Ponovo PW460 Assembly Instructions

PW460 Hardware Instruction Manual
1
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
Office
TEL. [phone]
E-Mail
[e-mail]
Website
www.relaytest.com / www.ponovo.com.cn
PW460
HARDWARE INSTRUCTION MANUAL
VERSION: PW460-AE-2.60
DATE : AUGUST 2018
This manual is the publisher of PONOVO POWER CO., LTD. To make any kind of copy of this
manual please contact PONOVO POWER CO., LTD in advance.
This manual represents the technical status for the moment of publishing. The product information,
description and specifications mentioned in the manual do not have any contact binding force and
PONOVO POWER CO., LTD remains the right to make modifications to the technical
specifications and configurations without prior notice. PONOVO POWER does not take
responsibility to the possible error/mistakes in this manual.

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1. Preface ……………………… 3
2. Safety precaution …………. 4
3. Designed applications …… 7
4. Operation preparation …… 8
4.1 Preparation …………………. 8
4.2 Connecting PC …………….. 8
5. General description ……… 9
5.1 Block Diagram ……………… 9
5.2 DSP Card …………………… 9
5.3 Front Panel …………………. 10
5.4 Ethernet Port ………………… 10
5.5 Current Booster Interface……… 11
5.6 Pause Button ………………… 12
5.6 LED Indication ………………. 12
5.7 Rear Panel…………………….. 13
5.8 GPS Interface ………………… 15
5.9 IP Reset……………………….. 16
6. Hardware Configuration …… 17
6.1 Current Generators …………. 17
6.2 Current Output Configuration
in 3 Current Mode ……………. 17
6.3 Current in Series Connection in 3
Current Mode ………………… 19
6.4 Voltage Generators ………….. 20
6.5 Connect Two Voltage
Generators in Series..………. 20
7. Binary Inputs and Outputs.. 21
7.1 General Description …………. 21
7.2 Binary Input…………. …………. .21
7.3 Polarity of Binary Inputs …….. 22
7.4 Binary configuration…….. …….. 22
7.5 Isolation of Binary Inputs …….. 22
7.6 Threshold for Binary Inputs ….. 22
7.7 Binary Outputs ………………… 23
8. Getting ready for PC Controlled
operation……………………… 23
8.1 General Description …………… 24
8.2 Set IP Address ………………….. 24
8.3 Steps for Setting IP Address in PC
……………………………………. ...24
9. PW460-Related Products and
Accessories…………………… 27
9.1 PGPS02-GPS-based Synchronization
device …….……………………………28
9.2 PIRIG-B Based Synchronization
device…………………………………..28
9.3PSS01 Circuit Breaker Simulator…29
9.4 Phpc01 Current Booster…………..29
9.5 PACB108 scanning head………….30
9.6 Low Level Output and Counter Input
Cable…….………………………………. 30
9.7 Synchronization Control Cable… …30
9.8 Fiber Optic Cable…………………… 30
9.9 Standard Accessories...……………. 31
9.9.1 Soft Bag for Test Lead……..… 31
9.9.2 Transportation Case…………. 38
10. Troubleshooting………………...39
Contents

PW460 Hardware Instruction Manual
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This manual gives detailed introduction to
PW460 so that user can have the reasonable,
effective and safe operation of this test kit.
This manual mainly consists of the following
parts:
Equipment and functions:
This part describes the main hardware parts
and their functions.
Panel description
This part describes the interfaces on the
panels and their applications
Technical specifications
This part describes the technical specifications
Optional accessories
This part describes the optional accessories
which will be used for dedicated applications
At the test site user should also refer to other
safety and test regulations required by his
management authorities.
This test equipment must be operated by
professional test people and careful reading of
this manual is required before operating this
test equipment.
The complete test system consists of PW460
test equipment (used for generating analog
test signals), PowerTest test software,
Computer which has installed PowerTest
software, Test Leads/cables, etc. This manual
gives only the description to the hardware part.
Please refer to PowerTest software user
manual or PowerTest online help for details of
the software.
1．Preface

