Ponovo PDC15k User manual

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com
PDC15k
High DC Current Primary
Injection Test Set
Instruction manual
2018 V1.0

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com
Content
1. General Description ................................................................................1
2. Technical Specifications..........................................................................1
3. Hardware Description.............................................................................1
3.1 Main Control Unit.................................................................................................... 1
3.2 DC Current Output Unit ......................................................................................... 2
3.3 Portable Cart ............................................................................................................ 3
3.4 Testing Cable ............................................................................................................ 4
3.4.1 DC Current Output Cable ........................................................................................................4
3.4.2 Serial Connection Signal Cable ................................................................................................4
3.4.3 Binary Input Cable....................................................................................................................4
3.4.4 Voltage Cable .............................................................................................................................5
3.4.5 Power Cord.................................................................................................................................5
3.5 Assembling Method.................................................................................................. 5
3.5.1 Equipment Assembly.................................................................................................................5
3.5.2 Wiring Description.....................................................................................................................6
3.6 Environmental Conditions....................................................................................... 7
4. Operation Instructions............................................................................7
4.1 Main Control Unit.................................................................................................... 7
4.1.1 Buttons........................................................................................................................................7
4.1.2 LED Lights.................................................................................................................................7
4.2 Local Software Operation........................................................................................ 8
4.2.1 Main Interface............................................................................................................................8
4.2.2 System Setting............................................................................................................................8
4.2.3 Ramp...........................................................................................................................................9
4.2.4 Step Ramp ..................................................................................................................................9
4.2.5 DC Resistance...........................................................................................................................10
Appendix: Test Example ..........................................................................11

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 1
1. General Description
PDC15k consists of one control unit and three DC current output units and one portable
Cart. The 0-15000Adc, 0.5% high precision programmable DC current is used for
characteristics testing in Special high-voltage DC converter station, DC Circuit Breaker
release in Railway Transportation, both filed testing and R&D purpose in the lab.
2. Technical Specifications
Power supply
Single phase 220VAC/50Hz
Power supply input power
< 2KVA
DC Current Output range
0A~15000A
Accuracy at output current range
0.50%
Accuracy at output current range
< 0.5%
Output voltage range
0~5V
Current output options
individually or support parallel more sets
Current output generating duration
< 10mS
Note: The dimension and weight of each functional module device are described in the
corresponding description below.
3. Hardware Description
3.1 Main Control Unit
Device Name
Dimension
Weight
Quantity
Main Control Unit
150×760 ×570mm(H×W×D)
19.45kg
1 piece
The picture above is the main control unit, its operating panel is on the upper surface.
The panel is shown below:

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 2
The rear view of the main control unit is as follows:
These ports on the panel are connected to the port corresponding to the side of the DC
current output unit through the DC Current output Cable.
3.2 DC Current Output Unit
In the front, the red and black buttons are DC current output terminals. The red button is
positive and the black button is negative.
Device Name
Dimension
Weight
Quantity
DC Current output Unit
140×760×570mm(H×W×D)
27.8kg
3 piece

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 3
The side view of the unit is as follows:
These ports are connected to the ports on main control unit.
3.3 Portable Cart
Note: Used for installing the DC Current output Units and Control Unit on it so that the
PDC15k could be used as portable solution.
Device Name
Dimension
Weight
Quantity
Portable Cart
1020×850 ×600mm(H×W×D)
30kg
1 piece

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 4
3.4 Testing Cable
3.4.1 DC Current Output Cable
3.4.2 Serial Connection Signal Cable
3.4.3 Binary Input Cable
Cable Name
Length
Weight
Quantity
DC Current output Cable
2 meters
(Diameter: 300mm2)
6.15kg
6 piece
Cable Name
Length
Weight
Quantity
Serial Connection Signal Cable
0.8 meters
1.55kg
3 piece

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 5
3.4.4 Voltage Cable
3.4.5 Power Cord
3.5 Assembling Method
3.5.1 Equipment Assembly
The picture above is a photo of the PDC15k, from bottom to top is Portable Cart & Wire
box, DC Current output Unit 1, 2, 3, and Main Control Unit.

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 6
Step 1
Step 2
Step 3
Step 4
We can follow the above installation steps to place the devices.
3.5.2 Wiring Description
（1）Connection method of Serial Signal Cable
Rear view
Side view
The port on the back of the main control unit is connected to the corresponding port on
the side of the DC current output unit through the DC Current output Cable.
Under normal power-on conditions, each cable can output 5000A DC current, when the
three lines are connected in series, the PDC15k can output 15000A DC current.
（2）Connection method of DC Current Output Cable
A pair of DC Current output cables connecting the terminals of the DC Current output
Unit and the two ends of the device under test, such as a circuit breaker.

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 7
3.6 Environmental Conditions
Temperature: 0℃~40℃.
Relative humidity: ≤90% non-condensing Atmospheric pressure:
86kPa~106kPa.
4. Operation Instructions
4.1 Main Control Unit
4.1.1 Buttons
（1）Menu & ENTER
Entering the main menu, rotate ENTER button to select the test function and push the
ENTER go to specified function.
（2）F1, F2, F3
Push F1 in sub menu to go back the main menu.
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.
（3）Run & Stop
Push the Run button to start testing.
Push the Stop button to interrupt the test.
（4）Coarse/Fine
Shift to different digit when entering value by Enter button.
（5）USB
Manufacturer-specific software update interface.
4.1.2 LED Lights
（1）Run
The green flashing when the output is running.
（2）Overheat
The indicator light does not light under normal conditions, when the temperature of
PDC15k is too high and exceeded the set maximum temperature value, it turns red.

