DRTS.6 USER’S MANUAL - User Equip: New & Used Test …userequip.com/files/specs/5685/ISA DRTS-6 Manual.pdf · E-MAIL [email protected] WEB ... 4 CONNECTION AND TEST START WITH DRTS.6

Istrumentazioni Sistemi Automatici S.r.l.

VIA BERGAMO 41 - 21020 TAINO (VA) - ITALY OFFICES TEL. +39.0331.956081 - FAX +39.0331.957091 LAB: TEL. +39.0331.956483 - E-MAIL [email protected] WEB www.isatest.com

DATE: 01/12/2005 DOC.MIE10156 REV. 12

DRTS.6 USER’S MANUAL

Doc. MIE10156 Rev. 11 Page 2/87

REVISIONS SUMMARY VISA N. PAG. DATE 1 All 06/11/2001 Issued Lodi

2 Par. 11 05/04/2002 Added the AMI-99 option Lodi

3 22 28/08/2002 Added the reference to the CALIBRATION program

Lodi

4 17 23/11/02 Added the reference to low voltage outputs Lodi

5 4, 8 14/2/2003 Added the warning related to the grounding Lodi

6 8 17/3/2003 Added the Hazardous situation paragraph Lodi

7 20-30 04/06/2003 Added the troubleshooting paragraph Lodi

8 7-35 03/10/2003 Added information to paragraphs: Connection; Troubleshooting.

Lodi

9 7-26; 39-42 28/11/2003 For a better understanding, paragraph 4 has been re-organized. Added Paragraph 6.

Lodi

10 6, 23, 36, 70

15/03/2004 Added the USB interface Lodi

11 26-28 25/3/04 Added two fixes Lodi

12 64 1/12/2005 Added the mains synchronizer option Lodi


1 SAFETY AT WORK...................................................................................................................................... 5 2 GENERAL.................................................................................................................................................... 6 3 DESCRIPTION OF THE INSTRUMENT ................................................................................................... 6 4 CONNECTION AND TEST START WITH DRTS.6 ................................................................................. 7

4.1) Connection to the mains ......................................................................................................................... 7 4.2 Power-ON ................................................................................................................................................ 7 4.3 Connection to the relay........................................................................................................................... 9

4.3.1 Hazardous situations ...................................................................................................................... 9 4.3.2 Burden............................................................................................................................................ 11 4.3.3 Current outputs............................................................................................................................. 11 4.3.4 Low current ranges: option IN1-CDG........................................................................................ 14 4.3.5 Delta connection of current outputs............................................................................................ 14 4.3.6 Voltage outputs ............................................................................................................................. 15 4.3.7 Use of the AC voltage output for the relay auxiliary supply .................................................... 18 4.3.8 Auxiliary DC voltage .................................................................................................................... 20 4.3.9 Trip inputs ..................................................................................................................................... 20 4.3.10 Counting inputs ........................................................................................................................... 21 4.3.11 Auxiliary outputs ........................................................................................................................ 23 4.3.12 Low level signals ......................................................................................................................... 23 4.3.13 Optional measurement inputs ................................................................................................... 24

4.4 Connection to the PC ............................................................................................................................ 24 4.5 Execution of the test and problem solutions......................................................................................... 24 4.6 Power-off ............................................................................................................................................... 25

5 TROUBLESHOOTING................................................................................................................................ 26 5.1 Introduction............................................................................................................................................ 26 5.2 Opening the test set and first checks...................................................................................................... 26 5.3 The test set cannot be powered-on or diagnostic voltage error ............................................................. 30 5.4. Fault on the current amplifier ............................................................................................................... 32

5.4.1. Overload......................................................................................................................................... 32 5.4.2. Current amplifiers power supply error........................................................................................... 32 5.4.3. Over temperature ........................................................................................................................... 33 5.4.4. Temporary intervention ................................................................................................................. 33 5.4.5. Amplifier replacement ................................................................................................................... 34

5.5. Fault on the voltage amplifier power supply ........................................................................................ 34 5.6. Fault on the voltage amplifier............................................................................................................... 35

5.6.1. Overload......................................................................................................................................... 37 5.6.2. Counter feed................................................................................................................................... 39 5.6.3. Amplifier replacement ................................................................................................................... 39

5.7. Fault on the DC SUPPLY..................................................................................................................... 39 5.8. Fault on trip inputs................................................................................................................................ 41 5.9. Fault on the microprocessor board ....................................................................................................... 42 5.10. Problems with upgrade or with the diagnostic.................................................................................... 43

5.10.1. Upgrade problems ........................................................................................................................ 43 5.10.2. Diagnostic problems .................................................................................................................... 44

5.11. Problems with the USB interface........................................................................................................ 44 5.12 The fault cannot be fixed ..................................................................................................................... 45

6 SPECIAL SITUATIONS.............................................................................................................................. 47 6.1 Addition of the MISU option................................................................................................................ 47 6.2 Transformation of a 125 V unit into a 300 V one ................................................................................ 48 6.3 Transformation of the interface from RS232 to USB........................................................................... 50

7 FUNCTIONAL TEST .................................................................................................................................. 52 7.1 Introduction........................................................................................................................................... 52 7.2 Voltage outputs ..................................................................................................................................... 52


7.3 Current outputs ..................................................................................................................................... 53 7.4 Auxiliary DC voltage............................................................................................................................ 53 7.5 Trip inputs and auxiliary outputs.......................................................................................................... 53

8 DRTS.6 CALIBRATION ............................................................................................................................. 54 9 MEASUREMENT OPTION......................................................................................................................... 55

9.1 Introduction........................................................................................................................................... 55 9.2 Description of Measurement option ...................................................................................................... 55

10 IO6432 OPTION......................................................................................................................................... 56 10.1 Introduction......................................................................................................................................... 56 10.2 Description of IO6432 ......................................................................................................................... 56

11 GPS OPTION.............................................................................................................................................. 57 11.1 Introduction.......................................................................................................................................... 57 11.2 Description of GPS option................................................................................................................... 57 11.3 Directions for the use of GPS option................................................................................................... 57

12 OPTIONAL AMPLIFIER AMI150 ............................................................................................................ 61 12.1 Introduction......................................................................................................................................... 61 12.2 Description of AMI150........................................................................................................................ 61 12.3 Connection and test start...................................................................................................................... 61

12.3.1 Maximum burden ....................................................................................................................... 61 12.3.2 Power-on ...................................................................................................................................... 62 12.3.3 Connection to the relay under test ............................................................................................ 63

12.3.3.1 Use of AMI150 to increase the output power .........................................................................................63 12.3.3.2 Use of AMI150 to have nine currents .....................................................................................................63 12.3.3.3 Use of AMI150 to have six currents .......................................................................................................63

12.3.4 Connection to the PC and test start .......................................................................................... 63 13 OPTIONAL AMPLIFIER AMI-99............................................................................................................. 64

13.1 Introduction......................................................................................................................................... 64 13.2 Description of AMI-99 ........................................................................................................................ 64 13.3 Connection and test start...................................................................................................................... 64

13.3.1 Power-on ...................................................................................................................................... 64 13.3.2 Connection to the relay under test ............................................................................................ 64

13.3.2.1 Use of AMI-99 to have nine currents......................................................................................................65 13.3.2.2 Six currents rated 30 A............................................................................................................................65 13.3.2.3 Three currents rated 60 A .......................................................................................................................66 13.3.2.4 Single phase tests at 180 A......................................................................................................................66

13.3.3 Connection to the PC and test start .......................................................................................... 66 14 MAINS SYNCHRONISER OPTION......................................................................................................... 67 APPENDIX 1: DRTS.6 RS232 SERIAL INTERFACE.................................................................................. 68 APPENDIX 2: RS232 SERIAL INTERFACE CABLE .................................................................................. 68 APPENDIX 3: LIST OF DRTS.6 SPARE PARTS ......................................................................................... 69 APPENDIX 4: ERROR CODES AND CORRESPONDING AREA.............................................................. 70 APPENDIX 5: CONNECTOR 19; BOOSTERS............................................................................................. 75 APPENDIX 6: CABLE FROM DRTS.6 TO BOOSTERS ............................................................................. 76 APPENDIX 7: IO6432 CONNECTORS......................................................................................................... 78 DRTS.6 PART LIST........................................................................................................................................ 82 AMI150 PART-LIST....................................................................................................................................... 84 AMI.99 PART LIST ........................................................................................................................................ 85


1 SAFETY AT WORK The Product hereafter described is manufactured and tested according to the specifications, and when used for normal applications and within the normal electrical and mechanical limits will not cause hazard to health and safety, provided that the standard engineering rules are observed and that it is used by trained personnel only. The operating manual is published by the Seller to be used together with the system hereafter described. The Seller reserves the right to modify the manual without warning, for any reason I.S.A. This includes also but not only, the adoption of more advanced technological solutions and modified manufacturing procedures. The Seller declines any difficulties arising from difficulties due to unknown technical difficulties. The seller declines also any responsibility in case of modification of the instrument or of any intervention not authorized by the Seller in writing. The Product generates voltages and currents that may be lethal to the unadvertised user. Besides, in order to avoid any danger in case of fault inside the Product, the device under test should have the following characteristics: . Connection cables must use safety banana plugs; . Connection sockets must be not accessible; . Input circuits must have an isolation degree at least equal to the one of the product. DO NOT OPERATE THE PRODUCT IF NOT CONNECTED TO GROUND: BECAUSE OF FILTER CAPACITORS, THE CASE WOULD GROW TO A VOLTAGE EQUAL TO THE HALF OF THE SUPPLY, I.E. 110 V. BESIDES, IN THIS SITUATION THERE IS NO FILTERING AGAINST COMMON-MODE NOISE COMING FROM THE MAINS: THIS CAN CAUSE SUDDEN FAULTS. THIS TYPE OF FAULTS ARE NOT COVERED BY THE WARRANTY. The connection to ground is provided through the mains supply cable; however, for added safety, the Product should be connected to ground using the dedicated socket. IF THE GROUND IS NOT AVAILABLE AT THE MAINS SUPPLY, CONNECT THE TEST SET TO GROUND USING THE DEDICATED SOCKET. The connection to ground is provided through the mains supply cable; however, for added safety, the Product should be connected to ground using the dedicated socket. NOTE: on test sets after 12786, there is a circuit that verifies the connection to ground of the test set, and warns the operator if it is not connected. After this message, the test set cannot be operated unless a proper grounding is established. Note that the test set accepts to be supplied phase to neutral, or phase to phase. In case of doubt, please contact your Seller. The Seller and Manufacturer decline any and all responsibility due to improper usage, or any usage outside the specified limits.


2 GENERAL The DRTS.6 user's manual provides information about how to use the instrument. It informs also about the internal design and troubleshooting messages; last, it provides a suggested spare parts list. Technical specifications of the DRTS.6, of the resident firmware FWH6 and of the TDMS control software are provided in separate documents. The document includes internal options Measurement and IO6432, and external modules AMI-150, AMIV-33, AMI-66, AMI-99 and AMV-66.

3 DESCRIPTION OF THE INSTRUMENT The DRTS.6 has a basic configuration, two internal options and some external optional modules. The basic configuration includes: . Four voltage generators (the fourth one can be used as a standard one or to generate the zero-sequence voltage of the other three phases); . Six current generators; . The auxiliary DC voltage generator; . Eight trip inputs; . Two inputs for high-frequency impulses; . Four digital outputs; . A low power signal connector for the external modules; . The RS232 serial interface connector. From June 2004, also the USB interface connector. Internal options are: . The Measurement option, that allows testing the converters and of high voltage and current, that is made of the MISU printed circuit board; . The IO6432 option, that allows increasing the number of digital inputs and outputs (64 inputs and 32 outputs); it is made of two IO6432 printed circuit boards. External options are: . AMI-150, with three high power current outputs. When this module is connected to the DRTS.6, it is possible to increase the power of current outputs; it is also possible to control six currents at the meantime. . AMIV-66, with three current outputs and two voltage outputs at the same power of DRTS.6. When this module is connected to DRTS.6, it is possible to control nine currents (or to have three currents rated 45 A), or six voltages at the meantime. . AMI-66, with three current outputs at the same power of the DRTS.6. When this module is connected to the DRTS.6, it is possible to control nine currents (or to have three currents rated 45 A). . AMI-99, with three current outputs rated 30 A. When this module is connected to the DRTS.6, it is possible to control nine currents, or to have six currents rated 30 A, or three currents rated 60 A.


4 CONNECTION AND TEST START WITH DRTS.6

4.1) Connection to the mains Before connecting the relay, connect the DRTS.6 to the mains, by means of the power supply cord. The earth is connected to the supply plug. DO NOT OPERATE THE PRODUCT IF NOT CONNECTED TO GROUND: BECAUSE OF FILTER CAPACITORS, THE CASE WOULD GROW TO A VOLTAGE EQUAL TO THE HALF OF THE SUPPLY, I.E. 110 V. BESIDES, IN THIS SITUATION THERE IS NO FILTERING AGAINST COMMON-MODE NOISE COMING FROM THE MAINS: THIS CAN CAUSE SUDDEN FAULTS. THIS TYPE OF FAULTS ARE NOT COVERED BY THE WARRANTY. IF THE GROUND IS NOT AVAILABLE AT THE MAINS SUPPLY, CONNECT THE TEST SET TO GROUND USING THE DEDICATED SOCKET. The supply voltage range is 90 to 132 and 180 to 264 V AC, sinusoidal, single phase. Please consider that most mains stabilizer and uninterruptible power supplies generate a voltage that is a square wave rather than sinusoidal: this is out of range for DRTS.6. NOTE: on test sets after 12786, there is a circuit that verifies the connection to ground of the test set, and warns the operator if it is not connected. After this message, the test set cannot be operated unless a proper grounding is established. Note that the test set accepts to be supplied phase to neutral, or phase to phase.

4.2 Power-ON After power-on the test set starts a self-diagnostic procedure: digital circuits first; then, analogue circuits. The self-diagnostic procedure is the following one. - At power on the microprocessor programs the two XILINX’s XC5204 programmable logics. At the end of programming the programmable logic tests itself; the microprocessor checks for correct answer (DAN). If programming of XILINX A is not OK, lights OK and ERR turn on; if programming of XILINX B is not OK, lights ! and ERR turn on. - Next, the microprocessor tests the Static RAM: it writes at all locations 55 first, then AA, and checks for no error. In case of error, it turns on lights OK; !; ERR. - At the end of this test, all lights are turned on and off. - Next, the microprocessor tests the speed of the Static RAM, and decides whether to add one wait cycle. During this test all lights turn on and off from bottom to top. - At the end of this test, all lights are turned on and off. - Next, the microprocessor tests the Dynamic RAM. During this test all lights turn on and off from top to bottom. In case of error, it turns on lights ON and ERR.


- At the end of this test, all lights are turned on and off. - Last, the microprocessor tests the FLASH EPROM, with its CRC code. In case of error, it turns on lights ON; ! and ERR. - This is the last test of logic circuits ; next steps refer to analog circuits. The following table summarizes logic errors. LIGHT OK ; ERR !; ERR OK ; !; ERR ON ; ERR ON ; !; ERR SOURCE XILINX A XILINX B SRAM DRAM FLASH - First test is the check of the + 5 V logic circuits supply; then + 12 V for relays and fans; then + 15 V and – 15 V for analogic circuits. - Next step is the test of DC voltage supplies for current and voltage amplifiers. - Next step is the test of DAC’s that generate low power signals to be fed into current and voltage amplifiers. First test is zero voltage output; next maximum voltage; next minimum voltage. During this test outputs are inhibited: no output is generated by the instrument. - Other errors cause the ERR light to turn on; they are also reported to the P.C. with the corresponding error message. During this last session, the four LED’s blink in pairs. At the end of diagnostics, the green light OK turns on: this confirms that the microprocessor operates correctly. If there is a fault sensed on an amplifier (current, AC voltage, DC voltage), you have the two lights: OK and ! turned on, plus the buzzer beeping. In this situation, you can connect your PC and start the test program: it will display you the code message telling which one is the faulty amplifier. In order to proceed, please go to the Troubleshooting chapter. NOTE. Also diagnostic circuits can fail; in these instances the diagnostic fault is false. This is why if you press OK on the diagnostic message the program allows you to continue. If the alarm is wrong or if you do not use the corresponding feature tests can be performed at no further trouble. In this last instance, if the diagnostic alarm is annoying, it can be skipped as follows: - Remove the four screws on the rear; remove lids; - Microprocessor board is the second one to the left. Looking from the bottom, there is a group of

DIP switches. Switch 1 is the rightmost. Analog diagnostic is skipped setting OFF (pushing forwards) switch no. 7.


4.3 Connection to the relay

4.3.1 Hazardous situations The following table lists a number of situations that are potentially hazardous to the user and/or to the test set. Please consider this list, and check the situation in case of doubt. SITUATION CAUSE OF RISK CONTROL TEST SET NOT GROUNDED

Capacitor dividers take the case at 110 V. The unit is not protected against common mode noise. See below for details.

Ground connection

Voltage (or current) neutral connected to ground

The test set ground and the neutral ground are connected to very distant points of the grid. There is a voltage differential between the grounds; in case of fault, there is an heavy risk for the test set and for the operator. Besides, it is likely that transient spikes occur during the test; their value can exceed the rated isolation limits. See below for details.

VN (IN) connected to ground

Current neutral connected to VN instead of IN

Inside the test set there is an 1 Ohm resistor between IN and VN: it would be burned by the output current. This, in turn, can cause the oscillation of current outputs, and cause the damage of current amplifiers.

Connect the current neutral to IN.

Stand-by generator The frequency and amplitude variations and the

superimposed noise have caused the damage of the front-end circuit.

