MRD Rail Technologies RelayDoc User manual

RelayDoc User Manual
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RelayDoc™
User Manual
For Models:
RelayDoc
RelayDoc-HV

RelayDoc User Manual
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Manufacturer
MRD Rail Technologies Pty Ltd
Address
235 South St, Cleveland. QLD. 4163. Australia
Telephone
[phone]
Email
[email protected]
Web
www.mrd.com.au
Downloads
User Manual
www.mrd.com.au\dl\RelayDoc-UM.pdf
Installation Guide
www.mrd.com.au\dl\ RelayDoc-IG.pdf
Datasheet
www.mrd.com.au\dl\ RelayDoc-DS.pdf
EU Declaration
www.mrd.com.au\dl\ RelayDoc-DoC.pdf
Publication History* **
Version
Comment
Author
Approved
Date
Class
0.1
John Zhang
15Mar2013
Draft
0.2
Michelle Gersbach
30Sep2013
Preliminary
0.3
Michelle Gersbach
15Oct2013
Preliminary
1.11
John Zhang
05May2014
Preliminary
1.13
John Zhang
03Jun2014
Preliminary
1.23
Adam Shipway
01Jul2016
Issued
1.24
Adam Shipway
LI
08Nov2016
Issued
1.25
Image corrected
Adam Shipway
14Sep2017
Issued
*The latest version of this User Manual is available at http://www.mrd.com.au/dl/RelayDoc-UM.pdf
**Note: RelayDocs in service may not have the latest software.
RelayDoc™ User Manual
The
software described in this manual is provided under a license agreement and may be used only in
accordance with the terms of that agreement.
Trademarks
The MRD logo is registered trademark of MRD Rail Technologies Pty Ltd.
All other trademarks or registered marks in this manual belong to their respective holders.
Disclaimer
Information in this document is subject to change without notice and does not represent a commitment on
the part of MRD Rail Technologies Pty Ltd.
MRD provides this document
as is, without warranty of any kind, expressed or implied, including, but not
limited to, its particular purpose. MRD reserves the right to make improvements and/or changes to this
manual, or to the products and/or the programs described in this manual,
at any time.
MRD intends that the
Information in this manual is accurate and reliable. However, MRD assumes no
responsibility for its use, or for any infringements on the rights of third parties that may result from its use.
This manual, and the product
it relates to, might include unintentional technical or typographical errors. From
time to time, MRD corrects such errors, and these changes are included in the latest version.
Copyright Notice
© 2016 MRD Rail Technologies Pty Ltd. All rights reserved.
Technical Support Contact Information

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Table of Contents
1. INTRODUCTION.....................................................................................5
2. PRODUCT DESCRIPTION.........................................................................5
Model Identification........................................................................................... 5
Function ............................................................................................................. 5
Setup options ..................................................................................................... 6
Features ............................................................................................................. 6
3. PACKAGE CONTENTS .............................................................................7
4. INSTALLATION.......................................................................................8
Options............................................................................................................... 8
4.1.1 Wall mount ...................................................................................................8
4.1.2 Portable usage ..............................................................................................8
4.1.3 Bar Code Reader ...........................................................................................8
Network Communication Architecture ............................................................... 9
5. SETUP .................................................................................................10
Automatic configurations ................................................................................. 10
5.1.1 IP Address ...................................................................................................10
5.1.2 Profile updates ............................................................................................10
5.1.3 Application upgrades ..................................................................................10
5.1.4 Report upload to RelayDoc Web Server .....................................................10
5.1.5 Calibration Report upload to RelayDoc Web Server...................................10
General setup ................................................................................................... 11
5.2.1 Personal Identification Number (PIN).........................................................11
5.2.2 Advanced Settings.......................................................................................11
Relay Test Process Settings............................................................................... 12
6. TESTING RELAYS ..................................................................................13
7. TEST FUNCTIONALITY ..........................................................................15
Coil Resistance.................................................................................................. 15
Contact Resistance ........................................................................................... 15
Contact Conditioning........................................................................................ 15
Contact Switching Time .................................................................................... 15
Operating Voltage and Current......................................................................... 15
Release Voltage and Current ............................................................................ 16
8. TEST REPORTS (VIEWED ON DEVICE)....................................................17
Viewing Saved Reports ..................................................................................... 17
Adding notes to reports.................................................................................... 18
Filtering reports................................................................................................ 18
Saving Reports to USB Device........................................................................... 18
9. WEB SERVER (EMBEDDED ON DEVICE).................................................19
Web server features ......................................................................................... 19
Accessing the Web Server................................................................................. 19
Web Server Navigation and Functions.............................................................. 20
Home Page ....................................................................................................... 21
Login................................................................................................................. 21
Report Page...................................................................................................... 21
Profile Page ...................................................................................................... 22
9.7.1 Relay Profiles Tab........................................................................................22
9.7.2 Test Specification Tab .................................................................................23

