AC CIRCUIT BREAKER TEST SET MODEL NUMBER HC-100 (480V) SERIAL NUMBER

Transcription

1 AC CIRCUIT BREAKER TEST SET MODEL NUMBER HC-100 (480V) SERIAL NUMBER MJH/HWR/slu March 18, 1999

2 TABLE OF CONTENTS SECTION NUMBER DANGER TITLE PAGE 1 SPECIFICATIONS 2 INTRODUCTION 3 SAFETY 4 INSTALLATION INSTRUCTIONS 5 TURN ON/OFF PROCEDURE 6 DESCRIPTION 7 CONTROLLER DESCRIPTION 8 MAIN OPERATING SCREEN 9 EDIT SCREEN 10 INITIAL TEST SCREEN 11 SYSTEM SETUP 12 TESTING MODES 13 THEORY OF OPERATION 14 TROUBLESHOOTING 15 CALIBRATION 16 SERVICE AND MAINTENANCE 17 APPENDIX RETURNED MATERIAL WARRANTY PARTS ORDERING INFORMATION RECOMMENDED SPARE PARTS PARTS LIST ELECTRICAL SCHEMATICS A B C D E F ATTACHMENTS KBIC-120 Variac Motor Drive (Speed) Control, #

3 1-1 AC CIRCUIT BREAKER TEST SET Model Number HC-100 Serial Number Customer Cutler Hammer 6024 S W Jean Rd., Bldg C10 Lake Oswego, OR Customer's Purchase Order Number Manufacturing Date

4 2-1 SPECIFICATIONS Input: 480 VAC, 1 phase, 60 Hz Output: Parallel Connection: Continuously adjustable over eight tap ranges Tap 1: VAC open circuit Tap 2: VAC open circuit Tap 3: VAC open circuit Tap 4: VAC open circuit Tap 5: VAC open circuit Tap 6: VAC open circuit Tap 7: VAC open circuit Tap 8: VAC open circuit Series Connection: Continuously adjustable over eight tap ranges Tap 1: VAC open circuit Tap 2: VAC open circuit Tap 3: VAC open circuit Tap 4: VAC open circuit Tap 5: VAC open circuit Tap 6: VAC open circuit Tap 7: VAC open circuit Tap 8: VAC open circuit Duty Cycle: Instrumentation: Parallel Connection Duty Series Connection 0-16 VAC in 8 steps 0-32 VAC in 8 steps 10,000 Amps 30 min ON/30 min OFF 5,000 Amps 20,000 Amps 30 sec ON/3 min OFF 10,000 Amps 60,000 Amps 3 sec ON/2 min OFF 30,000 Amps Currentmeter: Resolution:.1% of full scale Ranges: 100/1000/10,000/100,000 Amps Accuracy: +/-1% of full scale continuous +/-5% of full scale seconds Timer: Resolution:.002 seconds.12 cycles Ranges: seconds cycles Accuracy: +/-.004 seconds of reading +/-.25 cycles of reading

5 3-1 INTRODUCTION Phenix Technologies' High Current Test Sets represent a new era of electrical testing technology, based on time-proven concepts and the power offered by a personal computer. High reliability SCR's have been combined with a phase angle firing system to deliver precisely repeatable current pulses with minimal distortion. The output is continuously variable over the entire range by means of tap selection and vernier adjustment. Utilizing a motorized vernier and programmable tap selector the test set has auto-jog and current-hold capability. The test set incorporates a standard measurement and control interface that is operated with special cards installed in a personal computer, under software control. The combination of automated hardware and a highly intelligent monitor/controller provides an extremely versatile test instrument capable of exceptional accuracy.

6 4-1 SAFETY Because the HC-100 is designed to supply high current, safeguards have been built into it. These safeguards are only effective if safe work practices are also used. The test set and these procedures have been designed for use by knowledgeable electrical workers who have been properly trained in its use. Please note the following: 1. The test set must be grounded before input power is connected. 2. All power must be disconnected before the test set is ungrounded. 3. The tests described here are to be used only on DE-ENERGIZED and isolated circuit breakers. 4. High currents are generated during the tests and extreme caution must be used. Follow all safety procedures. 5. See page 5-1 for Installation Instructions.

7 INSTALLATION INSTRUCTIONS 5-1 The following procedure should always be followed whenever the HC-100 is installed for operation. 1. Connect #4 AWG ground cable from a good electrical ground to the chassis ground terminal. Next, connect the isolated ground cable to the power ground. Do not connect the regulator chassis ground terminal to the high current section isolated ground terminal. Each section should have an independent ground cable. See connection diagram below. 2. Mount the computer controller on top of the regulator by positioning the controller and connecting the interconnect cable. Take special care not to pinch or damage the interconnect cable. Next, plug the computer into the provided ground fault outlet and position all wires and cables behind the computer to prevent catching or snagging during movement. 3. Perform the Power On Procedure as described on page 6-1. AC INPUT GRD

8 POWER ON PRODEDURE Ensure proper ground connection. 2. CONTROL POWER switch is in the OFF position. 3. Ensure that the interconnect cable between computer and the test set has no damage or missing pins. 4. Connect the computer interconnect cable to the outlet on top of the test set. 5. Place CB1 and CB2 in the OFF position. 6. Ensure proper power to test set prior to connecting input power leads. 7. Connect input power leads. 8. Energize the power distribution breaker. 9. Place the CONTROL POWER switch in the ON position. 10. Place CB1, then CB2 in the ON position. 11. Ensure computer is turned on. (Switch located on back of computer). 12. Follow test procedure. POWER OFF PRODEDURE 1. Exit test program. 2. Place CB2 in the OFF position. 3. Place CB1 in the OFF position. 4. Return to DOS prompt in computer program. 5. Place the CONTROL POWER switch in the OFF position. 6. De-energize power distribution breaker. 7. Disconnect test set as required. WARNING: Connecting or disconnecting computer with power applied may damage test set and/or computer.