Supply waveform

Filtered mains; electronic stabilizer

The AC voltage can be a squared waveform rather than sinusoidal; the test set operates at the minimum supply level, with low efficiency. Besides, the power sunk by DRTS.6 at full power is 3680 W: this is to be considered for a correct dimensioning.

Supply waveform

Loss of power supply while the test set was generating

There can be a loss of control because the microprocessor resets while energy was applied to the load.

Quality monitor

Contact to a live wire The contact can be dangerous to the user or even the

plant. The test set voltage outputs are protected only prior to the first test.

Test before connecting

Current outputs in series See text: the use of mis-matching resistors is mandatory. See the manual

Voltage outputs in parallel

See text: the use of mis-matching resistors is mandatory. See the manual

Long generation of all currents

Possible danger of over-heating components, specially with high ambient temperature

Check burden and duration

Very old relay, with heavily inductive load

Spikes as the relay switches the measuring circuits Check burdens


Of these points, the first three are very hazardous, both for the user and the test set. THESE TYPES OF FAULT ARE NOT COVERED BY THE WARRANTY. For the first hazard, see the figure below. Capacitors shown are included in the filter. Of course their value is low, so that the current flow is limited according to specification; however, you can feel it. Besides, there is no protection against common mode voltages, such as ESD, that are usually discharged to the ground. The connection of the test set to any metal frame connected to ground solves the problem. The second hazard does not apply if the relay to be tested is not connected to the plant. If, instead, the connection to the relay is performed by means of a test connector (or directly to terminal blocks), the operator must be sure to interrupt the connection to the V.T. secondary and to the ground. This is normally true; however, we experienced some instance were this was not performed.

TEST SET

VN (IN)

TEST SET GROUND CONNECTION

TEST CONNECTOR V.T. (C.T.)

REMOTE GROUND CONNECTION

THE BRIDGE MUST BE OPEN!

VOLTAGE

MAINS FILTER

TEST SET

MAINS V

V / 2

EXTERNAL GROUND (OPERATOR)

FRAME


The problem in this instance is that VN of P.T.’s (or IN of C.T.’s) is connected to ground in a point of the grid that is far away (sometimes very far away) from the control building. Between the ground of the test set and the ground of P.T.’s there is a voltage differential that is caused by eddy currents; in case of ground fault, this voltage grows to lethal levels, for both the user and the test set. Besides, high energy spikes between the two grounding points are easy to develop; these spikes have amplitudes and energy that can exceed the rated isolation limits. Checking the error is simple: just test with a resistance meter that there is no connection between VN and the ground. The third hazard is easily avoided just by checking that the relay neutral connection is connected to IN rather than VN.

4.3.2 Burden Before executing a test with the DRTS.6 it is necessary to check that the burdens of the relay under test are compatible with the DRTS.6 voltage and current output power. To this purpose, it is necessary to compare the burden declared by the manufacturer to the following maximum loads. Often the burden is expressed in terms of VA load at nominal voltage or current: it is necessary to convert it into Ohm, with the following formulas. V burden = (nominal voltage)^2 / VA load I burden = VA load / (nominal current)^2 When DRTS.6 is overloaded, a circuit generates a fault signal as soon as the output has an error in excess of 5% to 10% of the nominal output. This logic error is delayed in order to avoid faults caused by the relay itself (for instance as metering circuits are switched). For this reason, if test duration is very short (as during the test of first zone settings in distance relays), the overload signal can be not sensed: in this situation, test result can be different from the nominal setting. Therefore, if test result is very different with respect to the nominal, before proceeding test that there is no overload, with a test duration more than 0.3 s.

4.3.3 Current outputs Currents are connected to safety sockets (5). When an output is applied, the corresponding light (6) turns on. Note that the unit can operate two ways: - Mode 6 I: in this mode all currents are independently adjustable, maximum current is 15 A.

Note that if only three currents are used (I1, I2, I3) the corresponding output power is 100 VA; if more outputs are used, maximum power decreases to 80 VA.

- Mode 3 I. In this mode current outputs are to be set in parallel: I1 to I4; I2 to I5; I3 to I6. The program accepts currents up to 30 A, and accommodates for the correct commands to DRTS.6 and test results from DRTS.6.

The two neutral sockets are connected together. If up to three currents are generated one socket is sufficient; if more currents are generated it is advisable to use both sockets. Be careful as IN sockets are connected to socket VN via an 1 Ohm resistor, that would be damaged if the current neutral is connected to VN.


The instrument can drive up to 100 VA on outputs I1, I2, I3: if any other output is generated (I4 to I6), maximum load becomes 80 VA per phase. The corresponding maximum burdens are the following, as a function of the maximum test current. RANGE (A)

0.15 1.5 15

BURDEN; 3I (Ohm)

40 4 0.44

BURDEN; 6I (Ohm)

30 3 0.35

Special care is to be taken when evaluating the burden of the current input, as the burden of connecting wires is to be added to the relay burden. If the relay load is 2 VA at nominal current, the relay burden is 80 mOhm. In this case it is possible to test at 15 A only if the connection and cabling are maximum 8 m long, with a cross section of 2.5 sq. mm at least, and if cables are tied together, in order to minimize the reactive component. In case it is desired to have a three-phase generator, rated 30 A and 160 VA per phase, it is possible to select the 3I mode. In this situation, DRTS.6 output currents are to be connected in parallel: I1 to I4; I2 to I5; I3 to I6, taking advantage of the PAI option (figure 1). The program accepts test currents up to 30 A on DRTS.6, and takes care to drive half and half the amplifiers, and to display the total current on the display and in the test report. I1 PAI I2 ZL IN Figure 1 - Parallel connection of current outputs The corresponding maximum burdens become the followings. RANGE (A) 0.3 3 30 BURDEN; 3I (Ohm) 15 1.5 0.18 In case it is desired to run tests at even higher currents, it is possible to connect more amplifiers in parallel, and to perform single-phase tests. The angle between currents must be 0°; the current amplitude must be the same. By this, current increases, power increases, but the maximum burden decreases, as summarized in the following table. RANGE (A) 45 60 90 N. OF OUTPUTS 3 4 6 BURDEN (Ohm) 0.12 0.088 0.059 POWER (VA) 240 320 480


In these instances, please take care of the connection and of test duration: 4 mm sockets are unable to deliver 90 A for a long while. Use both neutral sockets in parallel, and an adequate (biggest than possible) wire size, such that connection sockets are not damaged because of over-heating and the burden is minimized. If the problem is having more than 100 VA at 15 A, then it is possible to connect two amplifiers in series (figure 2). The angle between currents must be 180°; the amplitude of two currents must be the same. In this instance it is possible to have up to 160 VA; however, with this connection, minor differences of current outputs can tend to overload the amplifier, that would make it impossible to get the desired power. To overcome this problem it is possible to balance current outputs with the SEI option, that includes a shunt resistor that causes a maximum output current error of - 1.6%. The following table summarizes maximum burden Z at 160 VA. RANGE 0.15 1.5 15 BURDEN Z (Ohm) 70 7 0.7

DRTS.6 SEI OPTION LOAD I1 22 Ohm IN Z 22 Ohm I2 Figure 2 - series connection of current outputs USE THIS SETTING ONLY IF THE POWER OF A SINGLE OUTPUT IS NOT SUFFICIENT BECAUSE OF A TOO HIGH BURDEN. DO NOT USE SERIES CONNECTION WITHOUT THE SHUNTING RESISTOR, AS THIS COULD DAMAGE THE AMPLIFIER. CONNECT IN SERIES ONLY I1 TO I4; I2 TO I5; I3 TO I6. Note that it is impossible to connect in series more than two current generators because the neutral is in common.


In conclusion, it is always possible to parallel currents and to connect in series voltages; the opposite, i.e. parallel connection of voltage outputs and series connection of current outputs is to be performed with attention.

4.3.4 Low current ranges: option IN1-CDG With DRTS.6 the full power of 100 VA is available only at the current of 15 A. This is good for the test of relays with the nominal current of 5 A; if relays are rated 1 A, the available power can be not adequate to perform the test of high burden relays. In addition to this, some relays (as CDG of GE) have very low current settings. The option IN1-CDG solves this problem, by means of a set of three current transformers, with the following characteristics: . Primaries: 12.5 A and 15 A; . Secondaries: 0.5 A; 1 A; 2.5 A; . Nominal power: 100 VA. - Connections: . Four primary side sockets (I1, I2, I3, IN); . Three independent outputs, with one phase socket and 2 zero sockets; . Ease of connecting outputs in star or delta configuration. . For the single phase tests it is possible to have three times the above power, connecting current outputs in series. The option includes four connecting cables to DRTS.6 current outputs, 1 m long, 2.5 sq. mm cross section. Outputs are do not have a common neutral; this eases the star or delta connection. Included is a bridge for star connection. The test program TDMS accepts the transformer ratio, so that currents can be programmed with their value after the option.

4.3.5 Delta connection of current outputs We have had a fault on current outputs that has been caused by a type of connection we never heard before. This connection can very quickly cause the fault of the test set current amplifier(s): for this reason, we explain you in the following what is it, why does it damages the amplifiers, and how to perform it in the way that avoids faults. In this type of connection, the device under test has only three inputs, not four; so, only current phase outputs are connected, and not the neutral.

I1

I2

I3

IN


The test can be started only if the three currents are equal in value, and phase shifted by 120°; else, the test set would immediately generate an over-load fault alarm. If currents are the same, our test sets are so good that each current closes its path on the other two, and no alarm is generated. The only instance where this connection could be necessary is testing differential transformer relay protections, where one side has a Delta connection and the compensator is included in the relay. The test with Delta connection can be performed using three SEI options. SEI is made of four banana and plug connector, and of three 22 Ohm resistors, that have the purpose of balancing the current load as seen by the test set. There is some current flowing into resistors: its amount, and therefore the error on the nominal current into the load, depends upon the load itself: the lower the load the less the error. If the load is just a short circuit, the current into SEI resistors is negligible (less than 0.1%); with the maximum load, the current error increases to – 1.6%. This inconvenience must be accepted, against the almost sure damage of the test set. The connection of SEI is straightforward, as shown in the connection schematic.

4.3.6 Voltage outputs Voltages are connected to safety sockets (10). When an output is applied, the corresponding light (9) turns on.

TEST SET DELTA LOAD

I1

I2 I3

TEST SET DELTA LOAD

I1

I2

I3

IN

SEI OPTION 3 * 22 Ohm


Output V4 can be operated either as a fourth voltage, program controlled, or as the zero sequence voltage of the other phases; the selection is performed in the pre-fault settings. Another selection is the value of the zero-sequence voltage, that can be (V1+V2+V3)/3 or (V1+V2+V3)/1.73 (vectorial sum), also program selectable. Be careful because with the latter selection the zero-sequence voltage can be higher than 125 V (300 V with the option): in this case the instrument gives an over-load error. Purpose of V4 is to test relays that need an independent fourth voltage; example is synchronization relay for the reclosure of HV lines (matched to a distance relay). Purpose of Vo is to test relays that need the zero sequence voltage along with three phase voltages. For this purpose also the V4 selection is applicable; however, the user should compute V4 from V1, V2 and V3 with the above formula. For normal use, select V4. The neutral of V4 is VN. Be careful that socket VN is connected to sockets IN, while it is isolated from the zero of the auxiliary DC supply voltage (8). Maximum burdens are the following, as a function of the maximum test voltage. RANGE (V) 1 12.5 125 300 (OPT) BURDEN (Ohm) 100 100 200 1125 For tests at 125 V with a burden greater than 80 VA, it is possible to connect two amplifiers in parallel, using the PAV option (figure 3): this causes a maximum error of 0.5% on voltage applied to the load. DO NOT PARALLEL VOLTAGE OUTPUTS WITHOUT PAV, AS THIS COULD DAMAGE THE AMPLIFIER. The angle between voltages must be 0°; the amplitude of two voltages must be the same. With this connection, the power at maximum voltage grows to 160 VA; maximum loads are the following: RANGE (V) 1 12.5 125 300 (OPT) BURDEN (Ohm) 60 50 100 570 PAV includes a selector for the case that the 300 Option is available. Before starting the test, set the switch according to the voltage output. V1 PAV V2 ZL VN Figure 3 - Parallel connection of voltage outputs


It is also possible to double the output voltage by connecting the burden between phases phase-shifted at 180°; in this instance burdens are the following.


RANGE (V)

2 25 250 600 (OPT)

BURDEN (Ohm)

200 200 400 2250

Note that it is impossible to connect in series more than two voltage generators because the neutral is in common. V1 ZL V2 Figure 4 - Series connection of voltage outputs

4.3.7 Use of the AC voltage output for the relay auxiliary supply In some relays the auxiliary voltage is an AC voltage rather than a DC voltage. In this instance the AC voltage generator can be used to feed the relay; however, this must be performed with some care. The first check to perform is about the power consumption. On DRTS.6 the available power is 80 VA at the maximum voltage; the power decreases linearly with the voltage. However, the maximum relay consumption should be no more than one fifth of this power. The reason is that with an AC supply the load is made of a rectifying bridge plus filter capacitor: in this situation, the consumption is concentrated on the 2 ms of the voltage peak; therefore, the current is five times as higher than the one expected.


For example, if the relay voltage is 100 V and the power consumption is 10 VA, the current sink should be: 10 / 100 = 0.1 A. Due to the concentration of current, current peak is actually 0,5 A, that multiplied by 100 V makes 50 VA instead of 10 VA. Second problem, when the voltage is first applied to the relay, the filter capacitor is a short-circuit. The test set overload signal is delayed by 60 ms to overcome transient situations; during this time, the capacitor is loaded, at the maximum current yield of the amplifier: this could cause a fault. Besides, at the end of 60 ms the capacitor is normally not yet charged: as a consequence, DRTS.6 signals a fault on voltage output. To avoid it, we need to increase slowly the voltage supply, and to keep it constant during the test: this is performed as follows. . Go to pre-fault definition, and program a low voltage, say 5 V. . Press Apply pre-fault values: 5 V are generated. Thanks to the low voltage, the current is limited. . Program now 10 V, and generate them. . Continue with 10 V steps, until you reach the desired voltage supply. . This performed, go to fault definition, and program the same value for the voltage; then, perform your tests, but DO NOT USE THE RESET BUTTON, AS IT TAKES TO ZERO ALL OUTPUTS, AND THE SEQUENCE SHOULD BE REPEATED. In conclusion, if the AC voltage output is used as the relay auxiliary supply: . Compute the power sink; maximum available power from the test set is one fifth of the specified one; . Apply the voltage slowly, as explained.

V AC

I AC

V AC

I AC


NOTE. Suppose that the auxiliary DC voltage generator is broken, and you have to feed the relay auxiliary supply with a DC voltage. In this instance you can use the AC voltage output, selected at 0 Hz. In this instance, you can have the full power output, but the problem at start-up is still there, so APPLY THE VOLTAGE SLOWLY, as explained above; else, the amplifier will signal overload, or can be damaged.

4.3.8 Auxiliary DC voltage The auxiliary DC voltage is available on safety sockets (8), and is isolated with respect to voltages and currents. The DC voltage can be used to supply the relay under test or to polarize trip contacts. Before test start and when the voltage is zero the output is open. If a counter-feed voltage is erroneously connected the error is sensed and reported on the test program as counter-feed on DC supply. The voltage must be removed for the test to continue. When the output is present, the corresponding light turns on. The DC voltage generator can yield at maximum 100 W or 2 A: as a consequence, the maximum load is a function of the supply voltage. The following table lists the maximum load for the most used voltages. V dc (V)

R MAX (Ohm)

260 680 220 490 110 120 48 24 24 12 For the DC voltage, pay attention to the input filter capacitor: this is a short circuit as the voltage is applied. When connected to this type of load, the instrument drives 2 A for the maximum time of 0.5 s; after this, the instrument signals over-load. At 110 V the DRTS.6 can drive a capacitor of 1000 uF; bigger values can cause an overload alarm. In this instance, it can be enough to reduce the voltage.

4.3.9 Trip inputs Trip inputs are separated in two groups, with isolated zero reference: C1-C4 and C5-C8. The connection can be made to safety sockets (14). The selection of input voltage clean or under voltage is performed on the healthy values of the test program, together with other selections: debounce time and value of input voltage. If the input is voltage clean the program selects automatically the threshold of 24 V, that is the voltage wetting the contacts. If the input is under voltage, select 5 V for logical inputs, or the nominal voltage of the site. In case the 5 V level is selected with a voltage of 110 V, trip delays can be false; however, circuits will not be damaged. If the selection is voltage clean while it is under voltage, the contact can be seen closed


while it is open. The following table summarizes the nominal voltage and the corresponding nominal threshold. SELECTION

V THRESHOLD

V 5 4.5 24 22 48 42

> 100 57 De-bounce is the time during which the input must be confirmed before being Accepted as true; this selection is taken into account by the program, so that trip time does not change with this parameter. The importance of this setting is that spurious noise can be ignored with high settings; on the other side, fast trip times cannot be measured with high settings. The default value of 500 us is normally a good compromise. If the input is AC voltage, the program selects automatically the de-bounce delay of 2 ms, in order to avoid stopping on the zero crossings of the input. When the input with voltage is selected, the corresponding light (32) turns on. The state of trip inputs is signaled by lights (15): if the contact is closed or the voltage applied the LED turns on.

4.3.10 Counting inputs At sockets (7) are available the count inputs Imp1 and Imp2, that serve to test energy meters. The threshold level of these inputs is the respectively same of inputs C1-C4 and of inputs C5-C8, but there is no debounce. Input Imp1 has the same common of C1-C4; input Imp2 has the same common of C5-C8. The following figure shows how to perform the connection in two instances: the DRTS.6 is the reference, or the reference is made upon a sample meter. NOTE: as the counting input operates at high frequency, make sure that there is no bounce in the input, as otherwise they would all be counted.

