Recloser Controller
Recloser Controller Testing
Modern recloser controls are powerful, but their growing complexity has made reliable testing more demanding. The need for higher precision, deeper intelligent network integration, smart grid and distributed energy resources (DER), and stricter reliability requirements have all intensified the challenge.
Overcoming these obstacles means performing basic functional checks quickly and handling advanced protection and automated tests with embedded expertise and high-level automation.
Working for a recloser manufacturer requires reliable, efficient test processes you can trust in the lab and production for modern digital controllers.
We design testing solutions that support your daily work.
Solutions for Recloser Controller Testing
Our broad portfolio makes recloser controller testing efficient and straightforward.
The ARCO 400 and dedicated adapters provide an easy-to-use plug-and-play solution for many types of controllers. Combining the CMC 500 and RIR1 lets you perform reliably accurate tests on IntelliRupter® controllers.
The RelaySimTest software lets you validate complex distribution automation schemes with confidence.
The COMPANO 100 gives you maximum field-flexibility for self-powered, single-pole reclosers.
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Plug-and-play Testing with the ARCO 400
The ARCO 400 is a smart and rugged testing solution for recloser controls, providing a fast, straightforward way to perform manual trip and close checks.
Combined with our Smart Connect technology, the ARCO 400 automatically detects recloser-specific test adapters. Its recloser simulation enables three-phase controller testing in the lab and field.
The device features precise three-phase 12.5 A current amplifiers and six-phase voltage amplifiers with an 8 V or 150 V range, as well as six binary inputs and nine binary outputs for flexible testing.
IntelliRupter® Testing with the CMC 500
Combining the CMC 500 and RIR1* enables you to test the S&C IntelliRupter® thoroughly. You can verify the settings, functions, and logic of the PulseCloser control modules in the lab and in the field.
This enables you to perform analytical tests on the S&C PulseClosing Technology™ feature and validate complete operational sequences used in an automatic restoration scheme. A dedicated S&C IntelliRupter® test template helps you get started quickly and perform your tests with confident efficiency.
* The RIR1 is a CMC 500 accessory. For further information please refer to the CMC 500 Ordering Information.
Using RelaySimTest for Distribution Automation Testing
As distribution automation schemes expand and grid resilience requirements increase, simple device checks are no longer sufficient.
RelaySimTest can be combined with multiple CMC and ARCO 400 test sets. CMC test sets are used in substations, while the ARCO 400 is used in the field. Combining both devices is best suited for factory acceptance testing (FAT).
RelaySimTest supports synchronized, system-based tests for protection and automation logic. It helps you identify logic and communication issues with efficiency, regardless of the controller type or manufacturer.
RelaySimTest is a software solution for system based protection testing independent of relay type or manufacturer, validating entire protection systems under realistic conditions.
The ARCO 400 is a universal test set for all recloser controls. Its plug-and-play setup with dedicated smart controller adapters enables fast, easy field testing.
COMPANO 100 and pole-mounted, single-phase reclosers
Grid resilience projects are increasing the use of single-phase reclosers, such as TripSaver®. In these compact, self-powered units, you cannot test the control separately. The COMPANO 100 allows you to inject primary current to verify a complete operating sequence until lockout. The entire device can be tested in realistic conditions with clear, reliable results.
“After 18 months, we still believe we made the right decision in purchasing ARCO 400. It has enabled us to identify areas where we can improve upon our mission, surpassed our expectations for performance, and holds the potential to be used in the future for testing other devices such as voltage regulator controllers.”
Christian Vermeulen P.E., Cherryland Electric Cooperative
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What kind of recloser controllers can be tested?
The ARCO 400 can test:
- Single-pole operated recloser units
- Three-phase gang-operated recloser units
- Pad-mounted recloser units
Combining the CMC 500 with the RIR1 provides a dedicated testing solution for IntelliRupter® control units.
The COMPANO 100 enables you to test self-powered, single-phase recloser units, such as the TripSaver®.
How does recloser control testing help you reduce outages in distribution networks?
When you test your recloser controllers regularly, you’re making sure they’ll operate correctly when a fault occurs. Solutions such as the ARCO 400 allow you to simulate faults, verify settings, and identify issues early.
Combining RelaySimTest with the ARCO 400 and the CMC 500 increases overall system reliability. This setup allows you to test complex distribution automation schemes in realistic conditions.
Proactive testing prevents unexpected malfunctions, improving the reliability of your distribution network.
What are the recommended intervals and best practices for testing recloser controllers?
There is no standard testing interval for recloser controllers. Although the IEEE 1547 guides application and maintenance, it recommends condition-based approaches rather than defined time cycles.
Testing intervals depend on environmental conditions, grid requirements, fault frequency, and controller technology. Typical field practice ranges from 3 to 6 years for comprehensive functional testing, with shorter inspection intervals.
Our solutions support testing throughout an entire lifecycle. They cover a wide range including commissioning testing, regular maintenance testing, and periodic coordination testing.
What protection functions from a recloser controller need to be tested?
Individual distribution grid operators define required protection function tests. Generally speaking, the following protection functions should be tested:
- Overcurrent protection: Monitor pickup values, recloser time/current characteristics, and trip time characteristics to confirm correct fault clearance performance
- Slow curve / fast curve recloser testing: Verify proper coordination and protection curve switching
- Reclosing sequence and timing: Test the number of shots, time intervals, and lockout logic
- Voltage-based restoration schemes: Validate voltage detection and automatic restoration behavior
- Harmonic blocking: Ensure secure operation during inrush conditions
- Anit-islanding: Test voltage and frequency protection, rate of change of frequency (RoCoF), and vector shift
- Communication and automation schemes: Verify proper interaction within your distribution automation system
What role does recloser controller testing play in FLISR distribution automation schemes?
In Fault Location, Isolation, and Service Restoration (FLISR) schemes, your recloser controllers must operate and communicate reliably. You need to ensure that they can respond correctly in real fault conditions.
Testing allows you to verify the control logic, communication links, and switching sequences in realistic fault scenarios. This way, you can make sure your FLISR automation works as intended, isolates faults quickly, and restores service safely and efficiently.
Why are reclosers relevant in Distributed Energy Resources (DER) integration?
Reclosers enable distributed energy resources (DER) to be integrated into the distribution grid. They connect DER to the grid and help manage protection in bidirectional fault-current networks. They also support anti-islanding protection and loss of mains protection. This strengthens the DER protection strategy, improves load management, and reduces outages by quickly and selectively restoring power.
Are the solutions listed on this page limited to recloser controller testing?
No. The CMC 500 and the COMPANO 100 are multifunctional test sets, supporting a wide range of applications that go beyond recloser controller testing. Refer to the respective product page for more detailed information about features and supported applications.
The ARCO 400 is designed for recloser controller testing. It can also test load break switches (LBS) and sectionalizer controls, making it possible to cover multiple assets with a singular dedicated test set.
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