ABB SACE PR010/T User manual

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SACE PR010/T test unit instructions

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ABB SACE SACE PR010/T
Contents
1. SAFETY NOTES ....................................................................................... 3
2. DEFINITIONS AND ABBREVIATIONS ............................................... 4
3. GENERAL INFORMATION ................................................................... 4
3.1. INTRODUCTION ........................................................................................ 4
3.2. PUT IN SERVICE ....................................................................................... 5
3.3. GENERAL DESCRIPTION ............................................................................ 5
4. FUNCTIONS.............................................................................................. 6
4.1. TEST FUNCTIONS ..................................................................................... 6
4.1.1. Trip test ........................................................................................ 6
4.1.2. Protection functions test ............................................................. 6
4.1.3. Communication functions test..................................................... 7
4.2. PROGRAMMING FUNCTION ......................................................................... 7
4.3. PARAMETER READING FUNCTION ............................................................... 8
4.4. PROTECTION UNIT INTERFACE ................................................................... 8
4.5. PC INTERFACE ........................................................................................ 8
4.6. TEST REPORT .......................................................................................... 8
4.7. SPECIAL FUNCTIONS ............................................................................... 10
5. SOFTWARE............................................................................................. 11
5.1. DESCRIPTION ........................................................................................ 11
5.1.1. Report downloading .................................................................. 12
5.1.2. Test unit configuration .............................................................. 12
5.1.3. Software updating ..................................................................... 12
5.2. COMMUNICATION WITH PC .................................................................... 12
5.2.1. SW updating procedure ............................................................. 12
5.2.2. Test report downloading procedure .......................................... 14
5.2.3. Test report erasing ..................................................................... 15
5.3. Protection Unit Reference ......................................................... 15
6. TECHNICAL SPECIFICATIONS ........................................................ 16
6.1. USER INTERFACE ................................................................................... 16
6.2. POWER SUPPLY ...................................................................................... 16
6.3. INPUTS/OUTPUTS .................................................................................. 17
6.4. MECHANICAL SPECIFICATIONS ................................................................. 17
6.5. STANDARD EQUIPMENT .......................................................................... 18
6.6. APPLICABLE STANDARDS ........................................................................ 18
6.7. ERROR MESSAGES AND TROUBLESHOOTING TABLE ...................................... 19
6.8. NOTES ................................................................................................. 21

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1. Safety notes
IMPORTANT: This symbol indicates information about procedures
or situations that may cause injury to personnel, damage to the unit or
financial loss.
Important!
Carefully read the entire contents of this handbook. Damage resulting from failure
to comply with the instructions given in this handbook effectively invalidates the
terms of guarantee. The manufacturer declines all liability for damage to the unit
caused by incorrect or improper usage.
ABB SACE also declines all liability for any ensuing damage or injury.
Do not use the unit in damp or wet environments.
If in doubt about the safety of the unit, take it out of service to prevent inadvertent
usage.
The units safety may be impaired if:
1. the unit shows visible signs of damage
2. the unit does not work
3. the unit is stored for a long period or has incurred damage during shipment.
Do not switch on the unit immediately after having transferred it from a hot
environment to a cold one, since the resultant condensation may damage or destroy
the unit. Wait until the unit adapts to the new ambient temperature before switching
it on.
Never leave discharged batteries inside the unit since the battery fluid may leak
and damage the unit.
Do not use abrasive detergents, petrol or alcohol etc. to clean the unit since these
may damage the units surface.

