Operating and Maintenance Manual: T & R Test Equipment Limited
Operating and Maintenance Manual: T & R Test Equipment Limited
The following safety precautions should be reviewed to avoid injury to the user and damage to the
product (and other products connected to it). To avoid potential hazards only use this product as
specified.
Only suitably qualified personnel should use this equipment. Servicing of this product
should only be carried out by suitably qualified service personnel.
Do not connect and disconnect leads whilst outputs are switched on. Breaking the output circuit
with current flowing may cause potentially fatal arcing.
Ensure that the product is grounded. To avoid electric shock, it is essential that the grounding
conductor is connected to the earth ground. An additional earth terminal is provided on the unit that
should be connected to a local earth. Ensure that the unit is properly grounded before making any
connections to inputs or outputs.
Terminal ratings must be observed to prevent fire hazards and risk of injury to the operator.
Consult the product manual for ratings information before making connections to any terminal.
It is ESSENTIAL to consult the product manual for rating information before making any connection
to a terminal or terminal group marked with a warning triangle.
Only use fuses of a type and rating specified for this product.
Do not operate the unit out of its case or with any covers or panels removed.
Do not touch exposed connections and components when power is present.
Do not operate the product if any damage is suspected. Refer the unit to qualified service
personnel to be checked.
Do not operate the unit in wet or damp conditions.
The CU-Ps systems have a very high output current (up to 12kA), and therefore generate large
magnetic fields around the output leads and loading transformer. Care must be taken in siting the
unit next to items sensitive to magnetic fields (such as computer monitors and other sensitive
equipment).
Warnings from cardiac pacemaker manufacturers state that strong magnetic fields may affect
operation. Any high current unit such as the CU-Ps should therefore not be operated by, or in the
vicinity of persons fitted with cardiac pacemakers or any other electronic or electrical medical
implants.
If any further queries occur regarding the usage and maintenance of the equipment
detailed in this manual, please refer these to the supplier of the equipment in the first case
or to the manufacturer, T & R Test Equipment Limited.
2
SAFETY TERMS AND SYMBOLS
Mains off
Mains on
3
CONTENTS
1 DESCRIPTION OF EQUIPMENT 9
1.3.4 Metering 17
1.5.1 Description 24
1.7 Construction 26
1.8 Installation 27
2 OPERATION 28
2.1.1 Connections 29
2.1.2 Testing 30
2.2.1 Connections 31
2.2.2 Testing 32
5
2.3.1 Timer Modes 34
2.4.4 Auto-store 38
3.1.2 Connections 41
3.2.2 Connections 42
3.3.2 Connections 43
3.4.2 Connections 44
3.5.2 Connections 45
6
3.5.3 Test Procedure 45
3.6.2 Connections 45
3.7 CT Polarity 46
3.7.2 Connections 46
3.8 CT Ratio 47
3.8.2 Connections 47
4 MAINTENANCE 49
5 STANDARD ACCESSORIES 51
7
7 REVISION 55
8
1 DESCRIPTION OF EQUIPMENT
The CU-Ps is a primary current injection system offering output currents up to 6000A. The
system consists of a separate control unit containing all metering and control functions and a
loading unit that provides the high current output. The CU-Ps is ideally suited to primary
current injection, stability testing and circuit breaker testing. In addition, the CU-Ps also offers
direct-reading CT ratio and polarity tests and a 100A secondary injection output.
Two loading units are available, delivering a maximum output current of 5000A or 6000A.
Each loading unit can be configured for series or parallel output to allow for a wide range of
load impedances. For example, the PLU-6k may be configured in series mode to give a
maximum current of 6000A at 6.6V range or configured in parallel mode to give a maximum
current of 12000A on the 3.3V.
The control units are rated at 12kVA for 1 second. All metering is digital. A memory facility is
provided to hold the current reading when the output trips or is switched off. The current is
thyristor controlled and is automatically switched off when the device under test trips.