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1. In case the power outlet for powering up the PW460 dose not have protective ground
customer must connect the ground socket of PW460 to the protective ground at the
test site
2. Please turn off the output before connecting/disconnecting the test object
3. The voltage output of over 36V is considered as dangerous and care must be taken
4. It’s not allowed to feed external voltage into the voltage/current output sockets
5. It’s not allowed to feed external current into the current/voltage output sockets
6. Disconnect the external circuit from the relay to avoid any influence to the test
7. Do not block the ventilation outlets
8. Avoid the equipment to be wet by rain
9. Do not switch-on and operate the equipment in the place having explosive gas or
water vapor
10. The 500V dangerous voltage can be in the equipment and please don’t remove the
cover by yourself
11. Please contact the manufacture for any maintenance
12. The guarantee will become invalid if PW460 is opened by the customer
2．Safety Precaution

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For Your Safety Please Note
This symbol indicates potential hazards by electrical voltages/currents caused by, for example,
wrong connections, short-circuits, technically inadequate or faulty equipment or by disregarding
the safety notes of the following sections.
Use Proper Power Cord
Only the power cord designed for the instrument and authorized by local country could be used.
Ground The Instrument
The instrument is grounded through the Protective Earth lead of the power cord. To avoid electric
shock, it is essential to connect the earth terminal of power cord to the Protective Earth terminal
before any inputs or outputs.
Observe All Terminal Ratings
To avoid fire or shock hazard, observe all ratings and markers on the instrument and check your
manual for more information about ratings before connecting.
Do not Assemble/Disassemble the Instrument without Authorization
The instrument should be assembled and or disassembled by professionalengineers; users are
not allowed to perform related operations except for some possible replacements in this manual.
Do not Move or Maintain the Instrument When it is Powered On
To avoid personnel injuries, any position adjustment, maintenance or parts replacement are
forbidden when instrument is on.
Use Proper Fuse
Please use the specified fuses.
Do Not Operate With Suspected Failures
If you suspect damage occurs to the instrument, have it inspected by qualified service personnel
before further operations.Any maintenance, adjustment or replacement especially to circuits or
accessories must be performed by authorized personnel.
Keep Well Ventilation
Inadequate ventilation may cause increasing of temperature or damages to the device. So please
keep well ventilated and inspect the intake and fan regularly.
Do Not Operate in Wet Conditions
In order to avoid short circuiting to the interior of the device or electric shock, please do not
operate in a humid environment.
Do Not Operate in an Explosive Atmosphere

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In order to avoid damages to the device or personal injuries, it is important to operate the device
away from an explosive atmosphere.
Keep Product Surfaces Clean and Dry
To avoid the influence of dust and/or moisture in air, please keep the surface of device clean and
dry.
Operate the Instrument in a Suitable Environment
The best condition for optimal measurement is: 5 ℃to 40℃; less than 2 ℃/hour changing, 20%
to 80% RH and the instrument should not be placed towards the air outlet.
Electrostatic Prevention
Operate in an electrostatic discharge protective area environment to avoid damages induced by
static discharges. Always ground both the internal and external conductors of the cable to release
static before connecting.
Proper Use of Solvent
Please use the solvent in compliance with instructions specified in its supplier. If necessary, wear
protective clothing, gloves and glasses to avoid any injuries.
Handling Safety
Please handle with care during transporting to avoid damages to surface, panel and parts resulting
from the falling from your hand.
NOTE: This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful interference to
radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense.

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PW460 can be used by power plants,
substations, and relay manufactures, etc, for
the following test applications.
1. Test protective relays
2. Test transducers
3. Test energy meters
Product Features
1. Output sources
6×15A current sources in two groups
4×300V voltage sources
2. Binary inputs
8 binary inputs for potential free or
potential contacts
3. Counter inputs
4 high speed counter inputs
4. DC measuring inputs
2 DC measuring inputs for testing
transducers
5. Binary outputs
8 binary inputs in two groups, 4 of dry
contact type and 4 of semiconductor
type
6. Low level outputs
12 low level outputs used for driving
external amplifiers or testing
Rogowski principle based relay
7. External amplifiers interface
8. GPS interface
Can receive GPS pulse signal from
optional PGPS02
9. Synchronized control interface
Used for synchronizing several
PW460 for specialized test purpose
10. Current booster interface (optional)
Used for increasing the compliance
voltage of current output for testing
high burden relays
3．Designed Applications

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Preparation
Be sure that the following preparation/system components are ready before operating the test
equipment:
PW460 test equipment
Main supply cable (delivered)
LAN control cable (delivered)
PC with PowerTest software properly installed
Test leads connected to the test object
Connecting PC
1. Connect the LAN cable between PC and PW460
2. Connect the power cables for PC and PW460
3. Connect PW460 ground socket to the protective ground
4. Power on the PC and PW460
5. Run PowerTest software
4．Operation Preparation

