ZENSOL CIRCUIT BREAKER PERFORMANCE ANALYZER

Transcription

1 COMPUTERIZED TEST INSTRUMENTS ZENSOL CIRCUIT BREAKER PERFORMANCE ANALYZER CBA-32P QUICK SETUP GUIDE August 5th,

2 CONTENTS CONTENTS... 2 STEP 1 REQUIRED MATERIALS... 3 STEP 1A ACCESSORIES... 4 STEP 2 CONNECTIONS... 8 STEP 2A CBA 32P CHANNELS CONFIGURATION... 8 STEP 2B CONNECTIONS TO THE BREAKER... 9 STEP 3 SOFTWARE INSTALLATION AND FOLDER STRUCTURE...10 STEP 3A DOWNLOADING THE APPLICATION FROM THE ZENSOL WEBSITE STEP 3B DECOMPRESSING AND INSTALLING ON WINDOWS XP (METHOD 1): STEP 3C DECOMPRESSING AND INSTALLING ON WINDOWS XP (METHOD 2): STEP 3D DECOMPRESSING AND INSTALLING ON WINDOWS VISTA / STEP 3E FOLDER STRUCTURE STEP 3F INSTALLING THE WINDOWS UPDATE FOR HELP FILES STEP 4 COMMUNICATION (USB DRIVER OR FIBER OPTIC INSTALLATION)...16 STEP 5 STARTING WITH THE SOFTWARE...17 STEP 5A LANGUAGE CONFIGURATION STEP 5B MAIN WINDOW STEP 5C DATA STRUCTURE...21 STEP 5D CALIBRATION CHECKUP STEP 5E TESTING THE COMMUNICATION STEP 5F TEST CABLES / BREAKERS STATUS STEP 5G CREATING/LOADING A NEW TEST PLAN STEP 5H ANALOG INPUTS CONFIGURATION STEP 5I EXECUTING A TEST STEP 5J SAVING THE TESTS STEP 6 TEST PLAN EXAMPLE: CHECK_CBA.WCF...28 APPENDIX 1 SYMBOLIC CIRCUIT DIAGRAM...31 APPENDIX 2 COMMUNICATION TESTS...32 APPENDIX 3 STATIC AND DYNAMIC RESISTANCE KIT

3 STEP 1 REQUIRED MATERIALS CBA 32P Power cable Ground cable Fiber optics module and cable ARCTIC / Standards contact cables Command cable 3

4 Step 1a Accessories Displacement transducers: Linear Rotary Optic encoder Voltage transducers: ZVD AC/DC 300 Contact ZVS DC 08 ZVD AC/DC 300 Contact (Wet Contact): detects alternative or continuous voltage. This item is excellent for a fast detection of possible malfunctions on control cabinets. ZVS DC 08: measures voltages inside a breaker control cabinet. Continuous voltage can reach 300 Volts. 4

5 Current transducers: ZCS 100 ZCS 600 ZCS 100 : Measures AC, DC or pulsed currents. This item is ideal for current measures in your breaker wires. Accept current up to 100A. ZCS 600 : Measures AC, DC or pulsed currents. This item is ideal for current measures in your breaker wires. Accept current up to 600A Static and dynamic micro ohmmeter kit: MO SD 100 / MO SD 200 This module is a diagnostic tool that assesses the state of circuit breaker contacts by measuring their dynamic arcing contact. 5

6 First trip monitoring : This module is designed to evaluate the breaker contacts opening time when «online». Internal resistance measurement module: Z FT RES 8 / RES 16 / RES 24 6

7 Digital inputs for optic encoders: Internal modules DIG INP 3 and DIG INP 6 were mainly created to measure the displacement of breaker contacts. DIG INP Weet contact module: WET CONT It detects continuous voltage: this module is highly efficient for a fast detection of any possible breaker malfunctions. 7

8 STEP 2 CONNECTIONS Step 2a CBA 32P Channels configuration Digital Contacts 17: first contact 18: second contact 40: twenty fourth contact PHYSICAL SIGNALS VIRTUAL SIGNALS Multiple Use Analog Inputs 3: first displacement 9: speed related to first displacement 4: displacement 10: speed related to second displacement 8: sixth displacement 14: speed related to sixth displacement Optical Encoders 89: first optical encoder 95: speed related to first encoder 90: second optical encoder 96: speed related to second encoder 94: sixth optical encoder 100: speed related to sixth encoder Command 1: close current input 2: open current input 61: close command 62: open command 8