DRTS.6

1C

V

I I

VRotatingdisk / led

Sensor

Energy meterunder test


A) ENERGY METER TEST WITH THE DRTS.6 AS A REFERENCE

DRTS.6

C 1

C 2

V

II I

V V

Samplesensor

Testsensor

Sampleenergy meter

Energy meterunder test

B) ENERGY METER TEST WITH A SAMPLE METER AS A REFERENCE NOTE: this test can be eased taking advantage of the optional SHA-6 reading head. IMPORTANT NOTE Some energy meters have the following internal connection (3-pin). In this situation, there is a common point between I and V inputs: it is pin 1. This pin MUST BE CONNECTED TO IN AND VN.

1 2

3

I

V

I1

IN

V1

1

2

3

ENERGY METER TEST SET


NOTE: The option SHA-6 eases the test.

4.3.11 Auxiliary outputs These outputs are relay, that can be operated via software; relay operation can be timed with respect to currents and voltages. The relay under test is connected to sockets (12), either on Normal Closed or Normal Open contact. Outputs are voltage free, and can be polarized if necessary. The closure of the output is warned by lights (13): contact closed = light on. Contact rating is: maximum voltage : 250 V AC; maximum current : 5 A. These contacts are foreseen to drive loads such as coils; to avoid EMI noise interference, contacts are protected by a capacitor and by a MOV rated 500 V AC. However, it is good practice to drive coils that are externally protected against voltage spikes when the coil is opened.

4.3.12 Low level signals Low level signal outputs are available on connector (34); pin-out is listed in appendix 9. Purpose of this output is to use external amplifiers, or to test relays connected to voltage dividers and Rogowsky coils. On the connector provided you should make a bridge between pins C and J: it tells the DRTS.6 to go to this operating mode. Connect the cable before powering on the instrument: after power on the DRTS.6 inhibits power outputs, and low level outputs become available. The control program takes into account this selection, and allows programming the corresponding conversion coefficients. In this mode, go to Preferences: the Zero Power area is active. You can program maximum voltages up to 300 V and maximum currents up to 500 A. The corresponding secondary voltage can also be programmed; the maximum RMS value is 7.24 V, corresponding to 10.24 V peak. The voltage output will be scaled according to primary and secondary voltage selections. For instance, if you program 100 A max primary current, and 7 V maximum secondary voltage, if you generate 20 A the secondary voltage will be 7/5 = 1,4 V. On current outputs only, the maximum secondary voltage can be selected to one tenth of the above value, that is 0,724 V. This serves to increase the accuracy when Rogowsky coils are to be simulated. The same connector (34) is used to drive the external amplifiers. In this instance, the cable provided with the amplifier includes the code of the amplifier type: control programs change accordingly. ATTENTION BECAUSE LOW LEVEL OUTPUTS ARE ACTIVE DURING NORMAL DRTS.6 OPERATION.

VN


4.3.13 Optional measurement inputs Optional measurement inputs (17) are four: low and high current; low and high voltage. Low current and voltage inputs are used to test transducer outputs, respectively with current (0-5; 4-20 mA) or voltage (10 V) outputs. High current and voltage inputs are used to measure currents up to 20 A, and voltages up to 200 V. The 20 mA input is protected against over-currents: a temporary fuse opens the circuit. However, take care not to apply 20 A to the 20 mA input. These inputs are used only if the optional MISU board has been installed. Connect converter inputs to DRTS.6 current and voltage outputs, and converter output to the measurement input. Start the manual or automatic test and verify the error of the converter.

4.4 Connection to the PC The test set is connected to the PC via the RS232 serial interface (4). The connector is a 9 way CANON type; logic signals and their positioning follow the standard for PC (see appendix 1). From May 2004, also the USB interface (11) is available: its operation is confirmed by light (16). The RS232 cable provided crosses the signals, from 9 to 9 ways; the wiring schematic is provided in appendix 2. The USB cable has lights to confirm the operation. The DRTS.6 is connected to the PC using the serial cable provided. The RS232 serial port is normally COM1. Connection specifications for RS232 are: - Interface type: RS232. - Baud rate: 57600. - Interface protocol: BUSY/READY. - Compatibility: PC with WINDOWS 95 or higher. The selection of the type of interface, RS232 or USB, is performed at test start; after it, the type of interface cannot be changed unless the test set is powered OFF.

4.5 Execution of the test and problem solutions During use, the DRTS.6 is set on a table, in horizontal position: to this purpose, the container is provided with suitable feet. Cooling air is flowing from the rear to the bottom of the instrument: do not impeach the free air flow, to avoid over-temperature alarms. Power on the PC and then connect it to the DRTS.6 using the serial cable. Before executing an automatic test, it is a good rule to start the manual X-PRO program, and to execute some tests to check that there is no error in the connections and in parameter setting, and also that it is possible to drive the load. Before test start the test set checks voltage output sockets. If a voltage greater than 10 V is detected, the PC gives a message of counter-feed on voltage outputs: this avoids connecting test set’s output voltage to a live wire. In this instance, remove the voltage before proceeding. On the auxiliary DC voltage supply, a voltage of 20 V is immediately sensed. The following table summarizes the situation.


SITUATION V1-V2-V3-V4 V DC At power-on Open; protected Open; protected Counter-feed alarm At test start, even if V = 0 Immediate During tests; STOP not pressed Closed; not protected Closed; not protected After RESET Open; protected Open; protected After STOP Closed; not protected Open; protected As a test is started, as soon as the DRTS.6 generates some output, the green ON LED turns on. This light stays on also during the pauses between tests, if healthy parameters foresee the generation of an output, including the DC voltage. If the red ! LED turns on (and a buzzer is heard) during the test, it alerts about the following problems: . Error on a voltage output, usually an overload. . Error on a current output, usually an overload (including the open circuit). . Over-temperature sensed on a voltage or current amplifier. The PC gives a message that helps selecting the type of fault. Usually, it is sufficient to correct the load and start over again. In case of over-temperature, go to zero with the outputs and start over again after some minute. Other faults have an internal origin: try again, and, if it does not disappear, it is necessary to repair the instrument. Appendix 4 lists error codes, and the corresponding fault area. Other logic errors can turn on the ERR LED of the DRTS.6. The error message explains which kind of error has been sensed. If the error is in the connection area, check the connection cable (see appendix 2). When everything is OK, it is possible to proceed with the execution of the test program. The program itself will tell the operator how to connect the relay. The way to use TDMS and the dedicated programs is explained in the corresponding manuals. In general, it is a good rule to save test results at the end of the test, so that they can be reloaded and printed.

4.6 Power-off After all tests have been performed, set all outputs to zero, remove all relay connections and power-off the test set. Do not power off with outputs being generated, and with the relay connected: high voltage spikes could be generated; the test set could be faulty at next power-on.


5 TROUBLESHOOTING

5.1 Introduction Sometimes, when my ears whistle, I wonder if it is because of some of my customers being angry at us because the test set doesn’t work: According to Murphy’s law, when it was most necessary. We at ISA do our best efforts to filter the so-called infant mortality of electronic components prior to delivery of all our test sets; and this after extensive testing of prototypes and pre-production units. Yet, sometimes faults occur, because everything dies, including electronic components; so, please, before shooting at us, see if the following instructions can serve you to fix the problem. If not, e-mail us the problem, not forgetting to mention the unit’s serial number: our business is to minimize your downtime. My e-mail address is: [email protected] Please mention in your e-mail how did the fault occur: this serves us for our continuous improvement program. In all instances, after replacement of the faulty board or module, it should immediately be returned to the agent or to ISA. Last, our experience is that our test sets withstand very heavy duty cycles for long wiles, if correctly used; most problems arise because of the problems that you have found listed in the former paragraph: please read it! There are many types of faults: this chapter refers to the most common ones. The message displayed by the program (unless when the unit cannot be powered on) tells you the faulty area; so, paragraphs are divided According to the type of fault.

5.2 Opening the test set and first checks . Open DRTS.6 by removing the four screws on the rear. The two metal sheets that enclose the test set can be removed, gaining access to the inside. The machine is made of the front panel, and of two side plates to which are screwed, above and below, some metal bars that support the guides of the printed circuit boards. In the instrument are located the following components, left to right: . One PASSIVE board, code 11316, with zero-power amplifiers; . The MICR-H control board, code 31300, that includes: the microprocessor, FLASH EPROM program memory, SRAM, DRAM, PLA, interface circuits; . One INTE-H2 board, code 21310, that handles digital inputs, with filters and isolation circuits; . One RELE.6 board, code 11373, with the four digital outputs; . The CONV-6 board, code 11372, that includes the DAC’s that generate the low-power analog signals; . Three AMCO-6 boards, code 11374, with two current amplifiers each; boards include also their power supply; . Two AMTE.3 boards, code 11356 (or 11405), with two voltage amplifiers each (code 11376 or 11393 for the option 300 V); . One voltage amplifiers supply module, code 11355 (code 11358 for the option 300 V); . One ALIAUX low-voltage supplies board, code 11370; . One FRONT.6 board, code 11386, with mains supply generation. . The auxiliary DC voltage module, code 11369, is mounted on the left.


. On the front panel are also mounted some boards, with LED’s and filters. PASS MICR INTE RELEICONV AMCO AMCO AMCO AMTE AMTE ALI V ALI FR I1-I4 I2-I5 I3-I6 V1-V2 V3-V4 AUX END (21) (22) (23) (24) (25) (26) (26) (26) (27) (27) (28) (29) (30) V DC (31) SKETCH OF DRTS.6 TOP VIEW WITH BOARD LOCATION The first check to be performed is to verify if boards are in place, fit into their guides, and if connectors are in place. The transportation of the test set can be the cause of the problem: we have tested that the unit withstands the specified drops and vibrations; however, we do not know if drops have respected these limits. If there is a connector out of its place, fit it into its position and power-on again. If boards are out of place, it is necessary to restore them into position, and then try to power-on again; however, in this instance, short circuits between boards may have caused the fault of some board. To fit back the boards, or to replace a board, follow these steps. . Unscrew the front panel by removing the two screws on the front and the four nuts on the corners, so that it can be lowered. . On the upper aluminum bar there is an aluminum strip that keeps in place the amplifiers: remove it. . In the center of the first and third bar, starting from the front, there are two rods that that, when tightened, block cards into their place, so that they cannot vibrate during transportation. Un-tighten them, until cards can be removed. To restore the test set, set the board, and then repeat the same steps.


If you have just received the latest issue of the software and some function does not operate correctly, it is possible that this is caused by the DRTS.6 resident program (firmware). In this situation, please get in touch with your agent: he will provide you the latest revision, that you can load using the UPGRADE program. In some sites (like mines) the air is very much polluted of conductive dust: we once occurred a case of a test set that did not work any more because of this. After cleaning, it recovered its operation. Last, in order to solve problems caused by transient spikes and by wrong operations (connection to VN rather than to IN), we have put in place two important fixes. If you have any intervention on your test set, you should also execute the following modification, in order to avoid any such inconvenience in the future. The fix no. 1 is necessary for DRTS.6 with serial number less than 11530 (September 2003); the fix no. 2 is necessary for DRTS.6 with serial number less than 11574 (December 2003). At any rate, please check: if fixes are not there, ask us for the materials, and then apply them. Fix no. 1: protection against spikes. It is made of a ZnO transient suppressor, rated 1 kV, and applied between the VN socket and the ground. In the picture, the suppressor is the red component: it is soldered to the VN (blue) socket on one side, and connected to ground on the other side by removing the nut nearby, and screwing it with the same nut.


Fix no. 2: protection against the wrong connection of current neutral to the VN socket. It is made of an 1 Ohm 4 W resistor, that has in parallel a diode bridge rated 8 A 800 V: if the current is applied to VN, it passes through the bridge, and the drop across the resistor is limited, so that it does not burn; as the load is too high, the test set signals overload. The pictures show the group prior to mounting, and the mounting on the front panel. One side is connected to IN; the other side (no matter which one) is connected to VN.


5.3 The test set cannot be powered-on or diagnostic voltage error When the unit cannot be powered-on, first of all check the fuse, that is incorporated in the power supply pug, into the small drawer. If the fuse is OK, the cause is most likely located in the front-end board PWA11386, that is the rightmost one looking from the front. The DRTS.6 power supply is split in two, each controlled by a front-end module mounted on the front of the card. The split is the following: . Voltage amplifiers + I3-I6; . Microprocessor + fans; I1-I4; I2-I5; DC module. If the test set behaves correctly at 220 V and gives problems (ERR signal; no power on) at 110 V, the fault is on one of the two front-end modules: the front card needs to be replaced. If the test set does not operate at any power supply, proceed as follows. On AMCO amplifiers are located two LED’s that turn on when the amplifier is powered. The first test is to verify if only one of the modules is failing, or both. Open the unit, power on and check for these lights. If I3-I6 is on and the other two are OFF, also the microprocessor and fans are off (case 1). If you see the light on the I1-I4 and I2-I5, but not on the I3-I6 amplifier, the test set starts and communicates the diagnostic error (case 2). In both instances, there is a risk that the fault has been caused by a fault on current amplifiers or DC module for the first one, or by the current amplifier or voltage amplifier supply for the other one. For this reason, proceed as follows: . Case 1. Remove the green connector from amplifiers I1-I4 and I2-I5, and from the DC voltage module. Power-on, and measure the voltage between pins o1 and 2 of a current amplifier connector: take care, because they are not isolated from the mains. The voltage should be 300 V. If so, the fault is not on the FRONT-END board, but it is on one of the amplifiers. To find out which one, connect one at a time, until the fault comes back. . If the power supply does not come back, it is necessary to replace the front-end board, and the modules powered by it, because they also could be damaged. . If no power is generated, it is better to return the test set to the agent, because the fault can be very severe. . Case 2. Remove the green connectors to current amplifier I3-I6 and from the voltage amplifiers. Power-on: if the test set turns on, the fault is not on the FRONT-END board, but it is on one of the amplifiers. To find out which one, connect one at a time, until the fault comes back. In case of voltage diagnostic error, and also for a first monitoring of the situation, it is possible that the fault is on the diagnostic circuit, or that there is an actual fault. In the first instance, press OK and then try to generate: if the generation is correct, the error can be ignored. If instead there are faults, then the fault is likely to be actual. Also in this instance, it is possible that one board causes a short circuit on the voltage. To verify this, proceed as follows: . Open the test set, and remove the rear protection. To the left, there is a small back panel, with three boards connected: the front-end, the ALIAUX, and the power supply module.


The following picture shows the board; the table lists all voltages that should be measured on the pins of the first connector to the left.

Pin N. VOLTAGE REFERENCE 1,2 C 0 LOGIC 3 AC +190V 0TEN 5 AC 0TEN 0 LOGIC 7 AC - 190V 0TEN 8 AC + 15 V 0 ANALOG 9 AC 0 ANALOG 0 LOGIC 10 AC -15 V 0 ANALOG 12,13AC +12 V 0 LOGIC 14,15AC 0 LOGIC 0 LOGIC 16,17AC + 5 V 0 LOGIC 18 AC + 16 V 0 LOGIC 19 AC - 16 V 0 LOGIC 26 AC + 300 V+I3 0 300 V+I3 29 AC 0 300 V+I3 CONNECTED TO THE MAINS!


NOTE: O LOGIC, 0 ANALOG, 0 TEN are all joined together, and between them there should be 0 V. The 300 V+I3 voltage IS NOT ISOLATED FROM THE MAINS: TAKE CARE! It feeds all voltages and the current I3. A low + 5 V causes loss of control of the MICROPROCESSOR board; low or missing + 15 V and – 15 V give problems on all analog circuits; low or missing + 16 V and – 16 V cause the false operation of AMCO amplifiers. These errors could be caused bay a fault on a board; so: . Extract first all the connectors of current and voltage amplifiers, and of the DC voltage module: if the voltage restores itself, we have found the faulty board. Without it, the diagnostic error should not appear any more. . If this is not enough, extract also the CONV board: also it can be the cause of the fault. . Last, extract the RELE board. If the fault persists with all boards removed, then the power supply module needs to be replaced.

5.4. Fault on the current amplifier Current amplifier faults are: . Overload: codes 67 (I1); 69 (I2); 71 (I3); 48 (I4); 49 (I5); 50 (I6). . Current amplifier power supply: codes 54 (I1-I4); 55 (I2-I5); 56 (I3-I6). . Over temperature: codes 185 (I1); 186 (I2); 187 (I3).

5.4.1. Overload In this instance, prior to contacting us, please verify that the load is not too much for the test set; please refer to the relay connection paragraph. The first check is to measure the voltage drop across the load: if it is more than 6 V, the load is too high. Another check is to short-circuit the current output and retry generating the current: if there is no overload message, maybe that the load is too high. In this situation, reduce the current and try again.

5.4.2. Current amplifiers power supply error In this instance, you have to know first of all that there is a protection in the power supply module that turns it off in case of severe spikes on the power supply. This protection resets after 15 minutes approximately only if the test set is not powered. So, with this kind of fault, turn off the test set and turn it on after half an hour of power off. If the error is there at power-on, the first thing is to understand if there is an actual fault or if there is a wrong fault indication. A: actual fault. Verify if the two LED's on AMCO are ON (as the other ones). If they are not, then the error message is correct: it can be caused by the missing of the 300 V supply on the green connector, or by the missing of the ENABLE signal, still on the green connector. You should have 300 V between pins 2 (negative) and 1 of the green connector, and about 12 V between pins 2 and 3


(ENABLE). If you don't, also voltage generators should be not operational, and the fault is in the FRONT-END board. If you have the supply but LED’s don’t turn on, then the amplifier is faulty, and should be replaced. B: wrong fault indication. If LED's turn on, then the error signal is wrong. The fault could be on the amplifier: check this by exchanging it with another one. If it is not in the amplifier, this signal goes through the 20-pin flat cable to the MICR board, passing through CONV and PASSIVA. Please check that there is no bent pin on the flat cable; then, if the error is still there, it is necessary to exchange the MICR board.

