Page 11-1
IL17569
Effective June, 2001
11 TESTING AND MAINTENANCE
11.1 Overview of Testing and Maintenance
The FP-5000 is designed to be a self-contained and maintenance-
free unit. The printed circuit boards and related assemblies are
calibrated and conformally coated at the factory; no field calibration
is required. They are intended to be serviced by factory trained
personnel only. The draw-out design allows for user hot swap out of
the inner chassis if a failure is detected without disturbing the field
circuit connections to the outer chassis. The outer chassis provides
shorting contacts for the current monitor inputs preventing breaks in
the power distribution current loop monitoring circuits. No external
shorting terminals are necessary.
The FP-5000 uses a multi-functional microprocessor, and an
Analog-to-Digital converter to monitor current and voltage inputs.
The microprocessor also monitors all external digital and analog
inputs. The microprocessor performs self-tests on power up
initialization and periodically, while powered, and will report
abnormalities if detected. Normal operation of the unit with source
power applied, is demonstrated by a flashing operational LED, an
engaged Healthy relay, along with normal communications and user
interface functions. The installer should verify proper operation and
circuit connections by noting normal input levels relative to field
circuit status.
The user interface can be used to perform verification. Alternatively,
Cutler-Hammer software products can facilitate verification of the
FP-5000 operation. Either the RS-232 communications port on the
front panel, or the INCOM PowerNet communications port can be
used for communications as well as other functional testing. See
Section 11.2.2 for more details. Use the following procedures for
bench testing, or for verification of inputs. It is recommended this be
done on a periodic basis.
11.2 Verifying the Product Hardware
The product hardware can be verified using the self-test feature
described in Section 11.3, in-service monitoring of the FP-5000
under normal operating conditions, or bench testing by injecting
currents and voltages into the various inputs. This section will
discuss in-service monitoring and injection testing methods.
11.2.1 In-service Monitoring
In-service monitoring refers to observing the unit under normal
operating conditions within the power system. The normal load
currents, system voltages, rms auxiliary voltage, system power,
frequency and power factor, % THD currents, as well as the system
clock should be periodically read from the FP-5000 monitor menu.
The “Operational” LED on the top center of the front nameplate is
the first indicator that should be verified. A blinking 1 Hz LED signifies
the microprocessor is executing its protection routine. A solid LED
signifies a product failure. If the LED is out, this could also signify
product failure or it may just indicate lack of adequate power to
TB101 and TB102.
Secondly, the Healthy Alarm relay should be used to indicate the
FP-5000 health status. This relay is energized when the FP-5000 is
powered-up and protection is active. If the power source goes out or
if the FP-5000 senses an internal error this relay will open. This is a
Form C relay and the NO contact can be used, for example, to drive
an “all ok” light indicator while the NC contact can alarm an enunciator.
The following features should be verified:
• Load conditions should be verified and recorded for future
reference.
• Zone interlock inputs. These should be verified to ensure proper
system coordination.
• Proper operation of output relays.
• Coil monitors and breaker status (52a and 52b).
• “Breaker control” operation can be performed but will interrupt the
system power. This feature will remotely close and open the circuit
breaker.
• Setpoints. Compare to setting record.
The setpoints should be verified by comparing to the system setting
records. The FP-5000 settings can be verified in the
self-test mode by selecting “disarmed” and performing a test.
Otherwise, the test feature can be used in the armed mode where
the user can expect to trip and interrupt power downstream of
the breaker.
11.2.2 Verification of Communications Ports
INCOM wiring rules are covered in Section 10. Ensure that proper
connections and terminations are being followed. A red transmit
LED can be viewed at the back of the outer chassis at the top of
TB3. It lights only when responding to a valid INCOM command to
its programmed address. If the unit under test is connected to
Cutler-Hammer’s PowerNet Systems software, normal communica-
tions can be verified in a number of ways:
• Active monitor screens are an obvious indication of a proper link.
If the communications is compromised then an alarm will be logged.
• An INCOM communications statistics buffer can be accessed
to determine the link quality. Use this information to determine the
quality of the link. Refer to your PowerNet manual for details. An
occasional error is acceptable, excessive errors can indicate
a problem either in the product or in the twisted pair interface
in general.
Make certain when configuring PowerNet that the baud rate and
INCOM address of the FP-5000 corresponds to the PowerNet
configuration. The FP-5000 supports 9600 baud FSK mode only. If a
connection is made through the RS-232 connector on the front
panel, Cutler-Hammer’s PowerPort software can be used for
configuration as well as RS-232 communications verification. Make
certain that the baud rate of the computer running PowerPort has
the baud rate set to the baud rate setting of the FP-5000 RS-232
port. You may select a baud rate of 9600, 19200, or 38400. See
Section 10 for more details.
The INCOM Accessory Buss port TB3 J2 is a future interface that is
not currently operational.
11.2.3 Bench Testing
Bench testing may be done prior to installation to test for coordina-
tion and many other features provided by the FP-5000. Current
injection can be performed using commercially available power test
sets such as: Omicron
®
, AVO
®
, or Doble
®
. These sources provide
accurate current and voltage signals and can be used to simulate
actual load conditions.
Note that these are typically three-phase sources and so the
Auxiliary 4th Current Transformer, TB4 X1 and X2, will have to be
accommodated by running in series with another phase or looked at
separately from the main three phases. The same holds for the
auxiliary voltage taps VX1 Aux. and VX2 Aux. The examples that
follow will focus on phase testing but can be applied to the auxiliary
circuits as well.
Summary of Contents for 66D2041G01
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