Introduction To The MTS-5000 PDF

MANTA TEST SYSTEMS:
Manta-5000 Training Manual

Introduction to the MTS-5000

Manta Test Systems:
MTS-5000 Training Manual

1-4060B Sladeview Crescent
Mississauga, Ontario L5L 5Y5, Canada

Tel: 905-828-6469 Fax: 905-828-6850
Toll Free: 1-800-233-8031

www.mantatest.com support@mantatest.com


All rights reserved by Manta Test Systems Inc. No part of this publication may be
reproduced or distributed in any form or by any means without the permission of Manta Test
Systems Inc.

The information and specifications contained with from Manta Test Systems are believed to
be accurate and reliable at the time of printing. However, because of the nature of this
product, specifications and features shown in this course are subject to change without
notice.

The features and capabilities described herein reflect those available in the MTS-5000
firmware release 1.90.

J anuary 2010

Document ID#CU Q010 01A

MANTA TEST SYSTEMS INC
1-4060B Sladeview Crescent
Mississauga, Ontario L5L 5Y5, Canada
Tel: 905-828-6469 Fax: 905-828-6850
www.mantatest.com support@mantatest.com
Toll-free technical support (USA & CANADA): 1-800-233-8031


Manta Test Systems
4060B Sladeview Crescent, Unit 1, Mississauga, ON, Canada
Phone: (800) 233-8031 Fax: (905) 828-6850
www.mantatest.com
Table of Contents

1. Outline...........................................................................................................1
A) Electromechanical Overcurrent (50/51) Relay Testing........................................................................1
B) Digital Overcurrent (50/51 P G N) Relay Testing................................................................................2
C) Over/Under Voltage (59/27) Relay Testing..........................................................................................2
D) Impedance (21) Relay Testing..............................................................................................................2
E) Meter Testing Productivity Mode.........................................................................................................3
F) Frequency (81) Relay Testing..............................................................................................................3
G) Differential (87) Relay Testing.............................................................................................................4
H) Waveform Playback.............................................................................................................................4
I) End to End Testing...............................................................................................................................4
J ) Parallel Test Sets..................................................................................................................................4
K) Computer Interface...............................................................................................................................5
L) Advanced Testing.................................................................................................................................5
2. Site Requirements ........................................................................................5
3. Safety Considerations ..................................................................................6
4. Limitation of Liability and Remedies ........................................................7
5. MTS-5000 Capabilities ................................................................................8
A) Inputs....................................................................................................................................................8
i) Main Supply...................................................................................................... 8
ii) Status Inputs...................................................................................................... 8
iii) Transducer Inputs.............................................................................................. 8
iv) GPS Antenna Input........................................................................................... 9
v) IRIG-B Input..................................................................................................... 9
B) Outputs.................................................................................................................................................9
i) Voltage.............................................................................................................. 9
ii) Current............................................................................................................ 10
iii) AC Output Frequency/Phase........................................................................... 10
iv) Digital Outputs................................................................................................ 10
v) IRIG-B Output................................................................................................ 10
vi) Waveform Playback........................................................................................ 10
C) Data Interfaces....................................................................................................................................11
i) Front Panel Display......................................................................................... 11
ii) RS-232 Serial Port.......................................................................................... 11
iii) Ethernet Port................................................................................................... 11
iv) USB Ports........................................................................................................ 11
6. Navigating the MTS-5000 Menu ..............................................................12


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Table of Contents (cont.)

Electromechanical Overcurrent Relay Testing............................................. 19
1. Objective .................................................................................................... 19
2. Time-Overcurrent (51) Electromechanical Relays................................ 19
A) Time Overcurrent (51) Characteristics.............................................................................................. 20
B) Pickup Testing................................................................................................................................... 23
C) Connecting the Test Set..................................................................................................................... 24
D) Pickup Testing using Prefault............................................................................................................ 28
i) Step 1: Apply a Current Greater than the Pickup Setting............................... 28
ii) Step 2: Determine Relay Dropout................................................................... 30
iii) Step 3: Determine Relay Pickup..................................................................... 30
E) Pickup Testing Using Static Fault...................................................................................................... 30
F) Time Overcurrent (51) Timing Tests................................................................................................. 32
i) Using Graphs to Determine Time Delay........................................................ 33
ii) Timing Test using Dynamic Faults................................................................. 34
iii) Timing Test Procedure.................................................................................... 34
G) Electro-Mechanical Relay Target Tests............................................................................................. 36
3. Instantaneous-Overcurrent (50) E-M Relays......................................... 39
A) Pickup Testing................................................................................................................................... 39
B) Connecting the Test Set..................................................................................................................... 39
C) Testing High Burden or High Current Applications.......................................................................... 45
D) Instantaneous Overcurrent (50) Pickup Testing Using Static Fault................................................... 46
E) Instantaneous Overcurrent (50) Pickup Testing Using Dynamic Fault............................................. 47
F) Sequence of Events (SEQ)................................................................................................................. 50
G) Instantaneous Overcurrent (50) Timing Tests................................................................................... 51
4. Productivity Mode: 51: Time Overcurrent Relay Test Mode .............. 52
5. Productivity Mode: 50: Instantaneous Overcurrent Relay Test Mode57


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Introduction
The purpose of this course is to provide a comprehensive introduction to the MTS-5000 and its most
commonly used features. We have attempted to provide information in a logical progression that will
create a better understanding of the MTS-5000, its features, and its ability to enhance your relay
testing tasks. This document is to be used for reference only and the actual course will be customized
by your instructor to meet your individual requirements for training. By the end of this course, you
should be able to:
Understand the capabilities of the MTS-5000 and operate the equipment safely
Navigate the MTS-5000 menu structure to the desired functions
Understand Pre-Fault and Fault modes.
Generate currents and voltage
Modify frequency, phase angles, and harmonic outputs
Perform pickup and timing tests
Change the Dynamic Display Area to display different values
Test electro-mechanical relays using the installed productivity modes.
Prepare, save, and open offline test plans
Load and generate outputs from Comtrade files.
1. Outline
The Manta Introduction to the MTS-5000 course will be comprised of the following topics:
Location of Inputs/Outputs on the MTS-5000
Navigating the MTS-5000 menu
A) Electromechanical Overcurrent (50/51) Relay Testing
1) Basic pick-up testing using the various fault stages
a) Pickup Testing in Pre-fault
b) Pickup Testing using Static Fault
c) Turn voltage or current channels on/off
2) Timing Tests using Dynamic Fault mode
3) Target Testing
a) Multiple frequencies and DC.
4) Testing 50 overcurrent relays using manual test.
a) Parallel currents
b) Input Power Control setting
c) Changing the Dynamic Display Area
d) Changing the Maximum fault Duration
5) Using Sequence of Events Data


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6) Using productivity modes to test 51 overcurrent relays
7) Using productivity modes to test 50 overcurrent relays

B) Digital Overcurrent (50/51 P G N) Relay Testing
1) Understanding Fault Types
a) -N
b) -
c) 3
2) Changing and applying V
DC
Voltage
3) Using 3 for initial metering tests
4) Simple overcurrent testing using -N
a) Rotate Fault and Static Fault
5) Simple Timing Tests using -N
a) Rotate Fault and Dynamic Fault
6) Using - to avoid conflicts with residual ground elements
7) Pickup testing using ramps in arbitrary mode

