ISA CBA1000 User manual

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Istrumentazioni Sistemi Automatici S.r.l.
VIA BERGAMO 41 - 21020 TAINO (VA) - ITALY
OFFICES TEL. [phone] - FA +39.0331.957091
LAB: TEL. [phone] -
E-MAIL [email protected]
WEB www.isatest.com
DATE: 12/12/2005 DOC.MIE12166 REV.1
CBA1000
INTRODUCTORY GUIDE

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SHORT FOREWORD ............................................................................................................................................................4
1 INTRODUCTION ................................................................................................................................................................5
2 TEST SET EXPLANATION ...............................................................................................................................................7
2.1 T HE FRONT PANEL AND THE KEY COMPONENTS ................................................................................................................7
2.2 P USHBUTTONS , DISPLAY , KEYPAD , CONTROL KNOB ..........................................................................................................9
2.3 T HE CONTROL WINDOW ....................................................................................................................................................9
2.3.1 Set...........................................................................................................................................................................10
2.3.2 Res..........................................................................................................................................................................10
2.3.3 Micro-Ohmmeter ...................................................................................................................................................10
2.3.4 View........................................................................................................................................................................10
2.3.5 Menu ......................................................................................................................................................................11
2.3.5.1 Test diagram........................................................................................................................................................................11
2.3.5.2 Trigger options....................................................................................................................................................................12
2.3.5.3 Test options.........................................................................................................................................................................15
2.3.5.4 Recording options ...............................................................................................................................................................17
2.3.5.5 Breaker and auxiliary channel settings................................................................................................................................19
2.3.5.6 Analog channel / coils settings............................................................................................................................................19
2.3.5.7 Micro-Ohmmeter test ..........................................................................................................................................................22
2.3.5.8 Results.................................................................................................................................................................................24
2.3.5.9 Preferences..........................................................................................................................................................................26
2.3.5.10 Set-up options ...................................................................................................................................................................28
2.3.5.11 Tests header.......................................................................................................................................................................30
2.3.6 Magnifying lenses..................................................................................................................................................31
2.3.7 t1, t2, dt...................................................................................................................................................................31
2.3.8 Printer ....................................................................................................................................................................31
2.3.8 Left column............................................................................................................................................................31
2.4 CB CONNECTIONS ...........................................................................................................................................................31
2.4.1 Main CB contacts...................................................................................................................................................31
2.4.2 Coil drivers.............................................................................................................................................................32
2.4.3 Auxiliary CB contacts............................................................................................................................................33
2.4.4 Travel transducer or analog input.........................................................................................................................33
2.4.5 Micro-Ohmmeter. ..................................................................................................................................................33
2.5 P OWER - ON ......................................................................................................................................................................33
2.6 C ONNECTION TO THE PC.................................................................................................................................................34
3 THE HELL, IT DOESN’T WORK...................................................................................................................................35
3.1 I NTRODUCTION ...............................................................................................................................................................35
3.2 P HYSICAL DESCRIPTION ..................................................................................................................................................36
3.3 E RROR MESSAGES ...........................................................................................................................................................36
3.4 T ROUBLE SHOOTING .......................................................................................................................................................37
3.4.1 No power at power-on............................................................................................................................................37
3.4.2 The test set is locked up .........................................................................................................................................38
3.4.3 The control knob does not operate........................................................................................................................38
3.4.4 A coil driver doesn’t close......................................................................................................................................38
3.4.5 A breaker contact is not detected...........................................................................................................................39
3.4.6 An auxiliary contact is not detected ......................................................................................................................39
3.4.7 The travel transducer does not operate.................................................................................................................40
3.4.8 The micro-Ohmmeter does not operate.................................................................................................................40
3.4.9 Problems during upgrade......................................................................................................................................40
3.4.10 The fault cannot be fixed.....................................................................................................................................41
3.5 A DDING OPTIONS ............................................................................................................................................................43
3.6 C ALIBRATION ..................................................................................................................................................................43
3.6.1 Introduction ..........................................................................................................................................................43

