Cl. 9.

9 28 DAYS TEST OPERATING CHARACTERISTIC:

Scope: To verify the 28 days operating characteristics of the MCB.

Objective: The operating characteristics of the MCB shall be such that they ensure adequate
protection of the circuit, without premature operation. The operating characteristics of the MCB should ensure
their reliability of the operation.

Requirement:

1) Test bench for testing.

2) Temperature: 30°C (as per the requirement of the customer)
3) Wire of Standard Size. (Given in table)
Procedure:

1) The circuit breaker is subjected to 28 cycles comprising 21 hours with a current equal to the rated
current at an open circuit voltage of at least 30 V and three hours without current under the test
conditions explained below:
a) The connections should be in the free air and spaced not less than the distance between the
terminals.
b) The minimum length of each temporary connection from terminal to terminals is:
b.1) 1 m for cross-section up to and including 10 mm².

b.2) 2 m for cross-section larger than 10 mm².

c) The tightening torques to be applied to the terminal screws are 2/3 of the table given below:

Nominal Diameter of the thread (mm) Torque (Nm)

I II III
Up to and including 2.8 0.2 0.4 0.4
2.81 to 3.0 0.25 0.5 0.5
3.01 to 3.2 0.3 0.5 0.6
3.21 to 3.6 0.4 0.8 0.8
3.61 to 4.1 0.7 1.2 1.2
4.11 to 4.7 0.8 1.8 1.8
4.71 to 5.3 0.8 2.0 2.0
5.31 to 6.0 1.2 2.5 3.0
6.01 to 8.0 2.5 3.5 6.0
8.01 to 10.0 4.0 10.0
Note: ‘I’ indicates screw without head. ‘II’ indicate hexagonal head with slot for tightening with screw driver. ‘III’
indicates screws and nuts are tightened by means other than screw drivers underline indicate the torque and size
of screw head used by the Havell’s India Ltd.

2) The circuit breaker is in the closed position. The current being established and interrupted by an
auxiliary switch.
3) During the last period of the current flow the temperature rise of the terminal shall be measured.
The temperature rise shall not exceed the value measured during the temperature rise test by more
than 15°C.
4) Immediately after this measurement of the temperature rise, the current is steadily increased within
5s to conventional tripping current.
5) The circuit breaker shall trip within the conventional time.
 Cl. 9.10 VERIFICATION OF THE OPERATING CHARACTERISTIC UNDER OVERCURRENT
CONDITIONS:

Scope: To verify the Thermal tripping characteristics of the MCB.

Objective: The tripping characteristics of the MCB shall be such that they ensure adequate protection of the
circuit, without premature operation.

Requirement:

1. Test bench for testing.

2. Temperature: 40°C (as per the requirement of the customer)
3. Wire of Standard Size.
Procedure:

The tripping characteristics of the MCB are checked according to the IS 8828:1996 following the
procedure written below

a) A current equal to 1.13 times rated current (conventional non-tripping current) is passed for 1 hour starting from
the reference temperature i.e, 40°C. At this time the current was increased within 5 seconds to 1.45 times rated
current (conventional tripping current) and the tripping time recorded.

b) The zone of the time current characteristic (tripping Characteristics) of a circuit breaker is defined below in the
table:

Test Type Test Current Initial Condition Time Limit of the Status Remark
Tripping/Non-tripping

A B,C,D 1.13In Cold t≥1h (for In ≤63A) Non-

tripping
(Without t≥2h ( for In> 63A)
previous Load)

B B,C,D 1.45 In Immediately t< 1h (for In ≤ 63A) Tripping Current

following the Steadily
test A t< 2h (for In >63 A) increased
within 5s
C B,C,D 2.55 In Cold 1s <t< 60s (for In≤ 32 A) Tripping

(Without 1s <t< 120s (for In> 32A)

previous Load)

D B 3 In Cold t≥0.1s Non- Current

tripping established
C 5 In (Without by enclosing
previous Load) an auxiliary
D 10 In
switch

E B 5 In Cold t<0.1s Tripping Current

established
C 10 In (Without by enclosing
previous Load) an auxiliary
D 50 In
switch
 Cl. 9.10 VERIFICATION OF THE OPERATING CHARACTERISTIC UNDER OVERCURRENT
CONDITIONS:

Scope: To verify the Thermal tripping characteristics of the MCB.

