Raytech TR-MARK III User manual

90100.1.02 Instruction Manual TR-MARK III Page 2 of 70
Contents
1 Safety Precautions.......................................................................................................................... 4
2 Unpacking ....................................................................................................................................... 6
3 Introduction ..................................................................................................................................... 7
3.1 History .................................................................................................................................................. 7
3.2 General................................................................................................................................................. 7
3.3 Advantages & Features ........................................................................................................................ 8
3.4 System Details...................................................................................................................................... 9
3.4.1 System Check:................................................................................................................................. 9
3.4.2 Transformer Turns Ratio Testing: .................................................................................................... 9
3.4.3 Transformer Turns Ratio Meter uses: ............................................................................................ 10
3.4.4 Limitations of Turns Ratio Testing: ................................................................................................ 11
4 Quick Start Guide ......................................................................................................................... 12
4.1 Instrument operation........................................................................................................................... 12
4.2 Connection to Test Object.................................................................................................................. 13
4.2.1 Hooking up a transformer .............................................................................................................. 13
4.2.2 Comparison of International Standards ......................................................................................... 14
5 Operation Elements Field Case.................................................................................................... 15
5.1 Front Panel Overview......................................................................................................................... 15
5.2 Control Elements and Plugs ............................................................................................................... 15
5.2.1 Fuse, Mains Input and Mains Switch ............................................................................................. 15
5.2.2 Ground Terminal............................................................................................................................ 15
5.2.3 Emergency Stop ............................................................................................................................ 16
5.2.4 High Voltage Side.......................................................................................................................... 16
5.2.5 Low Voltage Side........................................................................................................................... 16
5.2.6 3 Phase Extension (T-REX)........................................................................................................... 16
5.2.7 External ......................................................................................................................................... 16
5.2.8 Interface......................................................................................................................................... 16
5.2.9 Safety Indicator.............................................................................................................................. 16
5.2.10 Display and Touch Panel .......................................................................................................... 16
5.2.11 Thermal Printer ......................................................................................................................... 16
6 Operation Elements Rack............................................................................................................. 17
6.1 Rack: Front Panel Overview............................................................................................................... 17
6.2 Rack: Rear Panel Overview ............................................................................................................... 17
7 Transformer, Measurement and Data Structure........................................................................... 18
7.1 Introduction......................................................................................................................................... 18
7.2 How it works ....................................................................................................................................... 18
8 Operating Menu ............................................................................................................................ 20
8.1 Main Screen ....................................................................................................................................... 21
8.1.1 Operating on a simple screen, no Transformer Data entered........................................................ 21
8.1.2 Further Options of Main screen ..................................................................................................... 23
8.1.3 Operating on an advanced Screen, Transformer Data entered ..................................................... 25
8.1.4 Taps............................................................................................................................................... 27
8.1.5 More Taps...................................................................................................................................... 29
8.1.6 Tertiary Winding System................................................................................................................ 30
8.2 New .................................................................................................................................................... 32
8.2.1 New Transformer ........................................................................................................................... 33
8.2.2 Load from Archive.......................................................................................................................... 36
8.2.3 Copy Actual Transformer............................................................................................................... 37
8.2.4 New Measurement......................................................................................................................... 38
8.2.5 Working with Templates ................................................................................................................ 38
8.3 Info ..................................................................................................................................................... 39
8.3.1 Enter Tap Changer Data by Wizard............................................................................................... 41
8.3.2 Enter Tap Changer Data manually ................................................................................................ 41