The CU-Ps system has a high accuracy timing system, allowing timing tests to be carried out
to a resolution of 1ms. Selection for normally open or normally closed contacts is automatic,
and the status of the contacts is shown on the front panel.
Timing modes are available to test under and over current devices, re-closers, under and over
voltage devices, current trips and circuit breakers. A full range of high current output leads are
available to complement the system in a range of lengths.
The CU-Ps and associated loading units are designed to be used on ‘dead’
systems (i.e. no externally supplied voltages are present on the test object).
Under no circumstances connect a CU-Ps to a live system. Always check that
the power to the device under test is off and the circuit is isolated and earthed
WARNING
before making any connections.
9
1.1 Control Unit Front Panel Layout and Functions
A B C D E F G H
T
I
Q
J
P O N M L K
10
ITEM FUNCTION
L Output ON and OFF pushbuttons Switch output on and off and indicate output
state
N Auxiliary metering inputs and Voltage and current input for auxiliary
selector metering circuit
R Timer and pulse selector Timer mode selection and pulse duration
switch
11
1.2 Loading Unit Front Panel Layout
The CU-Ps system is available with a range of optional loading units and output lead sets.
The loading unit is connected to the control unit using a metering cable and a power cable.
The load is connected between the terminals 1&5 and 4&8.
A B C
12
ITEM FUNCTION
13
1.3 Electrical Specification
Link
Configuration
terminals
2-3
Series
6-7
1-3
2-4
Parallel
5-7
6-8
14
To change the links, ensure the CU-Ps system is turned OFF from the main supply. Remove
all eight retaining nuts, and then remove the output terminal plates. Re-configure the links as
required, and then replace the output terminal plates and nuts. Ensure that all the nuts are
tightened.
The user selects whether the PLU loading unit is in Parallel or Series mode on the CU-Ps
control unit when:
The CU-Ps is turned ON from the mains supply AND the ammeter select switch is in
the main output range
OR;
The ammeter range select switch is moved from Secondary Injection to Main Output.
An LED will illuminate on the CU-Ps front panel next to the diagram of the selected mode.
15
Loading Unit PLU-5k PLU-6k
Max kVA 10 10 10 10
Max kVA 10 10 10 10
Max kVA 32 32 32 32
Max kVA 40 40 40 40
0.5 sec on/0.5 min off Current 10000A 5000A 12000A 6000A
Max kVA 40 40 40 40
0.2 sec on/0.5 min off Current 10000A 5000A 12000A 6000A
Max kVA 40 40 40 40
The main output from the CU-Ps control unit is a 0-230V supply rated at 100A for 5 minutes
on/15 minutes off. This output is NOT isolated from the mains and is not designed to be used
without an isolating loading unit. The units are designed to drive the T&R PLU-5k and PLU-6k
loading units, which provide an isolated low voltage high current output.
Each output is rated for a continuous current and for higher intermittent currents. The
maximum ‘on’ time for intermittent currents is enforced by the unit, and the output will be
switched off if the rating is exceeded. The display will then show the following message until
the green OFF button is pressed to clear the trip condition:
16
Output Tripped
Press OFF to Reset
NOTE: If the metering cable is not connected between the control unit and the external loading unit,
the ammeter will not function, and the output will not switch on when the output ON push-
button is pressed. The metering cable between the control and external loading unit acts as
an interlock circuit.
The control unit automatically selects the correct metering ranges and protection for the
loading unit connected.
Current
Unit Range Voltage
5 min on/15 1 min on/15
Continuous
min off min off
The secondary injection output will only activate if the power and metering leads to the loading
unit are disconnected.
Ensure both the power and the metering leads are disconnected to the PLU-xk
before using the secondary injection outputs.
WARNING
1.3.4 Metering
The CU-Ps systems are fitted with a memory ammeter that holds the output current’s reading
at the precise moment that the output circuit is switched off. In timing modes where the contact
inputs are used to signify the end of a test, the last valid current before the contacts changed
state is held. This also holds true for the current operated timer mode. The ammeter will
capture and calculate the rms of a single cycle of output current.
