Megger PCA2 User manual

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User’s Manual
Art No. ZP-CQ01E Doc. CQ0033CE V03 2013
PCA2
On-Load Protection Condition Analyser

PCA2
On-Load Protection Condition Analyser
NOTICE OF COPYRIGHT & PROPRIETARY RIGHTS
© 2013, Megger Sweden AB. All rights reserved.
The contents of this manual are the property of Megger Sweden AB. No part of this work may be reproduced or transmitted in any form or
by any means, except as permitted in written license agreement with Megger Sweden AB. Megger Sweden AB has made every reasonable
attempt to ensure the completeness and accuracy of this document. However, the information contained in this manual is subject to change
without notice, and does not represent a commitment on the part of Megger Sweden AB. Any attached hardware schematics and technical
descriptions, or software listings that disclose source code, are for informational purposes only. Reproduction in whole or in part to create
working hardware or software for other than Megger Sweden AB products is strictly prohibited, except as permitted by written license
agreement with Megger Sweden AB.
TRADEMARK NOTICES
Megger® and Programma® are trademarks registered in the U.S. and other countries. All other brand and product names mentioned in this
document are trademarks or registered trademarks of their respective companies.
Megger Sweden AB is certified according to ISO 9001 and 14001.
User’s Manual
Postal address:
Megger Sweden AB
Box 724
SE-182 17 DANDERYD
SWEDEN
T [phone]
F [phone]
[e-mail]
www.megger.com
Visiting address:
Megger Sweden AB
Rinkebyvägen 19
SE-182 36 DANDERYD
SWEDEN
CQ0033CE ZP-CQ01E PCA2 3

4PCA2 ZP-CQ01E CQ0033CE
Contents
1 Safety..................................................... 6
1.1 General........................................................6
Symbols on the instrument.......................................... 6
1.2 Safety instructions........................................6
2 Introduction......................................... 10
2.1 General......................................................10
2.2 Warranty statement ...................................10
2.2
Service/Technical support ................................11
2.3 Unpack system...........................................11
Packing list................................................................ 11
3 Panel .................................................... 12
The PCA2 display ..................................................... 13
Printer setting ........................................................... 13
4 System settings and configuration.... 14
4.1 System mode.............................................14
Zero DC .................................................................... 14
User defaults............................................................. 14
Set time .................................................................... 14
File manager ............................................................. 14
PCA config................................................................ 14
Help.......................................................................... 15
4.2 Configuring inputs.....................................15
5 On-Load current injection - Principle of
operation................................................ 16
5.1 General......................................................16
5.2 Examining load stage ................................17
6 Connections for AUTO or MANUAL
testing..................................................... 18
6.1 Basic connections ......................................18
6.2 Optional connections ................................19
7 Manual test mode............................... 20
7.1 Performing injections .................................20
7.2 Performing injections / Tests in
manual mode .........................................20
8 Auto test mode ................................... 22
8.1 Basic..........................................................22
8.2 Auto Test mode - Calculator ......................23
8.3 Auto Test mode - Interpretation of graphical
results/measurements .............................24
8.4 Auto test mode - Auto test analysis ...........26
9 Handling results / File manager ........ 28
9.1 Copying, moving and deleting files ............28
Deleting files............................................................. 28
Copying and moving files.......................................... 28
Changing directories ................................................ 28
Viewing previously saved COMTRADE records .......... 28
9.2 PC Viewer software ...................................29
10 Functional check procedure ............. 30
11 Specifications .................................... 32
A1 Glossary ............................................ 34
A2 Using additional current probes ..... 36
Probe DC offset ....................................................... 37
Index ....................................................... 38