Objective: The tripping characteristics of the MCB shall be such that they ensure adequate protection of the
circuit, without premature operation.

Requirement:

1. Deep Freezer vertical for testing.

2. Temperature: (-5)°C (as per the requirement of the customer)
3. Wire of Standard Size.
Procedure:

The tripping characteristics of the MCB are checked according to the IS 8828:1996 following the
procedure written below

a) A current equal to 1.13 times rated current (conventional non-tripping current) is passed for 1 hour starting
from the reference temperature i.e, (-5)°C. At this time the current was increased within 5 seconds to 1.9
times rated current (conventional tripping current) and the tripping time recorded.

b) The zone of the time current characteristic (tripping Characteristics) of a circuit breaker is defined below in the
table:

Test Type Test Current Initial Condition Time Limit of the Status Remark
Tripping/Non-tripping

A B,C,D 1.13In Cold t≥1h (for In ≤63A) Non-

tripping
(Without t≥2h ( for In> 63A)
previous Load)
B B,C,D 1.45 In Immediately t< 1h (for In ≤ 63A) Tripping Current
following the Steadily
test A t< 2h (for In >63 A) increased
within 5s

C B,C,D 2.55 In Cold 1s <t< 60s (for In≤ 32 A) Tripping

(Without 1s <t< 120s (for In> 32A)

previous Load)

D B 3 In Cold t≥0.1s Non- Current

tripping established
C 5 In (Without by enclosing
previous Load) an auxiliary
D 10 In
switch

E B 5 In Cold t<0.1s Tripping Current

established
C 10 In (Without by enclosing
previous Load) an auxiliary
D 50 In
switch

CONTINUE………..

Page:
. TESTING MANUAL

Rev. No. 00 / 00 Issue Date:

SECTION NAME: Testing Procedure

Cl. 9.10 VERIFICATION OF THE OPERATING CHARACTERISTIC UNDER OVERCURRENT

CONDITIONS:
Scope: To verify the Thermal tripping characteristics of the MCB.

Objective: The tripping characteristics of the MCB shall be such that they ensure adequate protection of the
circuit, without premature operation.

Requirement:
 1. Test bench for testing.
2. Temperature: 30°C (as per the requirement of the customer)
3. Wire of Standard Size.
Procedure:

The tripping characteristics of the MCB are checked according to the IS 8828:1996 following the
procedure written below

a) A current equal to 1.13 times rated current (conventional non-tripping current) is passed for 1 hour starting from the
reference temperature i.e, 30°C. At this time the current was increased within 5 seconds to 1.45 times rated current
(conventional tripping current) and the tripping time recorded.
b) A current equal to 2.55 times the rated current was passed for 60 seconds for ratings upto & including
32A, for 120 seconds for ratings greater than 32A from the reference ambient temperature i.e., 30°C.The
opening time of the breaker shall be not less than 1 second or; more than 60 seconds for rated currents
upto & including 32A, more than 120 seconds for rated currents greater than 32A.Tripping time recorded
in seconds.
c) The zone of the time current characteristic (tripping Characteristics) of a circuit breaker is defined below in the table:
Test Type Test Current Initial Condition Time Limit of the Status Remark
Tripping/Non-tripping

A B,C,D 1.13In Cold t≥1h (for In ≤63A) Non-

tripping
(Without t≥2h ( for In> 63A)
previous Load)

B B,C,D 1.45 In Immediately t< 1h (for In ≤ 63A) Tripping Current

following the Steadily
test A t< 2h (for In >63 A) increased
within 5s

C B,C,D 2.55 In Cold 1s <t< 60s (for In≤ 32 A) Tripping

(Without 1s <t< 120s (for In> 32A)

previous Load)

D B 3 In Cold t≥0.1s Non- Current

tripping established
C 5 In (Without by enclosing
previous Load) an auxiliary
D 10 In
switch

E B 5 In Cold t<0.1s Tripping Current

established
C 10 In (Without by enclosing
previous Load) an auxiliary
D 50 In
switch
APPROVED BY : UNIT HEAD ISSUED BY: M.R.

