TECHNICAL INSPECTION

Breaker Thermographic Scanning and Insulation

Resistance Test
GENERAL:

Thermal scans are best used as a preventative maintenance tool. The breakers should be
benchmarked (preferably early in their service life), and subsequent tests at periodic intervals
(typically annually) should be compared with the benchmark to see if anything has changed
significantly. If so, investigate the cause. If these readings are within limits, and the breaker
shows no evidence of overheating such as discoloration, nuisance tripping, smell, etc. record
the reading and monitor to see if it changes over time.

For isolated scans snapshots, a common practice is to compare the temperature of a breaker
with the temperatures of similar breakers with similar loading. All temperatures should also
be below the UL limits:

UL Surface Temperature Rise Limits

Non-metallic : 60 deg. C
Metallic : 35 deg. C

UL Terminal Temperature Rise

80% Rated CB : 50 deg. C

100% Rated CB : 60 deg. C

If any breakers with similar loading are significantly warmer than others, the cause should
be investigated. It is possible to have loose or high-resistance connections on either the line
or load side. Check the wire torque--and check for discoloration and odors which would be a
sign of excessive heat.

The way thermal scans are presented often needlessly alarms the customer. Colors on the
scans are relative, so look at the numbers. Also, have an experienced third-party review the
scan if there are recommendations for replacing breakers that have moderate temperatures
and no signs of overheating other than the colors on a thermal scan.

The Insulation Resistance Test is the second test required by the electrical safety testing
standards.

The Insulation Resistance Test consists in measuring the Insulation resistance of a device
under test, while phase and neutral are short circuited together. The measured resistance has
to be higher than the indicated limit from the international standards.
A megohmmeter (also called insulation resistance tester, teraohmmeter) is then used to
measure the ohmic value of an insulator under a direct voltage of great stability.
To measure a high value resistance, techniques for measuring a low value current are used. A
constant voltage source is applied to the resistance to be measured and the resulting current is
read on a highly sensitive ammeter circuit that can display the resistance value.
Two types of ammeter circuits are used on our range of insulation resistance tester, each
circuit being chosen depending on the resistance values to be measured.

CIRCUIT BREAKER OPERATING TEMPERATURES

The acceptable operating temperature of a circuit breaker is defined by UL in the UL489 standard
(June 2011), which is listed below.

 Terminations for standard rated breakers: UL 489 Paragraph 7.1.4.2.2 says the temperature
rise on a wiring terminal at a point to which the insulation of a wire is brought up as in actual
service shall not exceed 50°C (90°F).
 Terminations for 100% rated breakers: UL489 Paragraph 7.1.4.3.3 says the temperature rise
on the termination shall not exceed 60 deg. C (108 deg. F).
 Handles, knobs and other user surfaces: UL489 Paragraph 7.1.4.1.6 says the maximum
temperature on handles, knobs, and other surfaces subject to user contact during normal
operation shall not exceed 60°C (140°F) on metallic and 85°C (185°F) on nonmetallic
surfaces.

TYPES OF INSULATION RESISTANCE TESTS

Short-Time or Spot-Reading Test

In this method, you simply connect the Megger instrument across the insulation to be tested
and operate it for a short, specific time period you have simply picked a point on a curve of
increasing resistance values; quite often the value would be less for 30 seconds, more for 60
seconds. Bear in mind also that temperature and humidity, as well as condition of your
insulation affect your reading.
If the apparatus you are testing has very small capacitance, such as a short run of house
wiring, the spot reading test is all that is necessary. For many years, maintenance
professionals have used the one-megohm rule to establish the allowable lower limit for
insulation resistance. The rule may be stated: Insulation resistance should be approximately
one megohm for each 1,000 volts of operating voltage, with a minimum value of one
megohm.
Time-Resistance Method

This method is fairly independent of temperature and often can give you conclusive
information without records of past tests. It is based on the absorption effect of good
insulation compared to that of moist or contaminated insulation. Tests by this method are
sometimes referred to as absorption tests.
This test is of value also because it is independent of equipment size. The increase in
resistance for clean and dry insulation occurs in the same manner whether a motor is large or
small. You can, therefore, compare several motors and establish standards for new ones,
regardless of their horsepower ratings.
Insulation Resistance should be done to prevent hazards such as electric shock and short-
circuits caused when the insulation in electrical devices, parts, and equipment used in
industrial plants, buildings, and other settings degrades over long periods of use.

METHODOLOGY:

Our team conduct standard and typical inspection methods which can summarized as follows;

1. Visual inspection of electrical panel

2. Open electrical panel cover and scrutinized and visual inspection of each breaker and
terminals
3. Temperature check using Infrared Thermal Checking Device.
4. Conduct Thermographic imaging and scanning in each main breaker and sub-breaker
5. Termination and bolt check for loose connection
6. Retighten terminal with loose bolts and connection.
7. Double check breaker with high temperature readings compare to others breaker with
normal reading
8. Check Voltage or Ampere reading if significantly high temperature using Clamp Meter
9. Records all the data for future reference and benchmark
10. Return the electrical panel to normal safe condition and appearance.

The Equipment Used:

1. Infrared Temperature Devices

2. Thermal Scanning Devices
3. Assorted Electrical Tools

RECOMMENDATIONS

1. Maintain regular maintenance and safety check of breakers inside and outside. Beware of
pest, rats, spider web or other foreign objects inside the panel.
2. If possible in regular interval say 3-months, open the breaker panel to visually check
terminal discoloration on terminals.
3. Provide a visible and clear name tags on each breaker for easy identification. Turn-over of
personnel due to resignation will cause confused to the new personnel. Better if the
breaker records are in computerized format for traceability of historical trouble.