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3.6.2 Calibration procedure...........................................................................................................................................44
APPENDIX 1: SPARE PARTS LIST ..................................................................................................................................46
APPENDIX 2: TEST SET SCHEMATIC ...........................................................................................................................47

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SHORT FOREWORD
Dear CBA1000 user,
I often wondered why the user’s manual is not very much used, even if it includes valuable information.
As me too I am a user of such manuals, the answer I have given myself is that valuable information are
concealed somewhere in the thick thing, and I do not have time to waste to find it. So, either the manual
is actually of help, or I ignore it.
This is why I decided to split the CBA1000 manual in three: specification, with all performance details;
introductory guide, with the device description; application manual, with instructions about how to use
it one its operation is understood. The idea is that you may read once the introductory guide or the
specification, while you need to follow application examples more than once; so, why not to split the
manual in three?
This manual is the introduction to the test set; it includes also a troubleshooting guide.
Have a good work with CBA1000!
Primo Lodi
Q&A Manager

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1 INTRODUCTION
The circuit breaker analyzer and micro-Ohmmeter model CBA1000 is a two-in-one test set.
When used as a circuit breaker analyzer, it allows the off-line testing of the characteristics of all modern
MV and HV circuit breakers.
When used as a micro-Ohmmeter, it allows measuring the contact resistance of the circuit breaker
contact, or also of joints or other circuit parts. It allows also to perform the dynamic test of the contact
resistance, that is to record and display how does the contact resistance change while it is closing: this
allows detecting hidden defects, that are otherwise impossible to be diagnosed.
The instrument performs the following features:
. Test set control: via keypad plus selection knob plus dedicated keys, and a large transflective LCD
display (320 x 240 pixels; view area 122 x 92 mm).
. Optional internal thermal printer 58 mm wide or external thermal printer 112 mm wide.
. Huge recording capability: 64Mb (typically 1000 results).
. USB and RS232 interface for data communication with the PC.
. Two driving coil circuits (O+C); 4 opt. The coil current is independently measured on all outputs, with
three current ranges.
. Three sets of two main contact sensing circuits (two chambers tests). Test of the main contact and of
the pre-insertion resistor.
. Four digital event input circuits.
. For the main and event inputs, measurement of delays with respect to coil currents or other references.
. The Open or Closed state of main and event inputs is displayed by a light: thanks to these lights, the
status of the circuit breaker is continuously monitored..
. One analog circuit input circuit, with a voltage source for potentiometer transducers polarization.
Measurement is translated into stroke, speed, acceleration. In alternative, the input can measure the
auxiliary DC voltage during circuit breaker operation.
. Static resistance measurement; test current 200 A, 80 A or 25A.
. Dynamic contact resistance test; test current 200 A.
. Many triggers can start the recording.
. In case of more than two chambers per phase, capability of generating or sensing a trigger, so that a
number of units can operate at the meantime.
. All possible test sequences are programmable, including test cycling.
. Test result is shown on the display: it is possible to analyse, zoom and so on.
. Capability of storing and recalling both test settings and test results.
. The software CBA1000.PRO (that operates with WINDOWS 2000 up) is included: it allows
analyzing test results, adding notes, saving and so on. It allows also to store and recall test set settings.
. The external option DET1000 allows to perform the test while the circuit breaker has both ends
connected to earth, thus maximizing the test safety; it allows also to test circuit breakers with a graphite
nozzle.

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All circuits have been designed to ensure safe operation in the noisy environment of HV and MV
substations.
The instrument is housed in a transportable aluminium box, that is provided with removable cover and
handles for ease of transportation.
NOTE: WINDOWS is a trademark of MICROSOFT inc.

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2 TEST SET EXPLANATION
2.1 T HE FRONT PANEL AND THE KEY COMPONENTS
The following is the front panel; all components on the front, and the key ones inside the test set, are
listed here below (see also the CBA1000 schematic at the end of the manual).
1) Supply socket and main supply fuse, rated T5A, incorporated in the supply socket.
2) Earth socket.
3) Power-on switch, with light.
4) Buzzer: it tells that the test is about to be started.
5) MENU control knob, with switch.
6) Display: before testing it allows to select the test parameters; after test start it displays test results.
7) Keypad, alpha-numeric, to input the test heading.
8) Serial interface connector.
9) USB interface connector.
10) Options: 40 columns thermal printer, or auxiliary supply loss test.
11) Auxiliary inputs sockets: two groups of two contacts, isolated.