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8.4 Archive ............................................................................................................................................... 42
8.5 Setup .................................................................................................................................................. 43
8.5.1 General.......................................................................................................................................... 44
8.5.2 Operators....................................................................................................................................... 45
8.5.3 Standards ...................................................................................................................................... 45
8.5.4 Printer ............................................................................................................................................ 45
8.5.5 Color .............................................................................................................................................. 45
9 Technical Specification ................................................................................................................. 46
10 Interfaces ...................................................................................................................................... 48
10.1 Hardware............................................................................................................................................ 48
10.2 Raytech Toolbox................................................................................................................................. 49
10.3 TR-MARK III Communication Port...................................................................................................... 50
10.3.1 Hardware Protocol .................................................................................................................... 50
10.3.2 Software Protocol...................................................................................................................... 50
10.4 TR-MARK III Remote Commands ...................................................................................................... 51
A Application Notes.......................................................................................................................... 54
A.A Real Three Phase Voltage Option T-Rex ........................................................................................... 54
A.A.A Introduction:................................................................................................................................... 54
A.A.B Theory of Operation....................................................................................................................... 56
A.A.C Unpacking Procedure .................................................................................................................... 57
A.A.D Operating TR-MARK III with T-Rex................................................................................................ 58
A.A.E Operating a TR-MARK II with a T-Rex........................................................................................... 62
A.A.F Technical Specifications (T-Rex) ................................................................................................... 63
A.B Current Transformer Testing .............................................................................................................. 64
A.A.G Introduction ............................................................................................................................... 64
A.A.H Usual Measurement....................................................................................................................... 64
A.A.I Low Impedance ............................................................................................................................. 65
A.A.J Info................................................................................................................................................. 65
A.A.K CTs with Taps (Tapped Secondary) .............................................................................................. 65
B Firmware Update .......................................................................................................................... 66
C Error Messages............................................................................................................................. 68
D Warranty Conditions ..................................................................................................................... 69
E Trouble Shooting .......................................................................................................................... 70
F Contacts........................................................................................................................................ 70

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1 Safety Precautions
The following safety precautions must be observed during all phases of operation, service
and repair of this instrument. By purchasing this equipment the purchaser assumes all
liability for the operation and use of this equipment. The intended use of the instrument, its
design and manufacture, is to be conducted within the precautions or other specific warnings
located within this manual. Failure to comply with these precautions and other specific
warnings violates safety standards of design, manufacture, and intended use. Raytech
GmbH assumes no liability for the operation and use of this equipment.
SAFE OPERATION:
Only qualified knowledgeable persons should be permitted or attempt to operate this test
equipment. All test personnel should fully familiarize themselves with the correct application
and operation of this and all test equipment prior to operation. Persons directly and indirectly
engaged in the operation of this test equipment should keep clear of all high voltage
apparatus while conducting tests and measurements.
BEFORE APPLYING POWER:
Do not vary the input power source voltage level (IE...Connected to a variable AC power
source).
The TR-MARK III auto-senses the input power from the mains plus from 100 to 240 VAC
50/60Hz. Varying the input voltage will cause the test voltage to vary and result in a higher or
lower test voltage than indicated. Heavy changes may even damage the device.
GROUND THE INSTRUMENT:
To minimize shock hazard, the instruments Ground Terminal must be connected to a
properly grounded receptacle. In many cases, the quality of the safety ground provided by
the power cord does not fulfil safety needs. Also the power cord supplied with the equipment
must be connected an electrical receptacle with an electrical ground (safety earth ground).
Non grounded instruments are dangerous and may cause instrument damage.
KEEP AWAY FROM LIVE CIRCUITS:
Operating personnel must not remove instrument covers. Component replacement and
internal adjustments must be made by qualified service personnel. Do not replace
components with power cable connected. To avoid injuries, always disconnect power,
discharge circuits, and remove external voltage sources before touching components.
WARNING!
⇒Never connect TR-MARK III to a transformer, which is energized or
connected to power lines.

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DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE:
Do not operate the instrument in the presence of flammable gases or fumes.
DO NOT SUBSTITUTE PARTS OR MODIFY INSTRUMENT:
Because of the danger of introducing additional hazards, do not install substitute parts or
perform any unauthorized modification to the instrument. Return the instrument to a Raytech
service department for service to ensure proper operation and that safety features are
maintained.
Instruments, which appear damaged or defective, should be made inoperative and secured
against unintended operation until they can be repaired by qualified service personnel.

90100.1.02 Instruction Manual TR-MARK III Page 6 of 70
2 Unpacking
A complete shipment consists of the following items:
Instrument Cable Bag H and X Lead Cable Side
2 Extension Cables Power Cord (depending USB Memory Stick
on coutry of distribution)
Accessories: Instruction:
2 Paper Rolls and This Manual
and 2 fuses
If any of the above items are missing or damaged contact your local representative or
Raytech GmbH immediately.
NOTE
⇒The TR-MARK III field case is a waterproof design. When the case is
unlocked, a small hole automatically opens, to compensate
atmospheric pressure changes.