5.4.3. Over temperature In this instance, it is necessary to wait until amplifiers cool down. It is wise to keep the test set powered on, so that fans remove the heat much faster than when it is off. If the over-temperature fault persists, then the current amplifier is faulty.

5.4.4. Temporary intervention The first problem is that the software signals only one fault: in case of severe accidents, there could be a second fault undetected, that would pop up when the faulty amplifier is replaced. In order to avoid wasting time, after a fault it is necessary to perform a complete diagnostic test that will unveil all possible problems. The following procedure allows you to detect which amplifiers are in fault, and to continue working with the remaining current generators: if you use TDMS MANUAL control, you can use DRTS.6 to generate three currents from the good sources. If you have to perform an automatic test, perform it on the available current only, then shift connections to the other phase, until all of them are tested. In order to achieve this, follow these instructions. . Open DRTS.6. . Locate the AMCO amplifiers. . Power-on the test set. On AMCO boards are located the following LED’s: .. Two red LED’s in the center of the board. For normal operation they must be ON: if one or both is OFF, this means that the power supply is missing, see above, or that there is a fault either to the DC to DC converter module, or to the power MOSFET: the board is not operational, and must be replaced; .. Three green LED’s, that signal the selected output. The inner one corresponds to I1-I4; the second one to I2-I5; the external one to I3-I6. There must be only one LED turned on, corresponding to the output at which is connected; else, the switch setting is wrong. . On units having serial number more than 12876, we use a new version of the current amplifier, where: .. All LED’s are of the surface mount type, and the color is red; .. There is a sixth LED, on the centre and on the edge, signaling that the local microprocessor is OK. If it is turned off, either an auxiliary voltage is missing, what is signaled by the PC, or the board must be replaced. . Remove connectors from the faulty AMCO amplifier: above, a bigger, green one, with power connections, and a 20-way flat-cable one, with analog signals and logic control bus; below, another 14-way flat cable one, that carries auxiliary supplies. . Protect flat-cable connectors so that pin cannot touch any conductive part.


. Power-on DRTS.6, and control that there is no other fault displayed. If there is another fault, remove the corresponding amplifier connectors. When there is no fault, proceed with the following diagnostic: - Short-circuit current outputs and generate currents of 0.15; 1.5; 15 A on all available outputs: there should be no error message; - Generate also 1; 12,5 and 125 V on all voltage outputs, and check that there is no error; - Generate 110 and 220 V on the DC voltage output, and check that it works; - Close in sequence all trip inputs, C1 to C8, and check that they are detected; - Command the closure of A1-A4, and check that they operate. . At the end, it is possible to close the unit and operate with the other current amplifiers. If the faulty amplifier is I1-I4 or I2-I5, you could be wishing to exchange current amplifiers so that the first two are available. You have to know that AMCO are identical; in order to select the different positions we use the set of DIP-switches that you can note on the board. The selection is performed the following way: . There are three groups of eight DIP-switches; . The selection is performed setting ON all switches of one group, and OFF the other two groups; . The group marked SW1, located towards the center of the board, selects I1-I4; SW2 selects I2-I5; SW3 selects I3-I6.

5.4.5. Amplifier replacement To fix the problem you should replace the faulty AMCO board. To this purpose, open the unit and proceed as follows. . Withdraw the faulty AMCO and replace it with the new one. . Replace connections. . Power-on DRTS.6 and check that the fault message has disappeared, and that all outputs are operational. . Re-assemble the unit; do not forget to tighten the central rod, as it ensures that cards stay in place during transportation. . The replaced amplifiers need to be calibrated. To this purpose, use DRTS.6 user’s manual, CALIBRATION user’s manual and CALIBRATION program.

5.5. Fault on the voltage amplifier power supply The voltage amplifier power supply is tested at power-on, during the diagnostic procedure. The power supply generates a number of different voltages, positive and negative, that are automatically selected by the software to be slightly higher than the voltage output: this minimizes the power wasted on the voltage amplifier. The associated error codes change According to the standard voltage range of 125 V, or the optional 300 V. . 125 V error messages: 162 (+95 V); 222 (+125 V); 223 (+ 165 V); 224 (+200 V); 163 (-95 V); 225 (-125 V); 226 (- 165 V); 227 (-200 V) . 300 V error messages: 164 (+ 115 V); 165 (+ 210 V); 166 (+ 345 V); 167 (+ 460 V); 168 (- 115 V); 169 (- 210 V); 170 (- 345 V); 167 (- 460 V).


As these are diagnostic messages, there is a chance that the amplifier is operating correctly, and the fault is in the diagnostic circuitry. Also, if the error is for instance in the highest range, the unit can be used provided that the voltage output is reduced. This is why we have allowed the operator to reset the error message: by pressing OK the test can proceed. Next step serves to understand if the power supply is actually faulty, if the fault is in the diagnostic circuit, or if it is caused by a voltage amplifier. The procedure is the following. . Open DRTS.6. . Locate the AMTE amplifier; there are two equal AMTE boards: the left one generates V1 and V2; the right one V3 and V4. . Remove connectors from both amplifiers: a bigger, green one, on the front; one DIP-type above; another one, DIP-type, below. . Protect flat-cable connectors so that pin cannot touch any conductive part. . Power-on and check if the error message is still there. A) ERROR MESSAGE IS STILL THERE We have to verify if the fault is in the diagnostic circuit, so: . Set back AMTE connectors; . Try to generate the following voltage outputs: - 125 V: 55 V; 75 V; 95 V; 125 V. - 300 V: 65 V; 130 V; 220 V; 300 V. . If there is no error message, the power supply is OK, and the fault is located in the CONV-6 board (80% confidence level): the test set can be used with no problem, unless pressing OK on the error message; . If the error message is still there, please check that power supply to the module is there. To this purpose, go to the rear of the test set: the voltage supply module is connected to a small back panel. The back panel is protected by a plastic sheet, that is taken in place by four screws: remove them to gain access to connector pins, that are two parallel lines to the right. Starting from the bottom, pin 1 is connected to ground; pin 4 is the negative of the 300 V supply. Power on the test set, and verify that, with respect to pin 4, pin 5 is 12 V DC, and pin 7 is + 300 V dc (coarse). TAKE CARE AS THESE PINS ARE NOT ISOLATED FROM THE MAINS. If pin 5 is 0 V the fault is in the front-end board; if 300 V is missing, please check for continuity of the traces coming from the leftmost pins, that correspond to the front-end board. If + 300 V is missing, the fault is on the front-end board. . If above tests are OK, the power supply is faulty. You have to remove AMTE connectors again, and then you can operate current outputs only, until the power supply module is replaced. B) ERROR MESSAGE IS NO MORE THERE This means that the fault is located on an AMTE amplifier. To find out which one, connect one first and power-on: if the fault is no more there, then the fault is in the other one; if it is there, power off and repeat with the other AMTE amplifier. When the faulty AMTE amplifier is located, check that the other one is operational by generating on both outputs the voltages: 1 V; 12.5 V; 125 V (or 12.5 V; 125 V; 300 V). The test set can be used with these voltages, until the faulty AMTE is replaced.

5.6. Fault on the voltage amplifier Voltage amplifier faults are:

• Overload: 75 (V1); 77 (V2); 79 (V3); 195 (V4).


These faults can be displayed the first time an output is generated, even if it is zero, or only with the load. In this latter instance, it is possible that the output is overloaded. The first check is to measure the current sunk by the load: if it is more than 0.64 A (0.26 A above 125 V), the load is too high. Another check is to open the voltage output and retry generating: if there is no overload message, may be that the load is too high. In this situation, reduce the voltage and try again. If this is not the case, you can continue working as explained in the next paragraph.

• Over temperature: 182 (V1); 183 (V2); 184 (V3); 196 (V4). These faults are generated after a long while of use at high ambient temperature. In this instance, leave the unit powered-on for 10 minutes, so that amplifiers cool down, then start over again. If this is not the case, then the temperature sensing chain is faulty.

• Counter-feed (228): it does not specify on which output. About counter-feed, it means that there is a voltage on one or more of the output sockets, coming from the connection: you should check and correct the error. If there is no voltage applied, the fault comes from the diagnostic circuits. In this instance, see the instructions of the following paragraph.


5.6.1. Overload This fault can be displayed only with the load, or the first time an output is generated, even if it is zero. In the first instance, that is the most common, it is possible that the output is overloaded. The first check is to measure the current sunk by the load: if it is more than 0.64 A (0.26 A above 125 V), the load is too high. Another check is to open the voltage output and retry generating: if there is no overload message, then the load is too high. In this situation, reduce the voltage and try again. If this is not the case, you can perform a temporary intervention on the channel that gives the fault error, and then replace the faulty amplifier as you get it. . Open DRTS.6. . If the fault is on V1 or V2, it is important to verify if the error is also on V3 or V4. To this purpose, swap the boards and power-on. If the fault is still on V1 or V2, then also the next board is faulty; else, if the error signal moves to V3 or V4, only the original V1 or V2 was faulty. . If a faulty AMTE board is removed, at the subsequent power-on the test set would signal overload on the missing voltage channels. The temporary fix to overcome this problem and keep on using the rest of the test set depends upon the AMTE board serial number. Note that the fix serves to remove the error signal, but the output should be checked before using it, as it could be completely wrong. To this purpose, generate 125 V and verify that there is no DC component, and that the AC voltage is correct. Repeat the test for the outputs of 12.3 V, 1 V and 300 V (if available). Only after this test you can use the output: this means that the fault is in the overload sensing circuit. . Board no. 11356; 125 V. On the component side there are two small 3-pin male connectors, marked JP3 and JP4. You should bridge pins 1 and 3 on both connectors (the external ones): this inhibits the fault signal. After this, connect the connectors: the fault signal is inhibited. Before proceeding, perform the test above described. . Board no. 11405 (125 V) or 11396 (300 V). The temporary fix is the following.

- Remove the faulty amplifier. - Locate the test points marked TP36, TP52 and TP47. TP36 is the test point for an

oscilloscope probe, and carries the signal zero; TP52 and TP47 are small points sot protected by the solder resist. Of them, TP52 is the fault on V1 (V3); TP47 is the fault on V2 (V4). Connect to TP36 the test-point of the faulty channel with a thin wire, taking care not to cause short circuits.


After this, connect the connectors: the fault signal is inhibited. Before proceeding, perform the test above described. . Board no. 11376; 300 V. On the component side there are two small boards; on each is located a 3-pin male connector, marked JP2. You should bridge pins 1 and 3 on both boards (the external ones): this inhibits the fault signal. After this, connect the connectors: the fault signal is inhibited. Before proceeding, perform the test above described. . Board no. 11396 (300 V). The temporary fix is the following.

- Remove the faulty amplifier. - Locate the test points marked TP7, TP4 and TP2. TP7 is the signal zero; TP2 is the fault on

V1 (V3); TP4 is the fault on V2 (V4). Connect to TP7 the test-point of the faulty channel.

After this, connect the connectors: the fault signal is inhibited. Before proceeding, perform the test above described.


5.6.2. Counter feed The counter feed is sensed by an operational amplifier that is located in the power amplifier board; it is switched by an analog switch located on the CONV board, and it is measured by an AC to DC converter located on the microprocessor. The first test serves to locate the fault: either on a voltage amplifier, or on the CONV board. To this purpose, proceed as follows. . Open DRTS.6 as described above; . First of all, verify that the flat cables to AMTE boards are correctly fit; . If there is no problem on flat cables, disconnect both voltage amplifiers, protecting the connectors; . Power-on. If the diagnostic signal disappears, the fault is located in one of the amplifiers. Locate the faulty one by: . Connect an amplifier; . Power-on and check if the fault is there; . Repeat with the other amplifier. If the fault does not disappear with both amplifiers removed, then it is likely to be located on the CONV board. It is possible to replace the CONV board at the customer’s site; however, as the test set calibration corrects the errors of the amplifiers and of the CONV components, replacing CONV implies repeating the calibration of the test set: it is advisable to send it to ISA.

5.6.3. Amplifier replacement . Open DRTS.6. . Remove connectors from the faulty amplifier. . Withdraw the module and replace it with the new one. . Replace connections. . Power-on DRTS.6 and check that there is no fault message. . Re-assemble the unit: do not forget the rod, as otherwise cards would be too loose during transportation. . The replaced amplifiers need to be calibrated. To this purpose, use DRTS.6 user’s manual, CALIBRATION user’s manual and CALIBRATION program.

5.7. Fault on the DC SUPPLY D.C supply fault codes is 193 (overload). In case of fault on the DC supply, it is possible to perform a temporary intervention, so that the test set can be operated. . Open DRTS.6. . The DC voltage supply module is located to the left, when looking from the front. . Remove the two connectors (green and 8-pin flat cable); isolate them so that they cannot touch any metal part. . Power-on: the fault does not appear any more; the DC supply does not operate. If there is no fault signal, but the DC voltage is not available, proceed as follows.


. First of all, check for the cables going to the module. There are two different types of modules (see sketches). On module one, the 8-way flat cable comes out upwards; on module 2, the flat cable must leave the connector on the left. On the other side, verify that the 8-way cable is fit into its connector, leaving the board upwards. You should temporarily remove the connector, verify that all pins are straight, and fit the connector back into position: . Next, on module one there is a fuse, rated F3.15A: check it; if it is open, replace it and try again. . Observe now the green connector: it has 6 screws carrying wires. The screw closest to the front is number 6: it carries the earth connection. Power-on, and measure that between screws 4 (zero) and 5 there are 300 V DC. TAKE CARE BECAUSE THIS VOLTAGE IS CONNECTED TO THE MAINS. If 300 V are there, the module should operate. . On module one there is a fan. Power-on and verify if it is rotating: if not, the fault is on the module, that should be replaced. . If the fan is rotating (for module one), and at any rate on module two, last test is to verify if the module is blocked by a wrong command coming from the front-end board, and that is located at screw n. 3. Remove this wire by unscrewing it, and ISOLATE IT AS IT IS CONNECTED TO THE MAINS. Power-on and verify if the DC voltage is generated: if so, the front-end board PWA

FLAT CABLE UP FUSE

F3.15A

PIN 1

FAN

PIN 6

DC SUPPLY TYPE ONE

GREEN CONN.

SCREWS


For the replacement: . Open DRTS.6. . Remove the two connectors (green and 8-pin flat cable). . Unscrew the front panel. . Remove the four screws on the side of the module, so that it can be removed from the test set. . Replace it with the new one, and screw it to the side frame. . Set back connectors. . Power-on and check that the DC voltage is available. . Power-off and re-assemble the test set.

5.8. Fault on trip inputs In this instance there is no diagnostic message: the test set does not recognize one or more trip inputs. . Open DRTS.6. . Locate the input board INTE-H1, YWA11320: it is mounted on the front panel, just after the sockets. . There is a 14-pin flat cable that goes from connector J802 of this board to connector J802 of board INTE-H2, YWA11310: this flat cable carries signals for C1-C4. Please check that it is correctly fit. . If cable is OK, please check that there are no burns on inductors mounted on INTE-H1: this could have been caused by a wrong high voltage applied to inputs. In particular, check with an Ohm meter that there is continuity between the following points. SOCKET C C1 C2 C3 C4 PIN 14 8 9 10 11 And also that there is continuity between pins: 2; 3; 4; 5; 6; 7; 13.

FLAT CABLE TO THE LEFT

PIN 1

PIN 6

DC SUPPLY TYPE TWO

8-WAY CONN.

GREEN CONN.

SCREWS


. If everything is OK, power-on the unit and measure the voltage between C of group 1 and C1, C2, C3, C4: there should be – 30 V (as between the other C and C5 to C8). . If everything is OK and closing the circuit between C and C1 the corresponding LED turns on the fault is located on board INTE-H2, YWA11310. . Last check: via X-PRO, select inputs with voltage (for instance 24 V). Generate 24 V on the DC voltage generator and connect it to inputs C1 to C4: does the LED turn on? Is test stopped? If yes, this confirms that fault is on board INTE-H2. If a group of inputs does not trip with contact free selection, while it trips with the with voltage selection, the corresponding 30 V measurement is missing. In this situation, open the test set and verify first of all on the rear of the unit. Looking from the rear, there are two back panels: the one to the left receives the auxiliary supply voltages from the ALIAUX.6 board, PWA11370: these are marked: 0C1, 0C5, 30C1, 30C5. On these points should be soldered four wires, that go to the right back panel, where the INTE.H6 board, PWA21310, is fit. First of all, verify that wires are soldered. If so, measure the voltage between 0C1 and 30C1, and also between 0C5 and 30C5: it should be 30 V DC. If the voltage is there, there is a fault in the INTE board; if it is missing, there is a fault in the ALIAUX.6 board.

5.9. Fault on the microprocessor board If after power-on the test set is powered, but control LED’s are not in the standard configuration (ON turned on; the other ones off), or if it is impossible to connect the test set to the PC, it is possible that the fault is located in the microprocessor control board. . Open DRTS.6. . Locate the MICR board: it is the second leftmost, looking from the front. It is connected to another board, PASSIVA, with the connector on the front. . On the MICR-H board are mounted two LED’s: they are located in proximity of the rear of DRTS.6. These LED’s should turn on as the test set is powered on, and should turn off about one second after power-on: this confirms that the two programmable logic arrays we have on the board have been programmed; usually, this confirms that the MICR board is operational. If LED’s don’t turn off, at 90% of confidence the MICR board is broken, and should be replaced. The alternative to MICR is that the + 5 V auxiliary supply is low: as a consequence, the microprocessor is on hold.