C) Over/Under Voltage (59/27) Relay Testing
1) Configure Amplifiers for voltage-only
2) Understanding and choosing Fault Types
a) -N
b) -
c) 3
d) 3 - mode
3) Pickup Testing
a) Pre-fault for Undervoltage
4) Timing Tests
a) Using Dynamic Display Area

D) Impedance (21) Relay Testing
1) Understanding impedance relays
a) Standard MHO
b) Loss of field
c) Why pre-fault is important


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2) Manual impedance relays testing using productivity mode
a) Manual MTA Tests
b) Input Power Control setting
c) Manual Reach Tests
d) Manual Timing Tests
e) -N
f) -
3) Automatic impedance relay testing
a) Automatic MTA Tests (watch for no-ops)
b) Automatic Reach Tests
c) Automatic Timing Tests
4) Manual impedance relay testing in manual mode
a) Dynamic Display Area
b) Maximum fault Duration
c) Fault Modes, Pre-Fault (LOP and SOTF)
d) Saving Test Plans or configurations

E) Meter Testing Productivity Mode
1) Different Meters
2) Connections Change
3) Quick Set
4) Transducer Inputs

F) Frequency (81) Relay Testing
1) 3 mode
a) Pre-fault and Fault modes
b) Timing in seconds only
2) Timing in Cycles and Arbitrary mode
a) Advanced Settings and Frequency Columns
b) Dynamic Display Area and Freq1, 2, and cycles
c) Set all for Frequency 2
d) Save test plans and USB


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G) Differential (87) Relay Testing
1) Understanding Differential Relays
a) 87R
b) Slope
c) 87U
d) Harmonic Restraint
2) Using productivity modes for relay testing
a) Pickup
b) Slope
c) Harmonic Restraint
3) Testing GE digital relays using Manta Application Notes

H) Waveform Playback
1) COMTRADE
2) Choosing Files and USB
3) Setup Test Conditions
4) Channel Scaling
5) Setup outputs
a) Timed
b) COMTRADE

I) End to End Testing
1) Clock Sources
a) GPS
b) IRIG-B
2) Advanced Setting - GPS Synchronized fault
3) Waveform Playback
4) Manual test
a) E2E File Generator

J) Parallel Test Sets
1) Connections
2) Slave Mode


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K) Computer Interface
1) Web Browser
a) IP Addressing
b) Screen Capture
c) Custom Help
2) FTP
a) Window Explorer
3) Remote Consol

L) Advanced Testing
1) Testing Philosophies
2) Multi-stage fault testing
a) Multiple fault states
b) Maximum Fault Duration
c) Additional timers
d) Input contact configuration
e) Output contact configuration
f) SEQ
g) Saving and restoring test plans
2. Site Requirements
The following equipment and supplies are required to perform the Introduction to the MTS-
5000 Training Course if all topics are covered.
1) A classroom, training room, or boardroom environment free from distractions
2) LCD Projector and screen
3) A flip-chart, blackboard, or whiteboard
4) A workstation for 2-3 students maximum including the following:
a) 1 MTS-5000
b) 1 Electromechanical overcurrent relay (CO, IAC, etc)
c) 1 digital relay with overcurrent protection
d) 1 Electromechanical impedance relay (KD, etc) OR 1 digital relay with impedance
protection
e) 1 Electromechanical voltage relay OR 1 digital relay with voltage protection
f) 1 Electromechanical differential (BDD, etc) relay
g) 1 panel meter, multifunction meter, or digital relay with metering function
h) 1 Electromechanical frequency relay OR 1 digital relay with frequency protection
i) 1 USB memory stick


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3. Safety Considerations
This instrument can generate high levels of current and voltage. Incorrect usage may cause
personal injury or damage to the instrument.

The user must be qualified to work safely in the intended application environment of this
instrument. Non-adherence to the following minimum requirements constitutes mis-use of the
MTS-5000, and the manufacturer accepts no liability for damages arising from such mis-use
The instrument case must always be effectively grounded. The integrity of the power
supply cord ground should always be verified before use.
All leads and connectors should be in good condition and rated for the appropriate voltage
and current carrying requirements. Current outputs must be securely connected with
minimum 14 gauge leads.
The outputs must not be connected to live outputs or live equipment.
All outputs must be turned off before making changes in connections.
Never exceed the following maximum ratings:
o 300 Vrms to ground on any input (power or control)
o 300Vac/dc differential to external trigger inputs.
The red AC Output Warning LED between the
AC Voltage and current output terminals
indicates when any V1-V3 or I1-I3 channels are
potentially live. It will flash to warn that outputs
are enabled.

Whenever The Fault Status Box at the bottom
left side of the display is flashing red, there are
potentially live AC outputs.

The DC voltage output may be live at all times.
This is indicated by the red LED beside the V4
voltage output terminals, and red background of
the DCV data.


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4. Limitation of Liability and Remedies
It is understood and agreed that Manta Test Systems liability and purchasers sole remedy,
whether in contract, under any warranty, in tort (including negligence), strict liability or
otherwise, shall not exceed the cost of repair or replacement of Manta Test Systems products,
as set forth above, and, under no circumstances, shall Manta Test Systems be liable for any
special, incidental, or consequential damages, including, but not limited to, personal injury,
property damage, damage to or loss of equipment, lost profits or revenue, cost of renting
replacements, and other additional expenses.

Furthermore, it is understood and agreed that Manta test systems shall not be liable for any
damages, losses or expenses as a result of the purchasers or anyone else's:
1. negligence(whether deemed active or passive),
2. misuse, abuse, or modification of Manta Test Systems products,
3. use or operation of products not in conformity with the specifications and instructions
furnished by Manta test systems for its products,
4. repair or maintenance of Manta Test Systems products by persons or entities not authorized
by Manta test systems, or
5. damage to, or destruction of, products, during delivery to Manta test systems for any
reason.


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5. MTS-5000 Capabilities
The following capabilities have been summarized. Please review the MTS-5000 User Manual
for more detailed specifications.
A) Inputs
i) Main Supply
Single phase 110-130 V
AC
at 15 amps max. (220-240V option is available)

ii) Status Inputs
12 Status inputs with DC/AC voltage sensing, fully isolated
Inputs 1-8 monitor dry contacts or voltage controlled (wet) 300 VDC / 0-
300VAC
Inputs 9-12 are voltage controlled (wet) monitor 300 VDC / 0-300VAC

iii) Transducer Inputs
Maximum input level +/-20 mA or +/-10 V
DC

Measurement accuracy greater of 0.05% or full scale or 0.1% of reading.