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3 Introduction
3.1 History
Raytech first developed the Transformer Turns Ratio Spy (TR-Spy) for high degree of
accuracy for the research and development of transformers. This technology was then
packaged into a portable test system for use by transformer manufacturers, rebuild shops,
and electrical maintenance crews. This first system had become the most widely respected
precision instrument for the ease of use, design, and operation. It was developed with the
assistance of transformer manufacturer’s and utility test crews.
The TR-Spy MARK II took this initial development and added many new features to the
system including a large memory base, external control for tap changer testing, and
automatic voltage level detection test. The TR-Spy MARK II was a completely new approach
in technology and has become the standard for ratio testing.
Now the TR-MARK III offers new features and increased accuracy to make it a perfect
system. A color LCD with back lighting and touch screen increases handling and user
comfort. Two USB interfaces make it easy to store measurements on external storage
devices and transfer easily to a personal computer. And Test Reports; just print them on the
internal printer or from your computer.
3.2 General
Ease of use: This system is designed to be easily used and understood. Once the buttons
and few menus are learned the system is very simple to understand and operate.
This intelligent system analyzes the configuration of a transformer and performs all required
measurements automatically for Voltage Ratio, Turns Ratio, Current, and Phase
Displacement. The system can operate a full 3 phase testing sequence with a single push
button operation. Connect the leads, Select the transformer configuration then press GO to
test.
Impressive Accuracy: The TR-MARK III is a high precision, fully automatic, microprocessor
based, Single and Three Phase Transformer Turns Ratio Test system. This system is
designed for highly accurate readings on-site with laboratory precision. It is the most
accurate system available.
Unique Measuring Technique: This newly designed technique of measurement
incorporates a high precision dual-vector voltage meter for ratio readings and a rectification
resolution circuit for phase displacement (vector group). The phase displacement (vector
group) can be automatically detected and displayed without operator intervention.
Operation: The TR-MARK III first applies a small voltage on the HIGH winding side of the
transformer and measures back through the LOW side of the transformer. Analysis is made
and the system determines whether a test can be conducted. Then the system applies the
test voltage on the HIGH winding side of the transformer and measures the voltage back
through the LOW side of the transformer. This technique has been determined to be the
safest possible method of ratio testing. The results are reported on the easy to read touch
screen display.
Compact Design: The TR-MARK III is a lightweight system designed with its own rugged
waterproof field case.

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Simple Maintenance: There is no maintenance required. There is no calibration procedure
(no potentiometers to turn). This is due to the utilization of high precision components in the
design.
Advanced Protection: Upon powering on the system initializes itself with a self-calibrating,
circuit checking sequence. If any problems are detected during this initialization period, or
during operation, the operator is immediately notified. The system constantly monitors the
condition of the transformer under test. The TR-MARK III can even recognize shorted leads
and will terminate the test without any damage to the test equipment. This works especially
well when test leads accidentally fall free from the transformer while under full voltage
measurement. Accidental interchanging of the test leads on the High and Low voltage side
are also detected and the measurement is safely halted
3.3 Advantages & Features
•Color LCD with backlighting and touch screen
•Automatic measurements of Voltage, Turns Ratio, Current, and Phase displacement
•Easy one time hook up to the transformer
•Automatic test voltage range
•Displays deviation from a nominal ratio
•Graphical tap changer display
•Tap changer interface (In- and Output)
•Load on test object <0.05 VA
•Measures Power transformers, PT’s and CT’s
•Displays % error vs. name plate value
•Automatic phase vector detection
•Enhanced heavy-duty protection circuitry
•Extremely rugged (can withstand a drop test of 1 meter)
•Data exchange via USB-Key
•Internal Printer
•2 Years standard warranty