9 DESCRIPTION 7-1 Fuses and Circuit Breakers The single phase, 480 V power enters the regulator and is immediately connected to fuses, F1 and F2. These fuses provide the first level of overload protection. Fuses, F3 and F4, provide control power transformer protection. Fuse, F5, protects the 120 V control circuit. All the power transformers are protected with fuses, F6-F10. Circuit breaker, CB1, protects the main power section and is equipped with an undervoltage release coil. The undervoltage release coil is wired so that if the interlock is open or pulsed open for any reason, the main circuit breaker will open and disable the power section. Circuit breaker, CB2, protects the variable transformer. Interlock Circuit The interlock circuit is a safety mechanism that prevents the high power section from operating under unsafe conditions. In order to close the interlock the following conditions must exist: 1. Control power must be on. 2. The regulator section must be grounded at the power source from the isolated ground terminal. The cabinet must be grounded from the provided ground terminal. 3. The variable transformer circuit breaker, CB2, must be closed. 4. The computer controller must be on and reset. If the computer is displaying INTLK or OVERTEMP, the interlock will not close. NOTE: Always use #4 AWG wire or larger for grounding. After the interlock circuit is closed the panel INTLK light will go out and allow the main circuit breaker CB1 to be reset. Triggering The SCR's are controlled by a trigger board that will turn on the output when signaled by the computer. The trigger board receives its command from the input/output board and the computer controller. In this manner the computer controller can precisely time and control the phase angle of the output. Taps and Variable Transformer To achieve a variable output from minimum to maximum, a system of taps and a motorized variable transformer are employed. The tap selects the coarse range of the output and the variable transformer varies the output from zero to maximum for each tap. All of the taps and the motorized variable transformer are controlled by the computer controller. This method makes possible the current hold and auto-jog functions, as well as an easy to use, versatile, test set. A potentiometer is accessible on the front panel for varying the speed of the motorized variable transformer. All transformers and regulators are equipped with several thermocouples and a thermistor to monitor and protect against an over-temperature condition. The output of the thermistor is fed back to the computer controller so that temperature can be constantly monitored. In addition to these safeguards, the SCR's are forced air cooled to effect lower operating temperatures and longer service life.

10 7-2 DESCRIPTION (Continued) Metering There is a precision current transformer employed in the high current section to measure the output current. This transformer is placed directly around the output bus so actual output current up to 100,000 amps can be measured. Output Stabs The output stabs are configured for parallel or series connection. Parallel output connection is achieved by using the supplied stabs to short H1 and H2 for one output connection and shorting L1 and L2 for the other output connection. Series connection is achieved by shorting L1 and H2 and connecting the breaker to H1 and L2. The stabs are designed to be versatile and facilitate connection to a large variety of circuit breakers. The stabs are nickel plated for greater conductivity and long service life. Continuity Located above the output stabs are the continuity binding posts. These posts can be connected to an unused pole of the breaker so that the normally closed or normally open test modes can be used. If the continuity connections are not used, the set must be operated in current latch mode. The following is a brief description of the various parts of the HC Computer Controller. Performs all monitor and control functions. 2. Input Power Indicator, DS1. Indicates that 480 Volt power is available in the test set. 3. Control Power Switch, S1. Applies 120 Volt AC control power to the test set. 4. Fuse, F3. Control power transformer primary overload protection. 5. Fuse, F4. Control power transformer primary overload protection. 6. Fuse, F5. Control power overload protection. 7. Variable Transformer Circuit Breaker, CB2. Applies power and provides overcurrent protection for variable transformer. Must be energized for INTLK to be cleared. 8. Main Circuit Breaker, CB1. Applies 480 Volt power to the transformers and relays. An undervoltage safety release is tied to the interlock circuit for safety purposes. If the interlock light is lit on the control panel, the main circuit breaker cannot be turned on. If, during the operation of the test set, the interlock comes on, the main circuit breaker will trip. 9. Emergency Off Button, SW202. De-energizes the output and the main circuit breaker. 10. Control Power Indicator, LMP202. Indicates internal 120 Volt AC control power has been energized. 11. Output On Indicator, LMP204. Indicates that the output is energized. 12. Interlock Open Indicator, LMP203. Indicates that the safety interlock is not reset. The main breaker cannot be turned on when the indicator is illuminated. 13. Chassis Ground Terminal. Connect to the facility ground with the Ground Cable (#15). 14. Main Input Power Cables. Connect appropriate power to test set. 15. Ground Cable. Connect between the Chassis Ground Terminal and the facility ground. 16. Output Stabs. Connection to breaker under test.

11 DESCRIPTION (Continued) Continuity Binding Post. For use in contact mode, i.e., normally closed or normally open. 18. Regulator Speed Control. Controls vernier speed.

