Summary of Contents for Vanguard Instruments Company CT-6500 2 Series
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OPERATING INSTRUCTIONS for the CT-6500 Series 2 Digital Circuit Breaker Analyzer Vanguard Instruments Company 1520 South Hellman Avenue Ontario, California 91761, USA TEL: (909) 923-9390 May 2008 FAX: (909) 923-9391 Rev 2...
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CT-6500 test unit. To ensure that all designed safety features are maintained, it is recommended that repairs be performed only by Vanguard Instruments Company’ s factory personnel or by an authorized repair and service center. Unauthorized modifications can cause serious safety hazards and will nullify the manufacturer's warranty.
CT-6500 Series 2 Operating Instructions Table of Contents 1.0 Introduction .......................... 7 2.0 CT-6500 Description ......................8 2.1 Contact Timing Channels ..................8 2.2 Analog Voltage Monitoring Channel ................. 8 2.3 Digital Voltage Monitoring Channel ................8 2.4 Trip/Close Current Monitoring ................... 8 2.5 Travel Transducer Input Channels ................
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CT-6500 Series 2 Operating Instructions 9.2 Printing Tabulated Timing Results Using the Thermal Printer ........ 33 9.2.1 Tabulated Results Interpretation ................35 9.3 Get Graphic Timing Results Using the Thermal Printer .......... 36 9.4 Save Timing Test Records in the EEPROM ............41 9.5 Printing Timing Test Record Directory Stored in the EEPROM .......
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CT-6500 Series 2 Operating Instructions List of Figures Figure 1.0 CT-6500 Control Panel ..................12 Figure 2.0 CT-6500 Operating Voltage Setting ..............18 Figure 3.0 Contact Cable Connection ..................20 Figure 4.0 Series Contact Cable Connection ................. 21 Figure 5.0 DC Trip and DC Close, Initiate Circuit Cable Hook-Up ......... 22 Figure 6.0 DC Trip and AC Close, Initiate Circuit Cable Hook-Up .........
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CT-6500 Series 2 Operating Instructions List of Tables Table 1.0 CT-6500 Controls and Displays ................13 Table 2.0 CT-6500 Cable set ....................17 Table 3.0 Open Operation With No Insertion Resistors ............28 Table 4.0 Open Operation With Insertion Resistor ..............29 Table 5.0 Close-Open Operation Using Contact Channel #1 ..........
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CT-6500 Series 2 Operating Instructions Appendix APPENDIX A ITE Circuit Breaker model 14.4K Timing Chart ..........71 APPENDIX B CLOSE-OPEN Timing Chart for ITE Circuit Breaker Model 14.4K ....72 APPENDIX C CLOSE-OPEN Tabulated Report for ITE Circuit Breaker Model 14.4K ..... 73 APPENDIX D OPEN-CLOSE Timing Chart for ITE Circuit Breaker Model 14.4K ....
CT-6500 Series 2 Operating Instructions 1.0 Introduction The CT-6500 is the fifth generation microprocessor-based, digital time travel circuit breaker analyzer developed by Vanguard Instruments Co. The CT-6500 can fully analyze a utility circuit breaker’ s performance by measuring: the contact time, stroke, velocity, over-travel, bounce-back and contact wipe.
The CT-6500 will interface with a linear, a rotary and other special transducers developed by Vanguard Instruments Company. Please refer to Appendix I for more details. 2.6 Breaker Initiate Capability A built-in, solid-state, initiate device allows the user to operate the circuit breaker from the CT- 6500.
CT-6500 Series 2 Operating Instructions breaker's AC or DC control circuit. . The CT-6500 initiate circuit is capable of carrying up to 30 amperes. Separate 5 Ampere, fast-blow fuses protect each trip and close circuits. An interlock “ ARM” switch action is required by the operator to operate the initiate circuit. 2.7 Built-in Thermal Printer The breaker's contact analysis results can be printed in both tabular and graphical formats by a built-in, 4.5 inch wide, thermal printer.
CT-6500 Series 2 Operating Instructions The CT-6500 can detect insertion resistors ranging from 10 to 7,000 Ohms. Resistances over 7,000 Ohms are detected as an open contact. 3.2 Mechanical Measurement Results In the Time Travel Mode, the digital transducer channels provide the following test results: - CB contact stroke - CB contact over travel - CB Contact bounce back...