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 8
（3）Overload
The indicator light does not light under normal condition, When the DC current output
value exceeds the action value, the indicator light turns red.
（4）Fault
When the device is open circuited, the indicator light turns red.
4.2 Local Software Operation
4.2.1 Main Interface
Push the Menu button into the Main Interface, rotate ENTER button to select the test
function and push the ENTER go to specified module.
4.2.2 System Setting
Light: On and off two options, turn the LCD backlight on or off.
Buzzer: On/Off, turn the machine's beep on or off.

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 9
4.2.3 Ramp
Start value (I): Test set initial current value;
Stop value (I): Test set end current value;
Rise time(ms): Gradient change duration；
Injection time(ms): Current stability duration；
Electricity set: Set the electricity value of the energy storage module；
Output value (I): Real-time current value；
Output time (ms): Real time;
Trip time: Recorded action time value when the current exceeds the operating current;
Trip value: Operating current value during the test;
Electricity mode: Real-time energy storage value;
Series Qty: Number of series currents used.
4.2.4 Step Ramp
Start value (I): Test set initial current value;

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 10
Step Change (I): Step size of current change;
Stop value (I): Test set end current value;
Step Change (ms): Step change time;
Electricity set: Set the electricity value of the energy storage module；
Output value (I): Real-time current value;
Output time (ms): Real time;
Trip time: Recorded action time value when the current exceeds the operating current;
Trip value: Operating current value during the test;
Electricity mode: Real-time energy storage value;
Series Qty: Number of series currents used.
4.2.5 DC Resistance
Current set: Set test current value;
Time set: Set length of time;
Electricity set: Set the electricity value of the energy storage module；
Output time: Time of output current;
Output value (I): Output current value;
Electricity mode: Real-time energy storage value;
Series Qty: Number of series currents used.

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 11
Appendix: Test Example
1、Wiring Description
（1）Connection method of DC Current Output Cable
One end connects the terminals on the DC Current Output Unit. Red is positive and
black is negative. As shown in figure 1.
The other end is connected to the circuit breaker. Please note the positive and
negative poles.
Figure 2 shows the simulation circuit breaker experiment using an empty open
circuit breaker.
Fig.1 The wiring diagram 1 Fig.2 The wiring diagram 2
（2）Serial Connection Signal Cable
The three cables are of the same length and can be connected as follows.
Each group can output 5000A current, and all three groups can output 15000A.
Fig.3 connection diagram of serial signal lines

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 12
2、Main Control Unit
When the connection is completed, connect the equipment power. At this point, the
connection status of three series signal lines is displayed respectively in the upper left
area of the control unit: unit 1, unit 2 and unit 3. As shown in figure 4.
The power indicator is green; Five levels of energy storage are green.
Note: the power indicator of the upper and lower rows is a group. If they don't light
up at the same time, the trouble indicator lights up to give an alarm.
Fig.4 Current signal unit working status display
Operate the “ENTER”button and enter the interface to select the test module. For
general testing, the "Ramp" module can be used to meet the testing requirements and
accuracy.
Fig.5 Main Interface
3、Test parameter Settings
Enter the “Ramp” module to set the test parameters.
Fig.6 The operation interface of Ramp
(1) Start value (I): Test set initial current value;
(2) Stop value (I): Test set end current value;

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 13
(3) Rise time(ms): Gradient change duration;
（note : The rise time recommended is set to 500ms）
(4) Injection time(ms): Current stability duration;
（note : Injection time refers to the time when the termination current is maintained. It
is recommended to set it at 100ms）
(5) Electricity set: Set the electricity value of the energy storage module；
（note : Normal can be set to 50%. “Electricity set” is limited to the “Stop value” to
some extent. If “Stop value” is large or the line resistance is large, the set electric
quantity should be high. It is recommended to be between 50% and 100%）
(6) Electricity mode: Real-time energy storage value;
（note : Click to run. After the test starts, charge the device first. The Ramp test will
begin officially only when the “Electricity mode” reaches the “Electricity set”）
4、Test Procedure
（1）Preliminary test
When the circuit breaker's operating current is unknown, the preliminary test is
carried out first.
The value of setting the “Start value (I)”and “Stop value (I)”differs greatly, that is,
the action current of the circuit breaker is searched in the larger current range.
This test is the rough adjustment test, and the initial judgment value of the circuit
breaker's operating current is obtained. The error is in the ±0.5% range.
（2）Cyclic test
Cyclic testing can more accurately lock the action current.
Reducing the numerical range of the “Start value (I)”and “Stop value (I)”step by
step, and fining adjust the circuit breaker's operating current, and improve the accuracy
of test results.
Note:
1. In general, the circuit breaker operating current obtained from preliminary test
can meet the test requirements.
2. The above steps can also be carried out by testing the "Step Ramp" module.
The “Step Change”is greater than or equal to 75A.
Fig.7 The operation interface of Step Ramp

PDC15k High DC Current Primary Injection Test Set
__________________________________________________
PONOVO POWER CO., LTD
No. 139 Jinghai Third Road, BDA, Beijing, China, 100176
OFFICE: TEL. [phone]
E-MAIL: [email protected]
WEBSITE: www.relaytest.com 14
The result of simulated circuit breaker test is shown in the figure 8.
Fig.8 Ramp parameter setting and operation results of simulated circuit breaker test