9 Step 2b Connections to the breaker 9

10 STEP 3 SOFTWARE INSTALLATION AND FOLDER STRUCTURE Step 3a Downloading the application from the Zensol website Go to and in the products menu, select CBA 32P Circuit Breaker Analyzer. In the product page of the CBA 32P, scroll down to the CUSTOMERS section and click on the "CBAWin Software" link. Enter your username and password when prompted. Save the ZIP file on your computer at the location of your choice. 10

11 Step 3b Decompressing and installing on Windows XP (method 1): Right click on the icon for the file you just downloaded: Select "Extract to " (note: this example uses WinZip other extractors may vary in their method): CBAWin.zip (or file for latest version and date) Select the folder of your choice, and before proceeding, make sure that the option "Use folder names" is selected: A new folder will appear at the location specified in the previous step (example folder name): CBAWin 11

12 Step 3c Decompressing and installing on Windows XP (method 2): Use this method in case the one in Step 2b fails or cannot be executed. Double click on the icon for the file you just downloaded: CBAWin.zip (or file for latest version and date) Click the "Extract" button (note: this example uses WinZip other extractors may vary in their method): Select the folder of your choice, and before proceeding, make sure that the option "Use folder names" is selected: A new folder will appear at the location specified in the previous step (example folder name): CBAWin 12

13 Step 3d Decompressing and installing on Windows Vista / 7 Right click on the icon for the file you just downloaded (exact file name will depend on version downloaded): CBAWin Enter the destination folder where you want the files decompressed (click on Browse to search for a suitable folder example folder name shown or type in an absolute path, such as C:\CBAWin ): 13

14 Step 3e Folder structure Contents of the CBA Win folders: Autodiag Test and example to do an autodiagnostic of your analyser. Calibration Calibration files used by the software. Examples Examples of test plans and data files. Help Help files Plans_normalisés_HQ Standard test plan by Hydro Québec. Plugins Plugin which allows to export data in XML USB USB driver (optional) WinHlp Update Windows VISTA and 7 updates for help files (optional). 14

15 Step 3f Installing the windows update for help files This section is only for Windows Vista or Windows 7 users Double click on WinHlp Update folder, then on the file : VISTA KB x86 for Windows Vista users, OR Windows7 KB x86 for Windows 7 users. Follow the instructions displayed on the screen. Once the update is installed, you can open the help file. 15

16 STEP 4 COMMUNICATION (USB driver or fiber optic installation) Plug the fiber optic cable connectors into their respective receptacles on the front panel of the CBA unit. Connect the other end to the receptacles on the fiber optic module. Connect the power cable between the CBA and the wall socket. Turn on the unit using the power switch on the front panel. Connect the serial cable from the fiber optic module to a free serial port on your computer. If your computer doesn t have a serial port, we offer a Serial to USB converter: 16

17 STEP 5 STARTING WITH THE SOFTWARE Double click on file cbawinxxx.exe, where XXX is the version number. We recommend that you create a desktop shortcut to this file to simplify access. Right Click Send To Desktop (create shortcut) Under Windows Vista, you must start the application using administrator rights ; right click cbawinxxx.exe Run as administrator 17

18 Step 5a Language configuration If you wish to change the language under CBA Win : Go to File Preferences Language and in the dialog window, select the language of your choice 18

19 Step 5b Main window Signals information Toolbar Number and Name of the Test. Number and Name of the Page. File name. Recorded data Calculus related to data Date and time of the current test Information about the plan and current test 19

20 Toolbar : Files Manipulation Test configuration In the field Analysis Assistant mode Test configuration Check setup Previous page Open plan Plan information Test link Next page Save data Analog inputs Test cables/breaker status Examine Export Contacts Close Order Horizontal scalel EVA export Optical encoders Open Order Vertical scale Print displayed report Processing Connections / Infos Zoom Previous test Next test Execute test Static/Dynamic Micro Ohmmeter Graphic report design Viewr tabular report Help 20

21 Step 5c Data structure Tous les signaux Fichier : DEFAULT_CHECK_CBA.wdt EXCEL Report.xls TEST PLAN DEFAULT_CHECK_CBA.wcf TABULAR TXTREP652.rep RAW DATA DEFAULT_CHECK_CBA.wdt CALCULUS CBACAL86.cal 21

22 Step 5d Calibration checkup Once the Verification button is pressed, the software connects to your instrument, reads the calibration data and applies it to your test plan. It will also indicate you if the test plan is compatible with your instrument. It has to be done every time you open a new blank test plan. Step 5e Testing the communication Set the communication port : Go to File Preferences Communication and then click on the which port is used. button to auto detect 22

23 Step 5f Test cables / breakers status Check if the connectors are responding. Check the connection between the CBA unit and the breaker contacts via cables. Check the position of linear and rotary transducers. Ideally the rotary transducer should be near 50%. Check the optical encoders position. 23

