American Innovations MicroMax GPS300 User manual

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Interrupters User Guide
Interrupters
User Guide

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Revised May 2019

Contents
Interrupters User Guide iii
Contents
Chapter 1: Getting Started 1
Interrupter Overview 1
Relay and Interruption Features 2
Mounting and Power Features 3
Working with Other Brands of Interrupters 3
Supplied Power Cables and GPS Antenna 4
Required Tools and Equipment 6
Optional Hardware and Software 6
Contacting Technical Services 7
Chapter 2: GPS300 Installation 8
Installing the GPS300 Interrupter 8
Determining a Power Source 8
Connecting a Relay 9
Connecting the GPS Antenna 11
Setting Display Contrast 12
Viewing GPS Info 12
Running a Test Program 13
Chapter 3: GPS350 Installation 14
Installing the GPS350 Interrupter 14
Determining a Power Source 15
Connecting the Built-in Relay to a Rectifier 15
Connecting the GPS Antenna 17
Setting Display Contrast 18
Viewing GPS Info 18
Running a Test Program 19
Chapter 4: GPS360 Installation 21
Installing the GPS360 Interrupter 21
GPS360 Power and Battery Information 22
Determining a Power Source 22
Connecting the Built-in Relay to a Rectifier 23
Connecting the GPS Antenna 24
Connecting an External Relay with Line Power 26
Setting Display Contrast 27

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iv
Viewing GPS Info 28
Running a Test Program 29
Chapter 5: Interrupter Programming 30
Status Icons 30
Configuring with Unit Keypad 31
Setting Up and Running an Interruption Program 31
Setting Up an Interference Interruption Program 33
Options Features 35
Output Parameters 36
Setting the UTC Offset 37
Using Zero Crossing 38
Resetting to Factory Defaults with Keypad 38
Configuring with Bullhorn Tools 39
Installing Bullhorn Tools 40
Connecting Unit and Starting Bullhorn Tools 40
Configuring the Interrupter 41
Viewing Unit Information 42
Using Saved Templates 42
Setting Up Interruption Options 43
Setting Up Interruption Programs 44
Setting Up an Interference Interruption Program 47
Creating a Settings Template 49
Using Saved Templates 49
Importing a Saved Template 50
Applying a Saved Template 51
Exporting or Deleting Saved Templates 52
Resetting to Factory Defaults with Bullhorn Tools 53
Upgrading Firmware 54
Exiting Bullhorn Tools 54
Appendix A: Factory Defaults Settings 56
Appendix B: Technical Specifications 57
Appendix C: Derating Tables 59
GPS350 Derating Table 59
GPS360 Derating Table 59
Appendix D: Mercury Relay Advisory 61

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v
Appendix E: Regulatory Notices 63
Export Control Classification Number 63

1
Interrupters User Guide 1
Chapter 1: Getting Started
The MicroMax GPS300, GPS350, and GPS360 interrupters are programmable, GPS-synchronized,
current interrupters. The information in this guide is intended for authorized service personnel who
plan to install and program an interrupter for service.
This section includes the following topics:
lInterrupter Overview on page 1
lSupplied Power Cables and GPS Antenna on page 4
lRequired Tools and Equipment on page 6
lOptional Hardware and Software on page 6
lContacting Technical Services on page 7
Interrupter Overview
The MicroMax GPS300, GPS350, and GPS360 interrupters are fully programmable, satellite-
synchronized interrupters that are capable of interrupting rectifier, bond, or any other current. Cycles
can be programmed using any combination of time intervals between 0.1 seconds and 999.9
seconds (in 0.1 second increments) for "Off" and "On" cycles. The interrupters can store up to 9
interruption programs for later use.
Figure 1-1. MicroMax Interrupters
The MicroMax GPS350 and GPS360 also include a built-in solid state relay (normally closed) that can
interrupt either AC or DC, up to 60 A with on/off cycles of less than 4 seconds and 80 A with cycles
totaling 4 seconds or longer. The relay can be easily installed without concern for polarity. The
GPS360 includes a battery for use without an external power source.