CQ0033CE ZP-CQ01E PCA2 5

6PCA2 ZP-CQ01E CQ0033CE
1 SAFETY
1Safety
1.1 General
Always follow the local safety regulations that apply
to work with high-voltage equipment.
Make certain that all personnel who work with PCA2
have been trained in its use and that all applicable
safety precautions are taken.
Read and comply with the following instructions as
well as the warnings and instructions on the PCA2
control panel.
Symbols on the instrument
Caution, refer to accompanying docu-
ments.
Protective conductor terminal.
WEEE, Waste Electrical and Electronic
Equipment. Please utilize your local
WEEE collection facilities in the dispo-
sition of this product and otherwise
observe all applicable requirements.
1.2 Safety instructions
You must also read and follow the additional safety
precautions in each appropriate section of the manu-
al.
1. Read / Follow / Retain all instructions
▪All safety and operating instructions must be read
before using PCA2.
▪All safety and operating instructions for PCA2 must
be followed.
▪All safety and operating instructions must be retained
for future reference.
2. Connecting
▪Always ground PCA2
▪Before connecting PCA2, turn off its master ON/OFF
switch.
▪It is recommended that only the supplied safety
touch-proof cables, connectors and crocodile clips are
used
▪When changing the connections make sure that
current not can be generated accidently. Disconnect
the mains supply or turn off the master ON/OFF
switch
▪Use caution when working near bare conductors
or bus bars. Accidental contact with a conductor
may cause electrical shock. Follow the local safety
regulations.
▪Before connecting PCA2 to a circuit breaker,
make certain that the circuit breaker is closed and
grounded on one side.
▪When testing current transformer. Dangerous
voltages can appear in the secondary circuits if they
are open.
▪Unplug PCA2 from the mains supply when it is left
unattended or not in use.

CQ0033CE ZP-CQ01E PCA2 7
1 SAFETY
3. Grounding (Earthing)
▪PCA2 can be used only in electrical systems with
single Ground. User must verify before connecting
this unit to power, that High Voltage Ground and
Low Voltage Protective Ground create a single
protective ground with no measurable voltage
potential existing between these ground systems.
If a voltage potential is found between the ground
systems please consult local safety regulations.
▪Always use a grounded mains cable to connect the
unit to the mains. Always ground PCA2 using a
separate ground cable.
4. Mains cord protective conductor
▪PCA2 is equipped with a power cord with integral
safety ground pin.
▪The equipment must be connected to a grounded
mains outlet.
▪Do not defeat the safety ground in any manner.
5. Separate ground wire
▪The PCA2 case must also be grounded by the separate
protective ground wire with connection to the
Protective Conductor Terminal on top of the PCA2.
Check the continuity of the protective ground wire
before each use. Make sure the connector is fastened
properly to the PCA2 Protective Conductor Terminal.
Make sure the connection point at the ground
system is fastened properly. Route the wire so that
it is unlikely to be walked on or that it may loosen
accidentally by someone or something moving near
it.
▪The protective ground wire must not be loosened
while any input connector is attached to the contacts
of a high voltage circuit breaker or another device
being subject to inductive or capacitive coupled
interference from surrounding high voltage wires.
6. Placement
▪PCA2 must be situated away from any heat sources
such as radiators, heat registers, stoves, or other
products that produce heat.
Do not place the PCA2 in areas with excessive
dust, mechanical vibration or shock
▪Do not use PCA2 near water.
▪Do not expose the PCA2 to rain or moisture.
▪Do not touch the plug with wet hands. Doing so may
result in electrical shock.
7. Use
▪Do not use the instrument for any purpose other
than indicated by the manufacturer.
▪Do not use any accessories/cables not recommended
by the PCA2 manufacturer as they may cause
hazards.
8. EMC Warning
▪PCA2 can generate radio frequency energy. If not
installed and used in accordance with this manual
it may cause interference to radio communications.
PCA2 has been tested and found to comply with
the limits for measurement equipment designed
to provide reasonable protection against such
interference when used in an industrial environment.
Operation of PCA2 in a commercial or residential
area is likely to cause interference, at which case,
the user, at his own expense, will be required to take
whatever measures that may be required to correct
the interference.
9. Cables
▪Use only approved mains detachable cable set with
PCA2. Main supply cables shall be rated for the
maximum current for the equipment and the cable
shall meet the requirements of IEC 60227 or IEC
60245. Mains supply cables certified or approved
by a recognized testing authority are regarded as
meeting this requirement.
▪Connecting cables must be routed so that they are
not likely to be walked on nor pinched by items
placed upon or against them. Do not pull on or tie
them. Pay particular attention to the connectors.
▪To disconnect a cable, unlock the retainer (in case of
an XLR connector), grasp the connector firmly and
pull.
▪If an input- or output cable becomes damaged, stop
using it. Use of a damaged cable may result in fire or
electric shock.
10. Power sources
▪Use an easily accessible power outlet. This will ensure
that you can disconnect the power quickly in case of
a problem.
▪Never connect PCA2 to a mains voltage other than
that specified on the panel.
▪The plug to the mains inlet is not to be used as
disconnecting device.
▪The mains connector or the mains switch are to be
used as disconnecting device.