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Block Diagram
VOLTAGE CONTROL
DSP CARD
Aux DC generator
Analog record (optional)
(internal or external
recording)
Voltage generator
(independent design)
Current generators
(independent design)
16 bit D/A
Power supply and control
To PGPS02 GPS Synchronization Device
(optional)
PW460 Universal Test System Diagram
0-300V DC, 120W
0-15A/ 150 VA
VA
IA
VB
VC
0-300V/ 85VA
VZ
6×30A
Voltage generator
(independent design)
IB
IC
Current generators
(independent design)
Ia
Ib
Ic
4×300V
I1
I2
I3
I4
I5
I6
V1
V2
V3
V4
Power Supply
Control Signal
Binary output 1-4
(Relay)
Binary output 5-8
(Semiconductor)
Binary input 1-8
DC measuring input
(+/-10V, +/-20mA)
Synchronized control (optional)
LAN
interface Low level outputs and also used to control external amplifier
(optional)
To Phpc01- High burden relay test booster
(optional)
1
2
3
4
5
6
7
8
9
10
11
12
High speed counter 1-4
DSP card
High performance DSP (digital signal processor) is used on the DSP card to ensure the accurate
and fast signal generation.
To get the satisfied accuracy and resolution the 32 bit D/A data converting technology is applied.
5．General Description

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Front Panel
1. Current output group 1
2. Current output group 2
3. Voltage output
4. Auxiliary DC
5. DC measuring input
6. RJ45 Ethernet PC control port
7. Binary input group 1 (A-D)
8. LED indication
9. Earth socket
10. Binary output group 1
11. Pause button
12. Current booster interface
Ethernet Port
The Ethernet port is used to connect to external PC via Ethernet control cable.
Please refer to “Getting ready for connecting to PC” for details

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Current Booster Interface
This interface is used to connect to the external current booster (optional) for testing high burden
relays.
Please refer to “Current booster user manual” for details
Pin
Signal
1
Current IA
2
Current IN
3
Current IB
4
Current IN
5
Current IC
6
Current IN
7
Current Ia
8
Current In
9
Current Ib
10
Current In
11
Current Ic
12
Current In
13
Voltage VA (not used)
14
Voltage VB (not used)
15
Voltage VC (not used)
16
Voltage VZ (not used)
17
Voltage VN (not used)
18
Not used
19
Not used
20
+12V
（
100mA
）
21
+12V GND
22
Range switcher 1
23
Range switcher 2
24
Range switcher 3
25
Range switcher 4
26
Range switcher (GND)

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Pause Button
The Pause button on the front panel is designed to cut the current/voltage outputs either for test
purpose or under emergency case.
‘Manual’ control mode
‘Auto’ control mode
Push ‘Pause’ button
cut the current/voltage
cut the current/voltage, PC
software will continue to run
Release ‘Pause’ button
current/voltage output will be
recovered from the point
where we push the Pause
button
current/voltage output will be
recovered from the software
execution point at the moment
we release the Pause button
LED Indication
The LED indication on the front panel gives information about the hardware working conditions
In normal working condition the status of LEDs will have the following indication in ‘Power on’ and
‘Testing process’ conditions
Power on
condition
All current/voltage channels are
having outputs
Power lamp
Lighted
Lighted
Online lamp
Not lighted
Lighted and flashing
PAUSE lamp
Not lighted
（
push
to light
）
Not lighted
（
push to light
）
Overheat lamp
Not lighted
Not lighted
Overload
lamp
V
Not lighted
Not lighted

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Rear Panel
1. Binary input group 1 (E-H)
2. Binary output group 2
3. External amplifier / low level output
interface and binary input group 2
4. GPS interface
5. IP Reset
6. Ethernet 2
7. Connector for mains supply
8. Power switcher
External Amplifier and Low level Output
Interface
This interface is used to connect to external amplifier (optional) to increase the output channel and
output power.