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iv) GPS Antenna Input
Active antenna, low gain, BNC connector

v) IRIG-B Input
AM or TTL level, BNC connector

B) Outputs
i) Voltage
3 channels AC/DC voltage, overload, short circuit, and over-temperature
protected.
0-150 V
rms
phase-neutral, direct
coupled
100 VA AC per phase with all phases
loaded
200 VA AV single phase

1 channel DC voltage =10-300V
DC

85 W


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ii) Current
3 channels AC/DC current, overload, short circuit, and over-temperature
protected.
0-30 A
rms
per channel phase-
neutral, direct coupled - 600 VA
per channel
0-90 A
rms
single phase, three
channels in parallel - 1800 VA
0-5 A
DC
60W per channel

iii) AC Output Frequency/Phase
Frequency range =DC or 1-3000 Hz
Phase angle range =0-359.9
iv) Digital Outputs
4 channels fully isolated form A contacts
Maximum rating 0.4A resistive at 250V
DC
, 5 A
rms
at 240 V
AC

v) IRIG-B Output
5V TTL level, BNC Connector

vi) Waveform Playback
Programmable from IEEE C37.111 COMTRADE format files, 1991 or 1999
standard


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C) Data Interfaces
All interfaces are fully isolated from AC/DC or digital inputs and outputs.
i) Front Panel Display

ii) RS-232 Serial Port
Standard 9 pin DB-9 wired as DTE (data Terminal Equipment) at 4800-115.2k
baud rate
iii) Ethernet Port
10Base-T/100Base-TX, complies with Ethernet IEEE 802.3 standards
Connector: Standard RJ 45 connector
Speed: 10/100 Mb per second
iv) USB Ports
Connector: Standard 4 pin USB series A receptacle
Data Format: Standard USB 1.0
Speed: Standard USB 1.0 (12 Mbps)


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6. Navigating the MTS-5000 Menu
The MTS-5000 front panel is designed to allow quick access to nearly every function within a
couple of keystrokes. The control panel design is based on a bank machine with 10 function
keys surrounding the display. This is NOT a touch-screen for many reasons. The box and text
beside each function key gives a brief description of the screen that will appear when the
function key is pressed. Once you become familiar with the MTS-5000 features, you should be
able to find the desired function quickly and easily.

The first screen that appears after the unit is powered up is the start-up screen below. Pressing
any function key with a description will open the next screen to allow you to perform the
function described. For instance, if you wanted to customize the test set to your personal
preferences, push Setup [F10] and the setup screen will appear as shown in the next figure.

Function Keys
Description
of Screen
Description
of Screen
Function Keys


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Notice that the function key descriptions have changed to reflect the new possibilities available
for you to use. The most important key to remember is the [F1] key because it almost always
takes you back to the previous screen.

The controls below the display allow you to move inside the selected screen and change values
in selected fields. All MTS-5000 screens have consistent color schemes to help you understand
what values can be changed. A blue font indicates values that can be changed as circled in the
figure above. The field with a black background and yellow font is currently selected as shown
by the 10/10 text circled by the dashed oval above. Gray fonts indicate information-only
fields that cannot be selected or changed directly.

The arrow keys displayed in the figure above allows you to move between fields. For example,
if you want to change the LCD Color Scheme, press the down arrow key. If you wanted to
change the Internal RTC Time instead, pushing the up arrow key will cause the cursor to
jump to the bottom of the screen. Push the up or down arrow as many times as it takes to reach
the setting you wish to change.


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Press the up or down arrow key until the field beside Entry range for phase angles is
selected. The selected field contains numbers and text so its value can only be changed by
rotating the dial beside the arrow keys to open a pull-down menu. Turning the dial in any
direction will cause the pull down menu to appear and turning the dial clockwise moves the
selection down the list. Turn the dial counter-clockwise to move up the list. Turn the dial in the
required direction to select -180 to +180. The new value is saved by pressing [ENTER] after
the desired value is selected or waiting a few seconds until the pull down list disappears.

Use the arrow keys to select the field beside Nominal V4 DC Voltage. This field contains a
voltage and can be changed one of 2 ways:
Turn the dial until the desired voltage is displayed. Notice that as the dial turns faster, the
amount changed per revolution increases.
Type in the desired voltage using the keypad. Notice that the function keys change after the
first digit is pressed. The new value isnt saved until you press [ENTER], Accept Changes
[F10], or any arrow key.
Try typing in a different value in Nominal V4 DC Voltage using the keypad and notice that
you can cancel the change by pressing Abort Changes [F9]. Pressing Delete Last Character
[F6] provides another way to change data entry mistakes.

You can push the [HELP] button at any time and in any screen to get context dependant help
on whatever screen or field you have currently selected. Pushing [HELP] in the Setup screen
will cause this window to appear.


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The right-side Function keys provide additional information about the screen that was
displayed when you pushed [HELP]. You could press Function keys used in this menu [F6] to
learn what each function key would do if it were pressed, but it would probably be more
effective if you tried pushing each function key to see first-hand what happens. Dont be afraid
to explore. Pressing Settings and values shown in this menu [F7] will describe every value on
the screen. Custom Help Index [F3] will be there every time you press [HELP] and can contain
any text that you specify. Front Panel Controls Help [F4] will explain the controls described in
this chapter. Try pressing [F4] and turn the dial to learn more. Press [HELP] to exit the help
menu.

Press Main Menu [F1] to return to the main menu. Push Manual Test [F1] on the start-up
screen to open the Manual Test Menu where we will begin the course.

There is a lot of information on the Manual Test Screen but weve arranged it all in a
logical format that you should get used to fairly quickly. We are going to avoid the
function keys for now and start with some basics descriptions of the different areas on
the manual test screen.


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1

Output Channels - The column beneath 1 includes VA =V1 to IC =I3. V1, V2,
V3 refers to the MTS-5000 voltage output channels and I1, I2, I3 refer to the current
output channels as shown below. Each row provides all of the information for that
output channel. For example, a meter would measure 69.28V @ 0 across the MTS-
5000 terminals V1 - Vn if the test set was generating the outputs. The VA, VB, VC,
IA, IB, IC designations are default designations used in the Vector Display
9
and
can be changed in the Main Setup screen

2

Output Channel Color Bar - This column designates what color each output
channel will be in the Vector Display
9
. The colors can be changed to match your
organizations color scheme in the Main Setup menu.
3

Output Channel Value This column displays the voltage or current output
channel magnitude in RMS. Notice that the V1 field in this column has a yellow
font/black background. Any dial turns or keypad presses will change this value.
Also notice that all of the other values in this column are blue. Blue values can be
changed using the arrow keys to select the desired field.
4

Menu Identification Bar This area identifies the selected screen.
5

Phase Angle Value - This column displays the voltage or current output channel
phase relationship in degrees. The numbers in this column are referenced to 0 as
designated on the x-axis in the Vector Display
9
. The phasor direction is based on
the Meaning of Positive Angles setting and is set to Leading from the factory
which means the angles increase in the counter-clockwise direction. The VC =V3
angle is 120 which is 120 from 0 in the counter-clockwise direction or 120
leading 0.
6

Status Data This section describes the real-time status of the channels using the
following values:
Off =Channels are not producing voltage or current
On =Channels are producing voltage and current
CLIP =the circuit connected to the channel is open or its burden exceeds the
test sets capabilities with the existing input Power Control setting
clip =the MTS-5000 detected that the connected circuit recently displayed
CLIP but the situation has since been corrected.