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Configuration Page ........................................................................................... 24
Calibration........................................................................................................ 25
9.9.1 Contact Resistance......................................................................................25
9.9.2 Coil Resistance ............................................................................................25
9.9.3 Voltage ........................................................................................................25
9.9.4 Current ........................................................................................................25
9.9.5 Calibration Report.......................................................................................25
9.9.6 Calibration Equipment ................................................................................26
System Upgrade ............................................................................................... 27
9.10.1 Upgrade Embedded Web Pages .................................................................27
9.10.2 Upgrade Whole Package.............................................................................27
9.10.3 Recover Firmware .......................................................................................27
9.10.4 Manage Local Database ..............................................................................27
Download Logs ................................................................................................. 28
Logout .............................................................................................................. 28
10. MAINTENANCE....................................................................................29
General Maintenance....................................................................................... 29
Test Base Verification Test................................................................................ 29
Calibration........................................................................................................ 29
Reset to Factory Settings .................................................................................. 30
11. TECHNICAL DATA.................................................................................31
12. WARRANTY.........................................................................................32

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1. INTRODUCTION
This document provides information on the specification, installation and operation of the MRD RelayDoc and
RelayDoc-HV automatic relay testers. The differences between the two models are very slight: in this
document “RelayDoc” means either model, unless the RelayDoc-HV is specifically mentioned.
The standard RelayDoc configuration is suitable for testing variants of BR930 Relays (a.k.a. Q-Style), including:
•Single & Twin Coil Relays
•Heavy Contact Relays
•Current Relays.
The RelayDoc can be custom built to suit other common industrial relays.
2. PRODUCT DESCRIPTION
MODEL IDENTIFICATION
The original RelayDoc tests Relays requiring a supply voltage <50V DC.
RelayDoc-HV production commenced in July 2016. RelayDoc-HV tests
relays requiring a supply voltage <130V DC. It is otherwise identical to the
original RelayDoc, including embedded Application and Web Server.
RelayDoc and RelayDoc-HV are externally identical, and run the same
software. To identify your model, inspect the Serial Number tag. If the tag
includes hardware version, and the hardware version is C1 or higher, it is
a RelayDoc-HV. See sample tags at right.
FUNCTION
RelayDoc automates the process of Relay Testing, and the recording and management of Test Reports.
A Test Profile is stored for each unique Relay Type. The profile specifies the method for the individual tests
listed below. When a Relay is inserted, RelayDoc:
•Identifies the relay type using pin configuration
•Identifies the apparent contact configuration (normally open and normally closed contacts)
•Attempts to match the Relay to a stored Profile, and requests user confirmation if none or more than
one match is found
•Requests selection of the correct Coil Resistance if more than one option exists
The RelayDoc stores one default Relay Test Process, which is restored at Power ON. The Default Test Process is
changeable within usage sessions, selecting from the following tests:
•Coil Resistance
•Contact Conditioning (cannot be stored as default)
•Contact Resistance
•Contact Switching Time
•Operating Voltage and Current
•Release Voltage and Current
Test Reports can be stored and viewed locally, or copied to a remote server. RelayDoc uses a built-in Web
Server to enable remote examination and control of the device and stored report.