Interrupters User Guide
Chapter 1: Getting Started 2
Output parameters are set to accommodate any external relay configuration. Additionally, the menu-
driven synchronization configuration allows the interrupter to operate with almost any other brand
of GPS synchronized interrupter or data logger. Based on the number of satellites seen and the
quality of view, synchronization triggering accuracy is specified to within 1µs with any other
MicroMax interrupter.
A unique patent-pending Interference Mode interruption cycle allows rectifier influence studies with
greatly increased productivity and ease of data interpretation. By operating in interference mode, it
is possible to determine the influence from each individual rectifier being interrupted and get the
instant "Off" and "On" pipe-to-soil potentials, all during a single visit to a test station. The influence
from up to 99 rectifiers can be studied simultaneously using Interference Mode.
Figure 1-2. Interference Mode Example
The MicroMax interrupters also allow for full cathodic protection (CP) polarization when the
interrupter is not in use (rectifier "on" and no interruption).
Relay and Interruption Features
The GPS300, GPS350, and GPS360 interrupters can be connected to almost any external current relay
(or multiple relays) using a 12V control. Depending on the configuration, the interrupter supplies up
to 500mA (12V) relay control current. As a result, numerous relays can be controlled with one
interrupter. This leads to significant cost savings in areas where multiple current sources in a
confined area need to be switched. The MicroMax interrupters can be set to accommodate normally
open and normally closed relays. There are several relay options for switching either AC or DC at
various loads.
The GPS350 and GPS360 include a built-in solid state relay that can interrupt either AC or DC, up to
60 A with on/off cycles of less than 4 seconds and 80 A with cycles totaling 4 seconds or longer. The
internal relay can be easily installed without concern for polarity.
The MicroMax interrupter relay and interruption features include:
lThe interrupters can drive an external relay of 100 A / 100 V (higher capacities available).
lThe interrupters can be connected to any external current relay (or multiple relays). The
interrupter supplies up to 500mA.
lGPS300 can be used with a solid state relay (AC or DC) or mercury relay (AC or DC).

Interrupters User Guide
Chapter 1: Getting Started 3
NOTE: For important information about mercury relays, refer to Mercury Relay Advisory on
page 61.
lGPS350 and GPS360 have a built-in solid state relay that can interrupt either AC or DC, up to
60 A with on/off cycles of less than 4 seconds and 80 A with cycles totaling 4 seconds or
longer. The relay is Normally Closed.
lThe interrupters include the ability to use Zero Crossing to set when timed measurements are
taken. Zero Crossing allows you to use the instant when the AC crosses zero instead of using a
GPS reading.
lWith external relays, user-selectable control of the interrupters output to 0 V or 12 V for "On"
or "Off." (Accommodates normally open or normally closed relays.)
lSynchronization can be set on the leading or falling edge of the interruption cycle.
lInterruption continues automatically after power is disrupted.
lCycle range up to 999.9 seconds in 0.1 second increments.
lSynchronization triggering accuracy is within 1µs with any other GPS300or GPS350 interrupter
and collectively is less than 5µs after the PPS signal (precise positioning service signal) as
provided by the GPS satellite constellation, even when only one satellite is visible.
lThe interrupters are fully programmable between the following schedules: continuous, daily,
start/stop, and interference. Can store up to nine different interruption programs for later use.
Mounting and Power Features
lGPS350 and GPS360 are shipped with factory-installed mounting magnets that can be used to
easily attach the interrupter to an available surface.
lGPS360 includes an internal, rechargeable battery.
NOTE: Be sure to fully charge the battery before field use.
lInterrupters can be powered from either AC or DC, with a wide range of input voltages.
Working with Other Brands of Interrupters
The MicroMax GPS300, GPS350, and GPS360 interrupters will work with most GPS-synchronized
interrupters on the market. Most manufacturers use the same principle of calculating interruption
synchronization.