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7

Time/GPS Information This row displays information regarding the current time
recognized by the MTS-5000. The MTS-5000 can use any of the following signals
to use as a time reference:
RTC =The MTS-5000 internal clock displayed in 24-hour format that can be
set via the Setup menu at the main menu.
GPS =The GPS time source is selected and the time is displayed in UTC
format. If the supplied GPS antenna is connected and has synchronized to the
appropriate number of satellites, the status indication will display OK. If the
GPS is not properly synchronized, the status indication will display NO
IRIG-B =The IRIG time source is selected and the time is displayed in UTC
format. If the IRIG IN port is connected to a valid IRIG source, the status
indication will display OK. If the IRIG is not connected, the status indication
will display NO
8

Fault Type/Phase This area displays the Fault Type and Phase selected
Arbitrary =Arbitrary
-N =A-N, B-N, C-N
- =A-B, B-C, C-A
3 =3 -N, 3 -
9

Vector Display This section displays the output channel settings in real time in a
vector display to visually see the relationships between output channels. The display
is factory set to be consistent with previous Manta products but can be modified to
meet your specifications using the following setup settings from the Main Screen:
Entry Range for phase angles
Normal Phase Sequence
Meaning of Positive Angles
Direction of Rotation
10

Selected Fault Box This section gives a quick visual cue to determine which state
is currently selected for setting changes or generating outputs. The following
displays are possible:
Yellow background with Adjusting prefault =Prefault
Purple background with Adjusting Fault [n] =Fault [n]
Grey background with Adjusting Postfault =Postfault
11

Fault Status Box This color coded box provides a quick visual cue to help you
determine if the MTS-5000 is currently generating outputs:
Green background with Generating Off =None of the 3 current or voltage
channels are producing current or voltage.
Red and White flashing background =The test set outputs are enabled and
producing current and/or voltage.


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12

Digital Input/Output Status This area displays the status of inputs with the
following displays:
White background with grey font =The input is set for Dry contacts and the
contact is not closed
White background with grey font and red square around input number =The
input is set for Wet contacts and requires a voltage across its terminals to
operate. The input is not closed if connected correctly.
Red background with white font =The input is closed

The output displays the actual output status as follows and will not display state
programming offline.
White background with grey font =The output is open
Red background with white font =The output is closed
13

Dynamic Display Area This area allows you to choose to display additional
information about the current settings or tests in real time. You can add up to eight
rows of additional information including:
Electrical parameters such as Power, VARS, impedance (), etc
Frequencies
Timers in seconds or cycles
The V4 DC channel information


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Electromechanical Overcurrent Relay Testing
1. Objective
This objective for this section is for you to become familiar with the very basic operation of the
MTS-5000 by testing some simple overcurrent devices. Some of the topics you will learn in
this section include:
Selecting and changing output channel values.
Understanding pre-fault and fault modes and when to use them.
How to perform simple pickup and timing tests
How and when to parallel currents
How to use productivity modes.
How and when to use maximum fault duration
Generating DC signals from any of the 6 current/voltage output channels
2. Time-Overcurrent (51) Electromechanical Relays
Time overcurrent (51) electromechanical relays have been the backbone of electrical systems
for nearly a century and many are in service today. 51-relays monitor the electrical system for
faults or abnormal conditions and will cause an alarm or isolating device to operate to prevent
the problem from affecting the rest of the electrical system and minimize damage to
equipment.

Figure 1
These relays were constructed with the following major components:
An electromagnet that creates torque to drive the operating disc towards the trip position
when current flows through it. The relay pickup tap settings are actual taps on the
electromagnet to control the amount of current required to turn the disc. If the torque
produced by the electromagnet exceeds the Spiral or Resetting spring force holding the
disc in the reset position, the disc will turn to the trip position. The amount of torque
produced increases as the amount of current increases.


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An aluminum disc that sits between the electromagnet and damping magnet via jewel
bearings on the top and bottom. The disc is held in the reset position by a Spiral or
Resetting spring. One half of the trip contact is fixed on the disc and the other half of the
contact is set at a fixed position on the relay. If the disc turns to the trip position, the trip
contacts touch and send a trip signal to the operated device. The trip time is the amount of
time required to move from the reset position to the trip position. This time varies
depending on the current-flowing/torque-produced by the electromagnet, the distance
between the trip and reset position determined by the Time Dial at the top of the disc, and
the Damping Magnet position.
The Spiral and Reset spring is a very fine, coiled spring usually located below the
aluminum disc. Changing the spring tension allows fine adjustment of the pickup value.
Never touch the spring directly with any tools, especially magnetized ones, because the
spring coil is very fragile and may not operate if tampered with in any way.
The Damping Magnet is a large magnet surrounding the aluminum disc and affects the
aluminum disc speed when its magnetism interacts with the iron filings embedded in the
disc. Moving the damping magnet in or out will affect the relay timing characteristics to
provide fine timing adjustments.
A) Time Overcurrent (51) Characteristics
Time overcurrent relays are comprised of three major components:
Pickup the pickup setting determines the minimum amount of current that must be
present before the relay will start timing. In electromechanical relays, the pickup
setting is the relay tap which will provide a gross pickup current adjustment.
Curve One of the major functions of time-overcurrent relays is to protect
equipment from damage. Every type of electrical equipment (Transformer, breaker,
etc) has a different characteristic curve and protective relays have similar curves to
provide the best protection for each type of device with minimum system disruption.
The curve characteristic describes the shape of the relays operating curve and can be
Inverse, Moderately Inverse, Very Inverse, and Extremely Inverse as shown in the
following figures. Electromechanical relay characteristic curves are determined by
their model number.
Time Dial The time dial setting increases or decreases the amount of time required
to trip the relay. The time dial on electromechanical relays physically increase or
decreases the distance between the fixed and rotating contacts installed in the relay
and, therefore, increases or decreases the amount of time between the reset and trip
positions.


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Engineers use Time Coordination Curves (TCCs) to provide a visual reference of a
relays characteristics to help them choose the best settings for a relays application.
Figure 2 displays all of the different curve characteristics with identical settings on one
drawing. You can see that some curves cross and it is possible for two different relays to
trip at the same time. Notice that the x-axis is the amount of current in multiples of the
pickup setting and the y axis is time in seconds. The curves are logarithmic graphs and
the time between two reference lines on the graph are not linear.
Time Coordination Curve
0.10
1.00
10.00
100.00
1
1
0
1
0
0
Multiple of Pickup Current
T
i
m
e

i
n

s
e
c
o
n
d
s
Extremely Inverse
Normally Inverse
Very Inverse
Moderately Inverse

Figure 2


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Once a relay is selected, the relays characteristic curve can be plotted as shown in the next
TCC drawings. Increasing the pickup setting will cause the curve to move from left to right
as shown in figure 3. Increasing the time dial setting will move the curve shape up and
increase the relays operating time as shown in figure 4.
1.00
10.00
100.00
1
1
0
1
0
0
Secondary Amps
T
i
m
e

i
n

s
e
c
o
n
d
s
1 Amp Pickup
2 Amp Pick up
3 Amp Pickup
4 Amp Pickup
5 Amp Pickup

Figure 3
1.00
10.00
100.00
1,000.00
1
1
0
1
0
0
Secondary Amps
T
i
m
e

i
n

s
e
c
o
n
d
s
Time Dial 1
Time Dial 2
Time Dial 3
Time Dial 4
Time Dial 5

Figure 4


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B) Pickup Testing
There are two schools of thought regarding electromechanical relay pickup testing. The
first school follows the procedure in the manufacturers literature that will instruct the
tester to:
1) Apply a current higher than the pickup setting until the trip contacts close
2) Reduce the current until the contacts chatter and then slowly reduce the current
until the contacts just open. This is the dropout current.
3) Slowly raise the current until the contacts just close. This is the pickup current

This method has a great advantage because, by using contacts for indication, this test can
be repeated by different testers who will likely get a very similar result. However, if the
relay has a very long time delay (7 or higher), the difference between spring tension at
the trip position and reset position is very different and may affect the actual in-service
pickup during low-current faults.

