MCC Panel Operation Testing

Motor control centres are just an assembly of combination starters under one roof. A
combination starter is a solitary arena consisting of fuses, circuit breaker, motor starter and an
instrument for cutting off power. Other equipment related to the motor like indicator lights and
pushbuttons are also incorporated sometimes. These generally consists of main vertical and
horizontal bus bars, incoming air circuit breakers, outgoing starter modules with MCCB or
Switch Fuse Unit, contractors, overload relays etc.

Why is MCCP Operational Test Necessary?

Motor control centre panel mechanism funds opening of breaker when any errors arises such as
over voltage or over current, short circuit current etc. It consists of various different relay coils,
limit switches, tripping coil, motor, closing coil and also various contacts which are unified to
support accurate operations. The internal operations and added facilities, which consists of
various safety indicator and extra safety system differs from switchgear to switchgear. So we
have control panels whose internal structural component differs along with various pin socket
and different supply voltage along with separate wiring diagram.

Testing of MCCP system is one of the crucial step in the installation. Testing checks for defects
at early on and makes sure correct operation of the system and also gives more consistent and
secure functioning of the system. The whole operational test must be performed in order to
provide supreme precision and safety.

Our engineers are experts in testing & commissioning MCC panels and our objective is to lay
down the testing & commissioning necessities to be carried out on electrical installations in
corporate industries and needs to be permitted from government authorities. These necessities
are valid to both new installations upon completion and existing systems after huge alternations.

What is Done During MCCP Operational Test?

Insulation Resistance, Fault level withstand, continuity of conductors and earth (inc neutral earth
bonds if present) conductor identification, single pole CPD’s in the phase conductors, barriers,
electrical separation, current ratings and full functional testing including overload setting for
motors. Add to that all labels present, paint finishes acceptable, mechanical stability as a whole
and of components etc.

Testing requirements are:

• Test insulation resistance of MCC bus with a 1-minute test (phase to phase and phase to
ground).
• Test insulation resistance of instrument transformers and control power with a 1 minute
test at appropriate voltage.
• Test insulation resistance of contactor (closed position) with a 1-minute test (phase to
phase and phase to ground).
• Test contactor contact resistance with micro-ohmmeter.
• Test reliability of every vacuum interrupter on a vacuum contactor in agreement with
manufacturer’s standards.
• Calibrate and test each protective relay with settings on devices being in accordance with
approved relay settings summary or coordination study.
• Test contactor drop out time if power disturbance ride through is indicated.
• Test operation of all space heaters including switching and indicating devices.
• Test CT circuit by applying current to the CT primary circuit and verifying operation of
all applicable relays and metering devices.

Necessary tools are:

 • Portable Hand tools
• Step Ladder
• HV Test kit
• Secondary injection kit
• Insulation resistance tester
• Multimeter

How is MCCP Operational Test Done?

Pre commissioning procedure for motor control centre:

• Make sure that the MCC installation is perfect and all mechanical and electrical notes on
installation ITRs are finished & approved.
• Ensure that no damage has occurred between mechanical completions &
precommissioning.
• Repair/replace damage components, if any.
• Check for the location of installation is free or any water or construction debris.
• Make sure that the Motor Control Centre are correctly identified and tagged, service wise
and location wise as specified.
• Ensure that the wiring termination to the Motor Control Centre are complete, tight &
secure.
• Ensure that the outgoing cables, power & control from the MCC are terminated.
• Make sure that the earthing of the MCC has been executed.
• Ensure all BMS wiring has been completed.
• Ensure that the cables to the MCC are properly tagged & identified.
• Ensure that the rating of the breakers (ACB, MCCB.MCB ELCB, relays, contactors
timers etc. are as per approved shop drawings & schedules.
• Ensure that overload relays are selected & set as per the actual connected load.
• Ensure that emergency stop switches are provided.
• Ensure the metering connections are proper.
• Check manually the breakers of all the cubicles in the MCC.
• Check the electrical & mechanical interlock between star & delta starters.
• Check for proper sliding of the cubicles in the rails for all draw out modules.
• Check the termination of the cables to the bus bats are tightened to the required torque
using torque.

Insulation Resistance Test

• Isolate all incoming & outgoing cables.

• Apply a voltage of 500 volts Dc between phase R to earth for 1 minute with phase Y, B
& N shorted & earthed & record the values.
• Repeat the test for other phases as well

Power Frequency Voltage Test

 • Connect the HV lead from step up transformer to R-phase
• Short the Y & B phase and connect to earth. Also connect the enclosure to earth.
• Switch on the test kit control unit and apply the recommended test voltage (by increasing
gradually) for 1 minute to R phase with respect to other phases earthed and grounded
• Record the leak current
• After 1 minute gradually reduce the test voltage to zero and then switch off the test kit.
Discharge pole and also the test kit.
• Repeat the test for Y phase and B phase and tabulate the result.