To verify the + 5 V, proceed as follows. . The zero is the VN socket. . + 5 V is reached as follows. On the front panel there are a number of LED's by the side of voltage and current outputs. On the rear of the panel, these LED's are mounted on a small board. + 5 V is the rightmost pin of the line of LED's corresponding to voltage output.

+ 5 V


If the voltage is less than 4.7 V this is the cause of the problem. The low voltage can be caused by a fault of the + 5 V converter or by an overload in some amplifier. To verify this, remove all connectors: power (green) and flat cables, to current and voltage amplifiers (boards with heat sinks), and try again. If the + 5 V is now good, locate which one is the faulty board by connecting an amplifier at a time until the problem comes up again; if not, then the ALIAUX auxiliary supply board is faulty.

. If LED’s turn off, and yet there is no communication, the last test is to remove all connectors: power (green) and flat cables from current and voltage amplifiers (boards with heat sinks). After that, power-on: the test set should communicate. If not, the MICR board is to be replaced; else, one of the amplifiers is the cause of the fault. Locate which amplifier by connecting an amplifier at a time, until the problem comes up again. If MICR is to be replaced, proceed as follows. . Remove together the first two boards. . The boards are screwed together: remove the faulty MICR and replace it with the good one. . Set back the two boards, power-on and verify that the test set is operational. NOTE. The replacement of the microprocessor board involves the loss of the calibration parameters, that is the linearity and the phase angle. For this reason, in this situation we usually provide the .CAL file of the test set, that should be loaded into the unit using the CALIBRATION program. If the .CAL file is not available, if you have the suitable test meters, please refer to the Calibration chapter; else, the test set should be returned to your agent.

5.10. Problems with upgrade or with the diagnostic

5.10.1. Upgrade problems If during the Upgrade the power went off, or if the DRTS.3 firmware was loaded into the DRTS.6 test set, it is possible to recover the situation as follows. . Open the DRTS.6. . Locate the MICR board: it is the second one from the left. . From below you can gain Access to ten DIP-switches that allow setting different models. Switch no. 10 is the one closest to the rear of the unit. FRONT PANEL SWITCH NO. 1 SWITCH NO. 10


BACK PANEL REAR OF THE UNIT If you move these switches towards the edge of the board you set them ON; otherwise they are OFF. Now you should set switches as follows.

SWITCH 1 2 3 4 5 6 7 POSITION OFF OFF OFF X X X OFF

X = DON’T TOUCH. This is a special setting that should allow to re-load the firmware, no matter if there are hardware faults. . Copy into the UPGRADE directory the EPG file. . Power-on the unit: there should be no error message. Start the UPGRADE program: it should be possible to connect the unit and to execute the upgrade of the file. . At the end of upgrade, you should have again an error signal. . Power-off the unit and set switches as they were before:

SWITCH 1 2 3 4 5 6 7 *POSITION ON ON ON X X X ON

. Power-on again: the unit should perform the self-test and display no error.

5.10.2. Diagnostic problems If there is a false diagnostic signal, it is possible to remove it by jumping diagnostic at power-on. This is performed as follows. . Open the DRTS.6. . Locate the MICR board: it is the second one from the left. . From below you can gain Access to ten DIP-switches that allow setting different models. Switch no. 10 is the one closest to the rear of the unit (see above). . If you move these switches towards the edge of the board you set them ON; otherwise they are OFF. . Modify the switch, by setting OFF switch 7. This is a special setting that jumps the diagnostic. . Power-on the unit: there should be no error message.

5.11. Problems with the USB interface The problem may be caused by some factors, and the three commons are: - XTEST3000 was not installed by the PC administrator ; - The selected communication port is not "USB"; - The administrator refused (or canceled) to install our USB driver. Of these, the most important is to be the administrator of the PC; if you are not, the driver will not be installed. If the software was already installed, uninstall everything, turn off the PC, turn on the


PC as administrator and install it again. Please refer also to our installation manual.

5.12 The fault cannot be fixed If the fault is too hard to be fixed, you have to deliver it back to your agent. We have encountered problems caused by a poor packing of instruments that have been delivered us for calibration or repair. In order to avoid such inconveniences, please apply the following procedure. First of all, compile the following form, and attach it to the instrument. Please do not forget to compile it. With the instrument should come the mains supply cable, the RS232 and the USB interface cables and all cables that serve to connect modules (boosters). The user’s manual originally delivered with the test set is not necessary. Cover the instrument itself with a polyester film, in order to protect it against dust and foam. The instrument should be protected by anti-shock foam having a minimum thickness of 5 cm ON ALL SIDES. Use a new carton box as a container. On the box apply the UP and the FRAGILE labels. In the box the instrument will be placed horizontal or standing; not upside down. If the set is heavier than 20 kg it is better to use also a pallet: this ensures that the box will not be packed upside down. Last but not least, do not declare an high value for customs: this expedites clearance of the good and lowers fees.


INSTRUMENT RETURN FORM

DATE ____________ AGENT _________________ COUNTRY ___________________ TYPE OF INSTRUMENT ____________________ SERIAL NO. __________________ INSTRUMENT RETURNED FOR: CALIBRATION ____ REPAIR ____ In case of repair, please specify the following. DATE OF FAULT _______________ REPORTED BY E-MAIL, PHONE ___________ COMPANY _____________________ USER’S REFERENCE ____________________ FAULT DESCRIPTION ____________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ HOW DID IT OCCUR ______________________________________________________ ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ LOCAL ANALYSIS OR ATTEMPTS TO REPAIR _______________________________ ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ RECOMMANDATIONS AND NOTES _________________________________________ ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


6 SPECIAL SITUATIONS

6.1 Addition of the MISU option If the customer wishes to add the MISU option, he can ask ISA the upgrade kit, and add it by himself, with the following instructions. The upgrade is performed in four steps: . Solder the MISU board on the front panel sockets; . Close a jumper in the CONV board; . Connect MISU to CONV by the flat cable; . Correct the calibration. 1) Solder the MISU board. . Open DRTS.6. . Unscrew the front panel by removing the two screws on the front and the four nuts on the corners, so that it can be lowered. . On the rear of front panel, between and below the sockets, stick the isolating stripes provided: this serves to guarantee the isolation level. . Fit the MISU board into the socket connections. Between the MISU components and the panel leave a space of about 1 mm; do not press against the isolation stick, as they could be damaged. Solder MISU in this position. 2) Close a jumper on CONV board . On the upper aluminum bar there is an aluminum strip that keeps in place the board: remove it. . In the center of the first and third bar, starting from the front, there are two rods that that, when tightened, block cards into their place, so that they cannot vibrate during transportation. Un-tighten them, until the card can be moved. . Remove all connectors to CONV so that it is possible to withdraw it completely. . Just after the connector is located a 2-pin jumper, marked JP2: short-circuit the two pins. . Set back CONV and connect cables. 3) Connect MISU to CONV board . Connect MISU connector to CONV connector marked J802 by the flat cable provided. . Take care that pin 1 of MISU connector goes to PIN 1 of J802 on CONV. 4) MISU calibration. . On MISU board there are a number of trimmers, that have already been sealed as the board is calibrated. There is only a small adjustment to be performed, as follows. . On the edge of the board, starting from the left, there are five trimmers: trimmers P6 and P7 are respectively the fourth and fifth from the left: see sketch.


. Power-on the test set, connect it to the PC and start TDMS MANUAL control. Select the frequency of 0 Hz. . Connect the V1 output to the 10 V measurement input. . Select on the software the 10 V DC measurement. . Generate in sequence + 9 V and – 9 V. With trimmer P6, offset calibration, make the two readings equal between them. . After this, with trimmer P7, gain, make the readings equal to 9.000 V. Now generate again + 9 V and – 9 V and verify that the gain correction did not alter the offset calibration; else, repeat the procedure.

6.2 Transformation of a 125 V unit into a 300 V one If the customer wishes to have the optional 300 V version rather than the 125 V one that he has purchased, he can ask ISA the upgrade kit, and perform the change by himself, with the following instructions. The transformation requires two operations: . Replacement of power supply and amplifiers; . Change switch selection on MICR board. 1. Replacement of power supply and amplifiers . Open DRTS.6. . Remove the voltage supply module. . Remove connections to AMTE voltage amplifiers and remove the amplifiers. . Remove also connections to AMCO current amplifiers I2-I5 and I3-I6, and remove amplifiers. Mark them as they cannot be exchanged. . Next problem is that we have to modify the position of guides for the two AMCO and AMTE 1-2, else the two AMTE would not fit. The following is the sketch of guide positions as you will find them, and of new guide positioning.

P6 P7


AMCO AMCO AMCO AMTE AMTE 1-4 2-5 3-6 1-2 3-4 OLD 63-64 53-54 43-44 34-35 26-27 NEW 63-64 55-56 45-46 35-36 26-27 . The numbers below refer to hole counting starting from the rightmost. Movements are: - AMCO 2-5: rotate the guide position from right (dotted) to left, and screw it on holes 55-56 (two to the left); - AMCO 3-3: move it leftwards of one hole; - AMTE 1-2: move it leftwards of one hole. . Now you can fit back AMCO 2-5 and 3-6, the new AMTE and the new power supply. 2) Change switch selection on MICR board The test set must be instructed that the maximum voltage is 300 V rather than 125 V; this is obtained by modifying the switch setting on MICR board. The modification can be performed without dismounting MICR board from the test set. If you look at the test set from below, MICR is the second one from the left. The sketch shows the location of DIP switches.


For the switches, the ON position is towards the board edge; OFF is towards inside. The setting you will find is the following. SWITCH 1 2 3 4 5 6 7 8 9 10 SETTING ON ON ON ON OFF ON ON ON ON ON Now press switch no. 4 towards the inside of the board, so that it goes to OFF position. The final setting is the following. SWITCH 1 2 3 4 5 6 7 8 9 10 SETTING ON ON ON OFF OFF ON ON ON ON ON NOTE: if you do not feel safe to operate this way, you can dismount MICR to perform it. In this instance, please consider that: . MICR and PASS boards are screwed together: the must be removed together, this takes a certain amount of force. Same force is to be used when fitting them back; . On PASS is soldered a yellow/green wire that is screwed to the frame; unscrew it for the dismount; . PASS hosts two flat cables; they must be fit prior to insert back the two boards.

6.3 Transformation of the interface from RS232 to USB Test sets after S/N 12000 have both the RS232 and the USB interface; older units have only the RS232 interface. It is impossible to modify older units so that they have both interfaces; however, if

MICR PASS

DIP SWITCHES

1

10


the customer wishes it, it is possible to modify older units so that they have the USB interface instead of the RS232 one. In this instance, the customer can send the test set to ISA for the modification, or can ask ISA the upgrade kit, and perform the change by himself, with the following instructions. The overall note is to be careful, as some operation can lead to the damage of the test set. . Open DRTS.6; unscrew the front panel so that it can be lowered. . Remove connections to the DC voltage module. Remove the module by the four screws to the left. Pay attention to all flat cables! . Remove the RS232 connector and cable. . Drill a hole with a diameter of 5.5 mm below the rectangular hole of the connector: it will host the LED guide, that in turn hosts the LED mounted on the small USB connector board. Fit the LED guide into the hole: as it does not clip in, block it with a drop of ATTACK glue. . Chamfer the two mounting holes for the connector, as you will use 90° head chamfered screws for the mounting. . Now mount the USB connector board. The holes pitch does not exactly match with the board supports; so, it is normal that screws are a bit tight. Verify that the right USB board support does not touch the interface board XWB11391. Fit the LED into its support. . After mounting, cover the screws with the label provided. . Remove the MICR + PASS board group (the two leftmost): they are screwed together. Remove the old PASS board, replace it by the new one. Screw it back, and fit it in position. . Lay the cable from the connector to the PASS board below the DC voltage module. Besides, the cable should not go above the board support guides. . Clip the two ferrite shields on the connection cable, locating them close to the PASS board connector: they are located between the boards. . Now it is advisable to test that the test set operates correctly with the new USB interface. . The new PASS board has a connector for the RS232 interface. If you want, you can connect it to the RS232 cable you have dismounted, and leave the connector inside: this is just in case you have to operate with a PC that does not have the USB interface. . Mount back the DC voltage module; set back the test set.


7 FUNCTIONAL TEST

7.1 Introduction The DRTS.6 does not need to be calibrated, as all outputs are feedback controlled, both current and voltage, by high stability components. It is suggested to check the unit every 3 years. To this purpose, it is possible to use the X-PRO manual program. Following paragraphs explain the test procedure. For the calibration, the following instruments are necessary. 1. An high accuracy multimeter, that should guarantee a maximum AC measurement error of 0.02% for voltage and 0.05% for current. The maximum voltage range of more than 300 V is usually available; instead, for current, the maximum range is usually 1 A or 3 A at most. 2. For the higher AC current range, it is necessary either a Current Transformer with a rated accuracy of 0.05%, or a set of current shunts, again rated 0.05%. Usually, the C.T. is a cheaper solution. 3. For the calibration of the phase angle the TDMS CALIBRATION program foresees the use of a wattmeter. During the calibration, the phase angle between current and voltage is set at 90°: the nominal active power is zero; the deviation from zero is caused by the phase error to be adjusted. In conclusion, for phase angle calibration it is necessary to use a wattmeter. It can be single phase; the accuracy should be 0.1%. 4. An oscilloscope and a shunt could serve to verify the waveform distortion, in case of doubt. The current shunt could be rated 0.1 Ohm, 50 W; the test could be performed at 10 A. In fact, if there is a current distortion, it shows up at all current ranges. 5. In case of doubt about the available power, the following resistors should be used: . Voltage output: 195 Ohm, 200 W. The test should be performed at 125 V; . Current output: 0.35 Ohm, 200 W: the test should be performed at 15 A. In the following procedure voltages are tested with values of 1, 10, 100 V and currents at 0.1, 1, 10 A, while voltage ranges are 1, 12.5, 125 V (or 12.5, 125, 300 V) and 0.15, 1.5, 15 A. The reason is that the multimeter changes range around 1.1: measuring at 0.15 A implies a not acceptable measurement error. At the end of the test, if deviations are not Acceptable it is possible to proceed as explained in next chapter or to send the unit to the closest ISA agent.

7.2 Voltage outputs The test is performed as follows: . Connect the DRTS.6 to a PC and start the program X-PRO; . Program a maximum time of 999 s and the fault value of 1 V on all phases; . Connect the output to an high Accuracy multimeter; . Start the test: the output is applied to the sockets; . Verify that output errors are within the expected tolerance of 0.1%; . Stop the test and repeat the test with other ranges (10 V and 100 V).


7.3 Current outputs The test is performed as follows: . Connect the DRTS.6 to the PC and start the program X-PRO; . Connect output I1 to an high Accuracy multimeter; . Program the fault duration of 999 s and the value of 0.100 mA on output I1; . Start the test: the current is injected; . Verify that the output error is within the expected tolerance of 0.1%; . Stop the test, move the current meter to outputs I2 to I6, and repeat the test; . Program now the I1 current output to other current ranges (1.00 and 10.0 A), and repeat the procedure; . Repeat the procedure with other outputs I2 to I6. High current tests will be performed with a suitable current transformer, with a ratio error less than 0.05%.

7.4 Auxiliary DC voltage The test is performed as follows: . Program the voltage of 24 V on fault values; . Start the test and check that 24 V are generated; . Repeat the test at 110 V and 260 V. Output Accuracy is ± 1% of the regulated value ± 0,26 V.

7.5 Trip inputs and auxiliary outputs The test is performed as follows: . Select trip inputs without voltage; . Connect the DRTS.6 to a PC and start the program X-PRO; . Connect the two inputs C to the contact C of A1; . Connect all trip inputs C1-C8 among them, and connect them to the Open contact of A1; . On fault values, select all inputs as Normal Open; . Select the trip of A1 on fault values, and program trip delay equal to zero; . Start the test: all timers will display a trip time between 4 and 11 ms; this is the delay of relay A1; . Modify at will the delay of A1: trip delays will be equal to the programmed time, plus the delay of the relay itself; . Connect now C1-C8 to the Closed contact of A1: all lights will turn on. Go to the healthy values and select all trip inputs as Normal Closed; . Repeat the test with different delays of A1: the result will be the same as Normal Open; . Repeat the procedure with A2, A3, A4: by this also auxiliary outputs are tested. Errors on this area can be solved only with a repair intervention on the unit.


8 DRTS.6 CALIBRATION The calibration of all DRTS.6’s relevant parameters is performed using the TDMS CALIBRATION program. For the description of the program itself and of the calibration procedure, please refer to the CALIBRATION program user’s manual (MSE20098).


9 MEASUREMENT OPTION

9.1 Introduction The Measurement option has the purpose to allow measuring currents and voltages. Input ranges are: two low level, 20 mA DC and 10 V DC, and two high level, 20 A DC –AC and 250 V DC – AC.

9.2 Description of Measurement option The optional Measurement is made of two printed circuit boards: . MISU, mounted on the front panel; . AP_MISU, that is located in the control boards rack. Voltages and currents to be measured are connected to the safety sockets (17) on the front panel. In case of converters, connections are the followings. DRTS.6 V I IN I = V I (V=) CONV. DRTS.6 outputs are connected to converter inputs; converter output is connected to the 20 mA (10 V) metering input. The test can be performed manually, with X-PRO or automatically, with the program TRANSDUCERS (specification MSE10059). Test details are explained in software manuals. In case of high rating current or voltage measurement, inputs are connected to the corresponding sockets. Connect only one input!


