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Testing Of LV Switchgear

In line with providing the best quality LV switchgear panels & accessories to our clients, it is of utmost necessity to perform quality inspections and test all panels before delivery. The purpose of this document is to summarize the tests that are done in our factory on the low voltage electrical switchboards before being delivered to the site.

1. Visual Inspection

Visual inspection with customer will be carried out on the LV switchboard to:

  • Check the layout of fitted components.
  • Check the overall dimension of the switchboard, size of busbars, cables, and earthing conductors, and location of the feeder entry point.
  • Check and verify the brand, model, and circuit identification of components installed such as breakers, current transformers, fuses, ammeters, voltmeters, power meters, and protection relays, etc.
  • Check the rating of the components matches the approved drawings.
  • Check overall paintwork, door locking device, door gasket, door hinges, door cut-out holes.
  • Check the busbar and cable tightening, the marking, busbar clearance, base angle bar, and plinth.
  • Check the labels, nameplate, and phase identification.

Functional and Operational Test

Make sure the entire switchgear device in the open position. Check the incoming voltage and phase sequence. Energize the switchboard power circuit one by one. Check the measuring instrument showing the correct readings. Ensure padlocks are in position. Check the operation of the breaker.

Torque Test

The tightness of the bolts will be tested with a torque wrench to ensure proper tightness.

Continuity Test

Continuity testing is the act of testing the resistance between two points. If there is very low resistance (less than a few Ωs), the two points are connected electrically, and a tone is emitted. If there are more than a few Ωs of resistance, then the circuit is open, and no tone is emitted. This test helps ensure that connections are made correctly between two points. More specifically, it helps to detect any broken conductor, damaged components (breakers), or excessive resistance.

With all breakers in ‘ON’ position, apply 2.5kV AC voltage between each stressed phase and all other phases connected to exposed conductive parts for 60 seconds and measure the leakage current. This test will help to test the insulation.

High Voltage Injection Test

Insulation Test

Carry out 1000V megger test for phase to earth, neutral to earth, phase to neutral, and phase to phase to measure the insulation resistance with all breakers in ‘ON’ positions.

Primary Injection Test

Primary current injection testing is utilized in high current/high voltage scenarios found at large electrical installations such as substations. A large current (between 100A and 20,000A depending on system specifications and test requirements) is injected directly on the primary side of the electrical system such as a circuit breaker.