The other school of thought believes that relays should be tested using real life
simulations to ensure the relay will operate correctly when installed. This test procedure
is:
1) Wait until the disc is in the fully reset position.
2) Apply a current slightly below the pickup setting and ensure the disc does not turn.
3) Slowly increase the current until the disc begins to move in the trip direction. This
is the pickup current
4) Slowly decrease the current until the disc turns toward the reset position. This is the
dropout.

The advantage of this testing philosophy is that the tester has tested the relay using as-
left conditions. However, what one tester defines as begins to move could be
dramatically different than another testers definition leading to possibly large
differences in test results between relay testers.


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C) Connecting the Test Set
Treat the MTS-5000 as a power system simulator whenever connecting the voltage
and/or current channels to the relay under test. Look at the connection diagrams from the
relays instruction manual and replace any CTs or PTs with the output channels of the
test set. A standard electro-mechanical drawing is shown in the following figures.

Figure 5 Figure 6
We will test the A-phase relay in our example. You should first determine the A-phase
CT Connections. Terminal 51/9 is connected to the polarity of the CT and should be
connected to the MTS-5000 I1 top terminal. Relay terminal 51/8 is connected to the CT
common and should be connected to the MTS-5000 I1 bottom terminal. The relay disc
contacts are connected to 51/10 and 51/1 as shown in figure 6 and both terminals should
be connected to the MTS-5000 input 1 terminals with 51/10 connected to the top
terminal. Turn the disc to the trip position and make sure that Input 1 indicates closed to
make sure your connections are OK.


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1 2 3 4
1 2 3 4
I1 I2 I3
MAX
0.4A
MAX
250V
51-A ICS IIT
51
1
51
10
ICS
51
2
51-A
51
9
51
8

Figure 7
The MTS-5000 prefault mode is an easy way to perform pickup testing for users
unfamiliar with the differences between prefault and fault modes. Most users use
prefault for pickup testing because the only way to stop a prefault test is by pressing the
[RESET] button on the MTS-5000 or pressing State [F10]. Anything connected to Inputs
1-6 will not stop or change the output state of the MTS-5000 as programmed from the
factory. However inputs 7 and 8 will affect the test as we will show later in this course.


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Turn on the MTS-5000 and enter the Manual Test [F1] mode. Look at the Fault Type
[F8] area and notice the box around Arbitrary. Pressing [F8] will change the Fault Type
to the next value. You can always tell which Fault is in-use by looking at this button
description or looking at the top right-hand corner of the Vector Display. As you can see
by the amount of blue text on the screen, arbitrary mode allows you to change nearly
ever aspect of the current and voltage channels. Arbitrary mode is great for single phase
relays and very complicated relay tests and should only be used in these two cases. The
other fault types allow the MTS-5000 to simplify data entry and make you a more
efficient relay tester.

Figure 8
We are starting with a simple overcurrent relay and the voltage channels arent being
used so lets disable them to simplify the screen display. The voltage channels use
Amplifiers, so select Configure Amplifiers [F3] and select Voltage Outputs (V1, V2, V3)
[F2] to turn the voltage outputs off. The F1 key almost always takes us back to the
previous screen, so press Back to Test Menu [F1] to return to Manual Test. The screen
should look like the figures on the next page when you have finished.

Figure 9


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Look at State [F10] and make sure the box is around prefault. Pressing State [F10]
allows you to choose which fault state to adjust. You can also tell which state you are in
by looking below the Vector Display area at Adjusting Prefault with a yellow
background to determine that you are in Prefault mode. We want to set up our tests
before generating any current so make sure that the area below the Output display is
green with Generating Off

It is always a good idea to check your trip contact before starting the first test to make
sure that the connections are correct. Turn the disk to the reset manually and ensure that
the Input 1 display is On as indicated by a solid red background around a white 1 in
the Inputs display. Release the disk if the Input status illuminates or check the
connections if nothing happens.

Figure 10
For our examples, we will assume that you are using a CO-9 relay with a tap of 5.0 and
time dial 4. If you wish to use a different relay or settings, change all of the values that
follow in our example to match your settings.


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D) Pickup Testing using Prefault
We will use the manufacturers recommended procedure for our testing procedures
which include the following steps:
1) Apply a current higher than the pickup setting until the trip contacts close
2) Reduce the current until the contacts chatter and then slowly reduce the current
until the contacts just open. This is the dropout current.
3) Slowly raise the current until the contacts chatter. This is the pickup current

i) Step 1: Apply a Current Greater than the Pickup Setting
Make sure that IA=I1 magnitude adjustment is selected as shown in figure 11
with yellow text and a black background. We want to apply more current that the
pickup setting to operate the relay, so we will arbitrarily choose 2x the pickup
setting or 10 Amps. You can change any numerical selection on the MTS-5000
using the keypad. We want I1 to produce 10 Amps, so select IA=I1 Magnitude
and type [1], [10]. Notice that the function keys changed as soon as you touched
the first key and the screen now looks like the following figure.

Figure 11
[F6] has changed to Delete Last Character [F6] which allows you to correct
mistakes. Pressing [F6] at this point is similar to pressing the backspace key on
your keyboard. Abort Changes [F9] will cancel the change and take you back to
the point before you pressed the key. You can accept your changes in one of 3
ways.
1) Accept Changes [F10]
2) Pressing the [ENTER] key
3) Press any of the arrow keys to move to the next field. Your changes will be
saved and you can immediately start changing the next field you moved to.


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You can also change any numerical value by rotating the dial in the clockwise and
counterclockwise directions. We will use both methods during our pickup test.

Look at State [F10] and make sure you have setup Prefault and press the red
[PREFAULT] button to start generating current.

Figure 12

Figure 13
The bottom left-hand portion of the screen flashes red and white with the message
Generating Prefault to indicate that the voltage and/or current channels are
actively generating the values on the screen. A red LED between the current and
voltage connections also flashes as a warning.

The relays aluminum disk should start to rotate when the current is applied and
will continue rotating until the disc and fixed contacts meet. The closed contact is
displayed on the MTS-5000 by a solid red background around the number 1 on
the input display area. You can also hear a buzzer when any input is closed by
pressing TONE [F5]. Press Tone [F5] again to turn the buzzer off. This feature
allows you to tell if an input is open or closed without looking at the screen.


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ii) Step 2: Determine Relay Dropout
To test the relay dropout, we need to lower the current until the relay contacts
begin to chatter using one of two methods. Simply rotate the dial in the counter-
clockwise direction until the input status flickers or change the I1 magnitude to a
value slightly above the relay pickup setting (5.5 A) and then slowly rotate the
dial in the counterclockwise direction. Users using the first method may
unintentionally dial too fast and over-reach the dropout point and may need to
vary the test several times until the proper drop-out is reached. Once you
determine the amount of current that causes the relay to chatter then stay open,
record the stay open value on your test sheet as the relay drop-out.

iii) Step 3: Determine Relay Pickup
The relay pickup test is performed immediately following the dropout method and
must be combined into one test. After the dropout test value is recorded, perform
another dropout test and immediately increase the current by slowly turning the
dial in the clockwise direction. The pickup test value occurs when the contacts
begin to chatter. Use the flickering on the Input 1 display or press TONE [F5] to
listen to the tone. Record the pickup value on your test sheet.

