Ponovo PDA4000 Assembly Instructions

PDC4000A Instruction Manual
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PONOVO POWER CO., LTD
2F, 4Cell, Tower C, In.Do Mansion
No.48A Zhichun Road, Haidian District
Beijing, China (Post Code 100098)
Office TEL. [phone]-8887
FAX [phone]
E-Mail [email protected]
Website www.ponovo.com.cn
PDA4000
HARDWARE INSTRUCTION MANUAL
VERSION: PDA4000-AE-1.00
DATE: 25/10/2011
This manual is the publication of PONOVO POWER CO., LTD Any form of copy needs to
be consent by PONOVO POWER CO., LTD
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 does not take responsibility to the possible error/mistakes in this manual.

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Notes：
In order to prevent static electricity, the tester must be connected to ground
before testing.
Please note personal and equipments safety while huge current is putout.
Avoid short circuit or connecting load while testing.
Avoid external voltage and current being added at the output of equipments.
Avoid the equipment being wet by rain.
Connect the cables right.
Check if the three phase power is complete.
The output model should match with control software.
No danger exists when A, B power supplies are open circuit.
It continues working after over-hot recovery.
The output of serial connection is suitable for loaded voltage above 4V, and
when the loaded voltage is below 4V, serial connection is prohibited.
Over-loaded alarm exists when connecting in parallel.
The tester is working when it is overloaded in single circuit or parallel
connection, but the output time is less than 20 seconds. Meanwhile, user
should contact the manufacture.
Control huge current output time to improve accuracy of output current.
Cooling time should be guaranteed to assure the each output accuracy.
The DC current values are only for reference.
Contact manufacturer timely and do not repair it when device works
abnormally.

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Content
Precautions
1. General Description............................................................................................... 4
2. Panel Description................................................................................................... 4
3. Technical specifications ........................................................................................ 5
3.1 Output and Input ......................................................................................... 5
3.2 Binary input ................................................................................................. 6
3.3 Binary output ............................................................................................... 7
3.4 LED .............................................................................................................. 7
3.5 Power input ................................................................................................. 7
3. 6 Dimension and weight ............................................................................... 7
3.7 Environmental conditions ........................................................................... 7
4. Operation Instructions ........................................................................................... 7
4.1 Select test functions ................................................................................... 7
4.2 Choose variables ........................................................................................ 8
4.3 Set test parameter ...................................................................................... 8
4.4 Output control ............................................................................................. 8
4.5 Check and save test report ........................................................................ 9
4.5.1 Check test report .............................................................................. 9
4.5.2 Save test report ................................................................................ 9
4.6 System settings........................................................................................... 9
5. Test functionality instructions ............................................................................... 9
5.1 Manual test................................................................................................ 10
5.1.1 Channel A output............................................................................ 10
5.1.2 Channel B output.............................................................................11
5.1.3 A-B serial connection ..................................................................... 12
5.1.4 A-B parallel connection .................................................................. 13
5.2 Online test ................................................................................................. 13
6. Accessories .......................................................................................................... 13

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1. General Description
PDC4000A consists of control unit and DC current output unit. The 100-4000A 0.2% high
precision programmable DC current is used for characteristics testing in Special
high-voltage DC converter station, DC current transformer, control and protection.
2. Panel Description
1) Power output：A or B separated, A-B parallel connected, A-B serial connected to
output.
2) Binary：
Output binary: 1, relay connection point
Input binary: 2, no polarity. It can be used to receive protection connection point
and milliseconds test, and single or dual channel are optional.
3) Indication lamp
Run lamp: output indicator
Over-hot indicator: The lamp alarms and flash when the temperature of internal
power model is above 80 and output is cut.℃
Over load indicator: The lamp flashes when the current and voltage are
over-loaded, and manually stops the output.
4) Menu, setting, and adjustment output control unit
5) USB interface: for reading the report and connecting with PC.
6) Power input: Three-phase four-wire input
7) Power Switch
8) Three phase power indication lamp: the lamp flashes when current input is
complete.