17
The output metering ranges for the loading unit depend on the loading unit connected. The
metering ranges are identified as 10%, 50% and 100% on the control unit. These relate to the
maximum current that is available from the loading unit (on a PLU-6k the metering ranges are
600A, 3000A and 6000A when connected in series mode). When using the 0.2s, 0.5s and 1s
pulse modes the trip level is doubled e.g. the PLU-6k will trip at 12000A using all the pulse
modes except the 2s range.
1.3.4.1 Loading Unit Ammeter Ranges when set for series connection
Metering full
Loading unit Metering range Accuracy Trip current
scale
1.3.4.2 Loading Unit Ammeter Ranges when set for parallel connection
Metering full
Loading unit Metering range Accuracy Trip current
scale
Ammeter
Unit Accuracy Trip current
range
18
1.3.4.4 Auxiliary Meter Ranges
The CU-Ps has an auxiliary metering input with 300V/5A inputs. This can additionally
measure the phase angle between output current and auxiliary input or the ratio between
output current and auxiliary current.
Two inputs are provided, one for voltages up to 300V and the other for currents up to 5A. The
input in use is automatically selected by the unit. Do not connect to both inputs
simultaneously.
19
Auxiliary metering
Full scale Function
range
20
1.3.5 Timing System
The CU-Ps systems are fitted with an integrated timing system linked to the output and the two
sets of contact inputs. The system is highly flexible and allows for the timing of all common
protection devices and trips. The timer may also be used to time external events not linked to
the output of the set. The timer is auto-ranging.
Full details of operating the timer are given in section 2.
Off - - -
In current operated mode timing results obtained with test currents below 20% of the selected
ammeter range are of doubtful accuracy and should be ignored.
The CU-Ps systems have two contact inputs which are used to start and stop the timer
depending on the mode selected. Each input has a connection for volt-free contacts and for
triggering by a DC voltage. In each case, the input auto-selects for normally open or normally
closed contacts. The contact state is shown by an LED (off when the contact is closed, on
when the contact is open).
The maximum open circuit voltage across the contact input is 24V, and the short circuit current
through the contacts is limited to 20mA.
The contact inputs are fully isolated.
21
1.4 Displayed Values and Messages
Output Tripped
Press OFF to Reset
22
Over Temperature
Output Disabled
Figure 1.4.5 Secondary injection selected with loading unit power lead plugged in to CU-Ps
Figure 1.4.6 Primary injection selected with loading unit not connected
Press OFF to
continue
23
1.5 Primary Current Injection Lead Sets
1.5.1 Description
The optional 3000AL, 4000AL, 5000AL, 6000AL lead sets supplied for use with the CU-Ps are
made up from several 70mm2 cores and have different continuous and intermittent ratings.
The rating is also affected by the arrangement of the individual 70mm2 cables making up the
high current cable. The leads are supplied with the cables strapped together, but to achieve
their maximum rating the straps must be cut, and the cores laid out side by side whilst testing.
5 minutes on/15
1 sec on/1
Continuous rating minutes off
minute off rating
Lead set type rating
Cores strapped Cores laid out Cores strapped Cores strapped
together flat together together
CAUTION
The cables and terminals will become hot in use. Ensure adequate cooling time is allowed
before touching cables or connectors after tests.
Note: The output leads should not be rested against any sharp edges whilst testing. The insulation
on the cables softens as it heats up, and it is possible for sharp edges to damage the
insulation on the cable under these circumstances. Eddy current heating may occur in ferrous
metals that the pair of cable rests against, and this could heat the cable insulation further.
24
1.5.2 Factors Affecting Maximum Output Current
The maximum output current obtainable from each tap of the loading unit output depends on
the following factors:
Lead impedance
Lead length
Load impedance
The lead impedance is often dominant in defining the maximum current that may be injected
into the load. The cross-sectional area of the leads and the lead layout have a large effect on
impedance.
Figure 1.5 shows the ideal lead layout for the maximum current obtainable from a CU-Ps and
PLU-6k with a 3m 5000AL output lead set.
