IEC 61009-1 Residual Current Tester for Circuit Breaker 500A

IEC 61009-1 Residual Current Tester for Circuit Breaker 500A

Equipment Overview:

1. Leakage Control Cabinet:
The leakage control cabinet mainly consists of three leakage testers (S1 closed leakage, B type 10A leakage, and 500A leakage) along with the control circuitry.
It supports comprehensive testing of all types of residual current circuit breakers (RCCBs) currently in use, including:

• AC Type (50Hz sine wave AC)
• A Type (50Hz sine wave AC + pulsating DC)
• F Type (variable frequency AC and composite waves)
• B Type (all-function type)

It is capable of generating and testing various forms of residual currents, such as:

• Sinusoidal AC residual currents at frequencies of 150Hz, 400Hz, 1000Hz, and below
• AC residual current superimposed with smooth DC residual current
• Pulsating DC residual current superimposed with smooth DC residual current
• Pulsating DC residual current generated by two-phase or multi-phase rectifier circuits
• Smooth DC residual current

2. Automatic Control System:
The automatic control system is primarily composed of:

• Advantech industrial computer (i7 CPU, 8G RAM)
• 21.5-inch LCD monitor
• MCGS touch panel HMI
• Qingzhi electrical parameter acquisition modules
• Omron PLC
• Various low-voltage control components
• Sampling transformers and other supporting parts

3. 125A Load Current:
The load system provides a fully resistive load adjustable from 1A to 125A, composed of multiple parallel resistors with specific values (0.5A, 1A, 2A, 3A, 5A, 10A, 10A, 20A, 40A, 50A).
Load switching is controlled by contactors, with automatic adjustment and simultaneous operation across three phases.

Technical Parameter

Test Content

AC Type
(1) when there is no load, use the residual current to test.

(2) When the residual current increases steadily, verify the correctness of the action.

(3) When the residual current is closed, verify the correctness of the action.

(4) When the residual sinusoidal AC current suddenly appears, verify the correctness of the action.

S type: When the residual current and test time in Table 2 are suddenly added, the product does not trip.

(5) When the residual current value between 5In and 500A suddenly appears, verify the correctness.
The current grades are: 5A, 10A, 20A, 50A, 100A, 200A, 500A.

(6) When under load, test with residual current.
When under rated current, test according to 9.9.2.2 and 9.9.2.3.

(7) Special test conditions for RCDs whose operating function is related to the power supply voltage.
Test with 0.85 times and 1.1 times the rated voltage.

A Type
(1) Verify the correct operation when the residual pulsating DC current continues to rise

(2) Verification of correct operation in the event of a sudden residual pulsating DC current

(3) Correct operation under load. With rated current, test according to 9.21.1.1

(4) Verify the correct operation when residual pulsating DC current is superimposed on 0.006A smooth DC

F Type
(1)Verify correct operation when the combined residual current increases steadily.

(2)Verify correct operation when the combined residual current is suddenly applied. Verify the breaking time of the RCD, the test current is calibrated to 1.4In x 5In.

(3) Verify correct operation of a four-pole F-type RCD when a residual current appears when only two poles are powered.
Test the four-pole product according to 9.1.2, but only test the neutral conductor and one of the lines.

(4) Verify performance under inrush residual current. Apply a pulse with a peak current of 10Ind, measure 3 times in the forward direction and 3 times in the reverse direction, and the product does not trip.

(5) Verify correctness when a pulsating DC residual current is superimposed with a 10mA smooth current. Superimpose a 10mA smooth DC residual current on the AC residual current at rated frequency.

B Type
(1) Verification of correctness for sinusoidal AC residual currents of 1000 Hz and below
a. Slowly increase from 0.2In to the residual current action value specified in Table 2 within 30 seconds.
b. Verify the breaking current. If the current specified in Table 2 suddenly appears, test the tripping time of the product.
General RCD: T＜0.3s S-type RCD: 0.13s ≤ T ＜0.5s
IEC 62423 Circuit Breaker 500A Residual Current Testing System 0

(2)Verification of correct operation when AC residual current is superimposed on smooth DC residual current.
Superimpose 0.4 times the rated residual operating current on the AC residual current (AC type) at rated frequency.
Smooth DC residual current or 10mA smooth DC residual current (whichever is greater).

(3) Correct operation when pulsating DC residual current is superimposed on smooth DC residual current
IEC 62423 Circuit Breaker 500A Residual Current Testing System 1
A smooth DC residual current of 0.4 times the rated residual operating current or a smooth DC residual current of 10mA (the larger of the two) is superimposed on the AC residual current of rated frequency (Type A, 0° angle).

(4) Verify correct operation when a DC residual current is generated by a two-phase rectifier circuit
a. Slowly increase the current from 0.2In to 2In to test the product tripping current.
b. According to the current value specified in Table 1, suddenly add leakage current and test the product tripping time.
IEC 62423 Circuit Breaker 500A Residual Current Testing System 2

(5) Verification of correct operation when a DC residual current is generated in a rectifier circuit of a three-phase power supply
a. Slowly increase the current from 0.2In to 2In to test the product tripping current.
b. According to the current value specified in Table 1, suddenly increase the leakage current and test the product tripping time.
IEC 62423 Circuit Breaker 500A Residual Current Testing System 3

(6) Verify correct operation without load when smoothing DC residual current
a. Slowly increase from 0.2In to 2In to test the product tripping current.
b. Sudden increase of leakage current according to the current value specified in Table 1 to test the product tripping time.
IEC 62423 Circuit Breaker 500A Residual Current Testing System 4

(7) Under load, verify correct operation with smooth DC residual current.
Test the product tripping current by slowly increasing the current from 0.2In to 2In.

(8) Verify correct operation of three-pole and four-pole B-type RCDs when only two poles are supplied.
Perform the test in accordance with 9.2.1.2 and 9.2.1.7.1, supplying only neutral and phase (one phase) power.

(9) After the test, verify that the RCD is tripped by a test current of 2.5In smooth DC.

Current Output Waveform

1. Type A 0°

2. Type A 90°

3. Type A 135°

4. AC Type

5. DC+

6. AV Type 1000Hz

7. DC2P

8. Composite Wave

9. Action time AC300mA

10. Action time DC1000mA