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12) Auxiliary inputs: dry or wet selection lights.
13) Auxiliary inputs level: ON = closed or with voltage.
14) Main contacts input sockets: three phases with two chambers each.
15) Main inputs lights: GREEN = main input CLOSED; RED = main input OPEN or pre-insertion
resistor.
16) 5 V DC measurement input connector, for the micro-Ohmmeter circuit.
17) Measurement input sockets, for position transducers or other measurements.
18) Auxiliary 5 V 10 mA supply for the position transducer.
19) High current output sockets for the micro-Ohmmeter.
20) Auxiliary 5 V supply protection fuse, F 63 mA 500 V.
21) CLOSE coil command sockets: one side will be connected to the positive or to the negative of the
DC supply.
22) PARK sockets, unconnected, for the safe positioning of coil commands.
23) OPEN coil command sockets: one side will be connected to the positive or to the negative of the
DC supply. It drives phase 1 if the three phase open option is present.
24) Optional OPEN coil command sockets, for phases 2 and 3: one side will be connected to the
positive or to the negative of the DC supply.
25) Type of test selection pushbutton: as pressed, lights (26) move in a circular way. If unused, the
selection performed via knob (5) and display (6) is shown.
26) Selected test lights. O = Open; C = Close; OC = Open-Close; CO = Close-Open; OCO = Open –
Close – Open; USER = the programmed test sequence.
27) Test START push-button: as pressed, the selected test is started.
28) Test in progress lights: they are ON until the test is finished. When ON, no further START
command is accepted.
29) TRIGGER-IN and TRIGGER-OUT synchronization commands sockets. The Master CBA-1000
TRIG-OUT socket and zero sockets shall be connected to the Slave TRIG-IN and zero sockets.
30) Battery LED: it turns on during battery recharge.
60) Front panel board; code PWA11430.
61) Microprocessor board, code PWA51300.
62) INTE main and auxiliary contacts board, PWA11429.
63) Circuit breaker driver (2 channels) and measurements board, PWA11428.
64) Optional circuit breaker driver (2 channels) and measurements board, PWA11428.
65) Micro-Ohmmeter circuit board, with 14 driving circuits.
80) Rechargeable battery.
81) Auxiliary supply voltages module.
82) Capacitor of the micro-Ohmmeter circuit.

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2.2 P USHBUTTONS , DISPLAY , KEYPAD , CONTROL KNOB
The test set is controlled by two push-buttons: SELECT (25), with its LED’s (26) showing the current
selection , and START (27) with the light (28) , that starts the test.
Test selections are performed by the keypad (7), control knob (5) and display (6).
As With portable phones, pressing a button you access, in sequence, the letters, then the digit. Above
the zero is the space.
2.3 T HE CONTROL WINDOW
After power-on, the following window is displayed: it informs about firmware revision.

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After diagnostics, the following control window is displayed.
Selections to the right are short-cuts that allow to enter the corresponding selections. They can be
reached by means of the control knob (5), that incorporates a switch: this is possible selecting the item
moving the knob, and then pressing the knob to confirm. Once the item has been reached, moving the
knob the menu moves forwards backwards of one step, so that other programming can be performed;
else, selecting the arrow the menu returns to the main window.
2.3.1 Set
This selection is a short-cut to the “Setup options” selection of the Menu; see below.
2.3.2 Res
This selection is a short-cut to the “Results” selection of the Menu; see below.
2.3.3 Micro-Ohmmeter
This selection is a short-cut to the “Micro-Ohmmeter test” selection of the Menu; see below.
2.3.4 View
With this selection, it is possible to choose which channels will be displayed on the screen: this serves
to minimize the number of traces. Next to this selection, the display self-adjusts so that, so that it is
easier to watch test results. Pressing View, the following window is opened.