Press the green [RESET] button to stop current and voltage outputs.

E) Pickup Testing Using Static Fault
The advantage of pickup testing in prefault mode is that any contact connected to inputs
1-6 and 9-12 will not stop the test and the pickup test will continue until the [RESET] or
State [F10] keys are pressed. However, testing in prefault adds extra steps and key
presses when pickup tests are performed in rapid succession with timing tests.

The MTS-5000 has two separate fault modes. Static Fault is used to perform pickup tests
and Dynamic Fault is for timing tests. Static Fault mode is used for pickup testing for
several reasons:
Static Fault mode will only stop if the static fault initiate is removed. All
inputs except for input 8 can be connected to devices and operate without
affecting the test in progress.
Static fault mode settings are performed in the fault state making it easier to
perform timing tests because the fault conditions are already defined during
the pickup test.
The test duration is easily controlled by one action instead of multiple key
presses necessary to stop a test in prefault. For example, if you intend to apply
3.0 A but accidently type 30 A, you can stop the 30 A input to relay more
quickly and hopefully prevent damage to the relay.


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Static fault mode is initiated two ways. Press and hold the red [FAULT] button and
watch the display. The bottom-left hand corner changes to red and displays Generating
Static Fault and the red LED between voltage and current inputs flash to indicate that
the MTS-5000 is generating voltages and currents. Also, State [F10] has changed to
Fault and the bottom-right screen description has changed to Adjusting Fault. You
were in Prefault state before pressing [Fault] and the MTS-5000 automatically changed
to Fault state when it began generating the Static Fault to show you what values are
being generated. Release the [FAULT] button and the MTS-5000 stays in Adjusting
Fault mode, ready to setup your next test in the fault state.

Figure 14
You can change back to Prefault mode by pressing State [F10] and setup the Prefault
conditions offline or you could press [PREFAULT] which immediately starts generating
Prefault conditions and changes the display to Adjusting Prefault to display the
currents and/or voltages generated by the test set.

You can also initiate a Static Fault by connecting a switch/contact/footswitch between
the terminals for Input 8. Input 8 is pre-defined from the factory to initiate a Static Fault
and can be changed to a regular contact in the Advanced Settings [F4] menu. Connect a
footswitch or two leads to Input 8 and make contact. The MTS-5000 display screen
changes to Fault mode and generates the Fault currents and voltages exactly the same as
when the [FAULT] button was pressed and held. Stop the test by releasing the
footswitch or opening the contact.

Follow the dropout and pickup test procedures described in the previous section to test
the relay but use the Static Fault mode to generate current.


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You can use Prefault in conjunction with Static Fault to make pickup testing even easier
using the following procedure.
1) Press State [F10] until Prefault is selected. (Notice that State [F10] stops a
test in progress and moves to the opposite state)
2) Set Prefault I1 current to be 2x pickup current
3) Press State [F10] until Fault is selected.
4) Set I1 current to pickup setting plus 0.25 amps.
5) Press green [PREFAULT] button and wait until input 1 closes.
6) Press and hold [FAULT] button. Perform dropout and pickup tests. Release
[FAULT] button.
7) Press State [F10] to select the offline fault screen.
8) Setup timing test

F) Time Overcurrent (51) Timing Tests
Before we can perform a timing test, we need to know what the timing result should be.
A minimum of two 51-element timing tests should be performed to ensure that the relay
has been properly adjusted and some typical timing tests are performed at 2x, 4x, and 6x
pickup to get a good representation of the curve.

51-element timing tests are performed by applying a multiple of the pickup current to the
relay and measuring the time between the start of the test and relay operation as shown
in figure 15. The Test in Progress area represents the speed of the rotating disc as it
moves from the reset position to the trip position.
1 2 3 4 5 6 7 0
TIME IN SECONDS
2A
4A
6A
8A
TEST IN PROGRESS
PICK UP

Figure 15
Figuring out what the timing test result should be can often be the hardest part of 51-
element timing tests.


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i) Using Graphs to Determine Time Delay
You can determine the expected time delay using the manufacturer supplied time
characteristic curves using the following steps:
1) Locate the correct Time Coordination Curve.
2) Find the line associated with the time dial setting. (If Time Dial Setting is a
fraction of a whole number, round the time dial to the lower number)
Counting from the bottom, determine the time dial line number. (Time Dial
4.0 is the 5th highest line in our example)
3) Locate the vertical line associated to the first timing test multiple. (2x in our
example)
4) Follow the vertical line up and count the TD lines until you reach the target
TD line. (5th highest in our example). If the Time Dial setting is a whole
number, mark the intersection between the target TD line and the vertical
Line. If the Time Dial Setting is a fraction, approximate the fraction between
lines. (0.5 between 4 and 5 in our example) Remember that it is a logarithmic
graph and the scale is logarithmic.
5) Follow the previous mark using a straight edge to the time axis and record
the time.
6) Repeat for all test points.
6.0 s
1.39 s
0.8 s

Figure 16


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ii) Timing Test using Dynamic Faults
Timing tests are performed in the Dynamic Fault mode of the MTS-5000. A
dynamic fault is initiated by pressing and releasing the [FAULT] quickly (less
than 300 ms) which will generate any voltages and currents defined in the Fault
State and start the Fault Timer. The test will stop normally if any contact
connected to input 1 - 6 opens OR closes when the Fault State is active. This
means that the MTS-5000 can perform a timing test using a normally-open or
normally-closed relay contact with no configuration changes. You can change this
feature in Advanced Settings [F4] if you are looking for a specific operation and
want to ignore all other operations. A dynamic fault can also be stopped by
pressing the [RESET] button or State [F10] key.

iii) Timing Test Procedure
1) Make sure that you are configuring the timing test by checking State [F10]
and make sure Fault is selected.
2) Choose how many timing tests you will perform, at which magnitudes of
pickup current, and the expected time delay.
3) Set the Ia=I1 current to the first timing test magnitude. A 2x test of our
example relay would be 10 A (PU =5 A, 2 x 5A =10 A) and the expected
time delay should be 6.0 s as per figure 16.

Figure 17
4) Press and release the [FAULT] button quickly (<300 ms) to start the timing
test. Watch the Fault Timer and make sure it is timing.


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5) Wait for the test to stop. There are a number of ways to tell that a test is
finished.
o The Fault Timer stops
o The Fault Status Box indicates Generating Off and is green.
o Inputs 1-6 operate
o You hear a tone if the On is selected in Tone [F5]

Figure 18
6) If the test runs longer than the expected time delay, stop the test by pressing
[RESET] and troubleshoot the problem. When the problem is fixed, start the
test again.
7) Compare the test results to the expected test results and record the results if
the results are acceptable. If the relay test results are not acceptable, adjust
the relay, re-test the relay, and repeat until the test results are acceptable.
8) Repeat with different Ia=I1 magnitudes until all tests are completed with
acceptable results.


