Megger DDA-1600 Operator's Instruction Manual
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Megger DDA-1600 Operator's Instruction Manual

Megger DDA-1600 Operator's Instruction Manual

Circuit breaker test set
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OPERATORS
INSTRUCTION MANUAL
For
CIRCUIT BREAKER TEST SET
MODEL DDA-1600
It is essential that this instruction book be read thoroughly by the operator of the test
equipment before putting the equipment in service.
Part No._ 50551
Rev. 1, 3/12/1998

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Summary of Contents for Megger DDA-1600

  • Page 1 OPERATORS INSTRUCTION MANUAL CIRCUIT BREAKER TEST SET MODEL DDA-1600 It is essential that this instruction book be read thoroughly by the operator of the test equipment before putting the equipment in service. Part No._ 50551 Rev. 1, 3/12/1998...
  • Page 2 Revision History Revision ECN # Date 03/11/97 3/12/98 27999 IMPORTANT The information and data contained within this instruction manual are proprietary property of AVO International. The equipment described herein may be protected by one or more U.S. patents. AVO International specifically reserves to itself all rights to such proprietary information as well as all rights under any such patent, none of which is waived by the submission of this instruction manual.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION I ............................ 1 INTRODUCTION ....................1 GENERAL DESCRIPTION ................ 2 SPECIFICATIONS..................3 SECTION II ........................... 5 DESCRIPTION of CONTROLS and INSTRUMENTATION ........5 GENERAL DESCRIPTION ................ 5 CONTROLS AND INSTRUMENTATION........... 5 SECTION III ..........................10 FRONT PANEL DISPLAY AND PROGRAMMING MENUS........ 10 Flow Diagram of Display Menus................

  • Page 4: Section I

    BULLETIN SECTION I INTRODUCTION GENERAL DESCRIPTION...

  • Page 5: Specifications

    SPECIFICATIONS DDA-1600 Specifications Input DDA-1600 460 V ± 5%, 60 Hz, 150 A A variety of input power options, including 415 V/50 Hz, 380 V/50 Hz, are available. Output Output Current Model Number Maximum Max. Amps Through an Max. Amps...
  • Page 6 Dimensions and Weight ModelNo. Module Weig t h Dimensions H x W x D (in.) H x W x D (cm.) DDA-1600 Control and 9.9 x 14.1 x 11.3 27 x 54 x 24.8 nstrumentation Power 45.4 14 x29 x 12.5 35.6 x 73.6 x 31.8...

  • Page 7: Section Ii

    SECTION II DESCRIPTION of CONTROLS and INSTRUMENTATION GENERAL DESCRIPTION AVO International Circuit Breaker Test Sets are portable high current units designed for testing and adjusting low voltage circuit breakers and other current actuated devices. The units incorporate a variable high current ac output, and uses the latest in Digital Signal Processing (DSP) technology to control the circuit breaker test sets as well as measure the reactions of the breaker under test.
  • Page 8 Front View Reverse View...
  • Page 9 DDA CONTROL PANEL TEST START Button - Energizes the output STOP Button - De-energizes the output. EXT. START Terminals - An external switch can be plugged into these terminals (blue) to provide remote initiation of the test set. TEST FUNCTION TIMER STOP MODE - Three modes of operation are available to control the output and timer operation.

  • Page 10: Section Iii

    TIMER STOP Terminals - These terminals (yellow) facilitate connection to a set of contacts on the device under test to monitor contact opening and closure. The timer stops and output is de- energized when the device operates (used in conjunction with the TIMER STOP MODES of N.O. and N.C).
  • Page 11 SER/PAR - When operating the unit with the output in a series configuration, this switch must be in the SERIES position in order for the ammeter to read the correct amount of output current. (See Section IV, 2, A for more details.) The default setting is PARALLEL. FRONT PANEL DISPLAY AND INDICATORS LCD Display Panel - This panel displays Output Amperage, Vac, and Time.

  • Page 12: Front Panel Display And Programming Menus

    SECTION III FRONT PANEL DISPLAY AND PROGRAMMING MENUS...

  • Page 13: Flow Diagram Of Display Menus

    Flow Diagram of Display Menus METERING DISPLAY All of the programmable menu options may be accessed by pressing the soft key underneath the word MENU in the metering display screen. When pressed, the following display will appear. MAIN MENU From the MAIN MENU the user may select programming menus to make adjustments to the LCD display contrast, SCR controls, or Acquisition control (current calculation method).

  • Page 14: Lcd Contrast Menu

    LCD CONTRAST MENU The LCD CONTRAST MENU provides two options for optimizing a user’s ability to view the display. Pressing the soft key directly beneath UP will cause the intensity of the display to be increased. Pressing the soft key directly beneath DOWN will cause the intensity of the display to be decreased.