12 8-1 CONTROLLER DESCRIPTION The controller consists of a laptop-style portable computer with floppy and hard disk drives, a fullfeatured keyboard, and an EGA compatible gas-plasma screen. A custom-designed interface card installed in the computer, combined with an I/O card mounted in the test set, allows all measurement and control functions. The disk-based software allows very simple modifications and upgrades in the future. Binding posts for continuity operating modes are provided near the output stabs. A power switch and indicators for input power, control power, interlock, and output ON/OFF status are located on the control panel. The main menu for controller operation indicates the present date and time, as well as the test type, and circuit breaker information, including serial number, and phase being tested. Test mode is displayed, including MOM/MAINT operation, N.O./N.C./C.L. mode, and normal/autojog/current hold modes. Coarse tap, vernier position, range, and output connection are displayed. The output status, continuity, breaker status, and temperature are indicated. Measurement data, consisting of continuous and pulse current, and pulse time, are displayed. A menu of commands is accessible by means of moving the cursor and pressing the ENTER key, or by pressing the key letter for the command. The commands available in the main menu, with their associated key letters, are: 1. B (Base): Selects timer units in seconds or cycles 2. W (Waveform): Selects waveform analysis 3. R (Range): Selects the currentmeter range 4. E (Edit): Advances to test configuration menu for editing the test and breaker data 5. Q (Quit): Exits run menu 6. T (Tap Increase): Selects Tap ALT & T (Tap Decrease): Selects Tap H (Help): Displays help menu 9. I or + (Init): Initiates the output 10. S or (Stop): Stops the test in progress 11. Z (Zero): Resets currentmeter, timer, and clears interlock 12. L (Latch): Selects momentary or maintained output mode 13. C (Contacts): Selects normally open, normally closed or current latch mode 14. M (Mode): Selects Normal Test Mode, JogH Mode, Curr Hold Mode or JogT Mode 15. PG UP (Raise): Raises variable transformer while depressed 16. PG DN (Lower): Lowers variable transformer while depressed 17. Y (type): Type of test Long Time, Short Time and Instantaneous 18. P (Pole): Pole of breaker under test A,B or C

13 9-1 MAIN OPERATING SCREEN Timer: Displays the trip time in either seconds or cycles. This may be selected before or after the test, using the B key. 2. Currentmeter Range: Displays the currentmeter range. The proper range for the test current should be selected before the output is initiated. Select the lowest range that is greater than the maximum current expected for the test. If too low a range is selected, the controller will autorange to a correct value, but the accuracy of the reading will be impaired for the first pulse of current from the output of test set. If too high a range is selected, the accuracy will be diminished, and current flow may not be detected properly in current latch mode causing the test set to turn off. Select using the R key. 3. Output Currentmeter: Displays the current to the device under test. 4. Temperature Meter: Displays the primary winding temperature of the high current transformer, T305. Must be less than 75 degrees C. 5. Date/Time: Displays the current date and time derived from the computer s clock. 6. Circuit Breaker Test Type: Displays the type of test being performed, Long Time, Short Time or Instantaneous. Select using the Y key. Displays the pole of breaker under test, A, B or C. Select using the P key.

14 9-2 MAIN OPERATING SCREEN (Continued) 7. Output Tap Indicator: Displays the current tap selection. Press T to increment; press ALT & T to decrement. Each keystroke changes the tap setting by one. 8. Vernier Position Indicator: Displays the position of the variable transformer wiper arm as a percent of maximum. The output voltage range of the variable transformer varies from minimum to maximum for each tap resulting in a continuously variable total output voltage. Depressing the PG UP key raises the variable transformer output; depressing the PG DN key lowers it. 9. Output, Breaker and Continuity Status Indicators: Displays the status of these items; active status indicated by reverse video. 10. Test Set Status: Displays the current status of the test set. READY: Will allow initiation of a test. RUN: Test in progress. RESET: Test is completed; awaiting system reset (Press Z). INTLK: Interlock is not cleared. Press Z to clear. OVER TEMP: HC Transformer temperature too high. Allow transformer to cool. 11. Output Latch Indicator: Displays the MOMENTARY or MAINTAINED condition of the Output Latch Mode. In MAINTAINED, the output latches ON when the I (INIT) key is pressed and remains on until the current stops, the contacts change state, or another key is pressed. In MOMENTARY, the I key must be depressed and held to keep the output ON. 12. Mode/Output Connection: Displays the current operating mode of the test set with the parameters as defined by the EDIT screen. Modes include NORMAL, JOGH, CURR HOLD, and JOGT. Selected by pressing the M key. See Section 13 for a description of each mode. 13. Contact Mode Indicator: Displays the current Contact Mode: NORM OPEN, NORM CLOSED, or CURR LATCH. Selected by pressing the C key. In the Contact Modes, the Continuity Binding Posts are connected to an unused pole or an auxiliary contact of the circuit breaker under test. Important: Under no circumstances should the Continuity Binding Posts be connected to a pole or contact which is being tested. Normally closed refers to a contact which is closed when the main contacts are closed. The output may be initiated only when the circuit breaker contacts are in the position indicating that the main contacts are closed. Current latch mode must be used for single pole breakers and may be used for any other series connected breakers. Contact modes must be used to test shunt trip breakers. 14. WAVEFORM: Selects waveform analysis. Also selected by pressing W. See Section 13-4 for more detailed explanation. This displays the waveform of the current test and allows viewing of portions of the waveform. 15. EDIT: Advances to test configuration menu for editing the test and breaker data. Also selected by pressing E. See Section 10-1 for detailed explanation. 16. QUIT: Exits run menu. Also selected by pressing Q. You will be prompted if you want to print and save the results. Press Y if you wish to save the results to the database or to print the results.