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3.4 System Details
3.4.1 System Check:
The instrument is Line operated. It is designed to be used with voltage power sources (mains
power) between 100-240 VAC 50/60Hz. The system performs a self-check each time that it
is powered on. The User should always visually inspect all connectors, cables and devices to
be measured to avoid any safety issues.
3.4.2 Transformer Turns Ratio Testing:
A Transformer Turns Ratio Meter does exactly as its name implies; it is used primarily for
checking the ratio of Turns of wires of the primary side and the secondary side of a
transformer. The Turns Ratio test set does not tell exactly how many turns of wire are in the
primary and secondary coils. But rather, it measures and displays the Ratio of (or
comparison of) the number turns in the primary coil to the number of turns in the secondary
coil.
This is an extremely useful device for checking for shorted turns and incorrect settings of tap
changers. The TR-MARK III has an additional feature of allowing the operator to measure the
actual phase angle and vector relationship of the windings.
It is important to understand that the Nameplate Ratio on most transformers is the Voltage
ratio (Voltage in: Voltage out) and this Ratio is determined, basically, by the number of turns
of wire on the Primary (High side), the number of turns of wire on the Secondary (Low Side).
On a single phase Transformer the Turns Ratio is the same as the Voltage Ratio.
A Single Phase transformer:
H1
H2
X1
X2
For example: The High Side Winding may contain 940 Turns: Low Side Winding 440 Turns.
Therefore:
136.2
440
940
Pr
===
TurnsSencondary
imaryTurns
TurnsRatio
With three (3) Phase Transformers of different configurations, Turns Ratio and Voltage Ratio
can be, and usually are different.

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NOTE
⇒The TR-MARK III makes all the calculations and interconnections
required, when the correct configurations of single (1) phase and three
(3) phase transformers are selected. In most cases, no other external
connections, other than the test leads provided, are required.
But please check chapter ‘1 Safety Precautions’ for safety grounding.
⇒Hooking up to a transformer:
The TR-MARK III protects against a wrong hook-up to a transformer or
testing a severely defective transformer. Every effort has been made to
alert the operator when something is wrong.
⇒Negative (reverse polarity) hook up is also automatically detected.
3.4.3 Transformer Turns Ratio Meter uses:
A Transformer Turns Ratio Meter is very useful as a tool for investigating problems
associated with the core, the windings, and the tap changer of transformers and should be
used for:
1. Identify shorted turns and finding turn errors
2. Defective and incorrect tap settings
3. Finding mislabeled terminals and mislabeled nameplates
Turns Ratio testing is a required test during the manufacture of transformers. It is too a part
of a good routine preventative maintenance program as well as for Acceptance testing.

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3.4.4 Limitations of Turns Ratio Testing:
In general, there are few limitations on ratio testing of Transformers. However, there are
limitations to be aware of when attempting to test the following transformer:
•Phase relationships other than 30°.
•Non symmetrical Zig Zag windings
•Uncentered neutral points.
•Suspected broken, damaged, or missing core laminations.
In the cases listed above, Raytech recommends the use of the optional unit, model T-Rex, in
conjunction with the TR-MARK III. To get further Information on the T-Rex please check
chapter ‘A.A, T-Rex‘, or contact Raytech to get additional details and information.
Also current transformers are in effect nothing else than opposite wound voltage
transformers. Most current transformers can be tested by TR-MARK III. Please see chapter
‘A.B Current Transformer Testing’ for details about CT testing.
You may find some small low power current transformer difficult to test by TR-MARK III. In
this case, please contact Raytech for information about TR-1.

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4 Quick Start Guide
4.1 Instrument operation
⇒Wait until the green light shows “Save” before handling the cables
⇒If you are new to transformer turns ratio testing, please read the entire
manual carefully before operating this equipment.
⇒All operation can be done by the integrated touch panel.
⇒“Overcurrent” error will be displayed with some configurations.
⇒It is OK to run through all the transformer selections with the leads tied
together.
1. Switch on the instrument. 2. In case of ‘New Transformer’:
To repeat last Mesurement, tap Select Transformer Type and
’GO ABC’. Tap ‘New’ for a new Test Voltage, then touch ‘Go’
Transformer.
3. Press ‘Go ABC’ or ‘Go…’ to 4. Get the results
start a measurement.
WARNING!
⇒Do not touch the test clips if the safety indication is red.
Test voltage will be present.