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ABB SACE SACE PR010/T
2. Definitions and abbreviations
3. General information
3.1. Introduction
The SACE PR010/T test unit is designed to Test, Program and Read the parameters
of the protection units mounted on ABB SACE circuit breakers (both moulded-
case and air circuit breakers). For further information about specific functions,
refer to the corresponding protection unit. All functions are executed onboard
by connecting the SACE PR010/T test unit to the connector present on the front of
the protection units. The unit can perform both automatic and manual tests, as
well as trip tests.
The test units software may be updated simply by connecting it to a PC (using the
diskette supplied byABB SACE or the software downloaded from our ABB Internet
site). The unit can also save important test results, which may then be downloaded
to a PC following a request for a test report.
The SACE PR010/T test unit is a portable instrument operated by rechargeable
batteries and/or an external power supply.
Abbreviation Description
CB Circuit breaker (for example: ABB SACE Emax and Isomax
circuit breakers).
DUT Device Under Test.
HW Hardware: the physical and electronic components that make
up the device.
Password Secret password which denies unauthorised access to certain
SACE PR010/T functions.
PC Personal Computer.
Release Protection unit otherwise known as a protection release.
SW Software: the programs used by the microprocessors to
execute a set of programmed functions/tasks.
CT Current transformer
Trip test Special test designed to trip the C.B.
TT1 ABB SACE trip test unit for use with some releases.

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3.2. Put in service
To place the SACE PR010/T unit into service, proceed as follows:
·Fit the batteries in the corresponding battery compartment (13), taking care
to check the polarity before connecting the batteries.
·Connect the external power supply to the 12 Vdc outlet (11).
Wait for the batteries to charge (when the SACE PR010/T unit is switched
off, the battery charge status bar is stationary). Even when the batteries are
discharged, the unit can still operate if connected to the external power supply.
3.3. General description
1. Cable connector for connection to circuit breaker protection unit
2. Backlit LCD display (4 x 20-character lines) to display messages and test
results
3. Cable connector for connection to Personal Computer
4. Green/red unit status indicator led (power on  stand-by)
5. Stop test or special functions key
6. Return/cancel key
7. Arrow selection and setting keys
8. Alphanumeric setting and control keyboard
9. Confirm key
10. Red battery charge status indicator led
11. External power supply socket
12. Unit on/off switch
13. Battery compartment
14. SACE PR010/T unit serial number

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4. Functions
4.1. Test functions
The SACE PR010/T test unit tests protection units by monitoring both their HW
and SW components. The unit performs the following tests:
- Trip test: by means of SACE TT1 unit
- Protection functions test
- Communication functions test
4.1.1. Trip test
The trip test tests the operation of the microprocessor, release and opening solenoid
chain. This test may also be performed with the circuit breaker closed.
Such test is performed by means of SACE TT1 unit.
For safety reasons, the current flow inside the circuit breaker must
be zero during testing.
For this reason, the current flow is automatically monitored before testing and
registered as zero if the reading detected is below a preset value.
4.1.2. Protection functions test
The device under test is powered up and the fault condition for the protection
function to be tested is simulated. In case of units provided with internal bus, the
internal status of the protections (alarm and trip messages etc.) may also be
monitored.
In case of certain releases, the type of release and circuit breaker and the rated
current of the CTs installed are also automatically identified.
For safety reasons, protection function tests must only be performed
with the circuit breaker open.
These tests may be performed in both automatic and manual mode.
·Automatic mode: releases equipped with internal bus (see electrical diagrams
in Technical Catalogue) are automatically tested. The PR010/T unit is in fact
capable of self-learning the protection parameter settings and, based on these
parameters, to generate a fault signal for each function in order to test the
delay. In the event of an anomaly, the type of error detected is indicated by the

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corresponding message (setting or delay error). This sequence is automatically
repeated on all unit functions. Testing may be interrupted at any time using
the STOP button, thereby restoring the original conditions/settings of the
protection unit prior to testing. In the case of releases not equipped with
internal bus, the user must preset the protections before testing.
·Manual mode: this test may be performed on any type of protection. In this
case, the user must set all the protection parameters before testing. During
manual testing, the user selects the type of device to be tested from a menu,
whereupon device protection functions and settings are displayed so that the
user can set the required test parameters. If the user selects an intermediate
setting in relation to those actually available, the SACE PR010/T test unit
will automatically convert it to the highest one. The fault may be simulated
either separately or simultaneously on any combination of phases L1, L2, L3
and NE.
4.1.3. Communication functions test
The SACE PR010/T test unit can also test the serial communication circuits of
the protection releases.
4.2. Programming function
Using the SACE PR010/T test unit, the type of releases with internal bus mounted
on ABB SACE circuit breakers can be programmed.
You can also program all the protection function parameters (setting, curve,
interlock parameters etc.). The parameter-programming function does not interrupt
the normal operation of the protection unit, although parameters cannot be set if a
protection alarm is pending.
The SACE PR010/T test unit will not set parameters outside the permitted range.
A message is displayed at the end of programming to indicate that the parameters
have been successfully programmed.
Each operating parameter modified must first be confirmed before it is saved. In
the event of a programming error, simply press the ESC key to cancel the last
entry/action.