15 EDIT SCREEN 10-1 Audible Continuity: When enabled, the computer beeps while continuity is sensed on the contacts binding posts. The indicator says CONT'Y ON anytime there is continuity. Connection Mode: Parallel or series connection on output of test set. Current Hold Amps: Used in Hold mode. Set to desired output current. Current Hold Tol: Set to approximately 1% of Current Hold Amps. Speed control knob on front panel may be adjusted to prevent the variable transformer from hunting. Jog Off Seconds: This selects how long the variable transformer will raise with the output of the test set de-energized. Jog On Cycles: This will select how many cycles the test set will apply current on the output of the test set. Maximum setting 9.9. Maximum Amperes: specify the maximum current allowed on the output of the test set for the breaker under test. If set to zero, maximum amp protection will be disabled. Maximum Seconds: specify the maximum amount of time the output will be energized. If set to zero, maximum second protection will be disabled. Maximum Cycles: Specify the maximum amount of cycles the output will be energized. If set to zero, maximum cycle protection will be disabled. Phase Angle: Set to desired setting, used for repeatability of tests. Test Mode: Change test modes. Also change on main operating screen by pressing M until desired mode of test is selected. Other information from breaker under test. Pressing PG UP or PG DN will bring you to resistance measurement information. Input all relevant data.

16 11-1 INITIAL TEST SCREEN System Setup: The SETUP screen may only be accessed if the proper password was typed on the command line when the program was run. The information in this menu includes calibration factors, sampling rates, and analog to digital converter calibration factors. This information is preset during calibration and normally does not need readjusted. Test Configuration: Also accessible from main operating screen by pressing E for the edit menu. See Section Perform a Test: Access to main operating screen. See Section 9-1. View/Print Results: View or print previously stored test data. Database Maintenance: Manage test data. Quit: Quits program and returns to DOS prompt.

17 12-1 SYSTEM SETUP The SETUP screen may only be accessed if the proper password was typed on the command line when the program was run. The information in this menu includes calibration factors, sampling rates, and analog to digital converter calibration factors. This information is preset during calibration and normally does not need readjusted. The SETUP screen displays data in reverse video, and starts with the edit cursor in the first selection. The <UP> and <DOWN> cursor keys move the edit cursor to successive data, which is edited as alphanumeric strings, with no range checking. Data that is out of range can produce strange results. The function and range of values for SETUP data are as follows: DESCRIPTION MIN NORM MAX PURPOSE Average Sample Number of Counts for Average Cal Factor AC AC Calibration Multiplier Cal Factor DC DC 1kA Calibration Multiplier Cal Factor DC DC 10kA Calibration Multiplier Clock Factor System Timer Speedup Divisor Debug Low Level Debug Flag Freq AC Line Frequency Licensee Software Owner ID Max ADC Maximum ADC Waveform Data Queue Max CL Delay Msec Wait For Curr After INIT Max Data Maximum test results Max Intlk ADC Interlock Max Threshold Max Sample Maximum ADC Sample Queue Max Tap Maximum Test Set Coarse Taps Max Temp Maximum Temperature Degrees C Max Vern Pos Maximum Vernier Position % CONTROLLER OPERATION AND PROGRAMMING DESCRIPTION MIN NORM MAX PURPOSE Meas Mode 'A' 'A' 'D' AC or DC Measurement Modes Min Intlk ADC Interlock Min Threshold Min Threshold Current Sense Threshold Counts Min Vern Pos Minimum Vernier Position % Print Filename - "PRN" - Print Output File Name Range Delay Msec Wait After Range Change Set Impedance Output Volts/Short Circuit Amps Spline Samples Waveform Smoothing Function Tap Mode = BUCK/BOOST 1 = BOOST 2 = SEQUENTIAL (DC SET) 3 = HC100 Tap Volts Open Ckt Voltage Per Tap Vernier Factor ADC Counts For Vernier Span Vernier Offset ADC Counts At Vernier 0% Vernier Volts Open Ckt Vo ltage For Vernier

18 SYSTEM SETUP (Continued) 12-2 System Configuration The CONFIG screen displays the data in reverse video, and uses a moving reverse video cursor on the description. When <ENTER> is pressed, the selected data is either toggled among its valid conditions, or the data may be edited as alphanumeric information. If the data is numeric, it is evaluated and compared to preset limits. If outside the limits, an ERROR message is displayed, and the original value reappears for editing. If <ESC> is pressed, the edit of the selected data is terminated, and the original value is restored. If the edited text (e.g., "X123"), evaluates to zero, and zero is a valid value, zero will be displayed. Function and range of values for editable CONFIG data are as follows: DESCRIPTION MIN NORM MAX PURPOSE Audible Mode 'A' 'S' 'S' Audible or Silent Continuity Connection Mode SER, S/P, or PAR Connection Contacts Mode 'C' 'I' 'O' NC, CL, or NO modes Current Hold Current Hold Amperes Hold Tolerance Tolerance +/- For Hold Jog Off Seconds Off Time (Vern Raise) for JOG Jog On Cycles On Time for JOG mode Maximum Amperes Maximum Current Allowed Maximum Seconds Maximum Seconds ON Allowed Maximum Cycles Maximum Cycles ON Allowed Phase Angle Initial Firing Phase Angle Test Mode 'J' 'N' 'H' Jog, Normal, or Hold Modes Technician Technician ID Location Circuit Breaker Location Code Customer Circuit Breaker Customer Code Serial Number Circuit Breaker Serial Number Manufacturer Circuit Breaker Mfgr Code Type Circuit Breaker Type Frame Circuit Breaker Frame Size CONTROLLER OPERATION AND PROGRAMMING DESCRIPTION MIN NORM MAX PURPOSE Rated Amperes Circuit Breaker Rating Pole 'A' 'A' 'G' Pole Under Test or GFI Test Type Test Description Voltmeter Option The voltmeter option provides convenient panel display of input voltage, output voltage, or an external voltage connected to the binding posts above the output panel. The value displayed is TRUE RMS VOLTS AC. To use, simply select the desired mode (INPUT, OUTPUT, or EXTERNAL) and select the voltage range (2, 20, 200, 600 volts AC) best suited for the voltage being measured. If the voltage level is unknown, start with the highest range. If the display reads less than 200 counts, switch to the next lower range for greater accuracy.