24 Step 5g Creating/Loading a new test plan To load a test plan: 1st method: File > Open Plan 2nd method: 3rd method: If you want to create a new test plan, change the configuration of the tests with the first green button. 24

25 Step 5h Analog inputs configuration When you open a test plan, it probably has default analog values. Once you have verified the calibration in the previous step, you can scale this calibration to the real values you measure. A good habit to have is to save the test plan once your calibration data is entered, so that you won t have to do it twice. In the properties of the current analog input, you can change the current range for a better measure of the current coils. In the properties of the other analog input, you can change the calibration values of the transducer you are using and put the measurement units. In the following picture, it is the example of a displacement transducer. 25

26 Step 5i Executing a test To run the current test, click on the button. A warning message will be displayed prior to the actual execution of the test. Once the test is completed, a progress bar is displayed indicating the proportion of data received from the analyzer. Once the data transfer is complete, the graphic display is immediately updated with the new data. Note: To add an audible warning ( buzzer ) before the execution of the test, go to File Preferences Test execution delay Activate 26

27 Step 5j Saving the tests To save your data once your tests are complete, click on. You may also access this via the File Save data as Tip: After each test, save the current test (keeping the same file name). Thus you are sure to not lose your data in case of an unexpected problem. 27

28 STEP 6 TEST PLAN EXAMPLE: CHECK_CBA.WCF Test 1: Contact inputs This test involves testing all contact inputs in order to verify that they can detect a short circuit (closed) condition. To do this: Connect all the contact cables to the CBA 32P; For each contact cable, short the clips together, as seen at right in order to simulate closed contacts; In CBA Win, load the test plan AUTODIAG.WCF Execute the Test 1, Page 1 Use the Examine tool to verify that all the contacts are at level "1" 28

29 Test 2: Analog inputs This test involves testing all the analog inputs in order to verify that they can properly measure the voltage. To do this: Plug in all the analog displacement cables. These cables have: o o o A black clip (ground); A white clip (signal); A red clip (10 VDC); For each analog cable, short the red clip (identified 10 VDC) to the white clip (identified SIGNAL) as illustrated at right. This injects 10 volts DC into the analog signal input; Execute the Test 2, Page 2 with the test plan AUTODIAG.WCF Use the Examine tool to verify that all the analog inputs are at or close to 10 volts, ±5% the values are shown at the left of the graphic; 29

30 Test 3: Dynamic test of Contact inputs 1 2 and the Contactors This test involves dynamically testing contact inputs 1 2 (digital channels 17 and 18) and the internal contactors. The internal contactors are relays that behave like circuit breaker contacts and may be used to dynamically test the contact inputs. To do this: Plug the command cable into the CBA 32P; Plug a contact cable into the first contact input jack (17 18); Connect the two cables together as shown at right: o the white clip of the command cable to the red clip of the contact cable; o the black clip of the command cable to the yellow clip of the contact cable; o the red and green clips of the command cable to the black clip of the contact cable; Execute the Test 5, Page 5 with the test plan AUTODIAG.WCF The contact signals and the current signals should be similar in shape and timing; You can do the same test for any other contacts by moving the contact cable to the next contact inputs. If any of the tests show you an anomaly, contact ZENSOL for assistance. 30

31 APPENDIX 1 SYMBOLIC CIRCUIT DIAGRAM COMMUNICATION MODULE 31

32 APPENDIX 2 COMMUNICATION TESTS Before executing a test, check the communication link with the following button: 1) If it does not work, go to File > Preferences > Communication, and check the port number with the goggles. The port COM should be highlighted with a green point. Check the COM port and try again the test link. 32

33 2) If it still does not work, you can verify manually what the assigned COM port is. (Works with Windows XP, Vista, 7 and 8) Go to the Windows Configuration Panel, then System, Device manager, and Port COM. If the COM port is invalid, you can assign a new number by rightclicking and going into the properties. Go into the second tab called Port parameters and click on advanced. 33

34 Only assign the COM port to an unused one. Windows generally locks some ports for internal use. You can use a COM port from 1 to 64. Check the COM port number and put it in the Communication Settings window of CbaWin, then try the test link. 34

35 3) If it still does not work, do a loopback test. Unplug the optic fiber from the CBA and put the two BLUE connections in the communication module and go back to the Communication settings window. Find the good COM port with the goggles and push the test link button. Do the same with the two BLACK connections. If it works in both cases, it means that the computer, the communication module and the fiber optic are working properly. Then, try again to connect the fiber optic cable to the CBA. Be careful to respect the R and T connectors with the front panel and push the test link button. If it still does not work, contact ZENSOL. 35