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4.3. Parameter reading function
If the SACE PR010/T test unit is connected to releases with internal bus, its
possible to read the main parameters of the protection units.
At the users express request and, subject to availability, the SACE PR010/T test
unit can provide information about the following:
- protection status (settings, alarms, trips etc.)
- circuit breaker status (number of circuit breaker operations, contact wear etc.)
- phase, neutral and earth fault current readings.
The parameter reading function is permanently available, irrespective of the
protections, and CB status.
4.4. Protection unit interface
The SACE PR010/T test unit can perform all the operations described above
without drawing-out the protection units from the circuit breakers. The test unit
is in fact connected to the releases by a set of cables each fitted with a special
connector.
The SACE PR010/T test unit is connected to the various types of release using the
specific cables for each type of release.
4.5. PC interface
The SACE PR010/T test unit is fitted with a connector (3) for connection to a PC
(standard RS232 serial port). This interface is used to update the units software
and download test reports.
4.6. Test report
The SACE PR010/T test unit can save the main test results in order to compile a
test report. The unit can, store up to five test reports.
The unit also saves test data, even when disconnected from the power supply.
Test results are downloaded to a PC when the user requests a test report.
After a group of test reports is downloaded in the PC its advisable to delete them
from the PR010/T in order to have enough free memory available for new reports.
The test report contains the following information, which is both automatically
supplied by the unit and manually entered by the user:

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-date and time of test
-operator name Manually entered by user
-description of circuit breaker
-unit serial number (Sr. Nr.)
Automatycally supplied for
-type of unit tested electronic releases with internal
bus only
The following information is
automaticallyindicated for each protection function tested:
- type of protection
- setting selected
- curve selected
- phase tested
- test current
- expected trip time
- actual trip time
- test result
Test report example:
TEST REPORT WITH SACE PR010/T
SW Version: 3.2
********************************
Date: 03/05/00
Hour: 13:55
Operator: Belometti
Relay S.Nr.: M0047C03B
Relay type: PR112
Relay version: LSIG
CB type: E1B800
CT rated current: 250 A
Neutral: 50%
********************************
Protection: L
Threshold [In]: 0.400
Curve [s]: 3.00
Curve type: t=k/i^2
Tested phase(s): L1
Fault current [In]: 2.40
Expected time [s]: 0.750

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4.7. Special functions
With regards to the setting of the protection parameters is possible to carry-out
several tests by using different settings and curves to identify the optimum program
for the circuit breaker/installation .
The test unit can memorise a special frequent use program for each of the
protection units that may be electronically programmed (Define default).
The manual test function also enables a general current to be introduced into the
release in order to test the trip time (a particularly useful function for selectivity
studies between two or more circuit breakers).
Measured time [s]: 0.761
Test result: OK
Protection: S
Threshold [In]: 0.800
Curve [s]: 0.35
Curve type: t=k/i^2
Tested phase(s): L1
Fault current [In]: 1.60
Expected time [s]: 13.668
Measured time [s]: 10.956
Test result: OK
Protection: I
Threshold [In]: 4.000
Curve [s]: inst
Curve type: t=k
Tested phase(s): L1
Fault current [In]: 8.00
Expected time [s]: 0.060
Measured time [s]: 0.011
Test result: OK
Protection: G
Threshold [In]: 0.400
Curve [s]: 0.10
Curve type: t=k/i^2
Tested phase(s): -
Fault current [In]: 1.50
Expected time [s]: 0.320
Measured time [s]: 0.304
Test result: OK