19 13-1 TESTING MODES Basic Operation Before initiating the output, it is important to set up the controller for the proper mode of operation. First, select normally open (NO), normally closed (NC), or current latch mode. The mode is indicated in the TEST MODE box. The contact modes are selected sequentially by pressing the C key or moving the highlight bar to this selection and pressing the ENTER key. For most purposes, CURRENT LATCH operation is most convenient. MOMENTARY mode is best used at first. The MAINTAINED mode, toggled with the L (Latch) key, may be more convenient for long duration testing. Before initiating a test, the status indicator in the center of the screen must read READY, indicating breaker CLOSED, output OFF, and interlock CLEAR. To Test Circuit Breaker 1. Connect breaker under test to output of test set. 2. Energize test set as described in Section Select PERFORM A TEST on the computer screen. 4. Press Z on keyboard to clear INTLK. 5. Energize main breaker CB1. 6. Ensure variac is at 0% and Tap 1 is selected. If the breaker under test has been tested in the past, variac and Tap may be run up to previous setting. PG DN runs variac down, PG UP runs variac up, T changes taps up, ALT & T changes taps down. 7. Press M to select the desired mode of operation. 8. Press E to access the EDIT screen and input test parameters. Normal Mode Testing All functions are controlled by the test technician. Select a range that is appropriate for the test current expected, and select a tap and vernier position that is likely to produce the desired current. Make sure that the circuit breaker is closed, select MOMENTARY and briefly press and release the I or + key to initiate the output. The current-meter will read the value of the current pulse, and the timer will read the duration in seconds or cycles as desired. To repeat the test, the currentmeter and timer must be reset by pressing Z. Jog to Hold Mode The JOG to HOLD mode is used to reach a desired breaker holding current with minimal breaker stress. Best if used just prior to HOLD Mode to reach desired current. Hold Mode Testing The HOLD Mode is used to maintain a given current value for a long period of time, for testing constant current breaker trip times.

20 TESTING MODES (Continued) 13-2 Jog to Trip Mode The Jog to Trip mode is used for determining the instantaneous trip point. JOG MODE TESTING Jog to Hold Mode While in the EDIT screen. (Section 10-1) 1. Select CURRENT HOLD AMPS. Input the desired output current from test set. 2. Select JOG OFF SECONDS. Input the time period that the variac will increase its output with the output of the test set de-energized. 3. Select JOG ON CYCLES. Input the duration in cycles for which the output of the test set will be energized. Maximum setting Select MAXIMUM AMPS. Input the maximum current allowed on the output of the test set for the breaker under test. If set to zero, MAXIMUM AMP protection will be disabled. 5. Select MAXIMUM SECONDS. Input the maximum amount of time the output will be energized. If set to zero, MAXIMUM SECONDS protection will be disabled. 6. Select MAXIMUM CYCLES. Input the maximum number of cycles for which the output will be energized. If set to zero, MAXIMUM CYCLE protection will be disabled. 7. Enter information for breaker under test. 8. Press ESC to return to the main operating screen. 9. Press M to change mode to JOGH. 10. Press C to select contact sense from NC, NO or CURRENT SENSE. If using NC or NO sense, connect the sense leads to the unused set of appropriate contacts on the breaker under test. 11. Press L to select MAINTAINED output. 12. Press R to select the current range. Select the appropriate range for the expected current. Test set will auto range if the output current is exceeded on the selected range. 13. Press Y to select the desired type of test being performed. Select LONG TIME or SHORT TIME. 14. Press P to select the pole of the breaker under test. Select A, B or C. 15. Press I or + to initiate the test set and begin the test. 16. Test set will automatically run up to the desired current output and turn off the output when this current is reached. Press S or - to stop the test at any time. Jog to Trip Mode To adjust the output of the test set to a specific current, the Jog Cycles should be set to a time long enough to get a good reading, but short enough to avoid overheating. A good value is 5. The JOG OFF Seconds should be long enough to move the vernier a reasonable amount, such as 1 to 2 seconds. The Max Current may be set to the current desired. Now, the test set may be initiated, and the unit will produce increasing pulses until the Max Current value is reached. Now the test mode may be switched to NORMAL or HOLD, and Max Current should be set to a value higher than expected. As an additional safety precaution, the maximum cycles should be set to slightly more than the JOG ON Cycles.