CT-6500 Series 2 Operating Instructions transducer and dry contact channels. See section 9.13 for Slow-Close test Procedure. 4.0 Test Result Graphics 4.1 Thermal Printer Graphic Printout A 4.5 inch wide, built-in, thermal printer can output graphic waveforms of the contact channels, travel curves and actuator-coil currents.
CT-6500 Series 2 Operating Instructions 5.0 CT-6500 Controls and Display Before using the CT-6500, users should become familiar with all of the controls and display indications. The keypad and display are used to operate the CT-6500. Figure 1.0 represents the control panel and the numbered lines pointing to each control and indicator refer to Table 1.0, which describes the function of each control and indicator.
CT-6500 Series 2 Operating Instructions Table 1.0 CT-6500 Controls and Displays Fig. 1.0 PANEL MARKING FUNCTIONAL DESCRIPTION Index CONTACT INPUT Female connectors for the contact channels. 1-11 & (C1–C12) 0-300V 3-pin connector. V1 voltage input channel is dedicated to monitor circuit breaker DC power supply or coil voltages.
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CT-6500 Series 2 Operating Instructions Table 1.0 CT-6500 Controls and Displays (Continued) Fig. 1.0 PANEL MARKING FUNCTIONAL DESCRIPTION Index no. RS-232C RS-232C serial computer interface port. 1-9, 0, ENTER, START, 16 button keypad. The keys are momentary-contact, STOP, CLEAR, pushbutton switches. Allows users to make menu selections, enter alphanumeric data, adjust the LCD ? PAPER LCD, contrast and reposition the printer paper.
CT-6500 Series 2 Operating Instructions 6.0 CT-6500 Analyzer Specifications PHYSICAL SPECIFICATIONS 16” W by 11” H by 14” D (40.6 cm x 29.9 cm x 35.6 cm) Weight: 25lbs (11.3Kg). 8 Amperes, 90-120Vac or 200-240Vac (selectable), 50/60 Hz. INPUT POWER DRY-CONTACT INPUT 3 or 6 or 12 contact channels.
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CT-6500 Series 2 Operating Instructions Operating: -10 ? C to 50 ? C (+15 ? F to +122 ? F). ENVIROMENT Storage: -30 ? C to 70 ? C (-22 ? F to +158 ? F). Hard shipping case for CT-6500. OPTIONS Hard shipping case for Travel Transducers.
CT-6500 Series 2 Operating Instructions 7.0 CT-6500 Special Features 7.1 CT-6500 Supplied Cables Table 2.0 CT-6500 Cable set ITEM DESCRIPTION GND Cable Power Cord Contact Cable 3 or 6 or 12 Contact Extension Cable 3 or 6 or 12 Transducer cable Voltage &...
CT-6500 Series 2 Operating Instructions 7.2 CT-6500 Operating Voltages The CT-6500 operating voltage is selectable between 110-120Vac, 50/60 Hz or 220- 240Vac, 50/60 Hz. Operating voltage is set by the voltage selection switch as shown in Figure 2.0. To change the voltage setting, remove the CT-6500 from the case, locate the voltage setting switch and set the new operating voltage.
CT-6500 Series 2 Operating Instructions 7.5 CT-6500 Printer and Printer Paper The built-in, thermal printer uses 4.5 inch wide, thermal paper for printing test results. To maintain the highest, quality printing and to avoid paper jamming, it is highly recommended that the thermal paper be supplied by the factory.
CT-6500 Series 2 Operating Instructions 8.0 Test Hook-up Connections 8.1 Contact Cable Hookup A typical, contact cable connection to a circuit breaker is shown in Figure 3.0. Red and black clips are connected across the circuit breaker contact phase A, B and C. A typical circuit breaker with series contacts is shown in Figure 4.0.
CT-6500 Series 2 Operating Instructions 8.2 Initiate Cable Hookup The CT-6500 will trip or close breakers through a solid-state device, which will operate on any AC or DC control voltage ranging from 10 to 300 Volts. Both the trip and close circuits are protected by 5 Ampere fuses.
CT-6500 Series 2 Operating Instructions 8.3 Analog Voltage Monitor Hookup The analog voltage input, “ V1” permits the user to monitor a breaker's DC control voltage during an operation. The analog voltage input will record the nominal DC voltage at no load and the minimum DC voltage while the Trip or Close coil is energized.
CT-6500 Series 2 Operating Instructions 8.5 External Trigger Input The External Trigger Mode enables the user to start recording data when the CT-6500 senses a voltage. A typical application for the External Trigger Mode is to time a circuit breaker in a close operation and to start timing only when the close coil is energized, thus bypassing the 52X relay delay time.