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SETUP OPTIONS
Prior to use, the operator/installer must consider the following setup options
Item
Comment
Permanent installation
Four holes are for wall or panel mounting. What hardware will be required?
Default Test Process
What is the most commonly used or standard process?
IP address required
Static or Dynamic? The RelayDoc defaults to a dynamic IP address
Time Zone, Time and Date
Where is the unit to be used?
Interface Language
What language will the operator use?
PIN
A PIN is required to access on-device settings
User ID and Password
One named user can access the web-server settings
Company Logo
A company logo can be added to the Web-server Pages and Test Reports
FEATURES
*For Clarity, Power Cable has been electronically removed from image
Feature
Benefit
Full colour, backlit, 5” touch screen
Easy to use controls
Easy navigation
On-device Report viewing
Audible alerts
Event alerts following lengthy test processes
Network connected
Simple connection to a local network using Ethernet
Built-in web server
Remote viewing of on-device reports
Data downloads to remote databases
Access to advanced device settings
12-24vdc Input Power
Easily connect to any mains supply using a suitable power supply unit
Wall mountable
Easy to permanently install
1R Test Base
Power Switch
Calibration Label
USB-B Port
Ethernet Port
Factory Reset Switch
DB19 Female
Power Input*
Serial Number
Touch Screen
Relay Base
Screw Cover

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Robust enclosure
Can be used as a relocatable device
Default Relay Test
Easily revert to a standard test method
PIN security
Limits user access to on-device settings
Password security
Limits user access to web-server and device settings
Reset switch
Returns the device to locally stored Factory Settings
Connectors
Description
Purpose
USB Type A
Saving Reports; Upgrade software; Bar code reader;
Ethernet RJ45 10/1000mbps
Device configuration, network communication
D-Sub 15 pin Female
Verification; Calibration
Power Input Amphemol LTW BD-02
(12-24 VDC, ≤10W)
3. PACKAGE CONTENTS
Your new RelayDoc includes:
•RelayDoc
•Power Supply 19.5V
•1R Test Base
•User Manual
•Warranty Statement
•EU Declaration of Conformity
If any items are missing, please contact your RelayDoc supplier. Download the latest User manual at
www.mrd.com.au/dl/RelayDocUM.pdf

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4. INSTALLATION
OPTIONS
4.1.1 Wall mount
MRD recommends permanent installation of the RelayDoc, and the enclosure is easily wall mounted. The
enclosure includes four concealed mounting points, suitable for fasteners of thread diameter ≤5mm, Head
diameter ≤8mm.
•To access the mounting points, pry the left and
right hand snap-fitted covers from the front
panel
•Screw holes are spaced 262mm horizontally
and 120mm vertically as shown right
•Ensure sufficient clearance below the
RelayDoc to connect cables
•Minimise interference when changing relays;
Ensure sufficient clearance from walls or
shelves
•The device should be mounted at eye level,
typically 140-160cm above floor level.
Note: Relays must be retained in the base using the wire clip provided.
4.1.2 Portable usage
The RelayDoc contains electronic assemblies, and an exposed LCD screen. The enclosure is a robust product,
made from aluminium. There are no moving parts.
The RelayDoc has a nominal protection rating of IP30.
•Do not expose the RelayDoc to liquids: The device is not water resistant.
•Drops, vibration, or rough handling may damage the RelayDoc.
•External ports and switches must be protected from damage and contamination from dust and dirt.
MRD recommends using a shock-resistance carry case if the RelayDoc is moved frequently. Contact MRD to
arrange the supply of a suitable case.
4.1.3 Bar Code Reader
A bar code reader can be connected to the USB port, to capture the
serial number of equipment under test (EUT).
The data can be sent to an active Serial Number text box.