21 13-3 TESTING MODES (Continued) Set JOG ON Cycles to a value at least twice the expected instantaneous trip time and set Max Current to about 20% more than the maximum expected current. The vernier and taps will automatically increase the output until the circuit breaker trips; this is the instantaneous trip current. 1. Press M to change the mode to JOGT. 2. Press E to EDIT desired settings. (Section 10-1) 3. Select JOG OFF SECONDS. Input the time period that the variac will increase its output with the output of the test set de-energized. 4. Select JOG ON CYCLES. Input the duration in cycles for which the output of the test set will be energized. Maximum setting Select MAXIMUM AMPS. Input the maximum current allowed on the output of the test set for the breaker under test. If set to zero, maximum amp protection will be disabled. 6. Select MAXIMUM SECONDS. Input the maximum amount of time the output will be energized. If set to zero, MAXIMUM SECONDS protection will be disabled. 7. Select MAXIMUM CYCLES. Input the maximum number of cycles for which the output will be energized. If set to zero, MAXIMUM CYCLE protection will be disabled. 8. Press ESC to return to the main operating screen. 9. Press Y to type of test being performed. Select INSTANTANEOUS. 10. Press L to select MAINTAINED output. 11. Press R to select the current range. Select the appropriate range for the expected current. Test set will auto range if the output current is exceeded on the selected range. 12. Press P to select the pole of the breaker under test. Select A, B or C. 13. Press I or + to initiate the test set and begin the test. 14. Test set will automatically run until the breaker trips. Press S or - to stop the test at any time. Hold Mode Testing Set MAXIMUM CYCLES to zero or the test set will shut off on MAXIMUM CYCLES instead of MAXIMUM SECONDS. Set the HOLD CURRENT to the value desired, and set the HOLD TOLERANCE to the maximum variation that is allowable. If HOLD TOLERANCE is set too close, the test set will constantly adjust the variable transformer to try to hold the same current. If this occurs adjust the speed control knob on front panel down until the variable transformer movement is acceptable. If the desired current is obtained at a low tap and vernier position, it may be impossible to hold the set value accurately. Better results will be obtained by adding impedance (such as long cables), to raise the tap and vernier settings. Once the desired current is produced, the test set will hold that current until the breaker trips or the test is interrupted by the technician.

22 13-4 TESTING MODES (Continued) Testing in HOLD Mode 1. Press M to change mode to CURR HOLD. 2. Press E to change to the EDIT screen. (Section 10-1) 3. Select desired CURRENT HOLD AMPS. 4. Select desired CURRENT HOLD TOL. Set to approximately 1% of desired current. 5. Press ESC to return to the main operating screen. 6. Press Y to select the type of test to be performed. 7. Press I or + to begin test. 8. Test set will run until breaker under test trips. Press S or - to stop the test at any time. Waveform Analysis One of the advanced features of this test set is the ability to look at the waveform of the current that passed through the circuit breaker during the test. This can be particularly useful in instantaneous tests, where the current waveform can be badly distorted because of poor connections, DC offset or other problems, producing erroneous or misleading test results. After a test, and before the meters are reset (or zeroed), the first several seconds of the waveform may be observed by pressing W. The run menu will be saved and the screen will clear. A graph will appear, with a vertical axis in counts (maximum and minimum values for the 12 bit A/D), and a horizontal axis scaled in seconds, initially zero to about Each sample of the converter is plotted with an asterik (*), and the rough outline of the AC current waveform will be visible. Across the bottom of the screen is a menu of ten choices, which are selected by using the <LEFT> and <RIGHT> cursor keys. Their functions are as follows: <START START> <REF1 REF1> <REF2 REF2> <END END> SMOOTH QUIT Decrements the starting point of the display Increments the starting point of the display Decrements the position of the first reference line Increments the position of the first reference line Decrements the position of the second reference line Increments the position of the second reference line Halves total number of samples (Magnifies display) Doubles total number of samples (Contracts display) Connects samples with smooth line for easy viewing Erases display and returns to previous menu At the top of the screen are values for duration and RMS value. They correspond to the time interval between the REF1 and REF2 cursors, and the calculated true RMS value between them. Note that the reference cursors move outside the graph when their position cannot be displayed within the endpoints. If a cursor outside the endpoints is moved, it will first move to the end of the graph. The cursors move about 1/20 of the width of the graph, or one sample, depending on magnification.

23 13-5 TESTING MODES (Continued) Exiting Program and Saving Results After test is performed and while test results are still displayed press Q. Message will be displayed in lower left corner DO YOU WANT TO EXIT FROM THIS RUN MENU [Y/N]?. Pressing N will return to main operating screen. Pressing Y will display SAVE RESULTS TO DATABASE [Y/N]?. Pressing Y will save results to database. Pressing N will exit from main operating screen. To print or view saved results see Section Trademarks * "MS-DOS" is a trademark of Microsoft Corporation.