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G) Electro-Mechanical Relay Target Tests

Most electromechanical relays have a target that is dropped when the 51-element
operates and the trip contact is connected to a DC circuit as shown in figure 19. The
target relay typically has two taps (0.2 A and 2.0 A) that apply to specific applications.
The 0.2 A tap should only be used when the relay trip circuit is connected to a trip relay
or other inter-posing relay between the protective relay trip circuit and the circuit
breaker trip coil. The 2.0 A tap is used when the protective relay trip circuit is directly
connected to the circuit breaker trip coil. Always check that the correct tap is used for
the application because an incorrect application can cause damage to the protective relay
trip coil or the target may never operate at all.

A typical electrical schematic of the target relay is shown in figure 19. Testing this
device is a three step process.
1. Close the protective relay trip contact (51-A)
2. Increase DC Current between 51/10 and 51/1 until the relay operates. The operating
current should be less than the tap.
3. Open the protective relay trip contact (51-A) and ensure the latching contact (ICS)
stays closed.


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51-A ICS
51
1
51
10
ICS

Figure 19
Move the test leads connected to input 1 to Current I3 as per figure 20 to test this device.
I1 I2 I3
51-A ICS IIT
51
1
51
10
ICS
51
2
51-A
51
9
51
8

Figure 20


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I3 is set as AC current by default but we need DC current for this test. This is an
amplifier issue so press Configure Amplifiers [F3] and then Set I3 to DC [F9]. The MTS-
5000 will automatically switch to the Manual Test Menu where two new columns
appear. Notice that the I3 row frequency is set to DC and we are ready to test this device.

Figure 21
We must close the trip contact to close the DC circuit and many relay-testers manually
move the relay disc to the trip position which works, but requires unnecessary extra
effort. We can move the disc to the trip position by applying the 2x the pickup current
with a Static Fault. Press and hold the [FAULT] button or use your foot switch to apply
10.000 A from Ia=I1 into the relay and wait for the disk to close.

Step 2 tests the coil pickup current. Maintain the Static Fault and move the cursor to
Ic=I3. Apply of the target coil tap (0.1 A for 0.2 A tap or 1.0 A for 2.0 A tap) and
slowly increase the current until the target drops. The target should drop when the
applied DC current is less than the tap setting. If the target does not operate before you
reach the rated current, you can increase the current to a maximum of 150% of the tap
current. Record the test result but do NOT stop applying current. If the test stops at any
point in this procedure, set the Ic=I3 DC current to 0.000 A and start over.

Sometimes the seal-in is disabled by design at the side of the relay by moving the
contact configuration. Check the contact configuration before applying the next step.
Step 3 tests the seal in contact. Maintain the Static Fault and apply the rated tap DC
current from Ic=I3 and move the curser to Ia=I1 and set the AC current to 0.000 A. The
target relay should stay closed because the ISC (seal-in) contact should be closed. If you
are not sure whether the seal-in is working, you should not be able to reset the target.
The MTS-5000 will also beep and indicate a CLIP condition on Ic=I3 if the seal-in
contact opens. Stop the test by removing your finger from the [FAULT] button or foot
from the footswitch. Remember to start from the beginning with 2x pickup current on
Ia=I3 and 0.000 A on Ic=I3 if you need to run the test again,


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3. Instantaneous-Overcurrent (50) E-M Relays
The instantaneous overcurrent part of a typical electro-mechanical overcurrent relay has the
simplest operating characteristic. It is constructed with an input coil and a clapper contact.
When the input current creates a magnetic field greater than the mechanical force holding the
clapper open, the clapper closes and sends a 50-element trip signal. The relays pickup is
adjusted by changing the coil taps and/or varying the core material via an adjusting screw. The
relay has no intentional time delay but has a small inherent delay due to mechanical operating
times.

A) Pickup Testing
This element is a simple one, apply a current higher than the pickup setting and see if it
operates, but there are several obstacles that must be overcome. What happens if the
pickup current is greater than 30 Amps? How long can I apply high currents without
damaging the relay? How can I prevent accidental damage to the relay by applying too
much current for too long? What if the relay has a high burden? All of these questions
will be answered in the following sections.
B) Connecting the Test Set
You should treat the MTS-5000 as a power system simulator whenever connecting the
voltage and/or current channels to the relay under test. Look at the connection diagrams
from the relays instruction manual and replace any CTs or PTs with the output channels
of the test set. A standard electro-mechanical drawing is shown in the following figures.

Figure 22 Figure 23


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The AC 3-line drawing above from the manufacturers bulletin does not accurately
reflect the actual internal connection of the ABB CO relay in our example and is typical
of all electro-mechanical relay manufacturers. The following drawings represent the
internal connections of the relay and a revised 3 line drawing.

Figure 24
51-A
9
50-A
52
A B C
A
B
C
51-B 50-B
51-C 50-C
51-N 50-N
PH. A
PH. B
PH. C
GRD.
8
3
9 8
3
9 8
3
9 8
3

Figure 25

We will test the A-phase relay in our example and you should first determine the A-
phase CT Connections. Terminal 51/9 is connected to the polarity of the CT and should
be connected to the MTS-5000 I1 top terminal. Relay terminal 51/8 is connected to the
CT common and should be connected to the MTS-5000 I1 bottom terminal. Some test
procedures will instruct you to use terminals 51/9 and 51/3 to isolate the instantaneous
overcurrent element and reduce the circuit burden of the test set. This isolation is not
required because of the MTS-5000 high output capacity. Also, tests should be performed
using the most realistic simulations possible so the relay should connected terminals
51/8 and 51/9 when in-service as shown in figure 26.


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I1 I2 I3
50-A
51
9
51
8
51-A
51
3
1 2 3 4
1 2 3 4
MAX
0.4A
MAX
250V
51-A ICS IIT
51
1
51
10
ICS
51
2

Figure 26
Instantaneous overcurrent (50-element) testing often requires very high currents (15A
and greater) which can damage the relay if applied for an extended time which is a major
reason why Pre-Fault should not be used for pickup testing. Manual 50-element testing
should be performed using Static Fault Mode which is enabled by pressing and holding
the [FAULT] button or using the supplied foot-switch connected to Input 8.

Instantaneous overcurrent testing often requires current greater than 30 Amps but the
maximum MTS-5000 current output is 30 Amps per channel. Relay testers using older
test equipment would parallel the output channels by setting all of the current phase
output channels to the same angle, paralleling the output channels together, and adding
all the current magnitudes together to determine the actual output current.

The MTS-5000 has several shortcut keys to make this process simpler. This function
involves the Current amplifiers so press Configure Amplifiers [F3] to change the
amplifier configurations.


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You can group any channels together in the Group column. For example, we can group
channels 1 and 2 into Group A by selecting Ungrouped beside each channel and
using the dial to choose Group A for both of the channels. After the grouping is
completed, the bottom of the Group A column indicates a total of 60 A available for this
channel.

Figure 27
Pressing Back to Test Menu [F1] will return us to the Manual Test Menu where the
current channels have been reconfigured as per our new settings. The first channel row is
Ia which indicates that more than one channel is in parallel with the description
Parallel Connections: Ia = I1 + I2 located below all of the channels.