8PCA2 ZP-CQ01E CQ0033CE
1 SAFETY
11. Inputs and outputs
▪Do not apply voltage to the outputs.
▪Dangerous voltages can develop at exposed
connectors if the equipment malfunctions.
12. Ventilation
▪Slots and openings in the instrument are provided for
ventilation. They ensure reliable operations, keeping
it from overheating. These openings must not be
blocked nor covered during operation.
13. Lightning
▪For added protection for PCA2 during a lightning
storm unplug it from the AC outlet and from all
cables connected to the inputs. This will prevent
damage to the PCA2 due to lightning and power
supply surges.
▪Never touch the plug and power cord if it begins to
thunder. Touching them may result in electric shock
14. Cleaning
▪Unplug PCA2 before cleaning
▪Do not use liquid cleaners or aerosol cleaners.
▪Use only a damp cloth for cleaning.
▪Stubborn stains may be removed with a cloth lightly
dampened with a mild detergent solution.
15. Damage
▪Do not use PCA2 if the test leads appear damaged.
▪Do not continue using a damaged PCA2. Using a
damaged PCA2 may result in fire or electric shock.
16. Damage requiring service
▪Unplug PCA2 from all connections and refer servicing
to qualified service personnel under the following
conditions:
• When any connector is damaged, including mains
plug.
• If liquid has been spilled into PCA2.
• If PCA2 has been exposed to rain or moisture.
• If the PCA2 does not operate normally (following the
operating instructions).
• If the PCA2 has been dropped or damaged in any
way.
• When PCA2 exhibits a distinct change in
performance.
• If PCA2 begins to emit smoke, smells like
something is burning or makes strange noise.
17. Servicing
▪Do not attempt to service PCA2 yourself; opening
or removing covers can expose you to dangerous
voltage and other hazards.
▪Refer all servicing to Megger authorized personnel.
▪If you attempt to service PCA2 yourself the warranty
is no longer valid.
18. Returning
▪If, for some reason, you need to return PCA2, please
use either the original transport box or one of
equivalent strength

CQ0033CE ZP-CQ01E PCA2 9
1 SAFETY

10 PCA2 ZP-CQ01E CQ0033CE
2 INTRODUCTION
2Introduction
2.1 General
The Megger PCA2 is a multipurpose instrument
combining a special type of electronic current source
and extensive data acquisition and display capabilities.
It is designed for performing both On-Line and Off-
Line tests on Circuit breakers, protection Relays and
indeed, entire protection systems.
The PCA2 can be used to perform many different
types of tests:
▪Relay only (Off-Line or On-Line): as a general purpose
current injection unit for performing timing tests on
overcurrent relays (25A high burden capability), whether
or not the relay is connected and has a secondary current
already flowing.
▪Breaker only (On-Line): On-line breaker tester & timer with
trip-coil current profile and secondary current recording.
Main contact time(s) determined by collapse of secondary
current(s).
▪Breaker only (Off-line): Breaker tester with trip-coil current
profile recording and timing via auxiliary contacts or
(subject to usual safety precautions), directly at the main
contacts.
▪DSO: The PCA is a very capable multichannel Digital
Storage Oscilloscope and True RMS voltmeter/ammeter. It
can measure and record voltages/currents/contacts/digital
events at high speed and for long periods of time. Timing
and amplitude measurements on recorded data can be
performed on the PCA as well as exported and viewed on
a PC using the supplied software package or any third-
party software capable of displaying IEEE COMTRADE
format records.
▪Complete Protection & Breaker System Test (On-Line):
Tests an entire protection system (relay, breaker, battery,
wiring etc.) On-line via live injection into a relay thereby
capturing the first trip of relay and breaker. This test,
when performed in a systematic way, can yield useful data
for a Reliability Centred Maintenance or Condition Based
Maintenance approach.
2.2 Warranty statement
Megger warrants the product is free of defects in
material and workmanship for a period of one (1) year
from date of shipment. This warranty is non-trans-
ferable. This warranty is limited and shall not apply
to equipment that has damage, or cause of defect,
due to accident, negligence, and improper operation,
faulty installation by the purchaser, or improper service
or repair by any person, company or corporation not
authorized by Megger. Megger will, at its' option,
either repair or replace those parts and/or materials it
deems to be defective.
The warranty is in lieu of all other warranties, either
expressed or implied on the part of Megger and in
no event shall Megger be liable for the consequential
damages due to the breach thereof.