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The left side of the screen follows the selection.
NOTE: this selection is independent from other selections, and all selected channels are saved into test
results. On the same result, you can temporarily select to view on trace only, so that it can be examined
at ease.
2.3.5 Menu
With this selection, the following window is opened.
2.3.5.1 Test diagram
This is the selection that allows you to come back to the test control: the test diagram is displayed, it is
possible to start the test and to watch test result. The following is the example of a test diagram.

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Main contact lines mean:
. Thin line = Open contact;
. Thicker line = pre-insertion resistor closed;
. Thickest line = Closed contact.
Auxiliary lines are: Thin = Open; Thick = Closed.
Next lines are the coil currents profiles: they are four if the option is installed.
The time base is the test duration, with a scale that corresponds to the test time.
2.3.5.2 Trigger options
The selection defines the reference for time measurements: pressing it, the following window is
displayed.

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- The “Coil current” selection means that the timing is measured with the reference to the first coil
current detected, being it Open or Close, according to the test sequence. Next window allows to select
the coil current threshold percentage, from 1% to 30%, of the selected current range, that is displayed:
coil range selection is performed accessing “Analog channel / coils setting”.
This selection was used in the past, when coil drivers were made of relay contacts that bounced in a
way that the accurate time measurement was made difficult, and has been provided for comparison with
older test results. Also, changing the current threshold changes the timing result, as the current
increases slowly, because of the coil inductance. With CBA1000, coil driving is electronic: the voltage
edge is steep, and there is no bounce; so, the internal trigger selection is preferable. The difference
between the two selections is in the order of 1 ms.
- The “Internal trigger” selection means that the time measurement starts as the first Open or Close coil
command is issued by the driving circuit.
- The “Coil command reset” selection means that the time measurement starts as the Open or Close coil
command drops.
- The “Analog input” selection means that the time measurement starts when the analog input level
crosses (greater than, lower than) the selected threshold. Next window allows to select the analog input
threshold:

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- “External trigger on Slave input” selection. The test set features a Master output and a Slave input
(29), that allow synchronizing up to 4 CBA1000’s (1 Master, 3 Slave). In this mode, one CBA1000 acts
as the Master unit; its Master output will be connected to all other units, selected as Slave. As the
Master starts the test, all other Slave units will measure the timing on Main, auxiliary and analog
inputs, but don’t generate coil driving signals. This feature allows to test circuit breakers with more
than two chambers per phase, or to survey more than four auxiliary inputs, or to survey more than one
analog input at a time.
- The “Auxiliary input” selection means that the time measurement starts when the selected auxiliary
input turns ON or changes its state. The trigger can be performed also on a logical combination of
auxiliary inputs. The choice is performed on the following window.

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2.3.5.3 Test options
The selection defines the type of test: pressing it, the following window is displayed.
NOTE: the selected option is displayed by LED’s by the side of the SEL pushbutton .
If the operator acts on SEL, opening this window the performed selection is repeated.
This selection is useful in case of:
. Definition of Open commands if the of four coil drive option is available;
. Definition of the test sequence.
- With the “Open” selection, CBA1000 issues an Open command and records timings, according to
other selections. In case of four coils, the selected Open coil phase is driven: selections are performed
in the following window.

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The selection “Cycle single phase” means that, in a series of Open commands, the first Open command
will be issued on phase A; next Open command will be issued on phase B; next Open command will be
issued on phase C. With further Open commands the cycle will be repeated.
The selection “Cycle two phases” means that, in a series of Open commands, the first Open command
will be issued on phases A and B; next Open command will be issued on phases B and C; next Open
command will be issued on phases C and A. With further Open commands the cycle will be repeated.
The selection “Cycle all” means that, in a series of Open commands, they will be: Phase A; Phase B;
Phase C; Phases AB; Phases BC; Phases CA; Phases ABC. With further Open commands the cycle will
be repeated.
- With the “Sequence” selection, the user can edit the desired test sequence. This gives the following
possibilities:
. Issue a sequence of Open and Close commands: up to 200 commands can be programmed. With this
selection it is possible to program the delay between OC commands: delay range 30 to 999 s.
. In case of four coils, program any series of Open commands;
. Program a COC sequence.
. Execute a test that simulates the lack of Auxiliary Voltage.
To this purpose, the following window is opened.
. Time delays and durations are independently set for each cycle; these values are independent with
respect to those selected for the single test: see here after.
The user must take care of defining a proper sequence, in terms of timing and Open-Close sequence.
Add and Delete commands help editing the test sequence. The Delay selection must be set between two
commands: remember that the CB cannot be driven with timings less than 30 s.
- The Recording Options command opens the following window.