Secondary Injection Test

• Verify the stiffness of secondary connections to the entire metering circuits.

• Inject the nominal secondary values step by step using secondary injection kit to the
power schemes and tabulate the output values as per the ratings of meters.

Commissioning procedure for motor control center

• Make sure that all the pre-commissioning verifications are executed effectively.
• The incoming supply of the Motor Control Center shall be measured for current, voltage,
frequency & phase sequence
• The outgoing feeders shall be energised one by one and the supply shall be measured for
voltages
• Check the metering functions for proper operation and correct readings
• Check the functionality of starters in manual mode
• By keeping the selector switch in AUTO mode check the functionality of starters by
simulation
• Check the earth leakage trip facility
• Check incomer trip setting
• Check over load relay setting
• Check timer setting
LV/MV Motor Control Center (MCC) Testing Procedure | Method
Statement
June 7, 2021 by Zahid1078

LV/MV Motor Control Center (MCC) Testing Procedure |

Method Statement
Current transformer (CT) test procedure:

a- Test objective:

– This test is considered as one of the main test, it’s aimed to test:

1. Current transformer ratio.

2. Current transformer polarity.
3. Burden of current transformer.
4. Knee point of current transformer.
5. Current transformer winding resistance.
6. Magnetization curve of current transformer.
7. Megger test (insulation test).

b- Required Equipment:

1. Current transformer (CT) analyzer.

2. Megger.

c- Mechanical check and visual inspection:

1. Check tightness of all connection.

2. Check ferrules.

d- Current transformer analyzer connection:

1. CT analyzer has 4 leads, two should be connected to primary side which contains primary side of
CT and other two should be connected to secondary side of CT which you want to check its
ratio.
2. After connecting CT analyzer through laptop and using CT analyzer software, test can be started
and result can be printed out for CT ratio, CT polarity, CT burden, CT knee point & CT winding
resistance.
3. This result should be compared with current transformer factory test and be sure that result
within acceptable tolerance.
4. To measure the burden: Inject 1 ampere on secondary side of CT, and using multi-meter you can
measure voltage calculate burden by multiply voltage and current and compare it with CT
Buden.
 5. To test insulation: Using megger by 1 kilo volt injection for 1 minute, this test should be done
between primary to secondary, Primary to ground and secondary to secondary.
6. See figure.1 which shows CT analyzer connection for CT TEST.

Figure.1 CT analyzer connection

Voltage transformer (VT) test procedure:

a- Test objective:

– This test also is considered as one of the main test and its purpose is to test:

1. Voltage transformer ratio.

2. Voltage transformer polarity.
3. Voltage transformer winding resistance.
4. Megger test (insulation).

b- Required equipment:

1. CPC100.
2. Multi-meter (Fluke).
c- Mechanical checked and visual inspection:

1. Check tightness of connection.

2. Check ferrules.

d- Voltage transformer test connection:

1. Connect two leads from CPC device to primary side of voltage transformer and other two lead of
CPC with secondary side of VT, then press start from VT page of CPC.
2. Using CPC with same connection but from different page, you can measure winding resistance.
3. To check the loop burden: inject the rated secondary voltage and measure the current. Burden
will be the injected voltage measured current and then compare it with VT burden.
4. Insulation test: Using megger to test insulation by 1 kilo volt injection for 1 minute, this test
should be done between primary to secondary, primary to ground and secondary to ground.
5. See figure.2 which shows connection of VT Test.

Figure.2 show CPC100 connection to test

Trip Time test for Molded Case Circuit Breaker (MCCB) and megger test:

a- Test objective:

This test aimed to test the trip time for circuit breaker in case of over current or short circuit and
to be sure that tripping time within acceptable range.

b- Required equipment:

1. Primary injection tester. (Or special test kit to test the CB)
2. Megger

c- Timing and megger test connection:

 1. To test trip time: there are three setting in each MCCB first setting is (long = ‘L’), second is
(Short=’S’) and third is (Instantaneous=’I’).
2. To test (L): adjust L on min. setting which is considered percentage from rated current, inject the
setting current using primary injection tester and measure the time to be tripped, compare the
value of tripping time with the value of setting time if its within acceptable tolerance or not.
3. To test (S): adjust Son min. setting which is considered percentage from rated current, inject the
setting current using primary injection tester and measure the time to be tripped, compare the
value of tripping time with the value of setting time if its within acceptable tolerance or not.
4. To test (I): adjust I on min. setting which is considered percentage from rated current, inject the
setting current [if the value of injected current can be injected by tester as in some cases the
min value of (I) is equal to 10 and rated current is 500 A, so to test you should inject 5000
ampere which isn’t applicable] using primary injection tester and measure the time to be
tripped, compare the value of tripping time with the value of setting time if its within acceptable
tolerance or not.
5. To start megger test: this test is applicable for CB which rated current greater than 100 Amp.
when breaker open inject 5 KV for 1 minutes, between the same pole (red-red, yellow-yellow
and blue blue) and when breaker close inject 1 KV for 1 minutes between pole and ground,
between pole to pole.

Contact resistance test for bus bar and circuit breaker:

a- Test objective:

1. For contact Resistance, this test is aimed to measure the resistance of bus bar and for circuit
breaker after being installed in the site to avoid high resistance which may be results from
welding or installing in the site.
2. For high potential this test is aimed to measure and test the withstand of the insulations and
isolators against the high voltage without break down.

b- Required equipment:

Micro-ohm meter Contact resistance device.

c- Contact resistance test connection

1. Contact resistance device has 4 leads, two for current and others for voltage, it depend on
current injection on bus bar or circuit breaker then sense the voltage and calculate resistance by
divide voltage on current (ohm’s law)
2. Connect current leads between the device which you want to measure its resistance, connect
voltage leads on the same terminals of current then hold your hand on contact resistance
pushbutton, after few second the result will be displayed.
3. See figure.3 which shows connection of Contact Resistance Test.
 Figure.3 shows contact
resistance equipment connection

High potential for MV MCC bus bar and contactor:

a- Test objective:

For high potential this test is aimed to measure and test the withstand of the insulations and
isolators against the high voltage without break down.

b- Required equipment:

High potential test kit.

c- High potential AC test:

1. Insulation test by megger for 1 minute 3 phases line to line and line to ground.
2. Applying high potential AC voltage on the bus bar or contactor line to line and line to ground.
3. Take the record of passing current in mille Amperes from the high potential test kit.
4. Insulation test by megger for 1 minute 3 phases line to line and line to ground.
5. Compare the insulation test results to gathers before and after high potential test.

Miniature Circuit Breaker (MCB):

a- Test objective:

This test aimed to test the trip time characteristic of MCB if it’s within limits or no and check
MCB auxiliary contact if it is available.

b- Required equipment:
 1. Sverker (used as current source).
2. Multi-meter.

c- Mechanical checked and visual inspection:

1. Check tightness for all wires.

2. Check ferrules.
3. Check for physical damage or defect.

d- Test connection and procedure:

1. Connect sverker (which used as current source) direct to MCB, check MCB type and its rated
current value.
2. Inject from sverker twice of its rated current and measure the trip lime in which MCB will be
tripped, compare the measured trip time with its acceptable limit from MCB manual depending
on its type.
3. Auxiliary contact should be checked in both condition of MCB (open/close) and check that
auxiliary contact change its status from being open to close or vise, depending on its nature
Normally open or Normally close.

Auxiliary relay test:

a- Test objective:

This test aimed to test relay’s output contact, pick-up and drop off voltage, operating and
resetting time.

b- Required equipment:

1. Sverker (used as Voltage source and used its voltmeter).

2. Multi-meter [used as Ammeter].
3. Miniature Circuit Breaker 2Pole (MCB).

c- Mechanical check and visual inspection:

1. Check tightness for all wires.

2. Check ferrules.
3. Check for physical damage or defect.

d- Test connection:

i- Check output contact:

Our Auxiliary relay has several points, 2 used for Coil, before injecting any voltage on Auxiliary
relay’s Coil, check contacts at its normal condition which mean Normally Open (NO) contact is
being opened and Normally Closed (NC) contact is being closed, Inject the desired control
voltage of Aux. coil {which is normally 120 volt AC), at which Aux. relay will pick up that’s
mean its contact will change its position i.e NO contact will be closed and NC contact will be
opened.

ii- Pick-up and drop off current and voltage:

1. Pick up voltage can be measured using voltmeter when the coil voltage is increased gradually
from 0 volt , the Aux. relay will operate (i.e Contacts change its normal status No will be closed
and vice versa) at a certain voltage. This voltage is called pick-up voltage, Record the reading of
voltmeter and Ammeter which is pick-up voltage and current.
2. Drop-off voltage can be measured using voltmeter when the coil voltage on an operate relay is
decreased gradually, the relay will release (i.e its contact will return to its normal status) at a
certain
voltage. This voltage is called drop-off voltage, Record the reading of Ammeter which is drop-
off current.

iii- Operating and resetting time:

1. Adjust voltage source at the coil operation voltage of Aux. relay (in our case 120 v AC), To get
operating time, adjust sverker at (on+time location) and switched MCB ON, To get resetting
time, readjust voltage source at 120 volt AC and switch MCB OFF.

iv- Burden test:

1. Adjust voltage source (sverker) at 120 volt AC, select on position and make MCB ON.
2. Record reading of Ammeter.
3. Calculate burden by multiplying coil operated voltage and reading of Ammeter.