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NETWORK COMMUNICATION ARCHITECTURE
RelayDoc supports XML/HTML/JSON protocols to exchange data with external application servers, if installed.
RelayDoc also posts reports to the MRD Cloud server. Typical installation architecture is:

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5. SETUP
AUTOMATIC CONFIGURATIONS
When RelayDoc can connect to the Internet or a Local Network, it will attempt several upgrades.
5.1.1 IP Address
When an Ethernet Cable is plugged in, RelayDoc will try to obtain an IP address by sending a DHCP request.
RelayDoc will revert to any previously saved Static IP if an IP address is not assigned after three attempts.
5.1.2 Profile updates
5.1.2.1 Internet connected devices
If RelayDoc has access to the MRD Web Server unapplied Profile
Updates will be detected, and RelayDoc will prompt the operator.
•Touch “Yes” to download and install updates
•Touch “No” to ignore
5.1.2.2 Profile updates from USB
RelayDoc supports Profile updates from USB storage. When a USB
Device is connected, RelayDoc will scan for
\relaydoc_upgrade\profile\profile_updates.txt in the root directory. If
found, the user will be prompted to update the profile.
5.1.3 Application upgrades
The RelayDoc Application software can be updated from the Internet or USB device, noting:
•Usually, only the application only is updated
•Occasionally, the firmware will also be automatically upgraded
•Full system upgrades are completed using the Web Server, as described in Section 8.10.
5.1.3.1 Internet connected devices
If RelayDoc has access to the MRD Web Server unapplied Application
Updates will be detected, and RelayDoc will prompt the operator to
update.
5.1.3.2 Application updates from USB
RelayDoc supports Application updates from USB storage. When a
USB Device is connected, RelayDoc will scan for update files in
root\\:relaydoc_upgrade\application\. If found, the user will be
prompted to update the application.
5.1.4 Report upload to RelayDoc Web Server
Relay Doc supports the HTTP/HTTPS protocol for data interface. If RelayDoc is connected to the internet, and it
is configured to upload the report, the test reports will be automatically uploaded to the MRD Cloud Server.
Uploaded reports are in JSON format, including the test report data and an array of test detailed results data.
5.1.5 Calibration Report upload to RelayDoc Web Server
The most recent Calibration Report is uploaded to the RelayDoc Web Server when internet is available.

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GENERAL SETUP
5.2.1 Personal Identification Number (PIN)
A four digit PIN is required to view or change any settings on the RelayDoc. To change the PIN:
•Touch the Settings Icon on the Home Page and enter the current PIN
oCorrect PIN will advance to Settings Page
oIncorrect PIN will “shake” the dots
oTo Exit, touch Carriage Return Arrow anytime
•Touch “Advanced” icon
•Touch “Set PIN” icon
•Set & confirm the new PIN
oThe new PIN must differ from the current PIN
oThe dots will “shake” if the PIN is not different
5.2.2 Advanced Settings
RelayDoc has settable Language, Location, Date and Time. To change settings:
•Touch the Settings Icon on the Home Page
•Enter the current PIN
•Touch “Advanced” icon
•A menu of settings will appear. Touch the item to be changed
oLanguage- Select from the scrollable list
oTime zone- Select from the scrollable list
oDate- Set using the Rollover
oTime- set 24hr time using the Rollover

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RELAY TEST PROCESS SETTINGS
RelayDoc stores the last used process as the Default Relay Test
Process. To change and save the Default Test Process:
•Touch the Settings Icon on the Home Page
•Enter the current PIN. The Settings Page will appear
•On the left side of page, select the Tests to be completed
•Enter the number of cycles if requested (Note: Contact
Conditioning default is 20 cycles)
•On the right hand side of page, select the tests to be included in the Default Test Process (Note:
Contact Conditioning cannot be saved in the Default Process)
•To Save- Touch “Save”; “OK” on the confirmation screen; “Home” to Exit
•To Exit without saving- Touch “Home”. The current and default test processes will not be changed.

