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IB02602004E
For more information visit: www.eaton.com
Instructional Literature
Effective: May 2008
Page
187
Instructions for the FP-6000 Protective Relay
11 Testing and Maintenance
11.1 Overview of Testing and Maintenance
The FP-6000 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 drawout 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-6000 uses a multifunctional 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, Eaton software products can facilitate verification
of the FP-6000 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 11.2.1, In-service monitoring of the FP-6000
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-6000
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-6000 health status. This relay is energized when the FP-6000 is
powered-up and protection is active. If the power source goes
out or if the FP-6000 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-6000 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
Eaton’s PowerNet Systems software, normal communications
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-6000 corresponds to the PowerNet
configuration. The FP-6000 supports 9600 baud FSK mode only.
If a connection is made through the RS-232 connector on the
front panel, Eaton’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-
6000 RS-232 port. You may select a baud rate of 9600, 19200, or
38400. See Section 10 for more details.
The INCOM Accessory Bus 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
coordination and many other features provided by the FP-6000.
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 3-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.