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. With the first selection, the recording is continuous, including the delay between tests. This selection
is not to be used unless for short tests: the long delay reduces screen resolution and time measurement
accuracy.
. With the second selection, the recording is performed at the highest resolution, around the Open or
Close commands: this is to be selected in case of long sequences.
2.3.5.4 Recording options
This selection defines how test results will be recorded: pressing it, the following window is displayed.
The timing definition can be displayed pressing “HELP diagram: the following window is displayed.
As you see from timing definitions, it is possible to superimpose a Close command to the Open
command: this is obtained setting the “Open to close delay “ smaller than the “Open coil duration”.
The “Pre-trigger” duration applies only to the beginning of the test (or sequence).
The “Recording duration” includes all delays: it must be bigger than “Pre-trigger” + “OC delay” + “CO
delay” + the CB timings, so that no significant part of the test is lost. On the other side, it should not be
too big, as it defines the test result dimension, hence the number of test results that can be kept in
memory. Pressing HELP diagram, the following window explains the definition of terms.

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. Two recordings selection. In this mode, the measurement is performed in two steps, separated by a
pause: this avoids losing the timing resolution. It is possible to program a first recording duration, then
a dead time, then the second recording duration. In this mode, coil currents and the analog input are not
monitored. If the box is checked, the selection window changes as follows.
The following diagram explains timing definitions: it allows testing the action of the “pole
discrepancy” protection.
OPEN 1
OPEN 1
CONTACT 1
CONTACTS 2, 3 D 1
PAUSE D 2

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2.3.5.5 Breaker and auxiliary channel settings
This selection defines the channels that will be monitored and recorded: pressing it, the following
window is displayed.
- In the first set of selections, related to CB contacts, it is possible to select which contacts should be
monitored: “A1 only for preliminary tests; “A1 B1 C1” for single-chamber CB; “All” for 2-chamber
CB. Besides, it is possible to select the pre-insertion resistor test.
- In the second and third set of selections, it is possible to enable the test of auxiliary inputs, to label
them, and to select whether the contact is wet or dry: A1-A2 can be different with respect to A3-A4.
2.3.5.6 Analog channel / coils settings
This selection defines the parameters of the analog channel and of the coil currents that will be
monitored and recorded: pressing it, the following window is displayed.
- The first set of selection allows for the separate definition of the Close and Open coils current ranges.
The selected value must be greater than the nominal coil current, else the recording will be cut

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(saturated) at the selected range value, and peak current measurement will be impossible. However, in
case of wrong selection no damage to measurement circuits will occur.
For the Analog channel, if the box is checked the following lower part of the screen is displayed.
- The “analog input” selection means that the channel is connected to any other source than travel or
pressure transducer: for instance, auxiliary voltage, or Motor voltage, or Motor current. With this
selection, the following window is displayed.
It is possible to label the input, and to select the voltage range, that must be greater than the nominal
coil current, else the recording will be cut (saturated) at the selected range value, and the actual
measurement will be impossible. However, in case of wrong selection no damage to measurement
circuits will occur.
- The “Travel transducer” selection means that the channel is connected to a travel transducer, and that
it is desired to convert the input voltage into: stroke, speed, acceleration. The program will take into
account the fact that the beginning of the stroke is not 0 V, and that the end of the stroke is not the
voltage that supplies the transducer.
With this selection, the following window is displayed.