25
1.6 Overload Protection
The CU-Ps is fitted with a range of overload protection devices:
Location Protection
1.7 Construction
The CU-Ps control unit is housed in a robust steel case with castors for mobility. The front
panel is protected by a steel cover which is fixed to the main case with catches. The unit is
also fitted with steel handles at each end of the main chassis.
The external loading units, both the PLU-5k and PLU6-k, are housed in a steel case which is
similar in construction to the CU-Ps control unit. The loading unit is not fitted with a protective
cover.
26
1.8 Installation
The CU-Ps and associated loading units are designed for use in an indoor environment.
Before installation, a suitable mains connector must be connected to the 3-core mains input
cable provided. The connector and supply must be rated for 100A. It is also important to
ensure that the unit is adequately earthed. It is suggested that the earth stud on the side of the
unit is connected to a low impedance local earth. This is essential if the unit is used in a sub-
station environment.
The CU-Ps series control units and PLU series loading units are heavy. Avoid
lifting.
WARNING
27
2 OPERATION
This chapter describes how to use the CU-Ps systems in a variety of applications. Specific
examples are given in the applications section.
The connections between the CU-Ps and loading unit are shown in figure 2.1.
It is vital to ensure that secure, low impedance connections are made between
the output of the loading unit and the object under test. Ensure that the output
WARNING cables are suitably rated for the test current to avoid danger of fire. If the
connection to the load is broken whilst current is flowing, arcing may occur.
28
The output terminals and test leads may become hot during use. Allow
adequate time to cool after the test before touching.
CAUTION
If the supply earth to the CU-Ps is of doubtful integrity, the earth terminal on the CU-Ps should
be connected to a solid local earth.
The loading unit output from the CU-Ps control unit is ONLY for connection to a T&R Test
Equipment PLU series loading unit. The loading unit provides isolation from the mains.
The main output is switched on and off using the ON and OFF pushbuttons. The current level
is controlled by the main output control and protected by the output circuit breaker.
Never break the high current output circuit when the output is switched on
– this may cause arcing.
WARNING
2.1.1 Connections
Ensure that the unit is switched off and the test object is isolated and grounded before making
any connections.
Configure the loading unit for either parallel or series output depending on the voltage and test
current required. Ensure that all the nuts are fully tightened. See figure 1.3.1 for connection
details.
Connect the loading unit to the control unit as shown in figure 2.1. When switched on the
control unit will automatically detect the loading unit type.
Select the desired output on the loading unit; the unit will ask if the unit is connected in parallel
or series configuration. Press the ON button for Series or the OFF button for Parallel mode.
Set the metering range switch to 10%, 50% or 100%. These ranges refer to % of maximum
rated current of the connected loading unit, so for an PLU-5k 100% is 5000A and for an PLU-
6k 100% is 6000A.
As shown in Fig 2.1, one output lead always connects to the link between terminal 1 dand 5,
and the other connects to the link between terminal 4 and 8. Connect the output cables to the
test object.
After testing, the output terminals and leads may be hot. Allow to
cool before touching connections.
HOT
29
2.1.2 Testing
Always start the first test with the output control knob at zero to ensure that the test object is
not subjected to an unintentional over-current.
Switch the output on using the ON pushbutton and then increase the output current to the
desired test current. If you cannot achieve the desired test current, one of the following will be
limiting the current:
Output leads in a large loop – minimising the area in the loop of the output leads will
maximise the current available.
Output leads of insufficient cross-sectional area. Either use thicker output leads or use
two output leads per connection.
30
2.2 Secondary Current Injection
The secondary current injection output of the CU-Ps allows currents of up to 100A to injected
for testing relays and trips.
To use the secondary injection output the loading unit power and metering
leads must be disconnected and one of the secondary injection metering
ranges selected.
2.2.1 Connections
Ensure that the unit is switched off and the test object is isolated and grounded before making
any connections.
Connect the test object as shown in figure 2.2. The contact/timer connections will vary
depending on the device type.