Ammeter and voltmeter test:

a- Test objective:

This test is aimed to calibrate and adjust the reading of ammeter and voltmeter test.

b- Required equipment:

FREJA 300.

c- Mechanical checked and visual inspection:

1. Checked tightness of all connections.

2. Checked ferrules.
3. Inspection for physical damage or defects.

d- Test connection and procedure:

1. Set the VT ratio (for voltmeter) and CT ratio (for ammeter).

 2. Inject different values (min. 3 values) of current (in case of ammeter) and voltage (in case of
voltmeter) and compare the injected values with reading values, calculate error in each reading
and check that its percentage error within the acceptable range.

Current transformer loop:

a- Test objective:

This test aimed to check all current transformer loop, starting from first panel and distributed in
thewhole switchgear depending on scheme, check shorting facility in terminal block [if exist].

b- Required equipment:

1. FREJA (used as current injection).

2. Multi-meter.
3. Mini- clamp.

c- Mechanical check and visual inspection:

1. Check tightness of all connection.

2. Check ferrules for the whole looping.
3. Check the single earth point.

d- Test connection

1. Connect three phase current from FREJA to secondary side of current transformer, inject three
phase current by different values and use mini-clamp to measure current in each phase and
follow the loop until the last point.

Voltage transformer loop:

a- Test objective:

This test is aimed to check the whole loop of VT starting from first panel and distributed in the
whole substation depending on scheme (i.e. metering or protection purpose)

b- Required equipment:

1. FREJA.
2. Multi-meter.

c- Mechanical check and visual inspection:

03 Check all voltage transformer loops.

d- Test connection:
Connect FREJA which considered as voltage source to secondary side of VT, inject three phase
voltage with different values on each phase and then use multi-meter to measure the voltage on
the whole loop starting from first panel to different location depending on the function of each
VT.

Primary injection test:

a- Test objective:

This test aimed to check that the selected ratio of current transformer is correct and current
transformer relay setting is OK and considered as back-up test of CT loop.

b- Required equipment:

1.
1. Primary Injection Tester.
2. Multi-meter.
3. Mini-clamp.
4. Power-clamp meter.

c- Mechanical check and visual inspection:

Check that all current transformer terminal block is tightened and normalized.

d- Test connection:

1.
1. Connect Primary Injection Tester to inject current on bus bar including current
transformer.
2. Start injection of current, using power clamp we can measure the injected current to
make sure that injected current which appear on screen of primary injection tester is
same as the actual injected current, then using of mini-clamp, we can measure the
current at each point of the loop and read the primary current value on each relay.

MCC Function test:

a- Test objective:

This test is considered as a major test or combined test for the whole work in MCC panels and
finalizing phase for MCC panels.

b- Required equipment:

No equipment used.

c- Mechanical checked and visual inspection:

Inspect for the whole panel if any missing or damage device which can be resulted from
installation.

d- Test procedure:

1. Check the circuit of closing command for contactor.

2. Check the circuit of opening command for contactor.
3. Check mechanical interlock.
4. Check interlock of closing the contactor.
5. Check alarm signal from source up to relay.
6. Check inter trip between upper voltage level CB and switchgear CB, between lower voltage
levels CB and switchgear CB.
7. Confirm the relay logic.

