Ponovo PW636I-F Assembly Instructions

PW636i-F 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
PW636I-F
HARDWARE INSTRUCTION MANUAL
VERSION: PW636i-F-AE-1.50
DATE : JUNE 2020
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 manua

PW636i-F Hardware Instruction Manual
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CONTENS
1. PREFACE................................................................................................................................................................. 4
2. SAFETY PRECAUTION ....................................................................................................................................... 5
3. DESIGNED APPLICATIONS .............................................................................................................................. 6
3.1 PRODUCT FEATURES ......................................................................................................................................................... 6
4. OPERATION PREPARATION ............................................................................................................................ 7
4.1 PREPARATION ...................................................................................................................................................................... 7
4.2 CONNECTING PC ................................................................................................................................................................ 7
5. GENERAL DESCRIPTION .................................................................................................................................. 8
5.1 DSP CARD ............................................................................................................................................................................ 8
5.2 FRONT PANEL....................................................................................................................................................................... 8
5.3 ETHERNET PORT ................................................................................................................................................................. 9
5.4 CURRENT BOOSTER INTERFACE ...................................................................................................................................10
5.5 PAUSE BUTTON..................................................................................................................................................................11
5.6 LED INDICATION ...............................................................................................................................................................11
5.7 FIBER OPTIC .......................................................................................................................................................................12
5.8 IEC60044-7/8 FORMAT FIBER OPTIC.........................................................................................................................12
5.9 GPS ANTENNA...................................................................................................................................................................12
5.10 REAR PANEL ....................................................................................................................................................................13
5.11 EXTERNAL AMPLIFIER AND LOW LEVER OUTPUT INTERFACE ..............................................................................14
5.12 GPS INTERFACE.............................................................................................................................................................15
5.13 IP RESET...........................................................................................................................................................................16
6. HARDWARE CONFIGURATION ..................................................................................................................... 17
6.1 CURRENT GENERATORS .................................................................................................................................................17
6.2 CURRENT OUTPUT CONFIGURATION IN 3CURRENT MODE ....................................................................................17
6.3 CURRENT IN SERIES CONNECTION IN 3CURRENT MODE .......................................................................................18
6.4 VOLTAGE GENERATORS..................................................................................................................................................18
6.5 CONNECT TWO VOLTAGE GENERATORS IN SERIES..............................................................................................................19
7. BINARY INPUT AND OUTPUT ........................................................................................................................ 20
7.1 GENERAL DESCRIPTION ..................................................................................................................................................20
7.2 BINARY INPUT ....................................................................................................................................................................20
7.3 POLARITY OF BINARY INPUTS.........................................................................................................................................21
7.4 BINARY CONFIGURATION.................................................................................................................................................21
7.5 ISOLATION OF THE BINARY INPUTS ..............................................................................................................................21
7.6 THRESHOLD FOR THE BINARY INPUTS ........................................................................................................................21
7.7 BINARY OUTPUTS..............................................................................................................................................................22
7.8 FIBER OPTIC .......................................................................................................................................................................22

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8. GETTING READY FOR PC CONTROLLED OPERATION ....................................................................... 23
8.1 GENERAL DESCRIPTION ..................................................................................................................................................23
8.2 SET IP ADDRESS ...............................................................................................................................................................23
8.2 STEPS FOR SETTING IP ADDRESS IN PC....................................................................................................................23
9. PW636I-F-RELATED PRODUCTS AND ACCESSORIES ........................................................................ 26
9.1 PGPS02-GPS-BASED SYNCHRONIZATION DEVICE (OPTIONAL).......................................................................27
9.2 PGPS04I-GPS-BASED SYNCHRONIZATION DEVICE (OPTIONAL)......................................................................27
9.3 PSS01 CIRCUIT BREAKER SIMULATOR (OPTIONAL)..............................................................................................28
9.4 PHPC01 CURRENT BOOSTER (OPTIONAL)................................................................................................................28
9.5 PACB108 SCANNING HEAD (OPTIONAL)..................................................................................................................29
9.6 LOW LEVEL OUTPUT AND COUNTER INPUT CABLE (OPTIONAL).........................................................................29
9.7 STANDARD ACCESSORIES..............................................................................................................................................30
9.7.1 SOFT BAG FOR TEST LEADS......................................................................................................................................30
9.7.2TRANSPORTATION CASE.............................................................................................................................................38
10. TROUBLESHOOTING...................................................................................................................................... 39

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1. Preface
This manual gives detailed introduction to
PW636i-F 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
PW636i-F 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.