Set the ammeter range switch to SEC. OUTPUT 10A, 20A or 100A.
Connect the supply lead to the mains and switch the supply circuit breaker on.
31
2.2.2 Testing
Always start the first test with the output control knob at zero to ensure that the test object is
not subjected to an unintentional over-current.
Switch the output on using the ON push-button and then increase the output current to the
desired test current.
32
2.3 Timing System
The CU-Ps timing system is closely integrated with the main output and is very flexible.
A summary of the start and stop events for the timer is shown in the following table:
Single Contact
C1 1st change
using C1 1st change C1 2nd change Auto-recloser
(timer start)
Contact 1
33
The timer resets automatically when the output ON push-button is pressed. In each mode that
the timer is active, the output of the unit must be switched on to arm the timer.
Each contact channel has a contact input for volt-free contacts and a VDC input for DC
voltages. The VDC input may be used to trigger the timer from a DC voltage. This will trigger
from either the voltage switching from zero (0VDC) to 24-240VDC or 24-240VDC to zero. The
voltage must be connected with positive to the red VDC terminal and negative to the blue
COM terminal.
34
Approximate timer
Loading unit Metering range Range full scale
start/stop current
10A 10A 2A
Secondary
20A 20A 4A
Injection from
CU-Ps
100A 100A 20A
2.3.2.1 Connections
Ensure that the unit is switched off and the test object is isolated and grounded before making
any connections.
Connect the loading unit to the control unit as shown in figure 2.1. In the case of the
secondary injection output, make the connections shown in figure 2.2.
35
Set the ammeter range switch to one of the main output ranges (10%, 50% or 100%). Connect
the output cables to the desired output on the loading unit and to the test object.
Connect the supply lead to the mains and switch the main supply switch on. The display will
come on, showing the unit type and loading unit type whilst starting up.
2.3.2.2 Testing
It is advisable to make a preliminary test on the test object, starting at zero voltage, in order to
test the load impedance, before performing the test with output control set at higher values.
Therefore, ensure the output control knob is fully anti-clockwise before switching on.
Ensure the timer mode switch is in the off position and depress the ON push-button. Increase
the current by rotating the output control knob in a clockwise direction until the desired current
is indicated on the ammeter. Press the output OFF push-button.
Connect the test object contacts to the contact terminals on the test set, select the internal
start timer mode. If the test object has no auxiliary contacts (e.g. thermal breakers), it will be
necessary to use the current operated timer mode.
When the output ON push-button is pressed, the following will occur:
a. The timer will start and current will flow through the test object.
b. When the test object's contacts change state, the timer will stop, and the test current
will be automatically switched off.
Time
Date
Main output current
Timer result
Comment
36
2.4.1 USB key
A standard USB flash memory key is used to store the results files. The unit has been tested
with keys up to 8Gb in size.
Insert the USB key into the upper USB socket on the unit before starting to test. Most USB
memory devices have an LED that indicates when the device is accessed. This will flash when
a result is written.
Do not unplug the USB key whilst data is being written – data loss will result.
hh:mm:ss dd-mm-yy
10:13:24 15-12-08
37
Esc Lose the changes made to the comment since entering comment mode and
revert to the last comment entered.
(backspace) Delete the character to the left of the cursor.
Del Delete the character under the cursor.
(cursor right) Move cursor one character to the right.
(cursor left) Move cursor one character to the left.
Shift+ Move cursor to end of comment.
Shift+ Move cursor to start of comment.
End Move cursor to end of comment.
Home Move cursor to start of comment.
The following keys have no effect: caps lock, shift lock, alt, Windows key, tab, , , page
up/down, F1-F12.
2.4.4 Auto-store
Set the STORE RESULTS switch to AUTO-STORE.
Set TIMER MODE to internal start, 1 contact, 2 contacts or current operated.
A result record is added to the current result file whenever the timer stops (this includes when
the output is switched off in internal start mode).
If results are to be stored and are not dependant on the timer, set the timer mode to internal
start, and press the OFF button for the main output when a result is to be stored.