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4.2 Connection to Test Object
4.2.1 Hooking up a transformer
This section describes a typical, step by step, operation of the TR-MARK III.
Plug the TR-MARK III into an available grounded outlet with 110/240 VAC 60/50 Hz power
source.
Connect the TR-MARK III to the transformer under test with the colored test leads and if
required use the 10 meter red measuring lead extensions. The extensions will connect to the
multicolor leads and the connectors on the front panel. Check the nameplate information of
the transformer. If the nameplate is missing it is still possible to test the transformer by a trial
and error method. The TR-MARK III test set is designed to detect errors in transformer hook
ups. Contact Raytech Service & Support department if you need assistance.
NOTE
⇒No extra external leads or jumpers are required when using the
TR-MARK III . All interconnections are made internally.
Single Phase Transformer Three Phase Transformer
The colored leads are marked to indicate to which transformer terminal they must be
connected for correct operation.
For a Single (1) phase transformer or Auto-transformer use leads:
Primary Secondary
WIRE COLOR ANSI IEC ANSI IEC
- RED indicates H1 U phase (Red clip) or X1 u phase (Black clip)
- YELLOW indicates H0 N neutral(Red clip) or X0 n neutral (Black clip)
For a Three (3) phase transformer use leads:
Primary Secondary
WIRE COLOR ANSI IEC ANSI IEC
- RED indicates H1 U phase (Red clip) or X1 u phase (Black clip)
- BLACK indicates H2 V phase (Red clip) or X2 v phase (Black clip)
- BLUE indicates H3 W phase (Red clip) or X3 w phase (Black clip)
- YELLOW
indicates H0 N neutral(Red clip) or X0 n neutral (Black clip)

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4.2.2 Comparison of International Standards
High Winding Side:
Wire Color ANSI Wire Color IEC Wire Color Australian
RED H1 RED U RED A
BLACK H2 BLACK V YELLOW B
BLUE H3 BLUE W BLUE C
YELLOW H0 YELLOW N BLACK N
Low Winding Side:
Wire Color ANSI Wire Color IEC Wire Color Australian
RED X1 RED u RED a
BLACK X2 BLACK v YELLOW b
BLUE X3 BLUE w BLUE c
YELLOW X0 YELLOW n BLACK n
NOTE
⇒This manual refers to the ANSI standards for all examples. To change
the standard in the test instrument please refer to chapter ‘8.5.3
Standards’.
WARNING!
⇒BEFORE OPERATING THIS OR ANY OTHER TEST EQUIPMENT
READ ALL SAFETY WARNINGS AND UNDERSTAND THEM FULLY.
⇒DO NOT VARY INPUT VOLTAGE (MAINS) AFTER POWERING ON
TEST SET.
⇒The TR-MARK III auto-senses the input (mains) voltage from 100 TO
240 VAC 50 / 60 Hz.
⇒The TR-MARK III then “locks–in” the test voltage range. If the input
voltage (mains) is varied after the TR-MARK III was powered on the
actual test voltage may be higher or lower than indicated and system
may get damaged

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5 Operation Elements Field Case
5.1 Front Panel Overview
5.2 Control Elements and Plugs
5.2.1 Fuse, Mains Input and Mains Switch
A 2A fuse (slow blow) protects the device. Use only the correct fuse type to replace it.
5.2.2 Ground Terminal
Use this terminal, to connect an additional ground line, if your mains cable does not provide a
ground line. Use it also if you are not sure, that the local installation provides a low resistive
ground.
4: High Voltage Side
5: Low Voltage Side
7: External
(Tap Changer)
6: 3 Phase
Extension
(T
-
REX)
8: Interface
(USB and RS232)
11: Thermal
Printer
10: Display and
Touch Panel
9: Safety
Indicator
3: Emergency Stop 1: Fuse, Mains Input and
Mains Switch
2: Ground Terminal

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5.2.3 Emergency Stop
Press to Stop. The measurement will cease and halt Voltage to the test leads immediately.
Turn clockwise to release. The device will remain in a safe state.
5.2.4 High Voltage Side
The connection for the High side lead (H) to the test object.
5.2.5 Low Voltage Side
The connection for the Low side lead (x) to the test object.
5.2.6 3 Phase Extension (T-REX)
The TR-MARK III provides this separate plug to connect and control the 3 Phase Voltage
Extension T-REX.
5.2.7 External
This port is used for an external connection to a tap changer dry contact. This port can also
be connected to the optional external control switch TRO-203 (Part No. 30047) for a remote
start of the test sequence. Please see chapter ‘10.1 Hardware’ for details
5.2.8 Interface
RS232 and USB 1.1. Please see chapter ‘10.1 Hardware’ for Details.
5.2.9 Safety Indicator
Green Light on: No voltage applied to test leads. System in safe standby mode.
Red light on: Indicates there is test voltage on test leads. System is testing.
5.2.10 Display and Touch Panel
The TR-MARK III can be easily manipulated and fully controlled by the touch screen panel. If
preferred, an external mouse can be connected to the USB Port to control the system.
5.2.11 Thermal Printer
Allows you to quickly get your results on paper by using the built-in thermal printer.