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5. Software
5.1. Description
When the SACE PR010/T test unit is first switched on, it runs an initialisation
test. Following the successful conclusion of this test, the software version and
battery charge status are displayed on the units screen.
To open one of the sub-menus from the main menu, simply position the cursor at
1.Operation mode
2.Report download
3.PR010/T config.
4.SW test updating
ABB SACE S.p.A.
PR010/T
Version x.x
Batterylevel ____
SELECT DUT
1.PR111
2.PR112
3............
1. Download
2. Erase
PR010/T CONFIG.
1.Configuration
2.Test
3.Define password
SW test updating
ENTER to start
1234
Main menu

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the required menu using the
òor ñarrow keys and press Enter.
To return to the main menu, simply press ESC.
The moving sequence indicates that the test unit is busy, which means you
must wait until it has finished.
Sub-menu 1. Operation mode is different for each type of protection unit (see
Operation mode menu tree).
Sub-menus 2. Report download, 3. PR010/T Config. and 4, SW test updating
are instead the same for all the protection units.
5.1.1. Report downloading
The SACE PR010/T test unit can download a test report onto a PC which contains
all the information indicated under the heading Test report.
5.1.2. Test unit configuration
The configuration of the SACE PR010/T test unit may be customised to suit specific
requirements.
It may, for example, be programmed with a special password to control access to
the units test and programming functions and also its brightness/contrast
adjustment and language setting controls (default password: 00000).
The unit may also be tested by selecting the Test menu.
The self-explanatory software progressively guides the user by means of the simple
instruction displayed.
5.1.3. Software updating
The software installed on the SACE PR010/T test unit may be upgraded simply by
connecting it to a PC and following the procedure described below in the section
Communication with PC.
5.2. Communication with PC
Using the cable supplied, connect the SACE PR010/T test unit to a PC and proceed
as described below:
5.2.1. SW updating procedure
1. Switch on the SACE PR010/T test unit.

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2. Connect the SACE PR010/T test unit (connector 3) to one of the PCs serial
ports (COM1... COM4) using the cable supplied.
3. Insert the software update diskette in the corresponding PC drive and run the
010_PCI.EXE program.
4. In the OPTIONS menu, select TRANSMISSION PORT, then the required
COM port and press OK.
5. In the FILE menu, select NEW PROGRAM FILE_NAME, then file
PR010T_x.Hex (x=version) and press OK. The software update window will
now open.
6. From the main menu of the SACE PR010/T test unit, select ‘4.SW test
updating’. The following message will now be displayed:
‘SW test updating’
Press ‘ENTER to start’
7. Press ENTER on the SACE PR010/T unit to display the following message:
’Waiting update’
8. Before one minute elapses, press OK in the window displayed on the PC. The
SACE PR010/T unit will now display the following message:‘Updating
in progress’
accompanied by a progressive status bar indicating the download time
remaining. This process takes just a few minutes.
9. If the file is successfully downloaded, the SACE PR010/T unit will display
the following message:
‘End SW updating’
‘SW Ver. X.X’
Press ‘ESC to restart’
The PC will instead display the message:
OK, END OF FILE.
Press ESC on the SACE PR010/T unit to restart the unit with the new software
version. Close the PC application.
10. If the file is not successfully downloaded, the SACE PR010/T unit will display
the following message:
‘WARNING.SW updating failed’
Press ‘ESC to restart’
The PC will instead display the message:
TOO MANY ERRORS, PROGRAM ABORTED.
11. Press ESC on the SACE PR010/T unit to return to the screen:
‘Program failed’
‘ENTER for recovery’
12. In the PCs UNIT menu, select START UPDATE PROGRAM.
13. Proceed as described in point 7 onwards.