Page:

TESTING MANUAL Issue Date:

Rev. No. 00 / 00

SECTION NAME: Testing Procedure

Cl. 9.10.2 VERIFICATION OF THE OPERATING CHARACTERISTIC UNDER SHORT-

CIRCUITS CURRENT CONDITIONS:

Scope: To verify the Magnetic Tripping characteristics of the MCB.

Objective: The tripping characteristics of the MCB shall be such that they ensure adequate protection of the
circuit, without premature operation.

Requirement:

1. Test bench for testing.

2. Temperature: 30°C (as per the requirement of the customer)
3. Wire of Standard Size.

Procedure:

1. The current equal to 3 times of the rated current is passed through the MCB for 45 seconds for ratings upto
& including 32A, for 90 seconds for ratings greater than 32A from the reference ambient temperature i.e.,
30°C.
2. The opening time of the breaker shall be not less than 0.1 second and, not more than 45 seconds for rated
currents upto & including 32A, not more than 90 seconds for rated current above 32A.Tripping time
recorded.
3. The current equal to 5 times of the rated current is passed through the MCB from the reference ambient
temperature i.e., 30°C.The opening time of the breaker shall be less than 0.1 second. Tripping time
recorded.

Sample Testing Curve B6 B8 B 10 B 16 B 20 B 25 B 32 B 40 B 50 B 63

No. parameters
 At 3.0 In B 280 380 470 320 540 610 210 340 290 -
(>100ms)
1
At 5.0 In B 20 30 40 30 50 60 40 50 60 -
(<100ms)

At 3.0 In B - - - - - - - - - 320
(>100ms)
5
At 5.0 In B - - - - - - - - - 20
(<100ms)

At 3.0 In B - - - - - - - - - 690
(>100ms)
6
At 5.0 In B - - - - - - - - - 30
(<100ms)

At 3.0 In B - - - - - - - - - 730
(>100ms)
7
At 5.0 In B - - - - - - - - - 70
(<100ms)

APPROVED BY : UNIT HEAD ISSUED BY: M.R.

.
Page:
TESTING MANUAL

Rev. No. 00 / 00 Issue Date:

SECTION NAME: Testing Procedure

Cl. 9.7 VERIFICATION OF DIELECTRIC PROPERTIES OF MCB

Scope: To verify the Dielectric Properties of the MCB.

Objective: The Dielectric Properties of the MCB shall be such that they ensure adequate operation of the circuit
breaker, without premature operation.
Requirement:

1. Testing Oven.
2. Temperature: 20°C-30°C (as per the requirement of the customer)
3. Humidity 91-95%

Preparation of the circuit breaker for the test:

Inlet openings, if any are left open. If knock-outs are provided, one of them is opened. Parts which can be
removed without the aid of tool are removed and subjected to the humidity treatment with the main
parts; spring lids are kept open during this treatment.

Procedure:

1. The test specimen is kept under humidity chamber for 48 hours.

2. The humidity of the chamber is maintained by the humidity controller. `

Condition of the Circuit breaker after the test:

After this treatment the specimen shall show no damage within this standard and shall withstand the following
tests:

A) Insulation Resistance of the main circuit:

After an interval between 30 minutes and 60 minutes following this treatment insulation resistance is measured 5s
after the application of d.c. voltage of approximately 500V, consecutively as follows:

a) With the circuit breaker in the open position, between each pair of the terminals
which are electrically connected together when the circuit breaker is in closed position, on each pole in turn.
b) With the circuit breaker in closed position, between all poles connected together
and the frame including a metal foil in contact with the outer surface of the internal enclosure of the insulation
material, if any.
If the circuit breaker is provided with the a terminal intended for the interconnection of the protective conductors,
this terminal is connected to the frame.
The insulation resistance shall not be less than 2M. No flashover or breakdown shall occur during the test. Glow
discharge or breakdown without drop in the voltage is neglected.
A test voltage of 2.5 kV fro main circuits and 1 kV for auxiliary circuits where the insulation voltage does not
exceed 60V is applied for 1 minute as follows:
 1) Between all the auxiliary and control circuits, which are not normally connected to the main circuit connected together and the
frame of the circuit breaker;
2) Where appropriate between each part of the auxiliary and control circuits which may be isolated from other parts of the
auxiliary circuits and these other parts are connected together.