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6 Operation Elements Rack
Please find legend of elements on previous page.
6.1 Rack: Front Panel Overview
6.2 Rack: Rear Panel Overview
1 Mains Switch
2: Ground Terminal
3: Emergency Stop
4: High Voltage Side
5: Low Voltage Side
6: 3 Phase
Extension
(T
-
REX)
7: External
(Tap Changer)
8: Interface
(USB and RS232)
9: Safety
Indicator
8: Interface (USB)
10: Display and
Touch Panel
1: Fuse and
Mains Input

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7 Transformer, Measurement and Data Structure
7.1 Introduction
There are many other instruments, that do a measurement and offer the possibility to store a
measured value. This is a very useful feature which saves a lot of time and eliminates errors
of writing down values by the operator. But still you have to do the handling and organisation
of the measured data on your own. This may introduce one day mistakes into your data set,
especially when several measurements will be taken at once and sorted after words, or if
several operators use the same storage device.
7.2 How it works
With TR-MARK III we offer another powerful tool, that increases comfort in handling many
transformers which are tested time after time. You do not have to sort a stored measurement
anywhere. Once a transformer, or let’s say a transformer profile is created, several
measurements directly can be attached to it.
The profile or transformer contains the general (header) data. An attached result contains the
measurement of all transformer phases. Or to define it more exactly:
A transformer / profile contains:
•Number of winding systems
•Type of winding systems
•Test voltage
•Rated voltages (primary, secondary, tertiary)
•Name plate info (name, serial number, location, manufacturer, type and remarks)
•Max. ratio deviation and standard (ANSI, IEC, Australian,…)
A measurement contains
•Measured results of all phases (ratio, deviation, current, phase angle)
•Date and time of all measurements
What you usually will do is creating a new transformer (profile), do a measurement and store
it. In this case the profile and the actual measurement will be stored.
Or you load an existing transformer, do a measurement and store it. In this case, the new
measurement will be attached or let’s say stored with the loaded transformer.
Please find this illustrated on the following page.
NOTE
⇒There is no difference for you between saving a transformer or attach
the actual measurement. Both is done with the button ‘save’ in Main
screen. See chapter ‘8.1.2.3 Turns Ratio or Voltage Ratio, Print and
Save’

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Transformer Profile
(Header)
Measurement 1
(1. June 2010)
Measurement 2
(1. July 2010)
Measurement 3
(1. August 2010)
Load it
Do
measurement
Measurement 4
(1. September 2010)
Measurement 4
(1. September 2010)
Save it
This shows a Transformer, that has been created and measured for the first time on June 1
th
2010. Profile and Measurement was saved by touching the ‘save’ button in Main Screen.
1
Then, this transformer was measured again, every 1
st
of a month. This means, that the
transformer was loaded from archive again
2
, measurement was done and the measurement
was attached by touching the ‘save’ button in main screen.
In our example, now it is the 1
st
of September. And again, the transformer is loaded and
measurement is done. This means, that a new measurement data block is created. And it is
saved and attached by touching ‘save’.
1
Please see chapter ‘8.1.2.3 Turns Ratio or Voltage Ratio, Print and Save’ for details
2
Please see chapter ’8.2.2 Load from Archive’ or ’8.4 Archive’ for details

90100.1.02 Instruction Manual TR-MARK III Page 20 of 70
8 Operating Menu
TR-MARK III Menu structured as shown in the figure below. Pressing a Cancel button, will
bring you one layer towards Main Screen.
Main Screen
(Measurement)
New Info Archive Setup
Delete Export Load
General
License About Clock Cursor
Update Language Service
Standard Printer Colours
Load
from Archive
Copy Actual
Transformer
New
Transformer
New
Measurement
Diagram Print Result