CQ0033CE ZP-CQ01E PCA2 11
2 INTRODUCTION
2.2 Service/Technical support
For technical assistance please contact your local
representative or direct your request to Megger in
Sweden.
E-mail: [e-mail]
Tel: [phone]
Fax: [phone]
Internet: www.megger.com
When sending the instrument, please use either the
original crate or one of equivalent strength
Add the return authorization number to the address
label of the shipping container for proper identifica-
tion and quicker handling.
Note Ship the equipment without nonessential
items such as test leads, etc. These items are
not needed by the factory to perform service.
2.3 Unpack system
Unpack the unit and check for evidence of any ship-
ping damage. If there is any visual damage, imme-
diately notify the freight carrier to make a damage
claim, and notify Megger of the damage.
Packing list
Pcs Item
1 PCA2 Test set
1 User's Manual
1 CD containing PC Viewer software
1 Mains Lead
1 Hall-effect clip-on current sensor, (Relay Cur-
rent Sensor)
1 Hall-effect clip-on current sensor, (Trip Coil Cur-
rent Sensor)
4 Red/Black connection leads
4 Red & Black insulated crocodile clips
1 Ground Connection Lead (for grounding PCA
to suitable exposed metalwork on panel being
tested)
1 USB Memory Stick (for storing and/or transfer-
ring results to a PC)
1 Padded storage case

12 PCA2 ZP-CQ01E CQ0033CE
3 PANEL
3Panel
1. ▪Grounding (earth) terminal
2. ▪TRIP COIL I SENSOR
Itc
3. ▪CURRENT OUT
The current out terminals should be connected to
the relay or circuit under test
4. ▪RELAY I SENSOR
Irly
5. ▪Green lamp button
Power on indicator and button to open the printer
paper lid.
6. ▪Print button
7. ▪COM
Two USB and one Ethernet port. The supplied USB
flash drive can be connected to either of these USB
ports and used for transferring results to a PC. The
Ethernet (network) port is not currently utilised.
8. ▪Fuses
2 x T 6.3 A, 250 V AC
9. ▪Mains inlet
10. ▪ON/OFF switch
11. ▪INPUTS
V1 V2 V3 V4
CAT II 300 V
Connect voltages /binary contacts that are to be
measured/recorded here, e.g. battery voltage (on
V1), relay trip contacts, trip coil voltage, breaker
auxiliary contacts etc.
Note that these can also be configured to
measure and display current if additional
current sensors are utilised.
12. ▪Touch screen Colour LCD
1
119
67 3
12
10
2 4 5
8

CQ0033CE ZP-CQ01E PCA2 13
3 PANEL
The PCA2 display
Note Due to continuous improvements to the PCA
software and individual configurations, the
screenshots depicted will very likely not be
identical to that of your own PCA.
1. Standard buttons - these are used to con-
trol the PCA
2. Waveform display window - The input
waveforms are displayed here
3. Dialog Box - Displays important messages
from the PCA
4. Data display boxes - Each waveform has a
data display box, indicating the measured
results. Tapping an individual channel’s data
display box brings up a dialog box permit-
ting that channel’s displayed amplitude to
magnified/reduced and what channels are
displayed to be selected.
Printer setting
Picture below show the deafult settings.
If the settings have been altered by some reason or if
you want to check/change the setttings, proceed as
follows.
1] Set the PCA2 ON/OFF switch to OFF.
2] Touch and hold the Print button while you
switch to ON.
The PRINTER SETUP printout comes out. Now
release the button.
3] The value of a particular menu item can be
set or changed by a quick touch on the Print
button.
4] Move to the next menu item by pressing the
Print button for 2 seconds.
Note If a menu item is wrongly set or missed then
the entire process need to be repeated.