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Chapter 1: Getting Started 4
Use the following procedure to synchronize a JR-2 interrupter with the MicroMax interrupters. The
following procedure uses the optional, JR-2 adapter cable provided by AI.
1. Connect the JR-2 adapter cable to the JR-2 interrupter. Connect the other end of the adapter
cable to the relay control output cable provided in the installation kit. Do not connect the
banana plugs on the other end of the relay control output cable at this time.
2. Start the interrupter with the following output parameters and interruption settings:
lSwitch: Normally Closed (Low output = Off)
lInt. Cycle: OFF/ON
lOn = 59.5 Off = 0.5
3. After the interrupter has started interruption, use the exact time of the interrupter as a guide
when setting the JR-2 interrupter. Set the time ahead on the JR-2 interrupter to allow enough
time to finish the procedure.
4. Before the next OFF cycle on the interrupter, connect the banana plugs on the JR-2 adapter
cable to the INPUT connections on the power / relay assembly cable. Wait until an OFF cycle
has executed.
The power cable assembly for the interrupter is typically used for the relay control output
cable.
5. The interrupters should now be synchronized (clocks are set at the exact same time), and the
interrupter can be set back to the required program.
Supplied Power Cables and GPS Antenna
The following cables are provided in the installation kit with the interrupters. The interrupters
consume approximately 120 mA. External relay current consumption is additional, which is typically
less than 10 mA for a solid state relay and as high as 400mA for a mechanical mercury relay.
NOTE: Refer to the interrupter's installation chapter for instructions on how to connect the cables.
lPower Cable and AC/DC Power Input Cable with Alligator Clips
Specifications for the cables after assembly:
— INPUT: 8-42 V AC or 10-60 V DC.
— OUTPUT: 10-14 V DC (500 mA maximum).
Red indicates positive (+); black indicates negative (–).

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Chapter 1: Getting Started 5
Figure 1-1. Power Cable and AC/DC Power Input Cable with Alligator Clips
lGPS Antenna: The GPS antenna should be mounted on a metal surface with a clear view of
the sky.
Figure 1-2. GPS Antenna
Below is an example of the connections located on the side of the GPS300.

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Chapter 1: Getting Started 6
Figure 1-3. GPS300 Connections
Below is an example of the connections located on the side of the GPS350 and GPS360.
Figure 1-4. GPS350 and GPS360 Connections and Relay Cables
Required Tools and Equipment
The following tools and equipment are required for installing and configuring the unit for service:
lVoltmeter
lHand tools for installing relay
Optional Hardware and Software
MicroMax GPS300, GPS350, and GPS360 interrupters can be programmed through the unit's
keyboard (refer to Configuring with Unit Keypad on page 31). As an alternative method of
programming the interrupter, you can also configure the unit with Bullhorn Tools configuration
software using a Microsoft Windows-based computer with the following hardware and software
specifications:
lPentium processor or equivalent
l2 GB RAM (minimum)
l400 MB free hard drive space (minimum); 1 GB recommended

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Chapter 1: Getting Started 7
lSpare USB port
lUSB mini-b cable (standard mini USB cable typically used with most digital cameras)
lMicrosoft Windows 7 Home Premium, Professional, or Ultimate or later versions
lBullhorn Tools configuration software (available from Bullhorn Tools launch page)
lWindows Internet Explorer version 8.0 or higher
lAdobe Reader version 6.0 or higher (available from the Adobe website)
Refer to Configuring with Bullhorn Tools on page 39 for details on configuring with this software.
Contacting Technical Services
AI Technical Support is available to provide assistance with your unit, accept feedback about units,
or discuss your organization’s training needs. Use the following information to contact AI Technical
Support:
Telephone:
1-800-229-3404
Email:
[e-mail]
Address:
American Innovations, Ltd.
Attn: AI Technical Support
12211 Technology Blvd.
Austin, TX 78727

2
Interrupters User Guide 8
Chapter 2: GPS300 Installation
The GPS300 interrupter consumes approximately 120mA. Relay current consumption is additional,
which is typically less than 10mA for a solid state relay and could be as high as 400mA for a
mechanical mercury relay.
The GPS300 installation process includes the following steps:
lInstalling the GPS300 Interrupter on page 8
lSetting Display Contrast on page 12
lViewing GPS Info on page 12
lRunning a Test Program on page 13
Installing the GPS300 Interrupter
When completing the following procedure, refer to Supplied Power Cables and GPS Antenna on page
4 for input and output voltage specifications.
WARNING: Make sure to follow all precautions when working with the interrupter and high
voltage circuits.
WARNING: Do not connect the GPS300 to primary power.
The installation process includes the following steps. Refer to the individual sections for each step
for the complete instructions.
lDetermining a Power Source on page 8
lConnecting a Relay on page 9
lConnecting the GPS Antenna on page 11
Determining a Power Source
Determine how to power the MicroMax interrupter using one of these possible sources:

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Chapter 2: GPS300 Installation 9
1. Rectifier - with power turned on to the rectifier, use a voltmeter to locate a power source
across two available AC taps. The interrupter requires 8-42 V AC or 10-60 V DC.
2. A 120 V AC convenience outlet to use with the 12 V DC wall adapter.
3. A DC source, such as a 10-60 V DC battery.
Figure 2-1. Power Source Options
Connecting a Relay
The GPS300 requires an external relay to perform interruptions. The GPS300 can be used with an AC,
DC, or mercury relay. Refer to Mercury Relay Advisory on page 61 if working with a mercury relay.
1. Turn OFF all power to the rectifier.
2. If a relay is not already installed, install an AC, DC, or mercury relay according to the relay's
installation instructions.
3. Connect the GPS300 power cable to the GPS300 interrupter. Line up the notch on the cable to
the connection on the interrupter. Twist ring on cable to lock the cable into the connection.
Figure 2-1. Power Cable and GPS300 Connection

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Chapter 2: GPS300 Installation 10
4. Connect relay control or coil to the power cable OUTPUT. Be sure to observe proper polarity,
especially if a flyback diode is present on a mercury relay coil.
Figure 2-2. Power Cable Connections
5. Connect the AC/DC Power Input cable to the power cable's INPUT connection.
Figure 2-3. AC/DC Power Input Cable Connected to Twisted Wire Cable
6. Clip the AC/DC Power Input cable's alligator clips to the rectifier Coarse AC taps. Voltage
range is 8-42 V AC.
Figure 2-4. Alligator Clips Connected to Rectifier Taps
If you are connecting to a DC power source such as a battery, the power requirement is 10-60
V DC.

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Chapter 2: GPS300 Installation 11
Connecting the GPS Antenna
1. Connect the magnetic-mount, GPS antenna to the GPS connector on the GPS300.
Figure 2-1. GPS Antenna Connection
2. Mount the GPS antenna on a metal surface making sure the antenna has a clear view of the sky.
If a metal surface is unavailable, glue a flat washer on a suitable surface and then place the GPS
antenna on the flat washer.
After applying power to the GPS300 interrupter, unit information briefly appears in the
display.
After the initialization process completes, the interrupter displays the main menu. If the main
menu does not display (this may take several minutes), make sure the interrupter is not
currently running another program. If another program is running, press PREV and then
ENTER.
3. The main menu displays available menu options that you can select. To select a menu option,
use the keypad to select the number associated with the menu option. For example, press 1
on the keypad to select the Interrupt menu option.
The main menu also displays current time and date and satellite information. For information
on the symbols shown on the screens, see Status Icons on page 30.
Figure 2-2. Main Menu
Refer to Interrupter Programming on page 30 for more information on configuring the interrupter.

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Chapter 2: GPS300 Installation 12
Setting Display Contrast
Use the up and down arrow keys on the keypad to adjust the contrast level of the display.
Press and hold the up arrow to increase the contrast; press and hold the down arrow to decrease the
contrast.
You can adjust the contrast level at any time except when the interrupter is running an interruption
program.
Viewing GPS Info
The GPS Info screen includes status information for the current number of satellites in view, time
zone, antenna, and the current time and date.
Figure 2-1. GPS Info
To display the GPS Info screen, press 2 from the main menu. Press PREV to return to the main menu.
The following list describes the type of information shown on the GPS Info screen:
l15:32:01 02/20/14 — The current time and date. The time is shown in military time (24 hours)
and uses the HH:MM:SS format to represent hours, minutes, and seconds. The date is shown in
MM/DD/YYYY format to represent the month, day, and year. The plug symbol indicates that
power is present.
lGPS Antenna OK — The antenna status. If the antenna is disconnected or loose, the status
message Antenna OPEN displays. If the antenna is shorted, the status message Shorted
displays.
l3D Fix Sats 09/12 — Shows whether a 2D or 3D GPS lock has been obtained and the number
of satellites seen by the unit. In this example, 09/12 refers to 9 satellites in view out of 12
possible satellites. A 2D lock requires 3 satellites, while 3D lock requires at least 4 satellites. If
the unit sees an insufficient number of satellites, move the antenna until at least a 2D lock
(preferably a 3D lock) is achieved.
If no satellites are seen, the message Acq Sat appears in the display on the left side. The
message 3D Fix displays when the unit has established communication with at least four