  • Page 15: Pulse Duration And Firing Angle Menus

    PULSE DURATION AND FIRING ANGLE MENUS The PULSE DURATION MENU allows the user to program the number of cycles that the output of the test set will be energized during a momentary pulse. The number of cycles can be increased or decreased by pressing the soft keys directly beneath UP or DOWN. Pressing the soft key beneath EXIT will return the user to the previous menu.

  • Page 16: Acquisition Control Menu

    ACQUISITION CONTROL MENU The Acquisition Control MENU allows the user to select between two different current measurement methods. By pressing the softkey directly beneath either PEAK or RMS, the user selects which calculation will be used in displaying measured current on the metering display. PEAK measures the highest peak and multiplies it by a constant 0.707.

  • Page 17: Section Iv Input And Output Circuits

    SECTION IV INPUT AND OUTPUT CIRCUITS INPUT: INPUT VOLTAGE: The AVO International Circuit Breaker Test Sets are designed to operate on a single phase voltage source. If the nominal rated voltage source is not available, or if use at various locations requires the capability to operate the test set from several different input voltages an optional input autotransformer may be used (see Sales Bulletin for description).
  • Page 18 NOTE: For input currents exceeding 600 amperes, it is recommended that 2/0 cable be used and not exceed 50 feet in length. LENGTH OF INPUT LEADS DISTANCE FROM TEST SET TO POWER SOURCE FOUR TIMES (4X) RATED INPUT POWER FEET MINIMUM WIRE SIZE A.W.G.
  • Page 19 The wire sizes in this chart will result in voltage drops of ten volts or less...

  • Page 20: Series Or Parallel Output

    OUTPUT: SELECTION OF OUTPUT CONNECTIONS: Two output connections, parallel and series, provide various voltage and current ratings to adapt AVO International Circuit Breaker Test Sets to a wide variety of test circuit impedances. The test sets can be operated most efficiently by utilizing the parallel connection, which provides the HIGHEST CURRENT rating consistent with being able to obtain the desired test current.

  • Page 21: Series Connection

    Figure #1 SERIES CONNECTION Connect the S-Bar to output terminals 2 and 3. Connect test cables to terminals 1 and 4. S-Bar...

  • Page 22: Parallel Connection

    Figure #2 PARALLEL CONNECTION Jumper output terminals 1 and 3 together and output terminals 2 and 4 together Connect one test lead to the left side (terminals 1 and 3). Connect the other test lead to the right side (terminals 2 and 4). The Stab Adapter Plates connect output terminals 1 and 3 and terminals 2 and 4 together for parallel operation.

  • Page 23: Duty Ratings And Overload Capacities

    Duration of the overload is governed by thermal considerations within the test set. The maximum current available is determined essentially by the impedance of the load. The duty cycles of the CB-9110 and CB-9116 are as follows: DUTY CYCLES ON DDA-1600 CIRCUIT BREAKER TEST SET (Current Rating Through Circuit Breaker)

  • Page 24: Test Procedures And Test Set Operation

    TEST PROCEDURES AND TEST SET OPERATION UNIT INTERCONNECTION Use the following steps for interconnecting the unit. NOTE: When connecting to the power supply, always connect from load to source. Insure that the supply power is off. Connect all interconnecting cables. Connect the control cable from the Control and Instrumentation Section to the Power Section.

  • Page 25: Section V

    SECTION V TEST PROCEDURES FOR TESTING OF MOTOR OVERLOAD RELAYS Always refer to the manufacturer's literature applicable to the particular overload relay before testing. The test operator should be familiar with the operating characteristics of the relay, the tolerances applicable to the operating characteristics and any means of adjusting the relay.
  • Page 26 TESTING OF TIME DELAY: Connect the test set to a suitable source of power. Be sure that the ON/OFF Switch on the test set is OFF. Make sure the motor circuit is de-energized. Connect the output of the test set to the terminal of the heater of operating coil to be tested. (See Section IV, 2, B - SELECTION OF OUTPUT CONNECTION).
  • Page 27 Set the desired test current by rotation of the VERNIER CONTROL, and then pressing the START button per the following procedure. NOTE: Depending on the position of the OUTPUT SELECTOR Switch, the current may be increased by either clockwise or counter clockwise rotation of the VERNIER CONTROL (refer to chart of OUTPUT RANGES).