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The 1-13 low level outputs are to be used for testing relays with Rogowski or voltage dividers input.
The 13rd Pin is the common GND.
The 15-19 are the binary input group 2.
The 19th Pin is the common GND.
For more information about the external amplifier please refer to “External amplifier user
manual”
Pin
Signal
1
Low level output 1
2
Low level output 2
3
Low level output 3
4
Low level output 4
5
Low level output 5
6
Low level output 6
7
Low level output 7
8
Low level output 8
9
Low level output 9
10
Low level output 10
11
Low level output 11
12
Low level output 12
13
Low level output GND
14
Control signal
15
High speed counter 1
16
High speed counter 2
17
High speed counter 3
18
High speed counter 4
19
High speed counter GND

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GPS Interface
This interface is used to connect to our optional PGPS02 GPS-based synchronization device.
DB9 Chassis contact, male
----------------------------------------------
Note: PPS means Pulse Per Second
----------------------------------------------
One popular application of GPS-synchronized control is for end-to-end test for line protection relay
Please refer to ‘PGPS02 user manual’ for details
Signal
Contact pin
Power
1
Ready
2
PPS
3
GND
5
GND
9

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IP Reset
This reset button is used to restore the IP address of PW460 to the default factory setting.
Press this button
Switching on the power for PW460
After this operation the IP address will be restored to the following settings.
IP address: 192.168.1.133
Subnet mask: 255.255.255.0
Note: The IP after reset is only valid for the current operation. If users need to fix the default IP,
please set it in “IP set” of PowerTest.

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Current Generators
PW460 has 6 current generators in two groups.
They can be configured as either 3 currents
mode or 6 current mode.
Test modules which requires 3 current mode
configuration
Basic
QuickTest (4V, 3I)
QuickTest (VL-L, 3V0)
QuickTest (Sequence)
QuickTest (Power)
QuickTest (Vf, If)
QuickTest (Z, I const)
QuickTest (Z, V const)
QuickTest (Z, Zs const)
Time
State Sequence
State sequence (4V, 3I)
Ramp(3I)
Harmonic
CB Operate
Non-electricity
Transient Playback (4V, 3I)
Protection
Distance(R-X)
Distance(Z-Phi)
Auto Reclosing
Differential(3I)
Time Inversed Current
Time Inversed Voltage
Frequency Relay
Voltage Relay
U,I,T Relay (AC)
U,I,T Relay (DC)
Advanced
Advanced Differential(3I)
Advanced TransPlay (4V, 3I)
R/X characteristic check
Synchronizer
Special
Energy Meter
High Burden Relay
Power Swing
Transducer
New modules
Loss of excitation
QuickTest(Harmonic)
Test modules which requires 6 current mode
configuration
Basic
QuickTest (4V,6I)
State sequence (4V, 6I)
Protection
Differential(6I)
Advanced
Advanced Differential(6I)
New modules
TransPlay (6V, 6I)
Current Output
Configuration in 3
Current Mode
In three 3 current mode the 3 current
generators (IA, IB and IC) in first group will be
used.
In 3 current mode the output range and power
for IA, IB and IC will be doubled as shown
bellow.
Range
3-phase ac (L-N) 3 × 0 … 30 A
1-phase ac (3L-N) 1 × 0 … 90 A
1-phase ac (L-L) 1 × 0 … 30 A
6．Hardware Configuration

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1-phase dc (L-N) 1 × 0 … 20A
1-phase dc (3L-N) 1 × 0 … 60 A
Power
3-phase ac (L-N) 3 × 270 VA at 30A
1-phase ac (3L-N) 1 × 540 VA at 90A
1-phase ac (L-L) 1 × 480 VA at 30A
1-phase dc (L-N) 1 × 200 W at 20A
1-phase dc (3L-N) 1 × 540 W at 60A
-------------------------------------
Note: Limit parameters for uninterrupted
current output
-------------------------------------
Single phase
output range
<10A
10A～
20A
20A～
30A
Output time
Continuous
output
>70s
>15s

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Current in Series
Connection in 3
Current Mode
In 3 current mode the two current generators
can be connected in series to increase the
compliance voltage.
Example: IA and IB are connected in series
Example: Settings in QuickTest (4V, 3I) for IA
and IB in series connection
Set Ia and Ib with the same amplitude
Set Ia and Ib angel as 180 deg
Set Ia, Ib as the quantity to change

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Voltage Generators
PW460 has 4 voltage generators.
Connect Two
Voltage Generators
in Series
We can connect two voltage generators in
series to get higher voltage output range.
Example: VA and vvB are connected in series
----------------------------------------------
Note: The maximum voltage output will
become 600Vac in this case
----------------------------------------------