing
Circuit Breaker Control Schematic

Explained
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Solve Series and Parallel Capacitors
Digital multi-meters are the most common form of meter used today. Photo: Circuit Breaker Accessories
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Switchboard Ratings
Also known as a VOM (Volt-Ohm meter), a multi-meter is a Transformer Insulation Classes
handheld device that combines several measurement
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functions (such as voltage, current, resistance and
frequency) into a single unit.
Multi-meters are mainly used to troubleshoot electrical

problems in a wide array of industrial and household
devices such as electronic equipment, motor
controls, domestic appliances, power supplies, and wiring
systems.
Digital multi-meters are the most common form of meter

used today; however analog multi-meters are still
preferable in some cases, like when monitoring a rapidly
changing value or sensitive measurements, like testing for
CT polarity.
Megohmmeter
Megohmmeters are one of the most frequently used pieces of test equipment.
Photo: TestGuy
Most commonly referred to as simply a “megger”, a

megohmmeter is a special type of ohmmeter used to
measure the electrical resistance of insulators.
Resistances values by megohmmeters may range from

several megohms to several million megohms (teraohms).
Megohmmeters produce high voltages via battery powered
internal circuitry or a manually operated generator with
outputs ranging from 250 to 15,000 volts.
Megohmmeters are one of the most frequently used

pieces of test equipment and can be used to measure the
insulation of various types of apparatus such as circuit
breakers, transformers, switchgear and cables.
Related: Basic Test Equipment: Insulation Resistance

Tester
Low-Resistance Ohmmeter
10A DLRO (left) and 100A DLRO (right). Photo: Megger
Often called a DLRO in the field, the low-resistance

ohmmeter is used for making high-precision resistance
measurements below 1 ohm. Low-Resistance ohmmeters
produce low voltage DC currents via battery power with
outputs of up to 100A.
Resistance measurements are achieved with four

terminals, called Kelvin contacts. Two terminals carry the
current from the meter (C1, C2), while the other two allow
the meter to measure the voltage across the resistor (P1,
P2). With this type of meter, any voltage drop due to the
resistance of the first pair of leads and their contact

resistances is ignored by the meter.
Low-Resistance ohmmeters are one of the most frequently

used pieces of test equipment and can be used to
measure the resistance of various types of apparatus such
as circuit breaker and switch contacts, cable and busway,
transformers and generators, motor windings, and fuses.
Hipotential Test Set

(AC/DC/VLF)
Hipot test sets consist of a high voltage lead, a return lead, and a ground lead.
Photo: HV, Inc.
Dielectric withstand (or hipot) testing checks for good

insulation in medium and high-voltage apparatus, the
opposite of a continuity test. Insulation is stressed above
nominal values to ensure minimal current leaks from the
insulation to ground.
Hipot test sets consist of a high voltage lead, a return lead,

and a ground lead. The high voltage lead is connected to
the device under test with all other components grounded

and the resulting current is measured through the return.
If too much return current flows, the test set internal

protection will trip. The hipot test is a “go, no go” test,
meaning leakage current must not trip the test set but
there is no minimum acceptable value.
Output voltage can range anywhere from 1kV-100kV+ ac

at line frequency or dc depending on the device under test.
Very low frequency (VLF) withstand testing is the
application of an AC sinusoidal waveform, generally at
0.01 – 0.1 Hz, to assess the quality of electrical insulation
in high capacitive loads, such as cables.
Related: Power Cable Testing and Diagnostics Overview
High Current Test Set (500A to

15000A+)
Primary injection high current test set with circuit breaker attached. Photo:
Megger
A high current test set may consist of two pieces known as

a “control unit” and an “output unit”, or these functions may
be combined in a single package. Low voltage, high
current outputs are used for primary-injection testing of low
voltage circuit breakers.
The high current or “primary-injection” test set consists of

large transformers that step down line voltage (ex. 480V)
to a very low level, such as 2-15V. The large reduction in
voltage allows for a large increase in available current
output (15kA+), especially for a short duration.
Current output is controlled by a tap changer and variable

resistor. Integrated timers display the period between
current on and current off to indicate how long it takes for a
circuit breaker to trip.
Circuit breakers may be connected directly to the high

current test set via bus or cable. Depending on the size,
this type of test equipment can also used to test ground
fault and other current relays by connecting directly to
switchgear bus.
Secondary Test Set
Secondary test sets are designed by trip unit manufacturers to be used with a
single style or family of trip unit using a proprietary connection. Photo:
Switchserve
Circuit breakers with solid state and microprocessor trip

units can be tested by injecting secondary current into the
trip unit directly rather than passing primary current
through the CT’s using a high current test set. The main
shortcoming of the secondary current injection test method
is that only the solid-state trip unit logic and components
are tested.
Secondary test sets are designed by trip unit

manufacturers to be used with a single style or family of
trip unit using a proprietary connection. Test kits can range
from simple hand held, push button style in design to more
sophisticated “suitcase” units that operate similar to a
primary injection test set.
Hand held units are often used to defeat trip unit protective
functions, such as ground fault, when testing circuit
breakers via primary-injection.
Related: Primary vs. Secondary Injection Testing for