  • Page 28: Test Procedure For Testing Of Molded Case And Low Voltage Power Circuit Breakers

    Most modern low voltage power circuit breakers are of the "draw-out" type. These breakers should be tested using AVO International Model DDA-1600 equipped with the appropriate stabs to directly connect the breaker to the test set. When testing molded case breakers or any other breaker where leads are required to connect it to the test set, the leads should be as short as possible and twisted to minimize losses.
  • Page 29 TESTING OF TIME DELAY: Connect the test set to a suitable source of power. Be sure that the ON/OFF Switch on the test set is OFF. Make sure the line side circuit of the breaker to be tested is de-energized or disconnected. Close the breaker to be tested.
  • Page 30 Verify proper ammeter range. Set the desired test current by rotation of the VERNIER CONTROL, and then pressing the START button per the following procedure. NOTE: Depending on the position of the OUTPUT SELECTOR Switch, the current may be increased by either clockwise or counter clockwise rotation of the VERNIER CONTROL (refer to chart of OUTPUT RANGES).
  • Page 31 TESTING OF INSTANTANEOUS PICK-UP: Connect the test set to a suitable source of power. Be sure that the ON/OFF Switch on the test set is OFF. Make sure the line side circuit of the breaker to be tested is de-energized or disconnected. Close the breaker to be tested.

  • Page 32: Maintenance Of Protective Apparatus Maintenance Of Motor Overload Relays

    MAINTENANCE OF PROTECTIVE APPARATUS MAINTENANCE OF MOTOR OVERLOAD RELAYS APPLICATION: The primary function of the motor overload relay is to prevent operation of a motor for too long a period of time to prevent damage to that motor when an overload condition exists. In general, motor starters are applicable to a given horsepower range of motors.
  • Page 33 Thermal - melting alloy or solder pot: In this type, tripping is the result of heat generated by the motor overload current passing through a "heater" in the overload relay. This overload relay consists of a brass shaft which is surrounded by solder.
  • Page 34 PLANNED MAINTENANCE PROGRAM: A scheduled program for maintenance of motor overload relays consists primarily of "good housekeeping" in conjunction with visual inspections, tightening of electrical connections, and electrical testing. A brief outline is given below: CLEAN - All types of motor overload relays should be cleaned periodically to ensure continued, reliable operation.

  • Page 35: Maintenance Of Molded Case Circuit Breakers

    MAINTENANCE OF MOLDED CASE CIRCUIT BREAKERS DESCRIPTION: The molded case circuit breaker essentially consists of two separate elements. One element is a set of contacts and suitable mechanical linkage for manual operation of the breaker as a switch in an electric circuit. The other element is a device to sense and react to an overload or short circuit.

  • Page 36: Maintenance Of Low Voltage Power Circuit Breakers

    MAINTENANCE OF LOW VOLTAGE POWER CIRCUIT BREAKERS APPLICATION: The low voltage power circuit breaker has a wide application and may be used to protect circuits up to 600 volts ac or 250 volts dc. These devices have essentially two separate elements. One element is a set of contacts with suitable mechanical linkage for operating the breaker as a switch.
  • Page 37 PLANNED MAINTENANCE PROGRAM: A scheduled program for maintenance of low voltage power circuit breakers consists primarily of "good housekeeping" in conjunction with visual inspection, tightening all connections and non-pivotal joints, and electrical testing. CLEAN AND TIGHTEN - Low voltage power circuit breakers should be periodically cleaned, tightened and inspected.

  • Page 38: Suggested Record Forms - Inspection And Test Results

    SUGGESTED RECORD FORMS - INSPECTION AND TEST RESULTS INSPECTION Circuit No Trip Device Mfg. Location Trip Device Type Breaker Mfg. Long Time Delay Range Breaker Type Short Time Delay Range Instantaneous Range Date Process Clearance Circuit De-energized Circuit Properly Tagged Breaker Removed Primary Fingers Arc chutes...
  • Page 39 Time Curr Time Inst. Curr.

  • Page 40: Section Vi

    SECTION VI 1. Trouble Shooting Note If the Control Panel Display is too dim to read when the test set is initially turned on, perform the following: A. Press the right hand menu softkey once. B. Press the left hand menu softkey until the display is appropriately illuminated. C.

  • Page 42: Service Data

    2. SERVICE DATA The test set utilizes straightforward circuits and components which require little or no service except for routine cleaning, tightening of connections, etc. The test set should be serviced in a clean atmosphere away from energized electrical circuits. The following maintenance is recommended: 1.
  • Page 43 Class One: A certificate is provided verifying the traceability and calibration of the equipment. Class N: That which is required for nuclear power plants. A certificate of traceability and calibration along with "as found" and "as left" data are provided. If an estimate is requested, provide the name and contact information of the person with approval/disapproval authority.

  • Page 44: Schematic Drawing

    SECTION VII. SCHEMATIC DRAWING...

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