Injection Test – Greenbox

Protection Relay Testing by Qualified Engineers

On-site injection testing of protection relays and grid protection equipment to satisfy DNSP commissioning requirements.

ABOUT INJECTION TESTIONG

Mandatory commissioning verification — done right

Injection testing is the mandatory verification process for protection relays on grid-connected renewable energy systems above 30kW. It confirms that your protection equipment will operate at exactly the settings approved by the DNSP — and is required before any system is approved for ongoing grid connection.

GreenBox provides qualified injection testing services using calibrated test equipment, delivering formal test reports accepted by all major Australian DNSPs. Our engineers have tested protection relays on hundreds of grid-connected systems across all Australian states.

Where your system fails to operate at specification, we document the issue clearly and advise on the fastest path to resolution — minimising commissioning delays.

WHAT WE TEST

Protection relay functions covered

51 Overcurrent

51N

Earth Fault

27 Under Voltage

59 Over Voltage

81U

Under Frequency

810 Over Frequency

81R

Rate of Change of Frequency (RoCoF)

78 Anti-Islanding (Vector Shift)

24hr

REPORT TURNAROUND

100%

DNSP ACCEPTANCE RATE

NATA

CALIBRATION STANDARD

WHY GREENBOX

Three things that make our testing service different

Calibrated NATA-Traceable Equipment

All GreenBox injection test equipment is calibrated and traceable to national measurement standards — ensuring our test results are defensible and accepted by all major Australian DNSPs.

Accepted by All Major DNSPs

Our injection test reports are accepted by Ausgrid, Endeavour, Essential, Energex, Ergon, SA Power Networks, Western Power, CitiPower, Powercor, Jemena, AusNet and TasNetworks.

Same-Day Test Reports Available

For projects on aggressive commissioning schedules, GreenBox provides same-day test report delivery — enabling your DNSP hold point inspection to proceed without delay.

TESTING PROCESS

Seven-stage testing methodology

Pre-Test Documentation Review

We review your protection relay settings sheet, DNSP approval documents, and single-line diagram before arriving on site — ensuring we test exactly what was approved.

Site Safety Assessment

On-site safety induction, risk assessment and SWMS review prior to testing. Our engineers hold the relevant electrical licences and safety tickets for high-risk work.

Test Equipment Calibration Check

Calibration status of all test equipment is verified against current calibration certificates before testing commences.

Primary / Secondary Injection

Comprehensive injection testing of all specified relay protection functions — overcurrent, earth fault, voltage, frequency and anti-islanding — using calibrated test sets.

Relay Setting Verification

All relay settings are verified against the DNSP-approved protection settings schedule. Any deviations are flagged and documented before the test report is issued.

Test Report Preparation

A structured test report is prepared with all test results, calibration references, relay settings confirmation and engineer sign-off — formatted to DNSP requirements.

DNSP Submission

The completed test report is submitted to the DNSP to satisfy the commissioning hold point. We follow up to confirm acceptance and advise on any outstanding requirements.

BENEFITS

Why project managers choose GreenBox for injection testing

DNSP-Accepted Reports

Our test report format and content is accepted by all major Australian distribution network service providers — no reformatting or re-testing required.

Experienced Test Engineers

Our engineers have conducted injection testing on hundreds of grid-connected systems — from small C&I rooftops to large utility-scale solar farms with dozens of inverters.

Fast Turnaround

Standard test reports are issued within 24 hours of site testing. Same-day reports are available for urgent commissioning requirements.

Calibrated Equipment

All injection test equipment is maintained in calibration with NATA-traceable certificates — ensuring your test results meet the evidentiary standard required by DNSPs.

National Coverage

GreenBox testing teams operate across all Australian states. For large-scale projects requiring multiple testing teams, we can deploy simultaneously to meet commissioning windows.

Own ATS Equipment

GreenBox manufactures our own automatic transfer switch (ATS) and protection test equipment — giving us hardware-level control over the testing setup for consistent, reliable results.

SYSTEM TYPES

Systems we test across Australia

CASE STUDY

12.6MW Fronius Fleet — QLD

CHALLENGE

12 individual commercial solar sites across South East Queensland totalling 12.6MW, comprising 47 Fronius inverter units — all requiring injection testing and Energex-accepted test reports within a 3-week commissioning window.

SOLUTION

GreenBox deployed two parallel testing teams across the 12 sites, utilising our own ATS test equipment for rapid setup between units. A standardised test report template was pre-configured for the Fronius inverter fleet and Energex format requirements.

RESULT

All 47 inverter units tested and certified within the commissioning window. Zero test failures. All test reports accepted by Energex on first submission.

UNITS TESTED

0 47

TEST FAILURES

COMMON QUESTIONS

Injection Testing FAQs

Everything you need to know before booking your injection test.

What is injection testing and why is it required?

Injection testing (primary or secondary injection testing) is the process of applying a calibrated test signal to a protection relay to verify that all protection functions operate correctly at their specified settings. It is required by DNSPs for all grid-connected renewable energy systems above 30kW in Australia, and must be completed by a qualified engineer using calibrated equipment before the system is approved for grid connection.

Which DNSPs accept your injection test reports?

GreenBox injection test reports are accepted by all major Australian DNSPs including Ausgrid, Endeavour Energy, Essential Energy, Energex, Ergon Energy, SA Power Networks, Western Power, CitiPower, Powercor, Jemena, AusNet Services, TasNetworks and NT Power and Water. If you are connecting to a smaller or regional DNSP, please contact us to confirm acceptance.

How long does injection testing take on site?

A single inverter or protection relay typically takes 2–4 hours to test, depending on the number of protection functions specified and site conditions. For systems with multiple inverters or complex protection arrangements, we can provide a site-specific time estimate following a review of your documentation. Large solar farms with many inverters can be efficiently tested using multiple engineers working in parallel.

What protection relay and equipment types do you test?

GreenBox engineers test all common grid protection relay platforms including SEL, Schneider Sepam, Woodward, Basler, ComAp, SMA grid guard protection and inverter-integrated protection functions. We also test standalone protection relay panels, automatic transfer switches (ATS), and power quality monitors. If you have specialist or legacy equipment, contact us to confirm compatibility.

Can you test protection equipment supplied by a different company?

Yes. GreenBox provides injection testing as an independent service — we test protection equipment regardless of the manufacturer or supplier. We require a copy of the approved protection settings schedule and relay data sheet prior to testing. Where equipment is not performing to specification, we will document the discrepancy in our test report and advise on next steps.

Do you provide same-day test reports?

Yes. Same-day test reports are available for projects on urgent commissioning schedules. Same-day reports are issued by 5:00 PM on the day of testing. Standard reports are issued within 24 hours. Please advise us of your commissioning schedule when booking so we can allocate the appropriate resource and report turnaround.