24 14-1 THEORY OF OPERATION All of the control functions originate from the computer controller, and all status data is reported back to the controller. In this way, when a test is initiated, the computer controller is in full control and can monitor and record all test data automatically hundreds of times per second. The operation of the computer controller is explained in the Controller Description section. Therefore, only the operation of the regulator and high current sections will be discussed at this time. Fuses and Circuit Breakers The first level of protection for the entire test set is two 400 Amp fuses, labeled F1 and F2. These fuses are connected directly to the 480 V input. The control section is protected by two 10 Amp fuses, F3 and F4, and the AC HI line is protected by a 15 Amp Fuse, F5. Two 3 Amp fuses, F11 and F12, protect the variable transformer motor drive controller. For the protection of the variable transformer regulator, there is a 50 Amp circuit breaker, CB2. The main power circuit breaker, CB1, 350 Amp, protects the high power section. Circuit breaker CB1 is also equipped with an undervoltage release coil that is connected to the interlock. This breaker must be reset the interlock opens. Interlock Circuit The interlock circuit will be held open by any one of several types of fault conditions. The indicator lamp on the control panel will light to indicate that the interlock is open and must be closed before the test can continue. The interlock can be held open by two basic sources, a failure to properly ground the test set or a computer detected fault. The ground fault is detected by relay K11. The computer controlled interlock relay K14A which is brought out to J12 on the I/O board can at any time open the interlock. The computer will hold the interlock open if any thermocouple closes or if the output bus temperature exceeds 75 degrees C. The computer also holds the interlock open during power on procedures to ensure safe and smooth operation. Triggering The SCR trigger board serves only one task, that is to turn on the SCR's. The computer controller sends the initiate output pulse to the trigger board when the output is to turn on and then terminates the signal when the output is to turn off. When the output is initiated, relay K6 is activated and the Output On indicator is lit. To prevent timing errors that may occur with this method, a phase reference signal is generated from the input voltage. This is done on the I/O board. The phase reference signal is optically isolated and conditioned to the form of a digital pulse. This signal is fed to the computer and used to control the turn on phase angle and increase accuracy. The various conditions that will turn the output on and off are explained in the Controller Description section. Taps and Vernier To achieve a variable output from zero to maximum, a system of taps and a motorized vernier are employed. Both the taps and vernier are controlled only through the computer. This can be done in several modes that are explained in the Controller Description section. The tap relays are controlled by relays K2, K3, K4 and K8 on the I/O board. These relays also provide isolation from the digital circuitry. The vernier is also controlled by relays on the I/O board. Relays K9 and K10 control both direction and start or stop. The vernier also has a variable resistor attached to its shaft that is used for position sensing. This position signal is fed to the computer as an analog signal called VER POS and is present on J11, pin 2.

25 14-2 THEORY OF OPERATION (Continued) Timer The timer is used to measure the width of the applied current pulse. The timer always starts at zero and begins counting at the start of the test. The timer can count either seconds or cycles and can be changed before or after the test. In the normally closed (NC) or normally open (NO) modes of operation, the timer will start when the computer sends the initiate signal to the trigger board and stops when either the contacts change state or the computer terminates the initiate signal. In the current latch mode, the timer will start when current flow is detected and stop when current flow stops. This mode must be used for single-phase breakers. Currentmeter To measure the output current, two precision current transformers are placed around the output bus. These transformers are wired in series for maximum output voltage and can measure up to 100,000 Amps. This voltage is fed to the interface board which is located inside the computer. The signal is then integrated and amplified. The gain of the amplifier is set by the computer depending on the range that is being used. The amplifier is a precision, differential instrumentation amplifier with a very high common mode rejection ratio for noise immunity. The signal is then fed to the analog-to-digital converter and then to the computer. The current is then calculated as an average of the current readings to reduce the effects of noise. Other than the initial adjustments of DC offset and common mode rejection there are no other adjustments that can be made on the interface board. The final adjustments are made from the system setup menu in the form of cal-factors. This procedure is explained in detail in the Calibration section of this manual. Continuity The continuity binding posts are located above the output stabs and can be used to indicate whether the breaker is open or closed. This is done by applying 15 VDC to an opto isolator through the binding posts. When the posts are shorted, the opto isolator conducts and the continuity signal becomes active. This signal is fed to the computer and is reported on the screen. The continuity signal is also used by the timer to detect when the breaker opens and the precise time to stop the timer.

26 15-1 TROUBLESHOOTING If the unit is suspected to be malfunctioning, refer to the following guide for testing the unit and isolating the problem. Some minor repairs can be made in the field. Otherwise, call the factory for assistance. NOTE: SOME TROUBLESHOOTING PROCEDURES REQUIRE OPENING THE TEST SET, WHICH HAS POTENTIALLY LETHAL VOLTAGES ON EXPOSED CONDUCTORS. ONLY FULLY EXPERIENCED TECHNICIANS SHOULD ATTEMPT TO PERFORM THESE PROCEDURES. IF YOU HAVE ANY DOUBTS, CONTACT THE FACTORY FOR ASSISTANCE. 1. Insufficient Output When the unit does not seem to yield sufficient current through a breaker, the problem could be one of the following: a. Insufficient power supply. b. Loose connection in unit. c. Incorrect controller range or output tap configuration setting. d. Poor connections or excessive contact resistance at the breaker. Check cable or stab connections. e. Improper selection of output configuration. 2. Cannot Energize Main Circuit Breaker a. Main breaker can only be energized when the interlock is clear. Check the status on the controller. b. Remove power and inspect the under voltage release mechanism for the main breaker. 3. No Output Current When Initiated a. Check to see that main circuit breaker is on. b. Verify that the breaker is reset and not in the trip position. c. Verify continuity of the breaker contacts. d. Check all internal fuses of the test set. e. Check LED indicator on SCR trigger board. It should light when initiated. f. Check voltage out of SCR's when initiated.