10 IO6432 OPTION

10.1 Introduction Option IO6432 has the purpose of increasing the number of digital inputs and outputs, respectively 64 and 32. These inputs and outputs add to the existing ones.

10.2 Description of IO6432 The option is installed in the rear of DRTS.6: input and output connectors are Accessible through a window in the rear screen. Input and output characteristics are the followings. TRIP INPUTS - Number of inputs: 64, divided in 4 groups of 16 that are isolated among them. - Type of input: opto-isolated circuits, with a constant current load. - Input level: from 5 V to 130 V DC; maximum input current 3 mA. DO NOT APPLY MORE THAN 130 V! - Connection: 68 way connector. - Designation of inputs. Standard inputs (on the front of DRTS.6) are numbered from C1 to C8; the additional ones are numbered from C16 to C80. The four references are: . COM-1: C17-C32; . COM-2: C33-C48; . COM-3: C49-C64; . COM-4: C65-C80. AUXILIARY OUTPUTS - Number of outputs: 32, divided in 4 groups of 8, that are isolated among them. - Type of output: MOSFET open collector. - Output level: maximum voltage 130 V; minimum drive capability 15 mA; maximum 50 mA. DO NOT SHORT CIRCUIT THE OUTPUT! - Connection: 50 way connector. - Designation of outputs. Standard outputs (on the front of DRTS.6) are numbered from A1 to A4; the additional ones are numbered from A16 to A48. The four references are: . RIF-1: A17-A24; . RIF-2: A25-A32; . RIF-3: A33-A40; . RIF-4: A41-A48. Appendix 7 provides the pinot configuration, and the position of mating connectors pins, with soldering contacts, provided with the instrument.


11 GPS OPTION

11.1 Introduction The GPS option has the purpose to allow testing the following relays: . Distance relays connected with permissive or blocking schemes; . Line differential. For the test are requested two test sets in distant sites, and the possibility to simulate faults at the meantime on both instruments. In the first instance the timing error can be in the range of some millisecond; for the second one, the maximum timing error is 100 us.

11.2 Description of GPS option The GPS option that can generate the synchronization impulses, that last 10 ms and have a maximum error of 2 us between two GPS. These impulses can be generated as the seconds of the absolute time are elapsed, with a pace selectable among 5 – 10 – 20 – 30 – 40 – 60 s. The first impulse is generated after one to two complete periods are elapsed from the moment the START/STOP pushbutton was pressed. If, for instance, the selection is 30 s, impulses are generated when the absolute time is: (hh; mm; 0”; hh; mm; 30“; hh; mm+1; 0“; hh; mm+1; 30“...).

11.3 Directions for the use of GPS option The operators at both sites should connect first GPS to the mains by the plug (1): the 1 pps light starts turning on, thus assuring that GPS is operational. After this locate the antenna, that should be located in a place that allows it to receive the synchronizing signals from 4 GPS satellites. Usually it is enough to put it outside the protections building; if the building is armored the distance should increase. The antenna provided has a cable 6 m long, usually enough for the purpose. The user can increase the distance by an extension cable, provided that it is made of satellite graded shielded cable, such as CT/100 or CT/167, with BNC connectors terminations. The maximum cable length should be such not to attenuate more than 10 dB the signal at 1.5 GHz: for CT/100 this means 50 m maximum. After the antenna is located, connect it to GPS with connector (7). The green GPS locked light (5) turns on within 15 minutes (typically 1 minute); if not, try to press the white key by the light. If this is not enough, the antenna should be located in another position. Connect on the two sites the two DRTS.6 to the relays to be tested; in particular, connect relay trip contacts to inputs C1 to C4 (see figure).


V, I V, I GPS TEST RELAY RELAY TEST GPS C5 SET CABLE SET C5 1 1 C1-4 1 2 C1-4 2 2 TEST SETUP Connect now GPS to DRTS.6. To this purpose, connect the black socket (8) to C5-8 common, and the red socket (8) to C5. Connect DRTS.6 to the PC and select in Preferences the type of relay trip contacts for C1– C4, and DC Voltage, 24 V, for C5-C8. Select also Debounce delay = 0 for C5-C8. Note that selections for C1-C4 and C5-C8 can be different. Select the pulse interval on switch (2): 30 s or more are a good choice, to avoid the risk to loose synchronization during the test. It is possible now to start the test. The two operators should keep in touch by phone, and start on the PC the test program they want to use. Let us assume for example that the program is Z-PRO, with the Intertrip test selected. Both operators can program the desired tests before starting the first one; then, they should press test START on PC at approximately the same time. After this, they should press the GPS START/STOP button (1): its light turns on, and the PULSE light (3) turns on as the first synchronization impulse is generated; it will be applied after one to two selected periods. After this, impulses are generated at the selected time interval.

When the two DRTS.6 sense the first pulse they execute the first test at the meantime, and provide the first test result. Pressing test START on PC again the second test can be initiated, and so on until all tests are over. START commands cannot be contemporary; they should be provided before the next synchronization impulse.


5

21

GPS SYNCHRONIZER

5

1020 30

40

60

PULSE INTERVAL(seconds)

START/STOP

PULSE

1 pps

GPS

LOCKED

4

3

100-240V~ 50/60Hz 5W

T0,5A 250V

7

GPS ANTENNA

8

6

00

PULSE

FRONT AND REAR GPS PANELS


GPS LIST OF COMPONENTS 1) START/STOP pushbutton, with light. 2) Pulse interval selector 3) Pulse available. 4) 1 pps light; GPS ON. 5) GPS locked. 6) Mains connector. 7) BNC connector to antenna. 8) Pulse output sockets.


12 OPTIONAL AMPLIFIER AMI150

12.1 Introduction The optional amplifier AMI150 has the purpose to provide more power on current outputs, if the power of the DRTS.6 is not enough; the software allows for the following selections. . 9I: nine currents in all; six from DRTS.6, with ranges up to 15 A, and three from AMI-150, with ranges up to 50 A. . 6I: six currents in all; three from DRTS.6, with outputs in parallel so that ranges reach 30 A, and three from AMI-150, with ranges up to 50 A. . 3I: three currents from AMI-150, with ranges up to 50 A.

12.2 Description of AMI150 The optional amplifier AMI150 includes: . Three current generators; . The power supply; . The control unit. Physically, the AMI150 (see drawing) is made of a 19” container, 4 U high, with handle for ease of transportation. All components are slide-in modules, that can be easily replaced for maintenance: . N. 3 AMI-150 current amplifiers; . N. 1 ALI 1K power supply. In the instrument are located also: . The connector to the DRTS.6; . The back-panel, that connects all amplifiers, and includes the control microprocessor.

12.3 Connection and test start Each amplifier has three connection sockets: one red and two black. The two black are bridged between them, and are provided for ease of connection. The zero of the three amplifiers are independent: the common connection is made by the metal bridge provided.

12.3.1 Maximum burden Before executing the test with the AMI150 check that the burdens of the relay under test are compatible with the current output power. To this purpose, it is necessary to compare the burden declared by the manufacturer to the following maximum loads. RANGE (A)

0.05 2.5 12.5 25 50

BURDEN (Ohm)

24 24 1.25 0.24 0.06

Usually the burden is expressed in terms of VA load at nominal current: it is necessary to convert it into Ohm, with the following formulas. Burden = VA / (nominal current)^2


Special care is to be taken when evaluating the burden, as the burden of connecting wires is to be added to the relay burden. If the relay load is 2 VA at nominal current of 5 A, the relay burden is 80 mOhm. In this case it is possible to test at 12.5 A only if the connection and cabling are maximum 5 m long, with a cross section of 2.5 sq. mm at least, and if cables are tied together, in order to minimize the reactive component. For tests at 50 A, it is advisable to use connection cables with at least a cross section of 10 sq. mm. In case it is desired to run tests at currents higher than 50 A, it is possible to connect all amplifiers in parallel: it is possible to have 450 VA. However, the maximum load decreases to 0.02 Ohm. If the problem is having more power at the current of 50 A or less, then connect all amplifiers in series. In this instance it is possible to have something less than 450 VA because of minor inaccuracies of current amplifiers in series. Considering 350 VA, maximum loads are the following. RANGE (A)

0.05 2.5 12.5 25 50

BURDEN (Ohm)

72 56 2.2 0.56 0.14

When the output is not the maximum of the range, the maximum burden increases: at 50% of the range the output power is three times the one available with one output. This is applicable to ranges 2.5 and 12.5 A: at 25 and 50 A range is automatically switched for outputs less than 50% of the range. The following tables summarizes maximum burdens for the range of 2.5 A, and the corresponding power. The table reports also the maximum voltage and the maximum error, that is the value of 1% of the range applied to the output. INOM (A)

MAX LOAD (Ohm)

MAX VA

MAX VOLT (V)

MAX ERR (%)

2.5 56 350 140 - 1 2 80 320 160 - 1.2 1.5 120 270 180 - 1.7 190 190 190 - 2.5 0.4 500 80 200 - 6.2 0.2 1000 40 200 - 12.4

12.3.2 Power-on Before connecting the relay, connect the AMI150 to the connector EXT. AMP. of the DRTS.6, with the cable provided. Then connect the DRTS.6 and AMI-150 to the mains, by means of the power supply cables provided. The earth is connected to the supply plug. Be careful to have the earth on the supply, as otherwise the DRTS.6 and AMI-150 would reach the voltage of 110 V (supply 220 V): this is caused by noise suppression capacitors on mains supply.


Power on the AMI150 first, then the DRTS.6. At power on, the green light OK of AMI150 and of DRTS.6 turn on: this confirms that the microprocessors operate correctly. At the meantime, the self diagnostic procedure is initiated in both units. Also green lights (8) of the amplifiers will turn on.

12.3.3 Connection to the relay under test The connection of the DRTS.6 and AMI150 to the relay under test depends upon the choice about the AMI150 function.

12.3.3.1 Use of AMI150 to increase the output power With selection 3I, currents will be connected to sockets (6) of AMI150: current outputs of the DRTS.6 are disabled, and SHOULD NOT BE CONNECTED. All other signals (voltages, trip input, auxiliary outputs) shall be connected to the DRTS.6, as explained in the former chapters.

12.3.3.2 Use of AMI150 to have nine currents With selection 9I, currents I1 – I6 will be connected to the DRTS.6, and currents I1-I3 (booster) to the AMI150. Voltage outputs V1 to V3 are also available, while V4 is not available; all other signals (trip input, auxiliary outputs) shall be connected to the DRTS.6, as explained in the former chapters. Current ranges and outputs of the two units are up to 15 A for DRTS.6, and up to 50 A for AMI-150.

12.3.3.3 Use of AMI150 to have six currents With selection 6I, currents I1-I4; I2-I5; I3-I6 are paralleled on the DRTS.6, in order to have a total of 30 A on one set, and 50 A on the other one. Voltage outputs V1 to V3 are also available, while V4 is not available; all other signals (trip input, auxiliary outputs) shall be connected to the DRTS.6, as explained in the former chapters.

12.3.4 Connection to the PC and test start The procedure to follow is the one explained for the DRTS.6. If the red ! LED turns-on on the AMI150 and the error is on a current output, the red light (9) of the AMI150 current amplifier in overload can turn on. Before continuing, it is necessary to press the corresponding reset button (10). At power off, turn off the AMI150 first; then the DRTS.6.


13 OPTIONAL AMPLIFIER AMI-99

13.1 Introduction The optional amplifier AMI-99 has the purpose to allow controlling nine currents at the meantime. The unit can also be used to generate six currents rated 30 A 160 VA, by connecting in parallel the outputs of DRTS.6. It is also possible to have three currents at 60 A 320 VA each, or one current at 180 A 720 VA.

13.2 Description of AMI-99 The optional amplifier AMI-99 includes: . Three current generators; . The power supply; . The control board that supervises the unit. Physically, AMI-99 (see drawing) is housed in a container that is the same as DRTS.6, 3 U high, with handle for ease of transportation. Amplifiers are the same as those used in the DRTS.6, and internally connected in parallel in order to have 30 A. In the front panel are located: . The connector to DRTS.6; . Current output sockets; . Unit status lights; . Active current output lights; . Power supply socket and power-on switch.

13.3 Connection and test start

13.3.1 Power-on Before connecting the relay, connect AMI-99 to the connector EXT. AMP. of DRTS.6, with the cable provided. Connect also IN of DRTS.6 to IN of AMI-99 with the cable provided. Then connect DRTS.6 and AMI-99 to the mains, by means of the power supply cord. The earth is connected to the supply plug. Be careful to have the earth on the power supply cord, as otherwise DRTS.6 and AMI-99 would reach the voltage of 110 V: this is caused by noise suppression capacitors on mains supply. Power on AMI-99 first, then DRTS.6. At power on, the front lights of both instruments turn on and off as the self-diagnostic is executed; at the end of which, the OK LED’s of AMI-99 and of DRTS.6 turn on: this confirms that the microprocessors operate correctly. If DRTS.6 is powered-on first, an error code can be displayed; in this instance, just press OK on the OK button of the P.C. display.

13.3.2 Connection to the relay under test


Before executing the test with AMI-99 check that the burdens of the relay under test are compatible with the maximum load. To this purpose, it is necessary to compare the burden declared by the manufacturer to the maximum load. Usually the burden is expressed in terms of VA load at nominal current: it is necessary to convert it into Ohm, with the following formula. Burden = VA / (nominal current)^2 for currents, and Special care is to be taken when evaluating the burden, as the burden of connecting wires is to be added to relay current burden. The connection of DRTS.6 and AMI-99 to the relay under test depends upon the choice about the AMI-99 function. Aside currents, all other signals (voltages, trip input, auxiliary outputs) shall be connected to DRTS.6, as explained in the former chapters.

13.3.2.1 Use of AMI-99 to have nine currents In this instance currents I1 – I6 will be connected to the DRTS.6, and currents I7-I9 to AMI-99. DRTS.6 voltage outputs V1 to V3 are available, while V4 is not available. Current ranges and outputs of the two units are independently set. Maximum current is 15 A on DRTS.6 and 30 A on AMI-99; the maximum load is 350 mOhm for DRTS.6 and 180 mOhm for AMI-99.

13.3.2.2 Six currents rated 30 A If it is necessary to perform a six phase test at 30 A, connect in parallel current outputs of DRTS.6: maximum burden is 0.18 Ohm for all outputs. DRTS.6 I1-I4 I7 AMI-99 I2-I5 I8 I3-I6 I9 IN IN Paralleling of DRTS.6 outputs is easily performed using option PAI. Current outputs must be connected in the order shown, as the program foresees this connection when computing current outputs: maximum test current is 30 A per output.


13.3.2.3 Three currents rated 60 A If it is necessary to perform a three phase test at 60 A, connect in parallel current outputs of DRTS.6 to those of AMI-99: maximum power is 320 VA; burden is 0.09 Ohm for all outputs. DRTS.6 I1-I4 I7 AMI-99 I2-I5 I8 I3-I6 I9 IN IN Paralleling of DRTS.6 outputs is easily performed using option PAI. Current outputs must be connected in the order shown, as the program foresees this connection when computing current outputs.

13.3.2.4 Single phase tests at 180 A Select 0° between currents, both on DRTS.6 and AMI-99. Connect all outputs among them and to one end of the load; connect IN (DRTS.6) to IN (AMI-99), and to the other end of the load. The corresponding maximum power is 760 VA; maximum load is 23 mOhm. DRTS .6 I1-I4 I7 AMI-99 I2-I5 I8 I3-I6 I9 Z IN IN

13.3.3 Connection to the PC and test start The procedure to follow is the one explained for DRTS.6. At power off, turn off AMI-99 first; then DRTS.6.


14 MAINS SYNCHRONISER OPTION The option is made of a plug that fits into the mains, and that has two banana sockets for the connection to the test set counting input. The purpose is to synchronize the outputs of two test sets to the mains: as the synchronisation is repeated every 2 minutes, the test set stays locked to the mains for the infinity. The option includes a circuit that squares the sinusoidal mains waveform; the isolated output is a square-wave with an amplitude of 18 V nominal, running at the mains frequency. There are two instances where the option can be necessary: . Generating a current or voltage into a device that is also taking a signal from the mains; . Synchronising two test sets to the mains, and then using them to test line differential relays. The following design applies to the test of line differential relays.

The outputs of the mains synchroniser have to be connected to the INP 2 sockets of both test sets. The inputs should be selected with voltage; the voltage threshold is 5 V. Start the program that allows performing the differential test with mains synchronisation: both test sets will be locked to the mains. Now it is possible to apply the nominal current to both ends: as if this is not at the meantime, just ignore the corresponding trip. This is the pre-fault situation From this moment on, it is possible to perform any test, of the type healthy – fault – healthy: it will be possible to explore the entire relay curve.

MAINS SYNCHRON. MAINS

SYNCHRON.

TEST SET 2 TEST SET 1 RELAY 1 RELAY 2

POWER CABLE

INP 2 INP 2


APPENDIX 1: DRTS.6 RS232 SERIAL INTERFACE CONNECTOR: D TYPE, FEMALE, 9 WAYS.