APPROVED BY : UNIT HEAD ISSUED BY: M.R.

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Page:

TESTING MANUAL
Rev. No. 00 / 00 Issue Date:

SECTION NAME: Testing Procedure

Cl. 9.14 RESISTANCE TO HEAT

Scope: To verify the HEAT RESITIVE CHARACTERSTICS of the MCB.

Objective: The heat resistive characteristics of the MCB shall be such that they ensure adequate
operation of the circuit breaker even at high temperature. This test checks the working of operation at
high temperature, means verify that whether the circuit breaker can work at desert area or not.

Requirement:

Testing Oven.
Temperature: 100° and 125°C (as per the requirement of the customer)
Standard Weight 20N (Ball Pressure)

Procedure:

1. The samples without removable covers if any, are kept for 1h in a heating cabinet at a
temperature of (100±2) °C; removable covers, if any, are kept for 1h in the heating cabinet ar
temperature of (70±2) °C.
2. after the test and after the sample have been allowed to cool down to approximately room
temperature, there shall be no excess to live parts which are normally not accessible when the
samples are mounted as per normal use, even if the standard test finger is applied with a force
not exceeding 5 N.
 3. External circuit breaker parts made of insulating material like chassis necessary to retain in
position current carrying parts of protective circuit are subjected to ball pressure test by means
of ball pressure apparatus.
4. The part to be tested is placed on a steel sport with the appropriate surface in a horizontal
position and a steel ball of 5mm dia is pressed against this surface with a force of 20N.
5. The test is made in a heating cabinet at a temperature of (125±2)°C
6. After one hour the ball is removed from the sample and then cools down within ten seconds to
approximately room temp.

Status of the test:

During the test samples shall not undergo nay change impairing their further use and sealing
compound, if any, shall not flow to such an extent that live parts are exposed. After the test, marking
shall still be legible.

Discoloration, blisters or a slight displacement of the sealing compound are disregarded provided that
safety is not impaired within the meaning of this standard.

The diameter of the impression caused by the ball is measured and shall not exceed 2mm.

APPROVED BY : UNIT HEAD ISSUED BY: M.R.

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Page:

TESTING MANUAL
Rev. No. 00 / 00 Issue Date:

SECTION NAME: - Testing Procedure

TEST CONDITION AS PER IS 8828/1996

Circuit breaker prepare for test as per IS 8828/1996 as following reference

Condition:
1. According to no. of poles ----individually

2. According to method of mounting -----vertically

3. According to reference ambient. Temp. -----25°C to 30°C

4 .According to protection ----Undue external heating and cooling.

5. According to method of connection. -----Circuit breakers are weird with the

appropriated cable specified in
following table-

Cross sectional area(S) mm² Values of the rated current In (A)

1 In≤6
1.5 6<In≤13
2.5 13<In≤20
4 20<In≤25
6 25<In≤32
10 32<In≤50
16 50<In≤63
25 63<In≤80
35 80<In≤100
50 100<In≤125

6. During the test no maintenance or dismantling of the sample is allowed.

7. The tightening torques to be applied to the terminal screws are two third of those
specified in the table.
APPROVED BY : UNIT HEAD ISSUED BY: M.R.

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Page:

TESTING MANUAL
Rev. No. 00 / 00 Issue Date:

SECTION NAME: Testing Procedure

Cl. 9.14 RESISTANCE TO HEAT

Scope: To verify the HEAT RESITIVE CHARACTERSTICS of the MCB.

Objective: The heat resistive characteristics of the MCB shall be such that they ensure adequate
operation of the circuit breaker even at high temperature. This test checks the working of operation at
high temperature, means verify that whether the circuit breaker can work at desert area or not.