Circuit Breakers
Relay Test Set
Relay test sets are fitted with multiple sources to test solid-state and multi-
function numerical protection. Photo: TestGuy
These are power system simulators used for testing

protection devices used in industrial and power systems.
Relay test sets are fitted with multiple sources to test solid-
state and multi-function numerical protection, each voltage
and current channel is operated independently to create
different power system conditions.
High end relay test equipment can test not only simple
voltage, current, and frequency relays but also complex
protection schemes, such as communication-assisted line
protection, and protection schemes that use IEC61850-
compliant IEDs (intelligent electronic devices).
Related: Protective Relay Testing and Maintenance

Overview
Power Factor Test Set
Power Factor Test Equipment Examples. Photo: TestGuy
Power Factor Test Sets provide a comprehensive AC

insulation diagnostic test for high voltage apparatus, such
as transformers, bushings, circuit breakers, cables,
lightning arrestors, and rotating machinery.
Test voltages are generally 12kV and below, the power

factor test set measures voltage and current of the device
under test using a reference impedance. All reported
results – including power loss, power factor, and
capacitance – are derived from the vector voltage and
current.
Tests are made by measuring the capacitance and

dissipation factor (power factor) of a specimen. The values
measured will change when undesirable conditions exist,
such as moisture on or in the insulation; presence of

conductive contaminants in insulating oil, gas or solids;
presence of internal partial discharges etc.
Test connections include a single high voltage lead, (2) low

voltage leads and a ground. Safety switches and a strobe
light are included for operator protection and a
temperature sensor is used to correct test values. Power
factor test sets are usually operated with a laptop
computer connected via USB or Ethernet.
Related: 3 Basic Modes of Power Factor Testing
Winding Resistance Test Set
Transformer Winding Resistance Test Equipment Examples. Photo: TestGuy
Winding resistance measurements are an important

diagnostic tool for assessing possible damage to
transformer and motor windings. Winding resistance in
transformers will change due to shorted turns, loose
connections, or deteriorating contacts in tap changers.
Measurements are obtained by passing a known DC

current through the winding under test and measuring the
voltage drop across each terminal (Ohm's Law). Modern
test equipment for this purposes utilizes a Kelvin bridge to

achieve results; you might think of a winding resistance
test set as a very large low-resistance ohmmeter (DLRO).
Winding resistance test sets have (2) current leads, (2)

voltage leads and (1) ground lead. Typical current range of
a winding resistance test set is 1A-50A. Higher currents
have been found to reduce test times on high current
secondary windings.
Related: Transformer Winding Resistance Testing

Explained
Transformer Turns Ratio (TTR)

Test Set
Three-phase TTR testing connection diagram. Photo: EEP.
The TTR test set applies voltage to the high-voltage

winding of a transformer and measures the resulting
voltage from the low voltage winding, this measurement is
known as the turns ratio. In addition to turns ratio, the units
measure excitation current, phase angle deviation

between the high- and low-voltage windings and percent
ratio error.
Transformer turns ratio test sets come in a variety of styles

and test connections, however all turns ratio testers have
at least two high leads and two low leads. The excitation
voltage of a TTR test set is generally less than 100V.
Related: Introduction to Transformer Turns Ratio Testing
Current Transformer Test Set
Current Transformer Test Equipment Example Photo: Megger
CT test sets are small, multi-function units designed to

perform demagnetization, ratio, saturation, winding
resistance, polarity, phase deviation, and insulation tests
on current transformers. High-end CT test equipment can
directly connect to multi ratio CT’s and perform all tests on
all taps with the push of a button and without changing
leads.
Current transformers can be tested in their equipment

configuration, such as being mounted in transformers, oil
circuit breakers or switchgear. Modern CT with multiple
voltage and current outputs can double as a relay test set
when operated with a laptop computer.
Related: 6 electrical tests for Current Transformers

explained
Magnetron Atmospheric
Condition (MAC) Test Set
Magnetron Atmospheric Condition (MAC) Test Set Example. Photo: Vacuum