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2. Safety precaution
1. In case the power outlet for powering up the PW636i-F dose not have protective
ground customer must connect the ground socket of PW636i-F 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 PW636i-F is opened by the customer

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3. Designed applications
PW636i-F 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
3.1 Product features
1. Output sources
6×32A 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. Ethernet Fiber optic(LC)
8 groups of fiber optics supporting
SMV, GOOSE, MMS and IEC61588
7. GPS built-in
built-in GPS for SMV and GOOSE
8. IEC60044-7/8 Fiber optic(ST)
8 channels of IEC60044-7/8 format
fiber optic outputs.
1 channel of IEC60044-7/8 fiber optic
input.
1 channel IRIG-B optic input.
9. Low level outputs
12 low level outputs used for driving
external amplifiers or testing
Rogowski principle-based relay
10. External amplifiers interface
11. GPS interface
Can receive GPS pulse signal from
optional PGPS02
12. Synchronized control interface
Used for synchronizing several
PW636i-F for specialized test
purpose
13. Current booster interface (optional)
Used for increasing the compliance
voltage of current output for testing
high burden relays

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4. Operation preparation
4.1 Preparation
Be sure that the following preparation/system components are ready before operating the test
equipment:
PW636i-F test equipment
Main supply cable (delivered)
LAN control cable (delivered)
PC with PowerTest software properly installed
Test leads connected to the test object
4.2 Connecting PC
1. Connect the LAN cable between PC and PW636i-F
2. Connect the power cables for PC and PW636i-F
3. Connect PW636i-F ground socket to the protective ground
4. Power on the PC and PW636i-F
5. Run PowerTest software

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5. General description
5.1 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.
5.2 Front panel
1. Current output group 1 and 2
2. Voltage output
3. Binary input group 1
4. Auxiliary DC
5. LED indication
6. Earth socket
7. Binary output group 1
8. DC measuring input
9. Current booster interface
10. Pause button
11. RJ45 Ethernet Ports
12. Optical Ethernet Port and indicators
13. Optical port for IEC60044-7/8 and
IRIG-B(Digital) inputs
14. Optical port for IEC60044-7/8 outputs
15. GPS antenna port (Only for Digital)
9
10
1112
13
14
15
12 3
4
56 7
8

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5.3 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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5.4 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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5.5 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
5.6 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
* include VA/VB/VC/VZ, and Aux. DC
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
V Overload lamp
Not lighted
Not lighted

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5.7 Ethernet Fiber optic
There are 8 groups of fiber optic ports to support IEC61850-9-1/2, GOOSE and IEEE1588
Fiber socket: TX (Send), RX (Receive)
Link indicator: if the fiber optic communicates well, the green indicator will light after power
on.
Rx/Tx indicator: it will light when there is data transferring. (Rx—Receive, Tx-Send).
When IEEE1588 signal is received, the RX indicator flashes per second.
5.8 IEC60044-7/8 format Fiber optic
There are 8 channels fiber optic of IEC60044-7/8 format outputs,1 channel fiber optic of
IEC60044-7/8 inputs,1 channel fiber optic of IRIG-B input.
Rx/Tx indicator: it will light when there is data transferring. (Rx—Receive, Tx-Send).
5.9 GPS antenna
This for built-in GPS antenna port (It is only for IEC61850 SMV and GOOSE)
LOCK: Light is on after receiving valid GPS signal.
PPS: Flash per second

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5.10 Rear panel
1. Binary input group 2
2. Binary output group 2
3. External amplifier and low level output
interface
4. GPS interface(Only for Analog)
5. IP reset button
6. Main power supply
7. Power switch
1 2
3
4
6
5
7

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5.11 External amplifier and low lever output interface
This interface is used to connect to external amplifier (optional) to increase the output channel and
output power.
The 12 low level outputs are to be used for
testing relays with Rogowski or voltage dividers
input.
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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5.12 GPS interface
This interface is used to connect to our optional PGPS02 and PGPS04i GPS-based
synchronization device (It is only for Analog).
PGPS04i
PGPS02
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’ or ‘PGPS04i user manual’ for details
Signal
Contact pin
Power
1 only for PGPS02
Ready
2
PPS
3
GND
5
GND
9 only for PGPS02

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5.13 IP reset
This reset button is used to restore the IP address of PW636i-F to the default factory setting.
Press this button
Switching on the power for PW636i-F
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 contact “[e-mail]”

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6. Hardware configuration
6.1 Current generators
PW636i-F 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)
6.2 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.
-------------------------------------
Note: Limit parameters for uninterrupted
current output
-------------------------------------
Single phase
output range
<10A
10A
～
20A
20A
～
32A
Output time
Continuous
output
>70s
>15s

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6.3 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
6.4 Voltage generators
PW636i-F has 4 voltage generators.

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6.5 Connect two voltage
generators in series
We can connect two voltage generators in
series to get higher voltage output range.
Example: VA and VB are connected in series
----------------------------------------------
Note: The maximum voltage output will
become 600V in this case
----------------------------------------------

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7. Binary input and output
7.1 General description
PW636i-F has 12 binary inputs in two groups.
There are 8 in the panels and other 4
connecting from the kit.
The first group of 4 binary inputs (A, B, C, D)
are on the front panel.
The second group of 4 binary inputs (E, F, G,
H) are on the rear panel.
7.2 Binary Input
The device has 8 binary inputs. Electricity is
isolated in A-H. Space contact or active
contact (15V-250V) can be set by software.
The threshold impedance for space contact is
shown below. The threshold impedance for
active contact can be set by software in
10V-250V.
When connecting active contact, the polarity
should be correct, red to positive, black to
negative, otherwise, false tripping will occur.
The polarity for A-H shows below figure.