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6. TESTING RELAYS
RelayDoc automatically completes testing according to the Saved Test Process (Section 4.2). Some relays share
a common base configuration: the RelayDoc will request selection of the correct Test Profile.
To test a relay:
1
Insert Relay into Relay Base. Secure with
wire clip if the RelayDoc is wall mounted
2
Touch “Test Relay” on the Home Page
3
RelayDoc will attempt to select a
matching Relay Profile according to the
Code Pins detected:
•If no match exists, testing is not
possible. RelayDoc will request a
profile be added to the database
•If there is more than one
matching profile, RelayDoc will
prompt to select from a list
4
Select the correct Coil Resistance (if
prompted)

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5
Enter the Relay Serial Number using the
Virtual Keyboard or Bar Code Reader.
Touch “Test” to continue or “Home” to
abort
6
If a Latching Relay is detected, the “Latch
off” Checkbox will be displayed:
Turn Coil Latching ON or OFF as required.
Touch the check box.
6
If the Contact Configuration does not
match the selected Relay Profile,
RelayDoc will prompt the user to select
from a list
7
As each test occurs, progress and status
are displayed.
Touch “Cancel” to abort any test. The
RelayDoc will beep three times.
Note: The report is written incrementally:
results are added as each test is
completed
8
At successful completion, the RelayDoc
will beep three times. Touch “OK” to
return to the Test Results
9
Touch “Report” to view the Test Results,
or touch “Home” to Exit.

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7. TEST FUNCTIONALITY
COIL RESISTANCE
The Coil Resistance Test passes a precise constant current through
the coil. The voltage drop across the coil is measured and the coil
resistance is calculated. The result is recorded.
The coil resistance measurement uses two different scales to
generate high precision results.
Scale
Current
Range
Precision
1
10mA
0 – 500 Ω
1 Ω
2
1mA
500 – 10 kΩ
1 Ω
CONTACT RESISTANCE
The contact resistance test passes a precise constant current through each contact. The voltage drop across
each contact is measured and the contact resistance is calculated. Accurate results are the result of using a
Four Wire Kelvin measurement method up to the Test Base contact. This eliminates any resistance error from
cables or connections between the RelayDoc and the EUT.
The RelayDoc manages the Contact Resistance Measurement,
automatically increasing the applied current in stages until the
measured resistance is in one of the ranges shown right.
Measured resistance over 500Ωis defined to be OPEN state.
CONTACT CONDITIONING
Contact Conditioning is a flash cleaning method. In the RelayDoc
implementation, a Constant Current Source (CCS) provides 100mA as
the relay contacts. There is a short current surge as the contact
opens or closes and the resulting plasma arc cleans the contact
surface.
RelayDoc prevents Contact Conditioning being included in any
default Test Process. If EUT fails an initial resistance test, RelayDoc
will ask the operator to authorise Contact Cleaning and re-test of any failed relays, prior to creating the Test
Report. Only Relays that fail the initial test will be conditioned and re-tested.
The Operator may select Contact Conditioning to be included in the current Test Process, in which case the
software will not offer conditioning following a Resistance Test failure.
CONTACT SWITCHING TIME
This test is performed by measuring the time it takes for a relay contact to change state from Open to Close or
vice versa. Open and Close values are factory set. Users cannot adjust the settings.
OPERATING VOLTAGE AND CURRENT
The Relay Operate voltage is measured using a Ramp Method: The coil supply voltage is swept from zero up to
nominal rated voltage, while monitoring from an open to closed contact state.
The ramp parameters are factory set and cannot be changed by the user.
Stage
Current
Range
Precision
1
100mA
0-5 Ω
0.001 Ω
2
10mA
5-50 Ω
0.01 Ω
3
1mA
50-500 Ω
0.1 Ω

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RELEASE VOLTAGE AND CURRENT
The Relay Release voltage is measured using a Ramp Method: The coil supply voltage is swept from the
nominal rated voltage to zero, while monitoring from an open to closed contact state.
The ramp parameters are factory set and cannot be changed by the user.