PIN N° SIGNAL 1 DCD 2 RXD 3 TXD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 --

APPENDIX 2: RS232 SERIAL INTERFACE CABLE DRTS.6 PC PIN SIGN PIN SIGNAL 1 DCD 1 DCD 2 RXD 3 TXD 3 TXD 2 RXD 4 DTR 6 DSR 5 GND 5 GND 6 DSR 4 DTR 7 RTS 8 CTS 8 CTS 7 RTS


APPENDIX 3: LIST OF DRTS.6 SPARE PARTS This appendix lists the suggested spare parts. The list is divided in two: main spare parts and other spares. The separation follows the level of probability of the intervention. A) DRTS.6 MAIN SPARE PARTS N. DESCRIPTION CODE 1 FRONT.6 YWA11386 1 AMCO.6 YWA11374 1 AMTE .3 YWA11356 B) OTHER DRTS.6 SPARE PARTS N. DESCRIPTION CODE 1 VALI.3 MODULE YWA11355 1 AUX. DC MODULE YWA11369 1 ALIAUX.6 YWA11370 C) SPARE PARTS FOR AMI-150 N. DESCRIPTION CODE 1 AMI-150 AMPLIFIER ZII21131 1 ALI 1K POWER SUPPLY ZII41131


APPENDIX 4: ERROR CODES AND CORRESPONDING AREA Error messages from the PC are listed in the following table. The table lists also the meaning of the code, and the fault area or the cause of the fault. FAULT CAUSE AREA CODE 1 - PARITY/FRAMING/OVERRUN CONNECTION 2 - NON-BCD CODE, LONGITUDINAL FIELD CONNECTION 3 - NON-BCD CODE, LRC FIELD CONNECTION 4 - NON-BCD CODE, ID PARAMETER FIELD CONNECTION 5 - INCORRECT LRC CONNECTION 6 - ETX PREMATURE CONNECTION 7 - ETX NOT ARRIVED CONNECTION 8 - NON-BCD CODE IN PARAMETER VALUE FIELD CONNECTION 9 - DROP IN DTR DURING TRANSMISSION CONNECTION 10 - FRAME LENGTH DOES NOT COMPLY CONNECTION 11 - ID PARAMETER CODE INCORRECT CONNECTION 12 - OVERFLOW BUFFER PARAMETERS CONNECTION 13 - UNDERFLOW BUFFER PARAMETERS CONNECTION 14 - START VALUES RECEIVED WHILE RUNNING SOFTWARE 15 - NEW VALUES RECEIVED WHILE RUNNING SOFTWARE 16 - REPEAT RECEIVED WHILE RUNNING SOFTWARE 17 - PARAMETER MEANINGLESS SOFTWARE 18 - PARAMETER VALUE OUT OF RANGE SOFTWARE 19 – NACK RECEIVED INSTEAD OF ACK SOFTWARE 20 - RECEIVED CHARACTERS DIFFERENT FROM ACK,NACK,STX SOFTWARE 21 – RECEIVE DATA FRAME TIMEOUT CONNECTION 22 – DATA FRAME READ ERROR CONNECTION 37 - CALIBRATION SEQUENCE ERROR SOFTWARE 40 - NUCI INCORRECT SOFTWARE 41 - CICO INCORRECT SOFTWARE 42 – TEST START WITHOUT HEALTHY VALUES SOFTWARE 44 - TRIP INPUTS NOT PROGRAMMED SOFTWARE 45 – COUNTING AND TRIP INPUTS ENABLED IN SAME CYCLE SOFTWARE 46 – COUNTING INPUTS ENABLED IN THRESHOLD TEST SOFTWARE 47 - FAULT CURRENT AMPLIFIERS SUPPLY I3 OF AMI99 AMPLIFIER 48 - OVERLOAD I4 LOAD 49 - OVERLOAD I5 LOAD 50 - OVERLOAD I6 LOAD 51 - I4 THERMAL ERROR LOAD; AMPLIFIER 52 - I5 THERMAL ERROR LOAD; AMPLIFIER 53 - I6 THERMAL ERROR LOAD; AMPLIFIER 54 FAULT OF POWER SUPPLY CURRENT AMPLIFIER 1 AMPLIFIER 55 FAULT OF POWER SUPPLY CURRENT AMPLIFIER 2 AMPLIFIER 56 FAULT OF POWER SUPPLY CURRENT AMPLIFIER 3 AMPLIFIER 57 FAULT OF POWER SUPPLY CURRENT 1 OF AMIV-99 AMPLIFIER 58 FAULT OF POWER SUPPLY CURRENT 2 OF AMIV-99 AMPLIFIER


59 COUNTER-FEED ON DC VOLTAGE GENERATOR CONNECTION 60 FAULT OF POWER SUPPLY CURRENT 3 OF AMIV-99 AMPLIFIER 67 - IR OVERLOAD LOAD 69 - IS OVERLOAD LOAD 71 - IT OVERLOAD LOAD 75 - VR OVERLOAD LOAD 77 - VS OVERLOAD LOAD 79 - VT OVERLOAD LOAD 82 – ERROR BOOSTER AUX. SUPPLY 16.5 V HARDWARE 84 - ERROR CONVERTER V1 LOW HARDWARE 85 - ERROR CONVERTER V2 LOW HARDWARE 86 - ERROR CONVERTER V3 LOW HARDWARE 87 - ERROR CONVERTER I1 LOW HARDWARE 88 - ERROR CONVERTER I2 LOW HARDWARE 89 - ERROR CONVERTER I3 LOW HARDWARE 90 - ERROR CONVERTER V1 MID HARDWARE 92 - ERROR CONVERTER V1 HIGH HARDWARE 94 - ERROR CONVERTER V2 MID HARDWARE 96 - ERROR CONVERTER V2 HIGH HARDWARE 98 - ERROR CONVERTER V3 MID HARDWARE 100 - ERROR CONVERTER V3 HIGH HARDWARE 102 - ERROR CONVERTER I1 MID HARDWARE 104 - ERROR CONVERTER I1 HIGH HARDWARE 106 - ERROR CONVERTER I2 MID HARDWARE 108 - ERROR CONVERTER I2 HIGH HARDWARE 110 - ERROR CONVERTER I3 MID HARDWARE 112 - ERROR CONVERTER I3 HIGH HARDWARE 128 - DO_REPEAT BEFORE TEST DEFINITION SOFTWARE 129 - CYCLE OPERATIVE MODE REDEFINITION SOFTWARE 130 - VALI FORMAT STRING INVALID SOFTWARE 131 - IMMEDIATE COMMAND FORMAT ERROR SOFTWARE 132 - NUCI E CICO DISCORDANCE SOFTWARE 133 - SAME CICO VALUE RECEIVED MANY TIMES SOFTWARE 134 - INVALID SELECTION CODE SOFTWARE 135 - PARAMETER RECEIVED BEFORE NUCI SOFTWARE 136 - PARAMETER RICEIVED BEFORE CICO SOFTWARE 137 - VOLTAGE RANGE OR AMPLITUDE ERROR SOFTWARE 138 - VOLTAGE RANGE OR AMPLITUDE ERROR SOFTWARE 139 - VOLTAGES ANGLE ERROR SOFTWARE 140 - CURRENTS ANGLE ERROR SOFTWARE 141 - ANGLE REFERENCE ERROR SOFTWARE 142 - ATTEMPT TO RECORD WHILE OPERATING SOFTWARE 143 - WAVE-FORM LOADING ERROR CONNECTION 144 - FIRMWARE LOADING ERROR CONNECTION 145 - ERROR IN FIRMWARE CRC CONNECTION 146 - TEST CYCLE SEQUENCE ERROR CONNECTION 147 - INCOMPATIBLE TEST CYCLE TYPE CONNECTION 148 - INCOMPATIBLE GRADIENT TEST PARAMETERS SOFTWARE 149 - INCOPATIBLE INPUTS PROGRAMMING CONNECTION 150 - REQUESTED H/W OPTION IS NOT PRESENT SOFTWARE 151 - RESULTS TOO LONG SOFTWARE


152 - FLASH EPROM BUILDER NOT VALID MICR 153 - FLASH EPROM MEMORY CODE ERROR MICR 154 - PROTECTED SECTOR FOUND IN FLASH EPROM MICR 155 - FLASH EPROM CLEANING ERROR MICR 156 - FLASH EPROM PROGRAMMING ERROR MICR 157 - OUT OF TIME IN PROGRAM UPDATING MICR 158 - UPDATING PROGRAM DATA ERROR MICR 159 – INVALID POINT OF WAVE SOFTWARE 160 – CYCLE WITH ZERO DURATION SOFTWARE 162 – DIAGNOSTIC ERROR ON + 95 V SUPPLY (DRTS.6) POWER SUPPLY 163 – DIAGNOSTIC ERROR ON - 95 V SUPPLY (DRTS.6) POWER SUPPLY 164 – DIAGNOSTIC ERROR ON + 113 V SUPPLY (300 V) POWER SUPPLY 165 – DIAGNOSTIC ERROR ON + 227 V SUPPLY (300 V) POWER SUPPLY 166 – DIAGNOSTIC ERROR ON + 340 V SUPPLY (300 V) POWER SUPPLY 167 – DIAGNOSTIC ERROR ON + 454 V SUPPLY (300 V) POWER SUPPLY 168 – DIAGNOSTIC ERROR ON - 113 V SUPPLY (300 V) POWER SUPPLY 169 – DIAGNOSTIC ERROR ON - 227 V SUPPLY (300 V) POWER SUPPLY 170 – DIAGNOSTIC ERROR ON - 340 V SUPPLY (300 V) POWER SUPPLY 171 – DIAGNOSTIC ERROR ON - 454 V SUPPLY (300 V) POWER SUPPLY 172 – DIAGNOSTIC ERROR ON + 95 V SUPPLY (DRTS.6) POWER SUPPLY 173 – DIAGNOSTIC ERROR ON - 95 V SUPPLY (DRTS.6) POWER SUPPLY 174 – DIAGNOSTIC ERROR ON + 113 V SUPPLY (AMIV.33) POWER SUPPLY 175 – DIAGNOSTIC ERROR ON + 227 V SUPPLY (AMIV.33) POWER SUPPLY 176 – DIAGNOSTIC ERROR ON + 340 V SUPPLY (AMIV.33) POWER SUPPLY 177 – DIAGNOSTIC ERROR ON + 454 V SUPPLY (AMIV.33) POWER SUPPLY 178 – DIAGNOSTIC ERROR ON - 113 V SUPPLY (AMIV.33) POWER SUPPLY 179 – DIAGNOSTIC ERROR ON - 227 V SUPPLY (AMIV.33) POWER SUPPLY 182 – V1 VOLTAGE THERMAL ERROR LOAD 183 – V2 VOLTAGE THERMAL ERROR LOAD 184 – V3 VOLTAGE THERMAL ERROR LOAD 185 - I1 CURRENT THERMAL ERROR LOAD 186 – I2 CURRENT THERMAL ERROR LOAD 187 – I3 CURRENT THERMAL ERROR LOAD 188 – VOLTAGE SUUPLY THERMAL ERROR POWER SUPPLY 189 - + 12 V SUPPLY THERMAL ERROR POWER SUPPLY 192 – BOOSTER ERROR LOAD 193 – DC SUPPLY OVERLOAD LOAD 194 – ZERO SEQUENCE OVERLOAD LOAD 195 – V4 OUTPUT OVERLOAD LOAD 196 – V4 THERMAL OVERLOAD LOAD 197 – DIAGNOSTIC ERROR ON - 340 V SUPPLY (AMIV.33) POWER SUPPLY 198 – DIAGNOSTIC ERROR ON - 454 V SUPPLY (AMIV.33) POWER SUPPLY 199 – ERROR BOOSTER MISMATCH CONNECTION 200 - + 5 V AUXILIARY VOLTAGE POWER SUPPLY 201 - + 12 V AUXILIARY VOLTAGE POWER SUPPLY 202 - + 15 V AUXILIARY VOLTAGE POWER SUPPLY 203 - - 15 V AUXILIARY VOLTAGE POWER SUPPLY 212 - + 16.5 V AUXILIARY VOLTAGE POWER SUPPLY 213 – ERROR BOOSTER TEMPERATURE LOAD 214 - OVERTEMPERATURE ON MICROPROCESSOR BOARD MICR


221 - ERROR UNKNOWN FAULT CODE HARDWARE 222 – ERROR + 125 V SUPPLY POWER SUPPLY 223 - ERROR + 165 V SUPPLY POWER SUPPLY 224 - ERROR + 200 V SUPPLY POWER SUPPLY 225 - ERROR - 125 V SUPPLY POWER SUPPLY 226 - ERROR - 165 V SUPPLY POWER SUPPLY 227 - ERROR - 200 V SUPPLY POWER SUPPLY 228 – COUNTER FEED ON VOLTAGE OUTPUTS LOAD 229 – BOOSTER LINK ERROR CONNECTION 230 – BOOSTER 16.5 V ERROR POWER SUPPLY 231 - OVERLOAD ON BOOSTER V5 LOAD 232 - OVERLOAD ON BOOSTER V6 LOAD 233 - OVERLOAD ON BOOSTER I7 LOAD 234 - OVERLOAD ON BOOSTER I8 LOAD 235 - OVERLOAD ON BOOSTER I9 LOAD 236 – ERROR + 15 V SUPPLY POWER SUPPLY 237 - THERMAL OVERLOAD ON BOOSTER V5 LOAD 238 - THERMAL OVERLOAD ON BOOSTER V6 LOAD 239 - THERMAL OVERLOAD ON BOOSTER I7 LOAD 240 - THERMAL OVERLOAD ON BOOSTER I8 LOAD 241 - THERMAL OVERLOAD ON BOOSTER I9 LOAD 242 - THERMAL OVERLOAD ON BOOSTER SUPPLY POWER SUPPLY 243 - THERMAL OVERLOAD ON BOOSTER CURRENT SUPPLY POWER SUPPLY 244 - COUNTER FEED ON BOOSTER VOLTAGE OUTPUTS LOAD 245 - + 12 V SUPPLY ERROR ON BOOSTER POWER SUPPLY 246 - - 15 V SUPPLY ERROR ON BOOSTER POWER SUPPLY 247 - + 125 V SUPPLY ERROR ON BOOSTER POWER SUPPLY 248 - + 165 V SUPPLY ERROR ON BOOSTER POWER SUPPLY 249 - + 200 V SUPPLY ERROR ON BOOSTER POWER SUPPLY 250 - - 125 V SUPPLY ERROR ON BOOSTER POWER SUPPLY 251 - - 165 V SUPPLY ERROR ON BOOSTER POWER SUPPLY 252 - - 200 V SUPPLY ERROR ON BOOSTER POWER SUPPLY 253 – BOOSTER PROTOCOL ERROR SOFTWARE 254 – BOOSTER SYSTEM ERROR SOFTWARE 255 – BOOSTER MAIN FAULT POWER SUPPLY 256 - MEMORY ALLOCATION ERROR MICR 257 - I/O DRIVER ERROR MICR 258 - RUNTIME ERROR MICR 259 - PROGRAM ERROR MICR 260 - XILINX A PROGRAMMING ERROR MICR 261 - XILINX B PROGRAMMING ERROR MICR 262 - FLASH EPROM INTEGRITY ERROR MICR 263 - MASS MEMORY ERROR MICR 270 - CALIBRATION PARAMETER BUFFER CORRUPTED SOFTWARE 271 - DIAGNOSTIC ERROR : CONVERTER V4 LOW CONV 272 - DIAGNOSTIC ERROR : CONVERTER V5 LOW CONV 273 - DIAGNOSTIC ERROR : CONVERTER V6 LOW CONV 274 - DIAGNOSTIC ERROR : CONVERTER I4 LOW CONV 275 - DIAGNOSTIC ERROR : CONVERTER I5 LOW CONV 276 - DIAGNOSTIC ERROR : CONVERTER I6 LOW CONV 277 - DIAGNOSTIC ERROR : CONVERTER V4 MID CONV 278 - DIAGNOSTIC ERROR : CONVERTER V5 MID CONV 279 - DIAGNOSTIC ERROR : CONVERTER V6 MID CONV


280 - DIAGNOSTIC ERROR : CONVERTER I4 MID CONV 281 - DIAGNOSTIC ERROR : CONVERTER I5 MID CONV 282 - DIAGNOSTIC ERROR : CONVERTER I6 MID CONV 283 - DIAGNOSTIC ERROR : CONVERTER V4 HIGH CONV 284 - DIAGNOSTIC ERROR : CONVERTER V5 HIGH CONV 285 - DIAGNOSTIC ERROR : CONVERTER V6 HIGH CONV 286 - DIAGNOSTIC ERROR : CONVERTER I4 HIGH CONV 287 - DIAGNOSTIC ERROR : CONVERTER I5 HIGH CONV 288 - DIAGNOSTIC ERROR : CONVERTER I6 HIGH CONV 290 – ERROR ALIAUX LINK HARDWARE 291 – ERROR ALIAUX PROTOCOL HARDWARE 292 – ERROR ALIAUX GROUND FIRST HARDWARE 293 – ERROR ALIAUX GROUND SECOND HARDWARE 294 – ERROR ALIAUX GROUND THIRD HARDWARE 295 – ERROR ALIAUX GROUND FOURTH HARDWARE 296 – ERROR ALIAUX GROUND FIFTH HARDWARE 297 – ERROR VM 16.5 HARDWARE 298 – ERROR V AC TOO HIGH SUPPLY 299 – ERROR MAINS FREQUENCY SUPPLY


APPENDIX 5: CONNECTOR 19; BOOSTERS On connection pins provided it is possible to crimp wires with AWG size 20 to 16 (0.52 sq. mm. To 1.5 sq. mm.). BOLDED: connection of low level signals. PIN SIGNAL PIN SIGNAL A RXD1B N V3 (0 POWER);

V5 (BOOSTER V); I9 (BOOSTER I)

B RXD1A P V1 (0 POWER); I7 (BOOSTER I)

C AMPEXT1 BRIDGE TO J FOR 0 POWER

R IN

D MODE S IN E I1 (0 POWER) T I3 (0 POWER) F I2 (0 POWER) U AMPEXT0 G SCK1A V SCK1B H TXD1B W ERRBOOSTER J LOGICAL 0 X IN K - Y IN L ANALOG 0 Z TXD1A M V2 (0 POWER);

V5 (BOOSTER V); I8 (BOOSTER I)