Protection relay (Main relay):

a- Test objective:

This test aimed to test function of main relay according to approved final setting for each one,
but here we generally discussed main function which should be exist in most of approved final
setting.

b- Required Equipment:

1.
1. FREJA 300.
2. Multi-meter.
3. Wires.

c- Mechanical check and visual inspection:

1.
1. Check for physical damage or defects.
2. Check case earth.
3. Check indication and LEDs.
4. Check test switch for correct operation either shorting CT if exist or isolation of binary
inputs/outputs.

d- Burden test

1.
1. Adjust voltage source at 120 volt AC.
2. Record reading of Ammeter in case of all binary output deactivated and in case of binary
output activation.
3. Calculate burden in case of normal operation (all binary output deactivated) and
abnormal operation (in case of binary output activated) by multiplying voltage and
reading of ammeter.
 4. Compare the result with existing burden exist in relay manual.

e- Test connection and test procedure:

i. Binary input/output check:

1.
1. To test binary input: Apply rated binary input DC voltage on each input and verify the
status of the input through relay’s software or from relay’s LCD [if exist].
2. To test binary output: Using relay’s software you can force binary output to close for
certain time and using multi-meter you can measure binary output contact resistance it
should be around zero which indicates binary output being closed.

ii. Measurements

1.
1. Set CT ratio and VT ratio which used to the relay by studying the scheme.
2. By using FREJA we inject secondary rated voltage and secondary rated current
3. Record the primary value reading at relay’s screen.

iii. Instantaneous earth fault (50N):

1.
1. Pickup and drop off test: gradually increase secondary current to each phase separately
in steps, until the LED which you used to indicate inst. Earth fault to operate this is
considered pick-up value.
The current must be reduced in the same manner until the LED reset and then this
considered as drop-off value.
2. LED reset and then this considered as drop-off value.
3. Limits: then calculate the error and compare the error value with acceptable tolerance
error that exists in manual of relay.
4. Timing test: set each phase separately to amount of current equal to 22ls, then inject
this value of current and measure the time taken to close binary output of the relay
which indicates that inst. E.F.
5. Limits: then calculate the error and compare the error value with acceptable tolerance
error that exist in manual of relay.

iv. Time delayed earth fault (51 N):

1.
1. Pickup and drop off test: gradually increase secondary current to each phase separately
in steps, until the LED which you used to indicate inst. Earth fault to operate this is
considered pick-up value. The current must be reduced in the same manner until the
LED reset and then this considered as drop OFF value.
2. Limits: then calculate the error and compare the error value with acceptable tolerance
error that exists in manual of relay.
 3. Timing test: set each phase separately to amount of current equal to 2’2ls, then inject
this value of current and measure the time taken to close binary output of the relay
which indicates that inst. Earth fault.
4. Limits: Limits: then calculate the error and compare the error value with acceptable
tolerance error that exist in manual of relay.

Timing test for MV MCC Contactors and megger test:

a- Test objective:

This test aimed to test the closing/opening time for contactors and to make sure that there is no
pole discrepancies between poles (red, yellow and blue) and contactors closing/opening time
within acceptable range according to factory test result.

b- Required equipment

1.
1. SVERKER 670
2. Megger
3. Miniature Circuit Breaker 2Pole (2MCB)

c- Timing and megger test connection

1.
1. Connect the line 120V AC supply Through 1 pole MCB and the neutral direct to
Contactor coil for closing (in case of measurement of closing time) circuit or opening (in
case of measurement of opening time) circuit, for switching device that should be
tested.
2. To get closing/ opening time, the other pole of MCB will make start initiation for the
SVERKER to measure the time and then put sverker at (on+time location) and switch
MCB ON and then the main poles of contactor will make stop.
3. The displayed time of contactor closing / opening is time between start and stop
initiation. To start megger test when contactors open inject 2.5 KV for 1 minutes
between the same pole (red red, yellow-yellow and blue-blue) and when
breaker/contactors close inject 2.5 KV for 1 minutes between pole and ground, between
pole to pole.

Contact resistance test for contactors:

a- Test objective:

This test is aimed to measure the resistance of contactor after being installed in the site to avoid
high resistance which may be results from welding or installing in the site.

b- Required equipment

Micro-ohm meter Contact resistance device.

c- Contact resistance test connection:

1.
1. Contact resistance device has 4 leads, two for current and others for voltage, it depend
on current injection on contactors then sense the voltage and calculate resistance by
divide voltage on current (ohm’s law).
2. Connect current leads between the device which you want to measure its resistance,
connect voltage leads on the same terminals of current then hold your hand on contact
resistance pushbutton, after few second the result will be displayed.
3. The contactor shall be removed during test for visual inspection.
4. See figure.3 which shows connection of Contact Resistance Test.

RTD Relay Check:

a- Test objective:
This test is aimed to measure the resistance of temperature of MOTOR.

b- Required equipment:

Variable Resistance.

c- Test procedure:

1.
1. Connect +ve probe of resistor to the end of RTD Relay.
2. Connect -ve probe of resistor to the end of RTD Relay.
3. Adjust the resistance at certain value.
4. As per relay manual check the corresponding temperature value which will meet this
resistance.
5. Set the trip and alarm setting into relay and check it actual.