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5.2.2. Test report downloading procedure
At the end of each test sequence the PR010/T allows to store the data for a test
report. The procedure for downloading a test report is the following:
1. Switch on the SACE PR010T test unit.
2. Using the cable supplied, connect the unit to one of the PCs serial ports
(COM1...COM4).
3. Insert the software update diskette in the corresponding PC drive and run the
010_PCI.EXE program.
4. In the FILE menu, select NEW REPORT FILE NAME, name the file and
path extension and press OK. The software DOWNLOAD window will now
open.
5. From the main menu of the SACE PR010/T unit, select
’2.Report download’
The following message will now be displayed:
‘REPORT’
‘1. Download’
‘2. Erase’
Select:
‘1. Download’
The following message will now be displayed:
’Report download’
Press ’ENTER to return’
Press ENTER on the SACE PR010/T unit to display the following message:
‘Waiting for report download’
Before one minute elapses, press OK in the window displayed on the PC.
The SACE PR010/T unit will now display the message: ‘Download in
progress’ accompanied by a progressive status bar indicating the download
time remaining. This process takes about one minute.
6. If the file is successfully downloaded, the SACE PR010/T unit will display
the message:
‘END report download’
Press ‘ESC to return’
The PC will automatically open a window (e.g.: in NOTEPAD) displaying
the downloaded test report.
7. Press ESC on the SACE PR010/T unit to return to the main menu.
8. If the file is not successfully downloaded, the SACE PR010/T unit will display
the following message:
‘Download aborted’
Press ‘ESC to return’

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The PC will instead display the message:
UPLOAD FAILED: TIMEOUT WAS RECEIVED.
Press ESC and resume as described in point 4 onwards.
In the event of problems not described in this section, refer to the Error messages
and troubleshooting table.
5.2.3. Test report erasing
The following procedure erases entirely the test reports stored in the PR010/T:
1. Switch on the SACE PR010/T test unit.
2. From the main menu of the unit, select:
‘2. Report Download’
‘2. Erase’
The following message will now be displayed:
‘Report erasing’
‘ENTER to proceed’
‘ESC to return’
Select ENTER to erase the reports.
5.3 Protection unit reference
See annex n.RH0029.002

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6. Technical specifications
6.1. User interface
The user interface comprises an alphanumeric display, membrane keyboard and
indicator led.
Each time a key is pressed, an acoustic signal is emitted. The back-lit LCD display
features 4 lines each containing up to 20 characters.
The displays back-lighting automatically switches off when the keyboard is idle,
unless connected to the external power supply.
If no key is pressed for at least 5 minutes the display switches off automatically to
minimise electrical consumption.
6.2. Power supply
The SACE PR010/T test unit is a portable instrument operated by 6 rechargeable
batteries and/or an external power supply.
The specifications of the external power supply supplied are as follows:
-Vin = 100...240 Vac (47...63 Hz)
-Vout = 12 Vdc ±5%
-Max output current = 2.7A
The specifications of the rechargeable batteries supplied are as follows:
- Size = AA
- Type = NiMH
- Voltage = 1.2V
- Capacity = 1300mA/h
The operating autonomy of the batteries during testing depends on the type of
release tested, the type of tests performed, the different release versions and
the operations performed by the user. When testing, for example, a PR112/P
unit the batteries operate for about 2 hours under test conditions and 6 hours
in stand-by mode.
The battery recharge time is about four hours with unit switched off.
The batteries recharge automatically when the SACE PR010/T test unit is connected
to the external power supply.
The rechargeable batteries are supplied discharged. The batteries must therefore
be recharged before using the PR010/T test unit for the first time.
The test unit may also be connected to the external power supply.

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6.3. Inputs/Outputs
The SACE PR010/T test unit uses a set of signals to perform its various testing,
programming and reading functions. The main characteristics of these signals are
as follows:
- Output voltage range: - 5  +12 Vdc
- Maximum output current: 1A constant
- Input voltage range: 0  +15 Vdc
- Minimum input impedance: 1 Mohm
6.4. Mechanical specifications
- Plastic enclosure
- Front panel protected against electro-static discharges
- Dimensions: Length = 210 mm
Max. width = 120 mm
Max. depth = 60 mm
- Protection class: IP30
- Weight (complete with rechargeable batteries): 600g
- Operating temperature range: 0°C ... +500C
- Storage temperature range: -20°C  +700C
- Maximum relative humidity: 90% (non-condensing)
- MTBF: 15 years @ 300C