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8. TEST REPORTS (VIEWED ON DEVICE)
VIEWING SAVED REPORTS
To view a saved report:
•Touch “Reports” on the Home Page
•Find the required report in the list
•Touch the “magnifying Glass” icon to open the report. The Report will open
•Scroll to the bottom of the report. Touch “Detail” to reveal the complete Contact Resistance Test
details
•Touch “Hide” to collapse the details
•Touch “Back” to return to the Reports Page

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ADDING NOTES TO REPORTS
To add notes to a report:
•Open the required report
•Touch “Notes” in the top right corner of the page
•Type Notes using the Virtual Keyboard
•Touch “OK” to Return to the Report
FILTERING REPORTS
Reports can be isolated from long lists using filtering. Filter reports by:
•Relay Type
•Relay Serial Number
•Range of Test Dates
To filter reports:
•Open the Reports Menu
•Select a Relay Type from the drop down list, or
•Enter a Serial Number into the text box, or
•Enter a range of dates, using the rollovers
•Touch “Search” to complete the search. Found items
are displayed in the Report List.
SAVING REPORTS TO USB DEVICE
Reports and Test Data can be saved to a USB device for storage or
other processing. To save data to a USB device:
•Insert a USB Storage Device into the USB Port. The RelayDoc
will advise “Mounting USB Storage Device”
•Select Reports to be Saved
•Touch the “Select All” checkbox, or
•Touch the checkboxes of individual reports
•To deselect Reports, touch the Checkbox again
•To deselect ALL Reports, touch “Select All” twice
•Touch “Save” to copy the selected Reports to the USB device
Reports are saved in PDF format. Contact Results are saved as CSV files. All files appear in a root directory
called “RelayDoc_TestReport”. Saving reports does not remove the original data.

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9. WEB SERVER (EMBEDDED ON DEVICE)
WEB SERVER FEATURES
RelayDoc includes an embedded Web Server. Any user can:
•Identify Software and Firmware Versions, and the RelayDoc Serial Number
•Search and Filter Reports, and Save as PDF
•Export all Reports to .CSV format, suitable for Spreadsheet or Database Import
•Search, filter and view Relay Profiles and Test Specifications
•View Activity Logs
Password access is required to:
•Delete Reports
•Change device configuration
•Change appearance of Web Server and Reports
•Change the Web Server Login
•Reset the RelayDoc PIN
•Modify Calibration Information
•Perform System and Database maintenance
Users of the web server are not able to modify Relay Profiles or Test Specifications.
ACCESSING THE WEB SERVER
The Web Server is located at the IP Address assigned to the RelayDoc, and supports popular browsers
including Internet Explorer and Edge, Firefox, Chrome, Safari etc. To open the Web Server on an intranet:
•Note IP address from RelayDoc Home Page
•Enter address to the browser search bar and press Enter.
•If the Web Server does not appear, check
oYour intranet connection
oRelayDoc is turned ON and connected to the intranet
Note: There is no benefit in Bookmarking the RelayDoc Web Server. In most installations, the RelayDoc has a
dynamic IP address that renews when the device is turned ON, or reconnected to a network.

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WEB SERVER NAVIGATION AND FUNCTIONS
The Web Server displays most information in tables. There are universal handling tools, as shown below.
•Some tools are not available in all windows
•Some tools are not available to all users
•Not all columns can be filtered or sorted
•Users must confirm changes. There is no UNDO function.
Click Heading to Sort
Collapse/Expand Table
Filter for Text
Check box to select a row
Clear Filters
Export All data to CSV
Double-click any row
to display details in a
pop-up window
Select Rows Displayed
Delete Selected Row
Add New Row
View Selected Row
Edit Selected Item
Click again to Reverse