Interrupter Testing
Traditional field testing of vacuum interrupters utilizes the

hi-potential test in order to evaluate the dielectric strength
of the bottle, this test produces a go/no-go result that does
not determine when, or if, the gas pressure inside the
bottle has dropped to a critical level. Unlike the hipot test,
testing vacuum interrupters utilizing magnetron
atmospheric condition (MAC) principles can provide a
viable means for determining the condition of vacuum

interrupters prior to failure.
The magnetic field test is set up by simply placing the

vacuum interrupter into a field coil, which will produce a
DC current that remains constant during the test. A
constant DC voltage, usually 10 kV, is applied to the open
contacts, and the current flow through the VI is measured.
Ground Resistance Test Set
Ground Resistance Test Equipment with Accessories. Photo: AEMC
The ground resistance test set works by injecting a current

into the earth between a test electrode and a remote
probe, measures the voltage drop caused by the soil to a
designated point, and then use Ohm's Law to calculate the
resistance.
Ground resistance test sets come in a variety of styles with

the most common being the 4-terminal unit for soil
resistivity testing and the 3-terminal unit for fall-of-potential
testing. Copper rods or similar stakes are used to make
contact with the earth along with spools of small stranded
wire to cover long distance measurements.
Clamp-On Ground Resistance Testers measure ground

rod and grid resistance without the use of auxiliary ground
rods. They offer accurate readings without disconnecting
the ground system under test but come with limitations.
Related: 4 Important Methods of Ground Resistance

Testing
Power Recorder
There are many different types of power recorder which range in size, accuracy
and storage capability. Photo: Fluke
Power recorders are devices used to collect voltage and

current data which can be downloaded into software in
order to analyze electrical system conditions. These are
troubleshooting tools used to pinpoint electrical problems
such as voltage swells, sags, flicker and poor power factor.
Power recorders may also be used to measure power

consumption over a period of time, which is useful for
engineers planning to expand a system or customers who
wish to audit their energy bills. There are many different
types of power recorder which range in size, accuracy and
storage capability.
Installation of a 3-phase power recorder involves wrapping

conductors with split-core CT’s and clipping a set of leads
to system voltage and ground. The recorder is set up to
measure according to the system configuration for a
specified time period and can also be viewed in real time
using a PC or integrated screen.
Infrared Camera
Infrared cameras are available in a variety of styles and resolutions. Which

camera is best for an inspection depends on the type of equipment to be
inspected and the environmental conditions. Photo: TestGuy
Thermal imagers are camera that detect invisible infrared

radiation and convert that data into a colored image on a
screen. Infrared cameras are most commonly used for
inspecting the integrity of electrical systems because test
procedures are non-contact and can be performed quickly
with equipment in service.
Comparing the thermal signature of a normally operating

piece of equipment to the one being evaluated for
abnormal conditions offers an excellent means of
troubleshooting. Even if an abnormal thermal image is not
fully understood, it can be used to determine if further
testing may be required.
Thermal imagers are classified based on their accuracy

and detector resolution. High end infrared cameras feature
high resolution image capture and temperature accuracy
down to a tenth of a degree or less.
Related: Infrared Thermography for Electrical Distribution

Systems
Vibration Tester
As the machine under test operates, the accelerometer detects its vibration
along three planes of movement (vertical, horizontal and axial). Photo:
BrithineeElectric
Vibration analyzers are used to identify and locate the

most common mechanical faults (bearings, misalignment,
unbalance, looseness) in rotating machinery. As
mechanical or electrical faults develop in motors, vibration
levels increase. These increases in vibration and noise
levels occur at different severity of a developing fault.
Accelerometers are used to take vibration measurements

with the equipment in service and data is loaded into
software for analysis. As the machine under test operates,
the accelerometer detects its vibration along three planes
of movement (vertical, horizontal and axial).
Ultrasonic Tester
… robe® 15.000 Touch: Arcing, Tracking, Corona
Arcing, tracking and corona all produce ionization which

disturbs the surrounding air molecules. An ultrasonic tester
detects high frequency sounds produced by these
emissions and translates them down into human audible
ranges.
The sound of each emission is heard using headphones

and the intensity of the signal is observed on a display
panel. These sounds may be recorded and analyzed
through ultrasound spectral analysis software for a more
accurate diagnosis.
Normally, electrical equipment should be silent, although

some equipment such as transformers may produce a
constant hum, or some steady mechanical noises. These
should not be confused with the erratic, sizzling frying,
uneven and popping sound of an electrical discharge.
Ultrasonic detectors are also useful in the detection of air

leaks in transformer tanks and gas insulated circuit
breakers.
Load Bank
Load banks are available for a variety of applications and are usually sized by
kW rating. Photo: ASCO Avtron
Load banks are used to commission, maintain and verify

electrical power sources such as diesel generators and
uninterruptible power supplies (UPS). The load bank
applies an electrical load to the device under test and
dissipates the resulting electrical energy through resistive
elements as heat. The resistive elements are cooled with
motorized fans within the load bank construction.
Multiple load banks can be connected together if required.