Requirement:

Testing Oven.
Temperature: 100° and 125°C (as per the requirement of the customer)
Standard Weight 20N (Ball Pressure)

Procedure:

7. The samples without removable covers if any, are kept for 1h in a heating cabinet at a
temperature of (100±2) °C; removable covers, if any, are kept for 1h in the heating cabinet ar
temperature of (70±2) °C.
8. after the test and after the sample have been allowed to cool down to approximately room
temperature, there shall be no excess to live parts which are normally not accessible when the
samples are mounted as per normal use, even if the standard test finger is applied with a force
not exceeding 5 N.
9. External circuit breaker parts made of insulating material like chassis necessary to retain in
position current carrying parts of protective circuit are subjected to ball pressure test by means
of ball pressure apparatus.
 10. The part to be tested is placed on a steel sport with the appropriate surface in a horizontal
position and a steel ball of 5mm dia is pressed against this surface with a force of 20N.
11. The test is made in a heating cabinet at a temperature of (125±2)°C
12. After one hour the ball is removed from the sample and then cools down within ten seconds to
approximately room temp.

Status of the test:

During the test samples shall not undergo nay change impairing their further use and sealing
compound, if any, shall not flow to such an extent that live parts are exposed. After the test, marking
shall still be legible.

Discoloration, blisters or a slight displacement of the sealing compound are disregarded provided that
safety is not impaired within the meaning of this standard.

The diameter of the impression caused by the ball is measured and shall not exceed 2mm.

APPROVED BY : UNIT HEAD ISSUED BY: M.R.

TESTING MANUAL Issue Date:

Rev. No. 00 / 00

SECTION NAME: Testing Procedure

Cl. 9.11 MECHNICAL AND ELECTRICAL ENDURANCE

Scope: To verify the Mechanical and Electrical Endurance of MCB.

Objective: The l Electrical Endurance test of the MCB shall be such that they ensure adequate operation
of the circuit breaker even Rated Current shall substantially sine-wave form and power factor shall be
between .85 to0.9. This test checks the working of operation of Circuit breaker is submitted to 4000
operating cycles
at Rated current.

Requirement:

1. Endurance Test Set-up Control Desk 2 .Load Bank (1A-125A)

3. Testing Bench with 3-phase with Neutral. 4. Cables as per IS 8828/1996

Procedure:

1 The Circuit Breaker is connected to the circuit with conductors of appropriate size as per IS 8828

the circuit Breaker is fixed to metal support as Din rail

2 The test is made at rated voltage at a current adjusted to rated current wise means of resistors
and reactors in series connected to load bank.
3 The current shall have substantially sine wave form and power factor shall be between 0.85
to0.9.
4 For single pole circuits breakers with rated voltage 230/400 V the test shall be carried out at the
lower voltage value.
5 The circuit breaker is submitted to 4000 operating cycles with rated current and each operating
cycle consists of making operation followed by a breaking operation.
6 For circuits breakers of rated current up to and including 32A the operating frequency shall be
240 operating cycle per hour. During each operating cycle the circuits breakers shall remain
open

for at least 13 Second.

7 For circuits breakers of rated current above 32 A the operating frequency shall be 120 operating
Cycle per hour during test C.B shall remain open for at least 28 Second.

Status of the test:

After the test samples shall not show

- Undue wear

- Damage to the enclosures permitting access to the live parts by the test finger.

- Loosening of electrical or mechanical connections.

- Seepage of sealing compound.

 APPROVED BY : UNIT HEAD ISSUED BY: M.R.

GLOW WIRE TEST

.
Page: 1 OFF I

SECTION NAME: : GLOW WIRE TEST

Cl. 9.15 RESISTANCE TO ABNORMAL HEAT AND FIRE( GLOW WIRE

TEST)

Scope: To verify the RESISTANCE TO ABNORMAL HEAT AND FIRE

Objective: The glow wire test is applied to ensure that an electrically heated test wire under defined
test conditions does not cause ignition of insulating parts

Requirement:
 Testing Appratus: Glow wire test apprataus
Temperature: 960±30°C and 650±15°C (as per the requirement of the customer)

Procedure:

1. The Moulding parts shall be positioned during the test in most unfavourable position of its
intended use (with surface tested in a vertical position). The tip of the glow wire shall be applied to
the specified surface of the test sample taking into account the conditions of intended use under
under which a heated or glowing element may come into contact with the sample..

Status of the test:

The sample is regarded as having passed the glow wire test if:

- there is no visible flame and no sustained glowing.

- flames and glowing on the sample extinguish themselves within 30s after the removal of the glow-
wire

There shall be no ignition of the tissue paper or scorching of the pinewood board
APPROVED BY : UNIT HEAD ISSUED BY: M.R.