CT-6500 Series 2 Operating Instructions 8.6 Digital Transducer Connection A typical transducer connection is shown on Figure 9.0. See Appendix I for more transducer connections. Figure 9.0 Transducer Connection...
CT-6500 Series 2 Operating Instructions 9.0 Operating Procedures The main steps to time a circuit breaker are listed in Figure 10.0. HOOKUP CT-6500 1. GROUND THE CT-6500 (See NOTE) 2. CONNECT CT-6500 CABLES TO BREAKER 3. INSTALL TRANSDUCER WITH CABLE APPLY POWER 1.
CT-6500 Series 2 Operating Instructions 9.1 Timing a Circuit Breaker The CT-6500 will initiate the breaker operation and do a timing test on the following operations: - OPEN - CLOSE - OPEN-CLOSE - CLOSE-OPEN - OPEN-CLOSE-OPEN NOTE 1. The CT-6500 can start the OPEN-CLOSE operations without a delay or by using a programmable delay between the OPEN and CLOSE commands.
CT-6500 Series 2 Operating Instructions 9.1.1 Timing an OPEN Operation (With No Insertion Resistors) The following example shows the steps for performing an Open Test on a circuit breaker. Table 3.0 Open Operation With No Insertion Resistors STEP OPERATION ACTION DISPLAY READY TIMER FOR BREAKER OPERATION..
CT-6500 Series 2 Operating Instructions 9.1.2 Timing an OPEN Operation with Insertion Resistors The CT-6500 can time breakers with insertion resistors. The insertion resistor can range from 10 to 7,000 Ohms. Any insertion resistor more than 7,000 Ohms is detected as an open circuit.
CT-6500 Series 2 Operating Instructions NOTE One-second timing windows are used for breaker timing. The 10 and 20 second timing windows are used for slower timing events (i.e. timing circuit-switchers). The user can set the CT-6500 to print tabulated and graphical reports automatically after it completes a test.
CT-6500 Series 2 Operating Instructions 9.1.4 Timing OPEN-CLOSE-OPEN Operation The OPEN-CLOSE-OPEN operation requires the user to enter two time-delays between the circuit breaker operations. The time delays are in millisecond intervals. The first delay is from the first OPEN command to the CLOSE command. The second delay is from the CLOSE command to the second OPEN command.
CT-6500 Series 2 Operating Instructions 9.2 Printing Tabulated Timing Results Using the Thermal Printer The circuit breaker timing results can be printed on the thermal printer by using the steps listed in Table 7.0. A typical circuit breaker timing result printed on thermal printer is shown in Figure 11.0. Table 7.0 Printing Tabulated Results STEP OPERATION...
CT-6500 Series 2 Operating Instructions 9.2.1 Tabulated Results Interpretation 1. Timing Record is time and date stamped by the CT-6500. 2. Timing record header information (Company, Substation name, Circuit, etc) is also saved with test record. 3. Timing test type (OPEN, CLOSE, O-C, C-O, O-C-O) is identified. A CLOSE timing shot is shown in Figure12.0.
CT-6500 Series 2 Operating Instructions 9.3 Get Graphic Timing Results Using the Thermal Printer Selecting the “ PLOT FULL CHART” command will plot the timing chart as follows: - Timing chart from 0 to 1000 ms with one second window and 50 ms time markers. - Timing chart from 0 to 10 seconds with 10 second window and 500 ms time markers.
CT-6500 Series 2 Operating Instructions Figure 13.0 Expansion Graph From 0 to 300ms Printed on Thermal Printer NOTE Analysis point # 1 and point #2 are shown on chart.
CT-6500 Series 2 Operating Instructions Figure 14.0 Graphical Interpretation of an Open Timing Shot Figure 15.0 Graphical Interpretation of a Close Timing Shot...
CT-6500 Series 2 Operating Instructions 9.4 Save Timing Test Records in the EEPROM Use the steps in Table 9.0 to save a timing test record in the FLASH EEPROM. Table 9.0 Save Timing Test Record In EEPROM STEP OPERATION ACTION DISPLAY SELECT SETUP MENU.
CT-6500 Series 2 Operating Instructions 9.5 Printing Timing Test Record Directory Stored in the EEPROM The user can obtain a timing-record directory that was stored in the CT-6500’ s FLASH EEPROM by using the steps in Table 10.0. Table 10.0 Print Timing Test Record Directory STEP OPERATION ACTION...