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6.5. Standard equipment
The SACE PR010/T test unit is supplied in a special case, complete with the
following accessories:
1. SACE PR010/T test unit, complete with rechargeable batteries
2. SACE TT1 trip test unit
3. External power supply
4. 1m length cables with connectors suited for several types of electronic releases.
5. External power supply connection cable
6. PC connection cable
7. User handbook and application software
8. Set of adapters for different types of releases.
6.6. Applicable standards
The SACE PR010/T test unit bears the CE quality mark and fully complies with
all major international standards on electro-magnetic compatibility (EMC).
Emissions: EN55022, Class B
Electro-static discharge: IEC/EN 61000-4-2
Radiated immunity: IEC/EN 61000-4-3
Conducted immunity: IEC/EN 61000-4-6 (1 kV)
2
8
1
SACE
3
6
TOP
75
TOP
4

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6.7. Error messages and troubleshooting table
·UPDATE ERROR
SW updating failed
Press ESC to restart
This message indicates a software updating error. To rectify, repeat the operation,
after first checking the PC-PR010/T connection and the name of the loaded file.
·COMMUNICATION ERROR
Communication error
Press ESC to return
This message indicates that the SACE PR010/Ts internal bus is unable to establish
a connection with the device under test.
·INVALID DIGITAL VOLTAGE
DUT internal voltage not valid
Press ESC to exit
This message indicates an internal DUT voltage reading that is outside the accepted
range.
·INVALID PROGRAM
Program failed
Press ENTER for recovery
If this message is displayed when the SACE PR010/T test unit is powered up, it
means that the program stored in the SACE PR010/Ts memory is incorrect due
to the failure of a previous software updating sequence.
In this situation, the SACE PR010/T test unit cannot work and must therefore be
reloaded with the updated software.
·INVALID WATCH DOG
Monitoring signal not valid
Press ESC to exit
This message indicates that the internal control signal is outside the established
range. Check the connection between the SACE PR010/T test unit and device
under test.The following error messages are displayed on the SACE PR010/T
unit:

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Troubleshooting guide
Nr. Faults Causes and errors Checks and remedies
The external power supply
is disconnected
Power up the unit with the
power supply provided by
ABB SACE
The external power supply
is disconnected from the
mains power supply
Connect the power supply
to a 220V power network
The ON/OFF switch is set
to OFF
Set the ON/OFF switch to
ON
No batteries fitted Fit batteries like the ones
specified under the heading
“Power supply”
1ThePOWER-ONledis
Light-off
The batteries are
discharged
Recharge the batteries by
connecting the unit to the
external power supply
2 The message display is not
clear
The contrast and/or
brightness setting(s) are
incorrectly adjusted
Adjust as described under
the heading “Test unit
configuration”
3 The display language is
incorrect
The language setting is
incorrectly programmed
Switch on the unit and 10”
later select:
3. ENTER
ENTER
ENTER
Select the correct language
with UP and DOWN.
W rong connection cable
used to connect the PC to
the PR010/T test unit
Replace with the cable
supplied and repeat the
operation
The serial cable is not
properly connected
Make sure the cable
connectors are properly
inserted
The PR010T unit is not
ready for Sw updating
Proceed as described under
the heading “Sw updating
procedures”
The PR010T’s time-out
elapses before the software
starts downloading from the
PC
Make sure the PR010/T unit
displays the message
“Waiting for update” at the
start of the file transfer
procedure
The update file is not
selected
Select the required software
version and repeat the
update procedure
The wrong type of file is
selected
Select file type
PR010t_x.Hex
4 Problems updating the
software installed on the
PR010/T unit
The file downloaded is
damaged
Use a spare copy or
download the updated
software version from our
Internet site
W rong connection cable
used to connect the PC to
the PR010/T test unit
Replace with the cable
supplied and repeat the
operation
5 Problems downloading the
test report to the PC The serial cable is not
properly connected
Make sure the cable
connectors are properly
inserted
The PR111-type release is
fittedwiththewrongadapter
Fit the correct PR111
adapter
The PR111 adapter is
damaged
Replace with the spare one
supplied
An Isomax cable is
connected to an Emax
circuit breaker, or vice versa
Use the correct cable for
the circuit breaker in
question
6 Problems connecting the
cable to the device under
test The cable is connected the
wrong way round
Correctly insert the
connector, taking care to
check the connector
polarity.