14 PCA2 ZP-CQ01E CQ0033CE
4 SYSTEM SETTINGS AND CONFIGURATION
4
System settings and
configuration
4.1 System mode
Zero DC
Calibration of the RELAY I SENSOR input and the TRIP
COIL I SENSOR input.
1] Plugg in all current sensors and touch "Zero
DC".
User defaults
Here you can add and edit the test details.
1] Touch "User Defults".
2] Touch "Add" for new items
Touch an item to edit and then touch "Edit".
3] Make your settings.
4] Touch "Ok" or "Cancel" to return to the start
screen.
Set time
1] Touch "Set Time".
2] Make you settings.
3] Touch "OK.
File manager
Here you manage the files e.g. copy to USB memory.
PCA config
1] Touch "PCA Config".

CQ0033CE ZP-CQ01E PCA2 15
4 SYSTEM SETTINGS AND CONFIGURATION
2] By double touching any of the lines "Fre-
quency" or "Examine Load" an new window
appears and you can make the desired set-
tings.
3] Touch "OK" to return.
Help
The "help" button is alwys available.
1] Touch "Help" to invoke the User guide".
4.2 Configuring inputs
1] Touch "Conf Inputs".
2] Check /uncheck the boxes as disired.

16 PCA2 ZP-CQ01E CQ0033CE
5 ON-LOAD CURRENT INJECTION - PRINCIPLE OF OPERATION
5On-Load current injection - Principle of operation
5.1 General
The special "On-Load Current Injection" subsystem
is able to inject a precise current into a relay element
irrespective of the actual load current. This software-
controlled current source uses an external feedback
element (clip-on hall-effect current sensor) and elec-
tronic amplifier. The current source is able to output a
precise current (as determined by the external current
sensor) even in the presence of other currents (e.g.
the secondary current from the protection CT).
This arrangement permits an overcurrent relay within
a live/on-load circuit to be injected with a precise cur-
rent even in the presence of an unknown or varying
load current.
On-Load current injection subsystem block diagram
The on-load current injection subsystem works in the
following manner:
▪User instructions (i.e. current to inject) are supplied to the
Computer by use of the touch screen.
▪The computer determines the required current waveform
sinewave to inject into the relay (starting at a low-to-
high zero crossing) and instructs the digital to analogue
converter (D/A) accordingly. If a load current is detected
then the start of injection is delayed until the next low-to-
high zero crossing of the load current. In this way, both
the load current and the injected current are started at
their low-to-high zero crossings and therefore become
synchronised (in-phase). If no load current is detected,
then the injection is simply immediately started at a low-
to-high zero crossing.
▪The D/A controls the power booster/amplifier which
outputs a voltage to the Current Out terminals.
▪Current flowing into the Relay is then measured with the
external clip-on current sensor (Irly).
▪The output of the sensor is read by an Analogue to Digital
Converter (A/D) and sent to the computer.
▪Based on the feedback from the A/D the computer
recomputes a new D/A value 20,000 times a second. By
means of this feedback system or control loop, the desired
current (as seen by the Irly sensor) is injected.
• If there is no load current then the PCA output current
will be the same as Irly.
• If there is a load current present then the relay current
(as sensed by the Irly sensor) will be the vector sum of
the PCA output current and the load current.