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3. Technical specifications
3.1 Output and Input
Single channel output of group A and B
Group A-B connecting in series
Model PDC4000A
Output model Single channel output of group A and group B
Output range 100A~2000A
Accuracy ±0.1%
Port voltage 100A 800A 2000A
4.1V 4.0V 3.8V
Precision of
Max current
fully-loaded
output time
100A 1000A 2000A
continuously 40s 80s 10s 20s
-0.1%~0.1% -0.1%~0.1% -0.2%~0.1% -0.1%~0.1% -0.2%~0.1%
Max. output
time
@ output
current
precision
Continuously
@100A
（-0.1%~0.1%）
240s
@1000A
（-0.8%~0.1%）
60s
@2000A
(-0.8%~0.1%)
1%-99%raising
Time
0A-200A 0A-500A 0A-1000A 0A-1500A 0A-2000A
50ms 100ms 100ms 100ms 100ms
99%-1% falling
Time
200A-0A 500A-0A 1000A-0A 1500A-0A 2000A-0A
50ms 50ms 50ms 50ms 50ms
Model PDC4000A
Output model Group A-B connecting in series
Output range 100A~4000A
Accuracy ±0.2%
Port voltage 200A 1600A 4000A
4.1V 4.0V 3.8V
Precision of
Max current
fully-loaded
output time
200A 2000A 4000A
continuously 40s 80s 10s 20s
-0.1%~0.1% -0.1%~0.1% -0.2%~0.1% -0.1%~0.1% -0.2%~0.1%
Max. output
time
@ output
current
precision
continuously
@200A
（-0.1%~0.1%）
240s
@2000A
（-0.8%~0.1%）
60s
@4000A
(-0.8%~0.1%)
1%-99%
raising time
0A-400A 0A-1000A 0A-2000A 0A-3000A 0A-4000A
50ms 100ms 100ms 100ms 100ms

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Group A-B connecting parallel
DC current table
Model PDC4000A
Output model Group A output Group B
output
Group A-B connecting
parallel output
Group A-B
connecting
parallel output
DC test range 100A~2000A 100A~20
00A
100A~
480A
480A~400
0A 100A~2000A
Accuracy
（read 3s
later）
0.2% 0.2% 0.2%
1.5%
（referenc
e only）
0.2%
3.2 Binary input
The two independent input ports can judge the circuit and space contact is compatible with
30V-250V potential. It is auto identification and time accurate of 1ms（0.001-1s），±0.1%
（1-999.999s）.
99%-1%
Falling time
400A-0A 1000A-0A 2000A-0A 300A-0A 4000A-0A
50ms 50ms 50ms 50ms 50ms
Model PDC4000A
Output model Group A-B connecting parallel
Output range 100A~2000A
Accuracy ±0.2%
Port voltage 100A 800A 2000A
8.2V 8.0V 7.6V
Precision of
Max current
fully-loaded
output time
100A 1000A 2000A
continuously 40s 80s 10s 20s
-0.1%~0.1% -0.1%~0.1% -0.2%~0.1% -0.1%~0.1% -0.2%~0.1%
Max. output
time
@ output
current
precision
continuously
@200A
（-0.1%~0.1%）
240s
@2000A
（-0.8%~0.1%）
60s
@4000A
(-0.8%~0.1%)
1%-99%
raising time
0A-200A 0A-500A 0A-1000A 0A-1500A 0A-2000A
50ms 100ms 100ms 100ms 100ms
99%-1%
Falling time
200A-0A 500A-0A 1000A-0A 1500A-0A 2000A-0A
50ms 50ms 50ms 50ms 50ms

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Figure 1.2
3.3 Binary output
One pair；contact rating：250V DC/0.5A、250V AC / 8A
3.4 LED
4.8 inch High-brightness LCD and visible in glare.
3.5 Power input
Rated input：Three-phase four-cable 380V 50Hz, input voltage range: -10%~+20% 50Hz.
3. 6 Dimension and weight
Dimension：660mm x 425mm x 765mm（L*W*H）
Weight：95kg
3.7 Environmental conditions
Temperature:-5℃～45℃
Relative humidity:≤90% non-condensing
Atmospheric pressure :86kPa～106kPa
4. Operation Instructions
4.1 Select test functions
There are four buttons F1, F2, F3 and menu in the test unit area. Choose main menu
button at any interface to enter the main menu.

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Entering the main menu, rotate ENTER button to select the test function and push the
ENTER go to specified function.
Push F1 in sub menu to go back the top menu.
4.2 Choose variables
Entering the test menu, rotate ENTER button to select variable. The selected operation is
displayed in white with background of black
4.3 Set test parameter
Change variable parameter by pushing ENTER button and rotating it clockwise and
counterclockwise. Select parameter step by pushing coarse/fine-tuning. The step changes
among 0.1,1 and 10.
Relative parameters can be set by selecting variable settings before testing. And the
parameters cannot be changed during testing.
4.4 Output control
Functions of output and stop output can be set by pushing run and stop buttons.