Results are not stored when the timer is set to OFF. This allows the output current to be set
without storing any results to the output file.
The example below shows data stored when testing a relay.
"CU-Ps ","V0.12","C00","P1","A1"
"Time","Date","Main A","Timer","Aux A","Aux V","Phase","Freq Hz","Aux Range","Comment"
"11:18:40","28/10/19","2.38","7.961","0.000","0.0","0.0","0.00","6","CDG11 relay"
"11:18:49","28/10/19","3.73","5.252","0.000","0.0","0.0","0.00","6","CDG11 relay"
38
2.4.6 File formats
Results file format
The results file is in CSV (comma separated value) format. The first line of the file details unit
type, software version and configuration information. The second line specifies column
headings for the data, and the third line onwards is data.
"CU-Ps ","V0.12","C00","P1","A1"
"Time","Date","Main A","Timer","Aux A","Aux V","Phase","Freq Hz","Aux Range","Comment"
"11:18:40","28/10/19","0.00","0.000","0.000","0.0","0.0","0.00","6","Comment – up to 39
chars"
39
3 APPLICATION NOTES – TESTING SPECIFIC DEVICES
3.1.2 Connections
Connect the relay current coil to the most appropriate output on the CU-Ps (5V 100A or 15V
33A).
Connect the trip contacts on relay under test to contact set 1 on the CU-Ps.
41
Ensure that the output control is in the zero position.
Press the output ON push-button and increase the output current to the desired level.
Press output OFF push-button.
Select the internal start position on the timer mode switch.
Press the output ON push-button.
When the device under test trips the timer will stop, and the output will be switched off
automatically.
3.2.2 Connections
Connect current output from loading
unit to desired input on device under
test.
Connect trip contact on the relay
under test to contact set 1 on the
control unit.
42
3.2.4 Using Pulse Mode to Set the Current
When setting the current into the load pulse mode may be used to avoid injecting current for
long periods of time. Set the timer mode to pulse 0.2s and inject a series of pulses, adjusting
the output current until the desired current is set. Set the timer mode to internal start and then
press the ON push-button.
3.3.2 Connections
Connect current output from
loading unit to desired input on
device under test.
Connect the trip contact on the
relay under test to contact set
1 on the control unit.
43
3.4 Timing Devices with NO Auxiliary Contacts
3.4.2 Connections
Connect current output from
loading unit to desired input on
device under test.
44
3.5 Using the Control Unit as a Single Contact Timer
3.5.2 Connections
Connect contact to be timed to contact set 1.
3.6.2 Connections
Connect contact to start timer to contact set 1.
Connect contact to stop timer to contact set 2.
45
3.7 CT Polarity
3.7.2 Connections
Connect current output from
loading unit to busbar through
CT primary (or loop lead
through the CT). Ensure that
CT P2 connects to COM
terminal on loading unit.
Connect S1 & S2 on CT
secondary to CU-Ps auxiliary
metering input S1 & S2. Check
that CT S1 connects to COM
input.
46
3.8 CT Ratio
3.8.2 Connections
Connect current output from
loading unit to busbar through
CT primary (or loop lead
through the CT).
Connect S1 & S2 on CT
secondary to CU-Ps auxiliary
metering input S1 & S2.
47
4 MAINTENANCE
The following actions should only be taken by suitably qualified
and competent service personnel. Before removing the unit from
its case, ensure that the unit is disconnected from the mains.
WARNING Under no circumstances connect the unit to the mains whilst it is
removed from its case.
49
5 STANDARD ACCESSORIES
51
6 OVERALL PERFORMANCE SPECIFICATION
Metering full
Loading unit Metering range Accuracy Trip current
scale
53
6.3.2 Secondary Injection Current Output
Ammeter
Unit Accuracy Trip current
range
54
7 REVISION
Product / Type: Primary Current Injection – CU-Ps & PLU Loading Units
File: CU-Ps manual v1.doc
Author: G Bond
Date: 17.06.19
55
Drawings Required
56