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Chapter 2: GPS300 Installation 13
satellites.
lCurrent UTC -06 — The Universal Time Constant (UTC) that is used by the GPS system.
IMPORTANT: GPS lock is not needed for the GPS300 to operate. The internal clock updates as
soon as the internal GPS locates satellites. For synchronized interruption or interference, make sure
the antenna position enables at least a 2D lock.
Running a Test Program
Before programming the interrupter, you can test the interrupter by running a test program.
With the main menu displaying, press to display and begin the Test Mode. Press PREV to cancel
the test or when the test is done.
Figure 2-1. Test Mode
The following list describes the type of information shown on the Test Mode screen and that is used
for the test:
lTEST MODE ON/OFF/DONE — The cycle that the interruption is running during the test. The
test runs through an off and on sequence for a few seconds. It will then display DONE when it
completes the test. The plug symbol indicates that power is present.
lSwitch: Norm Open — Shows whether the relay is normally open or normally closed. The
setting is determined by the Switch setting in Out Parameters (refer to Output Parameters on
page 36).
lSynch — Shows that synchronization begins with On. The setting is determined by the Int.
Cycle setting in Out Parameters (refer to Output Parameters on page 36).
lCYCLE 1s ON, .5s OFF — The timing of the on and off cycle.

3
Interrupters User Guide 14
Chapter 3: GPS350 Installation
The GPS350 interrupter consumes approximately 120 mA. The built-in solid state relay current
consumption is additional 100 V / 80 A max with > 4 s cycle or 100 V / 60 A max with 1 s-4 s cycle.
The relay is normally closed.
The interrupters are set to use Normally Closed relays by default. If you plan to use a Normally Open
relay, configure the interrupter prior to installing it.
The GPS350 installation process includes the following steps:
lInstalling the GPS350 Interrupter on page 14
lSetting Display Contrast on page 18
lViewing GPS Info on page 18
lRunning a Test Program on page 19
Installing the GPS350 Interrupter
When completing the following procedure, refer to Technical Specifications on page 57 for input and
output voltage specifications.
WARNING: Make sure to follow all precautions when working with the interrupter and high
voltage circuits.
WARNING: Do not connect the MicroMax GPS350 to primary mains power.
Metal relay casing on the GPS350 will get hot. Allow 5 - 10 minutes after interruption stops before
handling the unit.
The installation process includes the following steps. Refer to the individual sections for each step
for the complete instructions.
lDetermining a Power Source on page 15
lConnecting the Built-in Relay to a Rectifier on page 15 — or connect an external relay
lConnecting the GPS Antenna on page 17

Interrupters User Guide
Chapter 3: GPS350 Installation 15
Determining a Power Source
Determine how to power the MicroMax interrupter using one of these possible sources:
1. Rectifier - with power turned on to the rectifier, use a voltmeter to locate a power source
across two available AC taps. The interrupter requires 8-42 V AC or 10-60 V DC.
2. A 120 V AC convenience outlet to use with the 12 V DC wall adapter.
3. A DC source, such as a 10-60 V DC battery.
Figure 3-1. Power Source Options
Connecting the Built-in Relay to a Rectifier
The GPS350 includes a built-in relay. You can also connect the GPS350 to an external relay. Refer to
Mercury Relay Advisory on page 61 if working with a mercury relay.
1. Turn OFF all power to the rectifier.
2. Connect the interrupter's relay cables to the rectifier, depending on what you will be
interrupting.