A P

N

M

L

K

JH

VW

X

YR

S

T Z

U

GF

E

D

C

B

FRONT VIEW OF EXT. AMP. CONNECTOR


APPENDIX 6: CABLE FROM DRTS.6 TO BOOSTERS CABLE TO AMI-150 This cable connects DRTS.6 to AMI-150. DRTS.6 side: male pins; booster side: female pins. PIN DRTS

PIN BOOSTER

SIGNAL

A A RXD1B B P RXD1A C N AMPEXT1 D M MODE E L I1 F K I2 G J SCK1A H H TXD1B J G LOGICAL 0 K F - L E ANALOG 0 M D V2 N C V3 P B V1 R - IN S - IN T X I3 U W AMPEXT0 V V SCK1B W U ERRBOOSTER X - IN Y - IN Z Z TXD1A


CABLE TO OTHER BOOSTERS This cable connects DRTS.6 to all other boosters. DRTS.6 side: male pins; booster side: female pins. PIN DRTS

PIN BOOSTER

SIGNAL

A H RXD1B B Z RXD1A C C AMPEXT1 D D MODE E E I1 F F I2 G G SCK1A H A TXD1B J J LOGICAL 0 (K) (F) - L L ANALOG 0 M M V2 N N V3 P P V1 R R IN S S IN T T I3 U U AMPEXT0 V V SCK1B W W ERRBOOSTER X X IN Y Y IN Z B TXD1A


APPENDIX 7: IO6432 CONNECTORS THESE CONNECTORS APPLY TO UNITS DELIVERED BEFORE MAY 2003 J800 connector: trip inputs

PIN J800

SIGNAL PIN J800

SIGNAL

1 COM-4 35 COM-2 2 IN-80 36 IN-48 3 IN-79 37 IN-47 4 IN-78 38 IN-46 5 IN-77 39 IN-45 6 IN-76 40 IN-44 7 IN-75 41 IN-43 8 IN-74 42 IN-42 9 IN-73 43 IN-41 10 IN-72 44 IN-40 11 IN-71 45 IN-39 12 IN-70 46 IN-38 13 IN-69 47 IN-37 14 IN-68 48 IN-36 15 IN-67 49 IN-35 16 IN-66 50 IN-34 17 IN-65 51 IN-33 18 IN-64 52 IN-32 19 IN-63 53 IN-31 20 IN-62 54 IN-30 21 IN-61 55 IN-29 22 IN-60 56 IN-28 23 IN-59 57 IN-27 24 IN-58 58 IN-26 25 IN-57 59 IN-25 26 IN-56 60 IN-24 27 IN-55 61 IN-23 28 IN-54 62 IN-22 29 IN-53 63 IN-21 30 IN-52 64 IN-20 31 IN-51 65 IN-19 32 IN-50 66 IN-18 33 IN-49 67 IN-17 34 COM-3 68 COM-1

2 34

1 33 36 68 35 67 Connector J800: pin layout; soldering side


THESE CONNECTORS APPLY TO UNITS DELIVERED BEFORE MAY 2003 J802 connector: auxiliary outputs

PIN J802

SIGNAL PIN J802

SIGNAL

1 RIF-2 26 N.C. 2 N.C. 27 RIF-4 3 N.C. 28 N.C. 4 N.C. 29 N.C. 5 OUT-32 30 OUT-48 6 OUT-31 31 OUT-47 7 OUT-30 32 OUT-46 8 OUT-29 33 OUT-45 9 OUT-28 34 OUT-44 10 OUT-27 35 OUT-43 11 OUT-26 36 OUT-42 12 OUT-25 37 OUT-41 13 N.C. 38 N.C. 14 OUT-24 39 OUT-40 15 OUT-23 40 OUT-39 16 OUT-22 41 OUT-38 17 OUT-21 42 OUT-37 18 OUT-20 43 OUT-36 19 OUT-19 44 OUT-35 20 OUT-18 45 OUT-34 21 OUT-17 46 OUT-33 22 N.C. 47 N.C. 23 N.C. 48 N.C. 24 N.C. 49 RIF-3 25 RIF-1 50 N.C.

2 24

1 25 27 49 26 50 Connector J802: pin layout; soldering side


THESE CONNECTORS APPLY TO UNITS DELIVERED AFTER MAY 2003 J800 connector: trip inputs PIN - SIGNAL PIN - SIGNAL PIN - SIGNAL A1 = IN1 B1 = COM1 C1 = IN33 A2 = IN2 B2 = COM3 C2 = IN34 A3 = IN3 B3 = N.C. C3 = IN35 A4 = IN4 B4 = N.C. C4 = IN36 A5 = IN5 B5 = N.C. C5 = IN37 A6 = IN6 B6 = N.C. C6 = IN38 A7 = IN7 B7 = N.C. C7 = IN39 A8 = IN8 B8 = N.C. C8 = IN40 A9 = IN9 B9 = N.C. C9 = IN41 A10 = IN10 B10 = N.C. C10 = IN42 A11 = IN11 B11 = N.C. C11 = IN43 A12 = IN12 B12 = N.C. C12 = IN44 A13 = IN13 B13 = N.C. C13 = IN45 A14 = IN14 B14 = N.C. C14 = IN46 A15 = IN15 B15 = N.C. C15 = IN47 A16 = IN16 B16 = N.C. C16 = IN48 A17 = IN17 B17 = N.C. C17 = IN49 A18 = IN18 B18 = N.C. C18 = IN50 A19 = IN19 B19 = N.C. C19 = IN51 A20 = IN20 B20 = N.C. C20 = IN52 A21 = IN21 B21 = N.C. C21 = IN53 A22 = IN22 B22 = N.C. C22 = IN54 A23 = IN23 B23 = N.C. C23 = IN55 A24 = IN24 B24 = N.C. C24 = IN56 A25 = IN25 B25 = N.C. C25 = IN57 A26 = IN26 B26 = N.C. C26 = IN58 A27 = IN27 B27 = N.C. C27 = IN49 A28 = IN28 B28 = N.C. C28 = IN60 A29 = IN29 B29 = N.C. C29 = IN61 A30 = IN30 B30 = N.C. C30 = IN62 A31 = IN31 B31 = COM4 C31 = IN63 A32 = IN32 B32 = COM2 C32 = IN64


THESE CONNECTORS APPLY TO UNITS DELIVERED AFTER MAY 2003 J802 connector: auxiliary outputs PIN - SIGNAL PIN - SIGNAL A1 = OUT1 C1 = OUT17 A2 = OUT2 C2 = OUT18 A3 = OUT3 C3 = OUT19 A4 = OUT4 C4 = OUT20 A5 = OUT5 C5 = OUT21 A6 = OUT6 C6 = OUT22 A7 = OUT7 C7 = OUT23 A8 = OUT8 C8 = OUT24 A9 = RIF-1 C9 = RIF-3 A10 = N.C. C10 = N.C. A11 = N.C. C11 = N.C. A12 = N.C. C12 = N.C. A13 = N.C. C13 = N.C. A14 = N.C. C14 = N.C. A15 = N.C. C15 = N.C. A16 = N.C. C16 = N.C. A17 = N.C. C17 = N.C. A18 = N.C. C18 = N.C. A19 = N.C. C19 = N.C. A20 = N.C. C20 = N.C. A21 = N.C. C21 = N.C. A22 = N.C. C22 = N.C. A23 = N.C. C23 = N.C. A24 = RIF-2 C24 = RIF-4 A25 = OUT9 C25 = OUT25 A26 = OUT10 C26 = OUT26 A27 = OUT11 C27 = OUT27 A28 = OUT12 C28 = OUT28 A29 = OUT13 C29 = OUT29 A30 = OUT14 C30 = OUT30 A31 = OUT15 C31 = OUT31 A32 = OUT16 C32 = OUT32


DRTS.6 PART LIST

DRTS.6 FRONT PANEL 1) Power supply socket with filter and fuse, type T16A. 2) Power-on switch, with light. 3) Instrument state lights. 4) 9-way connector of the RS232 serial interface. 5) Current output safety sockets: six phases with two common neutrals (IN). 6) Output current lights (ON = current available). 7) Imp1 and Imp2 counting inputs. 8) DC voltage safety sockets. 9) Output voltage lights (ON = voltage available). 10) Voltage output safety sockets: four phases with common neutral (VN). 11) Connector of the USB interface. 12) Safety sockets of auxiliary contacts A1 - A4. 13) Auxiliary contacts lights (ON = switched). 14) Safety sockets of trip inputs C1 - C8, with two isolated references. 15) Trip input contacts lights (ON = closed). 16) Light confirming the USB connection. 17) Safety sockets of voltage and current measurement inputs. 18) Connector to the IO6432 digital inputs and outputs expansion. 19) Connector board YWA11322 for the optional amplifiers. 20) Control cards back-panel YWA11371. 21) PASSIVA printed wire board YWA11316, with connections to the back panel and zero power circuits. 22) MICR-H YWA31300, with: microprocessor, memories, programmable logics. 23) INTE-H2 trip inputs interface YWA11310. 24) RELE.6 YWA11373, with A1-A4 auxiliary outputs relays and connectors for the amplifiers. 25) CONV-6 YWA11372, with the digital to analog converters. 26) AMCO I1-I4; I2-I5; I3-I6, YWA11374: two-phase current amplifiers. 27) AMTE V1-V2; V3-V4, YWA11356 (11376 for 300 V option): two-phase voltage amplifiers. 28) Switching power supply of voltage amplifiers supplies, YWA11355 (11358 for 300 V option).

RS232 A1 C1

ANALOG INPUT

C5

A2 C2 C6

A3 C3 C7

A4 C4 C8

C C IMP1

250 5 A V ~

V ~ V ~ 250 V ~

EXT. AMP.

20 A ~

250 V ~ 10 V ---

20 mA ---

0

0

17 14 15 14 13 12 9 10

7

3 6 2 5

32 19 8 1

DRTS-6 AUTOMATIC RELAY TESTING AND MEASUREMENT SYSTEM

OK ! ERR ON

110/230 V 50/60 Hz ~

T16A 250V !

V1

V2

V3

I4

I5

I6 IN VN

V ---

15 A ~

260 V ---

125/300 V ~

V0/V4

I1

I2

I3

IMP2

IN

11

6

!

4 16


29) ALIAUX.6 YWA11370, that generates the auxiliary DC voltage supplies. 30) FRONT.6 YWA11386, that generates two 300 V DC supplies. 31) Auxiliary DC voltage module YWA11369. 32) Lights that turn on when trip inputs under voltage are selected. 33) Fans. 34) Front panel. 35) INTE-H1 trip input filters YWA11320. 36) Mains supply filter YWA11389. 37) LUSC signaling lights board YWA11380. 38) LEDALI.6 signaling lights board YWA11385. 39) LEDSC signaling lights board YWA11312. 40) On front-panel: optional MISU board YWA11328. 41) On rear panel: optional IO6432 boards, YWA11346. 42) Power supply back panel YWA11368.


AMI150 PART-LIST

3

1

4

528 910

7

6 1) Power supply socket. 2) Power-on switch with light. 3) Connector to the DRTS.6. 4) Additional ground socket. 5) Instrument state lights. 6) Current output sockets: one phase and two neutrals per amplifier. 7) Protection fuse, T2A. 8) Green power-on light. 9) Red alarm light. 10) Alarm reset push-button.


AMI.99 PART LIST

AMI.99 FRONT PANEL PASS MICR RELEICONV AMCO AMCO AMCO ALI FR I7 I8 I9 AUX END (21) (22) (24) (25) (26) (26) (26) (29) (30) SKETCH OF AMI.99 TOP VIEW WITH BOARD LOCATION 1) Power supply socket with filter and fuse, type T16A. 2) Power-on switch, with light. 3) Instrument state lights. 4) Current output safety sockets: three phases with two common neutrals (IN). 5) Output current lights (ON = current available). 6) Connector board YWA11322 to DRTS.6.


7) Fans. 8) Front panel. 9) Mains supply filter YWA11389. 10) LEDALI.6 signaling lights board YWA11385. 20) Control cards back-panel YWA11371. 21) PASSIVA printed wire board YWA31316, with connections to the back panel. 22) MICR-H YWA31300, with: microprocessor, memories, programmable logics. 24) RELE.6 YWA21373, with connectors for the amplifiers. 25) CONV-6 YWA21372, with connections to current amplifiers. 26) AMCO I7; I8; I9 YWA11374: one-phase current amplifiers. 29) ALIAUX.6 YWA11370, that generates the auxiliary DC voltage supplies. 30) FRONT.6 YWA11386, that generates two 300 V DC supplies. 31) Power supply back panel YWA11368.

120

13

I5

IMP2 TTL

49cm

4

T16A

I4

INGRESSO_250V

120

BPSEGN.6

11371

831

832

840

842

835

837

838

0C1

30C1

0C5

30C5

4NA

0V ALI INTE C1-C4

TERRA

14 LED

0,5Q

2NA

INGRESSO_20A

RELE-6

11373

808

801

802

803

805

807-1

807-3

807-2

807-4

807-6

807-5

807-7

807-9

807-8

807-10

807-12

807-11

861

810

MISU

11328

800

I2

10

+200

7

12

29

DSR

20P 8cm

R

PASSIVA

11316

890

801 802

891

34

C8

R

0,5Q

VN

6

14P 41cm

1Q

808-3 (EN I1)

R

R

+300V

260VCC

11369

862

861-6861-5861-3

861-4

861-1

861-2

4NC

R

5

27

A1

14

RX

9

36

N

20

3NA

I3

NEUTRO_CORRENTE

1Q

N2

CONN SERIALE

594837261

14

1Q

MAS.

5

ZVCC

2NC

3C

17

120

35

R

803-3 (EN I3)

R

R

IN

+200

-200

C6

N1

120

±15

I/O6432 INF.

21346

803801

841

840

842

2C

30V ALI INTE C1-C5

FEMM.

BI

25

891-3

1C

COPERTURA SOPRA

ESPANSIONE CONNETTORE

11322

890

BI

37

33

1NC

MICR-H

21300

801802

TTL5

INGRESSO_10V

891-4

808-5 (EN VCC)

-200

VCC

VS

5

MISURA

20P 14cm

A3

0_D

C7

891-1

50PIN32OUT

MAS.

N

VCC

68PIN

64I MAS.

20P 36cm

AMCO.D6_3 11374

801

803

0 300ENABLE

OUT AOUT AOUT B

OUT B

0 POTENZA0 POTENZA

0 POTENZA

GND

+300

V0/V4

BI

R

1Q

808-1 (+300 AL)

R

COPERTURA SOTTO

+12V

0,5Q

N

28

1Q

25

V1

I1

18

20P 7cm

LUSC.6

11380

810-14810-1

810-2810-3810-7

810-4810-5810-6

810-13

+300VAL

INTE-H1

11320

805 803

TP1TTL

TPC1

TP4

TP3

TP2

TP1

TP5TTL

TPC2

TP8

TP7

TP6

TP5

802

C4

AMCO.D6_1 11374

801

803

0 300ENABLE

OUT AOUT AOUT B

OUT B

0 POTENZA0 POTENZA

0 POTENZA

GND

+300

C2

N=3

V4

N

27

CTS

ALI V

11355

801

EXP.

28

ALIAUX.6 11370

803

891-14

8P

RTS

LED SCATTI

11312

804

891-2

31

R

808-2 (-300 AL)

I6

VT

C3

BI

0,25Q

14P 36cm

Monday, February 05, 2001

PII10156 0

CABLAGGIO DRTS-6

A3

1 1

Title

Size Document Number Rev

Date: Sheet of

Designer Check and Approval

1

R

VN

16P 29cm

INTE-H2

11310

803

802

804

801

+200

1Q

28cm

+200V

22

I1

N=4

24

I/O6432 SUP.

11346

800

841

801803

802

R

14P 22cm

32

VR

IN

808-4 (EN I2)

A4

0,25Q

C5

DTR

3NC

R

30V ALI INTE C5-C8

IMP1 TTL

FRONT.6

11386

804

802-1802-2

815

801805

808

802-3802-4

803

808

803-2 (-300 VI)

4C

19 10/250V

22µH

N

23

26

TX

±16,5

I3

R

0,02/20A

ENI3

-200

-200V

22µH

14

14P 26cm

3

8P 8cm

36

AMCO.D6_2 11374

801

803

0 300ENABLE

OUT AOUT AOUT BOUT B

0 POTENZA0 POTENZA

0 POTENZA

GND

+300

891-10

15

I/O21

7

AMTE.3 T_V4

11356

810-3

810-1

810-2

810-4

810-7810-6810-5

804

802

12

A2

0_D

0V ALI INTE C5-C8

N

C1

891-13

38

8

808-2 (-300 AL)

V3

LEDALI.6

11385

815

I2

0,5Q

11 LED

N

INGRESSO_20mA

30

891-12

803-1 (+300 VI)

0_D

+5

BL

IN

808-1 (+300 AL)

891-11

22µH

28

+5

B.P.POT.6

11368

+2000TEN-200

VENT0LOG

822

GND

821

823

0C1

30C1

0C5

30C5

IN808-2 (-300 AL)

22µH

0,5Q

4 LED

R

AMTE.3 R_S

11356

810-1

810-3

810-2

810-4

810-7810-6

810-5

801

804

1NA

2

808-1 (+300 AL)

NEUTRO_TENSIONE

0_D

LGND

340,5Q

CONV-6

11372

800802

801

FILTRO RETE

11353

TP1

TP3

TP4

TP7

TP6

TP2

TP5

R

V2

Documents

DRTS.6 USER’S MANUAL - User Equip: New & Used Test …userequip.com/files/specs/5685/ISA DRTS-6 Manual.pdf · E-MAIL [email protected] WEB ... 4 CONNECTION AND TEST START WITH DRTS.6