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4.5 Check and save test report
4.5.1 Check test report
The saved test report can be checked by entering the report check interface. Ten reports
can be displayed in each page and 30 reports can be stored. “1/3” means that there are
three pages and the present is the first page.
4.5.2 Save test report
After testing, the present project can be saved through screen tips and test report is saved
in the form of date and time.
4.6 System settings
Screen backlight, buzzer and time can be set by choosing main menu system settings.
5. Test functionality instructions
The following is the main menu of the set.

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5.1 Manual test
This unit can put out current of A, B channels, A-B serial connection and A-B parallel
connection. Current output of A,B，A-B serial connection can get 2000A maximum, and
A-B parallel can put out 4000A current which can control current amplitude and output
time manually and test opening time.
This is the operation interface:
5.1.1 Channel A output
Connect the cables as followings:

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Set current and time, and output time will be shown real-timely after run. Lout
will be shown which is the real output current collected in Channel A.
The set current will be put out by pushing RUN button and it stops output when
getting to the set time. If there is over load, the over hot lamp will give a signal
and the system will stop output. There is a period of cooling time which is
connected with the present current output time and maximum time is 120s. After
cooling, it can go to next output. The equipment needs 30s cooling time after
power on, and it counts from current output until that the binary receives signal
flip recording actions time.
Notes:
The cooling time means the minimum cooling time for the equipment normal working.
It is advisable that the real cooling time is 2-3 times longer than display cooling time
between two current outputs which can improve stability and precision of the device.
The following is the same.
5.1.2 Channel B output
Connect the cables as followings:

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All operations are the same to Channel A, in which lout means the real output current in
Channel B.
5.1.3 A-B serial connection
Connect the cables as followings:
All operations are the same to Channel A.
Lout means the real output current collected in Channel A.
IA means the real output current collected in Channel A.
IB means the real output current collected in Channel B.

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5.1.4 A-B parallel connection
Connect the cables as followings:
All operations are the same to Channel A.
Lout means the real output current collected in Channel A and B.
IA means the real output current collected in Channel A.
IB means the real output current collected in Channel B.
5.2 Online test
Main functions of online test are: transmitting test report to PC and test step grading and
state sequence.
6. Accessories
1. 250 fixture：2 sets【It is used for testing bus cable with diameter of 250mm, seeing the
installation below.】

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2. 50 fixture：10 sets【It is used for testing bus cable with diameter of 50mm, seeing the
installation below.】
3. 30 bush：10 sets【It is used for testing bus cable with diameter of 30mm, seeing the
installation below.】
4. 4000A installation bus cable：2 stripes【It is used for connecting equipments and
fixture, seeing the installation below.】
5. 2 wrenches

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6. Tandem arrangement, Parallel row
7. Power wires
Yellow, green, red Blue Yellow
green
L1、L2、L3（no phase
sequence）
Zero line
N
Earth
wire
Fitting one：Bus dedicated connector

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High-intensity air box is used for package box and there are three floors.
In the first floor, there is 250 fixture.
In the second floor, there are 50 and 30 fixture.
In the third floor, there is testing bus cables.

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Fitting two: Standard cable bags
There are two power wires, one ground wire, one crocodile clip, one tandem
arrangement, two parallel rows, two wrenches and a set of screw nuts.
Installation of test fixture
1.（Bus）Diameter is 250mm.
First clean the bus where the fixtures are installed, and connect 250 fixture and bus cables
showing in the picture.
Fasten the connection with screw nut, showing below:

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Connect the other end of bus cable with the equipment.
2.（Bus）Diameter is 50mm.
First clean the bus where the fixtures are installed, and connect 50 fixture and bus cables
showing in the picture.
Fasten the connection with screw nut. If there are several bus cables, 4 bus cables with
diameter of 50mm can be connected to the bus cables’ front, back, left and right
respectively and the loaded current is approximately 4000A, showing below:

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Connect the other end of bus cable with the equipment.
3.（Bus）Diameter is 30mm.
First clean the bus where the fixtures are installed, and put bushing 30mm into fixture
50mm and the tested bus cables. Installed as the following:
Fasten the connection with screw nut. If there are several bus cables, 4 bus cables with
diameter of 50mm can be connected to the bus cables’ front, back, left and right
respectively and the loaded current is approximately 4000A, showing below:

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Connect the other end of bus cable with the equipment.