CQ0033CE ZP-CQ01E PCA2 17
5 ON-LOAD CURRENT INJECTION - PRINCIPLE OF OPERATION
5.2 Examining load stage
'Examine Load' refers to the method by which the
PCA2 current-source sense usees two different modes
to generate.
If 'Updated' is selected (recommended) – The cur-
rent injection is dynamically corrected while injecting
current.
If 'Legacy' is selected - the sense determined by at-
tempting several very short injections (just one cycle
long at 50/60). This calculated value is then used
for the subsequent current injection. Note: This may
cause a relay to prematurely trip.
The updated method was introduced during a
software revision and is the recommended default
method. Legacy method suffered from sometimes
producing very short high current pulses before the
main injection that could cause a relay to prematurely
trip, hence why the updated method was developed.
The capability of reverting to the legacy method is
kept to be used in case any unforeseen reason, the
user would like to use it.
If for any reason the unit is not able to complete the
Examining Load stage then a warning is displayed (Er-
ror Examining Load) and the injection aborted. If this
error persists, see "4 System settings and configura-
tion" on page 14.

18 PCA2 ZP-CQ01E CQ0033CE
6 CONNECTIONS FOR AUTO OR MANUAL TESTING
6Connections for AUTO or MANUAL testing
6.1 Basic connections
IMPORTANT
Always follow the safety regulations in
chapter 1 of this manual.
Always comply with local safety regulations.
Basic connections for on-load testing
1] Make connections as shown in the figure
above for performing a basic on-load trip test.
For a basic on-load injection, only the current
out terminals & Irly (RELAY I SENSOR) need be
connected.
Note The direction of the relay current sensor does
not matter for the injection as the software
automatically senses how it has been connected
and adjusts accordingly. However, the displayed
waveform will always follow the arrow marked
on the current sensors so that relative current
polarities/phase angles can be measured on the
PCA2 display.
Note This sensor must sense the exact same current
as the relay.

CQ0033CE ZP-CQ01E PCA2 19
6 CONNECTIONS FOR AUTO OR MANUAL TESTING
6.2 Optional connections
1] Additional connections can be made from
the other unused PCA2 inputs to various
points on a breaker/protection panel:
Itc (TRIP COIL I SENSOR) for recording the trip-coil
current profile.
Note The polarity of the TRIP COIL I SENSOR does
not matter as the software automatically
senses how it has been connected and adjusts
the display accordingly.
2] V1...Vn. Connect these to voltages/contacts
on protection/breaker panel.
By connecting to the battery voltage, any
dips during protection operation can be
measured and battery health inferred.
Note All PCA2 inputs/outputs are galvanically iso-
lated from each other and earth thus simplify-
ing connections. If these inputs are being used
to sense a plain or dry contact input, then
they must be configured as "Plain Contact"
within the software, the default being "Volt-
age Sensing".
This enables a wetting voltage to be output
from these inputs so that a plain contact or a
dry contact contact can be sensed.

20 PCA2 ZP-CQ01E CQ0033CE
7 MANUAL TEST MODE
7Manual test mode
7.1 Performing injections
IMPORTANT
Always follow the safety regulations in
chapter 1 of this manual.
Always comply with local safety regula-
tions.
Manual mode is the mode the PCA2 first enters when
powered up and after the “Please check all Cur-
rent...” message is displayed. This mode enables all
the inputs to be displayed and measured and simple
current injections to be performed.
This display constantly updates any currents or volt-
ages that are connected to the PCA2.
Note This mode is very useful for performing
functional checks, quick relay timing tests and
confirming connections are correct.
Manual mode - basic screen
7.2 Performing injections /
Tests in manual mode
1] If injections are to be performed then con-
nections as per "5.1 - Basic Connections"
must be made.
Alternatively, connections as described in or
"9. Functional Check Procedure" can be used
in the absence of a real load.
2] Select the current to inject for the test using
the “+I” and “-I” buttons.
3] Touch the “INJECT I” button when ready to
inject.
An "Examining Load" message will briefly
appear, if Legacy mode is selected, followed
by the injection.
Note The PCA may indicate an error like “Current
Out Error" or "A Current error caused the
fault to be stopped early". This is usually due
to wrong connections. Check that the Cur-
rent Out terminals are correctly connected to
the circuit under test and that the feedback
element (Irly, the Relay Current Sensor) is con-
nected to the appropriate location.
Typical manual mode display showing an injection
Note Current generation over 17 Amps is limited to
20 seconds.