36 APPENDIX 3 Static and dynamic resistance kit Kit MO SD 100/200 Static & dynamic resistance kit QUICK SETUP GUIDE 36

37 Required materials : Current DC power supply Voltage transducer Current transducer Resistance caliber Battery cables, Contact cable and extensions 37

38 DC power supply: PS 140 or PS 200 Power source DC Power supply : 0 6 V, Amps, 1200 Watts or Power source DC Power supply : V, Amps, 1050 Watts Voltage Transducer : ZVS 100 or ZVS 200 TYPE A TYPE B Current Transducer : ZCS 100 or ZCS 200 TYPE A TYPE B Current transducer module continuous and alternative 140 Amps or 200 Amps, 150 Khz Resistance caliber : 150 micro ohms (or any other known values) 38

39 Step 0: Connections and test plan 39

40 Click on the MO SD specialized button when you push YES. and the test plan microohmmeter default.wcf will be loaded 40

41 Step 1 : Current and voltage transducers settings Choose the scale you want to use on the voltage transducer (3 milli Ohms or 200 micro Ohms) and enter the transducers settings related to your choice. Tip: values that you introduce in the MO SD Plan are automatically introduced in the transducers properties in the analog inputs window. Above is the example of the current transducer. Same thing with the voltage transducer. 41

42 Step 2: offset 1st method Short the contact cable: Yellow clamp with Black clamp. The current source is turned OFF. 2nd method Connect the cables as shown in the following picture. The current source is turned OFF. Then, click on the button to run the test. After the test, the offset values will be displayed and so the transducers settings will be adjusted accordingly. 42

43 Step 3: Static Micro Ohmmeter Connections Note: Voltage clamps (yellow and black, thin cable) must be placed as close as possible to the breaker contact, and current clamps (red and black, big cable) must be placed outside of voltage clamps (as shown in pictures above), in order to obtain best measurement results. Current source settings Voltage Current Set the voltage potentiometer to Max position and set the current potentiometer up to the value you want. This current source can be used manually and can be remotely operated through USB port, Ethernet, etc. If you want more information about the current source, please take a look at its manual. Then, start the current source in order to inject current and click on the button to run the test. 43

44 In this example, we inject 98.8 Amps (displayed on the current source) and the resistance caliber is of 150 micro Ohms. 44

45 Step 4: Dynamic Micro Ohmmeter For the dynamic test, the following mounting can be done: 2 resistors are in series, we first calculate the resistor value of one and then, by unplugging the black clamp, we have the total value. Click on the button to go to the following test and Click YES to the following window: Then, click on the button clamp as shown below: in the toolbar to run the test. You will have one second to unplug the black R1 R2 R1 R2 R1 + R2 45

46 Here is the result of the dynamic test: R1 + R2 R1 With this manipulation, we have simulated an arcing contact (We have done it in one second, the breaker will do it in milli seconds, but it is exactly the same behavior). 46

47 Theoretical approach 4 wire method Our measurement method is based on the simple but fundamental Ohm s law: U=R*I. Measurements are proceeded at a fixed current, and voltage is read directly across the breaker, with great precision and a low noise level, thanks to an effective method called 4 wire method. We explain this method here after. At first sight, measuring a resistance can be simply done with this method: A Ohmmeter plugged across the resistor we want to measure. But this is not measuring resistance accurately, because it includes wires resistance, which varies with wires length. In our case, test instrument is quite away from breakers, that s why wires resistance is not negligible, we have to remove these resistances. The 4 wire method consists in plugging 2 sensors: An ammeter connected in series with current source, an a Voltmeter plugged in parallel with resistor. Ammeter will give us the real value of the current passing through resistor. Voltmeter will still give us R wire +R subject +R wire, but here, current passing through Voltmeter loop is really low because of high impedance of voltmeter. Thus, wires in voltmeter loop will drop negligible voltage, and voltmeter value of resistor subject voltage drop will be really accurate. On the right is theoretical wiring for this method. Our wiring method is similarly the same; we just use two different types of cables, one for current injection and measurement, and one for voltage measurement. (Picture source: 47

48 Calculation of uncertainties Once current and voltage curves are obtained, this method can help us determine the uncertainty of our resistance measurement. First, Ohm s law says : We have also Equality of average values, Partial derivative of R with respect to U, Partial derivative of R with respect to I. With Variance formula, We obtain this equality: And so, we finally have: With this formula, we are able to access the resistance uncertainty (characterized by standard deviation) in calculating current and voltage standard deviations. 48

49 Finally, with resistance standard deviation and average value, we can draw Gauss curve, which permit us to give an interval corresponding to a several probability. This probability is, for each point of measurement, the probability that it is in the interval. (Picture Source: ). 49