CT-6500 Series 2 Operating Instructions 9.6 Recalling a Timing Test Record The following steps in Table 11.0 are used to recall a timing test record stored in the EEPROM to the working memory. Once a test record is recalled, the user can get a printout of the test results from the thermal printer.
CT-6500 Series 2 Operating Instructions 9.7 Deleting a Timing Test Record Users can delete a specific timing test record or all of the timing test records from the CT- 6500’ s EEPROM by using the steps in Table 12.0. Table 12.0 Deleting a Timing Record STEP OPERATION ACTION...
CT-6500 Series 2 Operating Instructions 9.8 Test Record Description The CT-6500 has the capability for users to enter the breaker and other identification information. The data usually consists of the name of the company, station, circuit and manufacturer. Other information could be the breaker's model, serial number and the operator's name.
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CT-6500 Series 2 Operating Instructions Table 13.0 Entering Test Record Identification Header (Continued) STEP OPERATION ACTION DISPLAY ENTER BREAKER MODEL. PRESS KEYS 0-9 AND SERIAL PRESS "ENTER" KEY. XXXX ? / ? TO POSITION "ENTER" TO ACCEPT ENTER SERIAL NUMBER. PRESS KEYS 0-9 AND OPERATOR PRESS "ENTER"...
CT-6500 Series 2 Operating Instructions 9.9 Computer Interface Each CT-6500 has one RS-232C and one USB port, where the Circuit Breaker Analyzer Software Series 2 package provided with each CT-6500, enables an IBM-compatible personal computer to communicate with the unit. The software operating under Windows XP environments allows the user to transfer timing records stored in the EEPROM into the computer.
CT-6500 Series 2 Operating Instructions 9.10 Breaker Travel Analysis The CT-6500’ s travel analysis includes the breaker’ s stroke, over-travel, bounce-back, contact- wipe distances and contact velocity calculations. 9.10.1 Breaker Stroke The CT-6500 uses a digital transducer to measure a breaker's contact stroke, over-travel and bounce-back.
CT-6500 Series 2 Operating Instructions 9.10.7 Analysis Point No.1 (AP1) Three selections are available to the user for setting analysis point No. 1: 1. PERCENTAGE OF STRK 2. DISTANCE FROM CLOSE 3. CONTACT #1 a. Percentage of Stroke Percentage of stroke is the distance based upon the percentage of the total breaker’ s stroke distance.
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CT-6500 Series 2 Operating Instructions NOTES 1. Average velocity through the arc zone is calculated by using the following formula: = Distance Time 2. The breaker contact velocity can be recalculated based upon the data stored inside the memory after any new analysis points were selected. The user does not need to operate the breaker again to acquire new contact velocity data after changing the analysis points because the new velocity is then calculated from the travel data stored in memory from the last operation.
CT-6500 Series 2 Operating Instructions 9.10.9 Set-Up Open Analysis Points The following procedure allows the user to set the analysis points to calculate velocity of the circuit breaker in the open operation. The open analysis point #1 is 1.00 inch from the fully closed position of the circuit breaker.
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CT-6500 Series 2 Operating Instructions NOTES 1. If an entry is not correct, re-enter the digits until the screen shows the desired numbers, then press the “ ENTER” key. 2. Analysis Point #1 is 1.00 inch from the fully closed position. 3.
CT-6500 Series 2 Operating Instructions 9.11 Select English or Metric Measurement Unit. The CT-6500 supports and displays both English and Metric calculations from the breaker's travel parameters such as the stroke, velocity and other parameters. The user can switch from one system to the other by following the steps in Table 16.0. Table 16.0 Select English or Metric Procedure STEP OPERATION...
CT-6500 Series 2 Operating Instructions 9.13 Slow-Close Test The CT-6500 offers a unique feature called a "Slow-Close" test. The test permits users to measure the distance a breaker's contact travels from the fully opened position to the point of contact or "touch" position, and the contact wipe or penetration distance. The test requires the operator to manually jack the breaker's contact from the fully open position to the fully closed position.
CT-6500 Series 2 Operating Instructions Figure 18.0 Typical Slow-Close Test Report NOTE The breaker’ s stroke is the sum of the contact touch and contact wipe distances.
CT-6500 Series 2 Operating Instructions 9.14 Transducer Self-Test The operator can check the transducer electronics by connecting the transducer to the CT- 6500 (D1 or D2 or D3) and running a “ Test Transducer” diagnostics. Table 19.0 Performing a Transducer Self Test STEP OPERATION ACTION...