Some load banks are purely resistive while others may be
purely inductive, purely capacitive, or any combination of
the three. Load banks are the best way to replicate, prove
and verify the real-life demands on critical power systems.
Battery Impedance Tester
Megger Bite 2P Battery Impedance Test Set
Battery Impedance Test Equipment is mainly used in

substation and UPS applications to determine the health of
lead-acid cells by taking measurements of important
battery parameters such as cell impedance, cell voltage,
inter-cell connection resistance and ripple current. All three
tests can be performed with a single unit.
The battery impedance tester works by applying an ac

current signal across an individual cell and measuring the
ac voltage drop caused by that ac current as well as the
current in the individual cell. It will then calculate the
impedance. The standard lead set used is dual-point,
Kelvin-style. One point is for applying the current and the
other for measuring the potential.
Battery Hydrometer
Specific gravity is measured using a hydrometer. Digital hydrometers like the one
pictured above are the easiest way to obtain readings. Photo: BAE Canada.
A battery hydrometer is used to test the state of charge of

a battery cell by measuring the density of the electrolyte,
which is accomplished by measuring the specific gravity of
the electrolyte. The greater the concentration of sulfuric
acid, the more dense the electrolyte becomes. The higher
the density, the higher the state of charge.
As a battery ages the specific gravity of the electrolyte will

decrease at full charge. The specific gravity is measured
by drawing a fluid sample into the test equipment and
obtaining a reading. Readings may be represented by a
float on a numerical scale or by a digital display.
Related: 3 Simple, Yet Effective Tests for Battery Systems
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10/20/2020 Test Equipment 101: The Basics of Electrical Testing

Test Equipment 101: The Follow TestGuy

Basics of Electrical Testing

the use of appropriate Personal Protective safety, maintenance &

Arc suppression circuits

Power Triangle Calculator

Test Equipment 101: The Basics of

Circuit Breaker Control Schematic

Protective Relay Protection Element

Capacitive Reactance - How to

Multi-meters are mainly used to troubleshoot electrical

Digital multi-meters are the most common form of meter

Most commonly referred to as simply a “megger”, a

Resistances values by megohmmeters may range from

Megohmmeters are one of the most frequently used

Related: Basic Test Equipment: Insulation Resistance

10A DLRO (left) and 100A DLRO (right). Photo: Megger

Often called a DLRO in the field, the low-resistance

Resistance measurements are achieved with four

resistance of the first pair of leads and their contact

Low-Resistance ohmmeters are one of the most frequently

Hipotential Test Set

Dielectric withstand (or hipot) testing checks for good

Hipot test sets consist of a high voltage lead, a return lead,

the device under test with all other components grounded

If too much return current flows, the test set internal

Output voltage can range anywhere from 1kV-100kV+ ac

Related: Power Cable Testing and Diagnostics Overview

High Current Test Set (500A to

A high current test set may consist of two pieces known as

The high current or “primary-injection” test set consists of

Current output is controlled by a tap changer and variable

Circuit breakers may be connected directly to the high

Secondary Test Set

Circuit breakers with solid state and microprocessor trip

Secondary test sets are designed by trip unit

breakers via primary-injection.

Related: Primary vs. Secondary Injection Testing for

Relay Test Set

These are power system simulators used for testing

Related: Protective Relay Testing and Maintenance

Power Factor Test Set

Power Factor Test Equipment Examples. Photo: TestGuy

Power Factor Test Sets provide a comprehensive AC

Test voltages are generally 12kV and below, the power

Tests are made by measuring the capacitance and

such as moisture on or in the insulation; presence of

Test connections include a single high voltage lead, (2) low

Related: 3 Basic Modes of Power Factor Testing

Winding Resistance Test Set

Transformer Winding Resistance Test Equipment Examples. Photo: TestGuy

Winding resistance measurements are an important

Measurements are obtained by passing a known DC

test equipment for this purposes utilizes a Kelvin bridge to

Winding resistance test sets have (2) current leads, (2)

Related: Transformer Winding Resistance Testing

Transformer Turns Ratio (TTR)

Three-phase TTR testing connection diagram. Photo: EEP.

The TTR test set applies voltage to the high-voltage