27 16-1 CALIBRATION Calibration is recommended at one year intervals. A High Current standard is required. The standard should have an accuracy of +/- 1/4%. A digital millivolt meter with an accuracy of +/-.1 mv is also required. Use the following procedure once for each range of the test set. 1. Connect the standard across the output and the millivolt meter to the metering points on the standard. 2. Initiate the unit at several current values within the range and record the current measured on the standard meter and the test set. 3. If the unit is out of tolerance, the new cal-factor can be calculated as follows: (Test Set Reading) - (Standard Reading) % Error = (Full Scale) Calibration is accomplished by changing the cal-factor. If the observed error was -.01, multiply the appropriate cal-factor by 1.01; if the error was +.01, then multiply the cal-factor by.99. The cal-factor should be adjusted until readings are within tolerance. If the cal factor must be adjusted by more than 5%, internal adjustments are required which require factory assistance. 4. To access the cal-factor, the proper password must be entered. Once the password is entered, enter the system setup menu and change the appropriate cal-factor. 5. The time base of the digital timer is derived from the computer s internal crystal controlled oscillator and does not require periodic recalibration.

28 17-1 SERVICE AND MAINTENANCE Periodic Maintenance Periodically, the following maintenance should be performed on the unit to insure that the test set maintains proper output and operation. 1. Disconnect the unit from the input supply. 2. Open all panels on the unit. Using a vacuum cleaner, remove any dust and debris from the interior of the unit, including wiring and components. Use caution when cleaning printed circuit boards and small components. 3. Tighten all connections, especially those on transformers, contactors, and input and output connectors. Special attention should be given to tightening all connections in the high current section every six months or less. If the unit is transported often, this procedure should be performed more often. 4. Remove the front cover on the main circuit breaker and clean the main contacts. Replace the contacts if they are beyond repair. 5. Inspect the powerstat brushes for wear. Replace if they appear worn. 6. Perform basic operational tests to determine proper operation. The above maintenance procedures should be performed at least once a year depending on the amount of use and the environment.

29 RETURNED MATERIAL A-1 If for any reason it should become necessary to return this equipment to the factory, the Service Department of Phenix Technologies, Inc. must be given the following information: Name Plate Information Model Number Serial Number Reason for Return Cause of Defect If Phenix Technologies, Inc. deems return of the part appropriate, it will then issue an "Authorization for Return". If return is not deemed advisable, other inspection arrangements will be made. NOTE: Material received at this plant without the proper authorization shall be held as "Customer's Property" with no service until such time as the proper steps have been taken. Your cooperation is requested in order to ensure prompt service.

30 B-1 WARRANTY Phenix Technologies, Inc. warrants to the original purchaser of any new merchandise that the merchandise is free from defects in material and workmanship under normal use and service for a period of 18 months from the date of shipment. The obligation of Phenix Technologies, Inc. under this warranty is limited, in its exclusive option, to repair, replace, or issue credit for parts or materials which prove to be defective, and is subject to purchaser's compliance with the Phenix Technologies, Inc. warranty claim procedure as set forth below. The happening of any one or more of the following events will serve to void this warranty and defect or damage resulting therefrom is specifically excluded from warranty coverage: A. Defects due to accident, negligence, alteration, modification, faulty installation by purchaser or purchaser's agents or employees, abuse, or misuse. B. Attempted or actual dismantling, disassembling, service or repair by any person, firm, or corporation not specifically authorized in writing by Phenix Technologies, Inc. C. Defects caused by or due to handling by carrier, or incurred during shipment, transshipment, or other move. This warranty covers only those parts and/or materials deemed by Phenix Technologies, Inc. to be defective within the meaning of this warranty. The liability of Phenix Technologies, Inc. shall be limited to the repair, replacement, or issuance of credit for parts deemed defective within the meaning of this warranty. Costs incurred by purchaser for labor or other expenses incidental to the inspection, repair, replacement, or issuance of credit for such parts and/or material shall be the sole responsibility of purchaser. This warranty shall not apply to any accessories, parts, or materials not manufactured or supplied by Phenix Technologies, Inc. and if, in the sole discretion of Phenix Technologies, Inc., purchaser's claim relates to any materials or workmanship manufactured or performed by the supplier of a component part, or of the manufacturer of a device of which the defective part is a component, Phenix Technologies, Inc. reserves the right to disclaim liability under this warranty and to direct that the purchaser deal directly with such supplier or manufacturer. Phenix Technologies, Inc. agrees to assist the purchaser in processing or settling any such claims without prejudicing its position as to liability. Warranty Claim Procedure Compliance with the following warranty claim procedure is a condition precedent to the obligation of Phenix Technologies, Inc. under this warranty. A. Purchaser must notify Phenix Technologies, Inc. in writing by certified or registered mail, of the defect claimed within 18 months after date of original shipment. Said notice shall describe in detail the defect, the defective parts and/or part, and the alleged cause of defect. B. At the exclusive option of Phenix Technologies, Inc., purchaser shall dismantle or disassemble at purchaser's cost and expense and shall ship the defective part or material prepaid to and from Phenix Technologies, Inc., Accident, Maryland 21520, for inspection, or permit an authorized service representative of Phenix Technologies, Inc. to inspect the defective part or material at purchaser's premises. If Phenix Technologies, Inc. shall inspect the part or material at the purchaser's premises, purchaser shall provide facilities for, and at purchaser's cost and expense, dismantle, disassemble, or otherwise make accessible the subject part of material whether or not same is a component of or installed in a device other than that manufactured or supplied by Phenix Technologies, Inc. If disclosure shows that the defect is not one for which Phenix