CT-6500 Series 2 Operating Instructions 9.15 Check Cable Hookup The following steps allow the user to check the CT-6500 contact cable connections to the circuit breaker. Table 20.0 Checking the Cable Hookup STEP OPERATION ACTION DISPLAY SELECT DIAGNOSTIC. PRESS # 4 KEY. 1.
CT-6500 Series 2 Operating Instructions 9.16 Set CT-6500 Time and Date The CT-6500 has an internal clock with a lithium battery. The clock's time and date is displayed on the LCD screen. When a timing record is stored in the EEPROM, the time and date are also stored along with the record.
CT-6500 Series 2 Operating Instructions 9.17 Automatic Print Setting The CT-6500 can be set to print graphs and tabulated results automatically after each timing shot. To turn on the “ Auto Print Results” mode, follow the steps in Table 22.0. Table 22.0 Automatic Print Setting STEP OPERATION...
CT-6500 Series 2 Operating Instructions 9.18 Selecting 50 Hz or 60 Hz for Contact Time Reading Tabulated contact time is printed in both milli-seconds and cycles. The cycle readings can be in 50 Hz or 60 Hz. The example below shows the steps to set for 60 Hz readings. Table 23.0 Selecting 50Hz or 60 Hz for Contact Time Reading STEP OPERATION...
CT-6500 Series 2 Operating Instructions 9.19 CT-6500 Channel Configuration The CT-6500 is available with 3 or 6 or 12 contact inputs. Most common timing conditions require the user to use only 3 contact timing channels and one travel transducer channel. There is no need to print more than 3 timing channels and one transducer channel on the graphic and tabulated report.
CT-6500 Series 2 Operating Instructions 9.20 Print Test Record Data Print data command allows the user to print the hexadecimal timing data collected by the CT- 6500. This feature is mainly for factory testing. The CT-6500 collects 20,000 data points in the one-second timing window.
CT-6500 Series 2 Operating Instructions 9.21 Transducer Encoder Filter Setting In a typical 1 second timing record, the CT-6500 records 20,000 data points for each of the Contact channels (C1-C6), Digital transducer channels (D1-D3), Voltage input channels (V1 & V2), CT channel, DCR channel, Resistor transducer channel and Initiate current channel. In most circuit breaker timing application, the breaker activities end after 200 ms.
CT-6500 Series 2 Operating Instructions 9.22 Contact Filter Setting The contact filter setting is applicable for timing shots with insertion resistors only. The CT-6500 automatically detects the contact time using its own algorithm. However, manual setting for contact time calculation is made available to the user. The filter setting of 1 allows the CT-6500 to pick up the first contact transition time after the resistor contact activity is detected.
CT-6500 Series 2 Operating Instructions Filter Setting @ 1 will select this contact time Filter setting @ 300 will select this contact time. Filter Setting @ 1 will select this contact time Filter setting @ 300 will select this contact time. Figure 22.0 Contact Filter Setting Illustration...
CT-6500 Series 2 Operating Instructions 9.23 Running CT-6500s in Tandem For timing application requiring more than 6 timing contact channels, the user can use two or more CT-6500s to time a circuit breaker. A typical application is to use one CT-6500-6 and one CT-6500-3 to create a 9 contact timing application.
CT-6500 Series 2 Operating Instructions 10.0 CT-6500 Trouble Shooting Guide Problems Suggestion 1. CT-6500 will not trip nor close the breaker. - Make sure you hold the “ ARM” switch down during each test. - Check the OPEN or CLOSE fuses. - Check the initiate leads.
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CT-6500 Series 2 Operating Instructions Problems Suggestion 9. How does one review the current analysis setting? - Go to SETUP (Press key #3). - Select Analysis (Press key #1). - Select PRINT SETTING (Press key #3). The CT-6500 will print out the current AP1 & AP2 settings. 10.
CT-6500 Series 2 Operating Instructions APPENDIX B CLOSE-OPEN Timing Chart for ITE Circuit Breaker Model 14.4K Contact Touch Distance Peak To Peak Travel...
CT-6500 Series 2 Operating Instructions APPENDIX I CT-6500 Transducer Illustration Linear Transducer on an OCB Rotary Transducer on Alstom HE 1014 Circuit Breaker...
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CT-6500 Series 2 Operating Instructions Rotary Transducer on ABB HMB Mechanism Rotary transducer on Federal Pacific Circuit Breaker...