Figure 28


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This description is an instruction and is not information. The current output connections
are only rated for 30A per terminal and all currents exceeding 30 A must be paralleled
externally to the test set as shown in the following drawing.
I1 I2 I3
50-A
51
9
51
8
51-A
51
3
1 2 3 4
1 2 3 4
MAX
0.4A
MAX
250V
51-A ICS IIT
51
1
51
10
ICS
51
2

Figure 29


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There is a much easier way to group and un-group channels. Press Configure Amplifiers
[F3] from the Manual Test Menu to enter the Amplification Configuration Menu.
You can quickly and easily parallel all channels by pressing Parallel All [F10]. Now all
channels are paralleled together for a total of 90 Amps as shown below.

Figure 30
Remember that the description Parallel Connections: Ia = I1+I2+I3 is an instruction
and the connection should change as follows.
1 2 3 4
1 2 3 4
I1 I2 I3
MAX
0.4A
MAX
250V
51-A ICS IIT
51
1
51
10
ICS
51
2
50-A
51
9
51
8
51-A
51
3

Figure 31
Now that the test set is configured to produce a large amount of current, we can begin
testing the instantaneous overcurrent element with a 40 A pickup for our example.


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C) Testing High Burden or High Current Applications
The MTS-5000 can produce 1800VA of output power and can be operated at full
capacity when connected to a dedicated 15A circuit. The "Input Power Control"
setting allows users to limit the energy used by the test set so they can share the circuit
with other devices, or eliminate problems caused by a weak power source. The range for
this setting is 1-10. 10 is the maximum setting which allows the test set to use and
produce 100% of its potential. Any setting less than 10 will limit the amount of energy
used by the test set and while the actual effect is not linear, it helps to think of the default
setting of 5 to be 50% power.

Changing the "Default Input Power Control" setting in the Setup Menu from the
MTS-5000 Main Menu and pressing Save [F10] will set the default limit that will be
applied whenever the test set is turned on. Setting the "Input Power Control" in the
Advanced Menu from Manual Test Menu will temporarily change the limit until the
setting is changed again or the test-set is powered down.

If you observe a "CLIP" or "clip" indication in the Status column of the output current
OR the Advanced Setting [F4] button flashes after a test: the input power control setting
may be set too low for the burden of the circuit you are trying to test. Increase the setting
until the clip indication is no longer observed. Alternatively you can shorten the test
leads connected to the device, increase the wire gauge of your test leads, or add test
leads in parallel.

If the panel circuit breaker operates during a test and a dedicated circuit is not available,
you can decrease the setting until you observe a clip indication then increase the setting
by one to continue testing with the lowest possible power draw from the test set.

If you are plugged into a wall receptacle directly or via an extension cord and the MTS-
5000 screen freezes and will not operate without cycling the test set power, the input
voltage from the receptacle may have dropped below 90V momentarily at the MTS-5000
which temporarily disabled its video card. You can decrease the setting until you
observe a clip indication then increase the setting by one to continue testing with the
lowest possible power draw from the test set. Alternatively, we have found that a #10
AWG extension cord helps reduce this problem significantly.

If you are plugged into a generator and the MTS-5000 screen freezes and will not
operate without cycling the test set power, the input voltage from the receptacle may
have dropped below 90V momentarily at the MTS-5000 which temporarily disabled the
test-set video card. Sometimes an inexpensive generator governor cannot respond
quickly enough for the inrush current associated with a high current burden test and
lowering the input power control setting can help. We've also had success pre-loading
the generator with 3-phase pre-fault current via the MTS-5000 or connecting and
operating another device such as light-stand or small vacuum cleaner to reduce the
generator's sudden switch from no-load to full-load.


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D) Instantaneous Overcurrent (50) Pickup Testing Using Static
Fault
Instantaneous overcurrent tests often require high current which, if applied for an
extended period, could damage the relay under test and associated equipment. It is very
important that you be able to control the magnitude and duration of the applied current at
all times and the easiest method for achieving this with the MTS-5000 is by applying
Static Faults. Some people perform a 50-element test by ramping the current until the
element operates but this method is not very accurate as the ramp-rate should be very
fast and a different pickup will be observed for every test as the ramp rate will not be the
same for multiple tests.

Setup your test by entering the Manual Test Menu and press State [F10] until Fault is
selected. Operate the 50-element contact manually and ensure that the Input 2 display
illuminates and release. Set the fault current 10% higher than the setting (40 x 1.10 =
44.0 A in our example). Watch the Input 2 status and start a Static Fault for 1 second by
pressing and holding the [FAULT] button or pressing the foot switch for about a
second. Did Input 2 turn on? If not, review the connections and settings to ensure that
everything is correct. Did the Status indication change to CLIP or Clip during the
test and is the Advanced Settings [F4] Flashing Red? If so, refer to the previous section
Testing High Burden or High Current applications.

If the Input 2 status did flash when the test was run, you are ready to start the pickup
test. It is important to look for the test set indication rather than watching the relay
because the relay can often look like it has operated but the contacts do not close. The
most important part of this test is the contacts close and trip the device. You can also
press TONE [F5] to turn on a buzzer when the relay operates Input 2.

Lower the current setting to 5% below the setting (40 x 0.95 =38A) and run the Static
Fault by pressing and holding the [FAULT] button or pressing the foot switch for about
a second. If the relay is set correctly, the element will NOT pickup because the
applied current is less than the setting. Increase the current by 0.5 Amps (38.5 A) and try
again. Keep increasing and re-applying the current until the relay operates. You can
reduce the change in current between tests to obtain a more accurate result but remember
that most organizations have a 5% error tolerance which would be between 38 42
Amps for our example.


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E) Instantaneous Overcurrent (50) Pickup Testing Using Dynamic
Fault
Performing an Instantaneous Overcurrent test using the Static Fault mode can lead to
inaccurate results and is only one possible method for pickup testing. A 50-element
should operate within 3 cycles or 0.05 seconds. If the static fault is applied for a
significantly longer period than this, then the relay may operate, but not instantaneously,
and the actual in-service pickup may be different than the test results. We can find out
the actual in-service pickup using the fault timer in a dynamic fault and a new setting
called Maximum Fault Duration.

The Maximum Fault Duration timer is an advanced setting which is enabled by pressing
Advanced Settings [F4] and using the arrow keys to locate Maximum Fault Duration
Enabled = Off near the middle of the screen. Use the dial to select seconds and press
F1 to return to the Manual Test Menu.

Figure 32


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There should be a new box above the Fault Timer display called Max duration that
controls the maximum amount of time a state will be enabled. A Max duration setting of
0.0000ss indicates that there is no limit on the state and it operates normally. However, if
the setting is any number other than 0.0000 s, the test set will automatically switch to the
next state. For example, if the Prefault Max duration is set at 3.0000 s and the Fault
Max duration is set at 1.0000s the MTS-5000 will generate the Prefault voltages and
currents for 3.000 s after the [PREFAULT] button is pressed. The MTS-5000 will
automatically switch to the Fault state and will stop generating after 1.000 s because
Fault is the last state enabled. If other states were enabled, the test set would
automatically switch to the next state. After pressing Prefault, you can over-ride the Max
duration by pressing [FAULT] before the 3.000 s timer has expired and the test set will
switch to the Fault state the moment the [FAULT] button is pressed. Pressing the
[FAULT] button when the test set is off will start the Fault state and the test will stop
when any of Inputs 1-6 operate or the Max duration expires, whichever happens first.

Figure 33
An instantaneous overcurrent relay should operate within 0.05 s if it is operating
correctly which means that we can set our Max duration timer slightly higher (0.08 s)
and run a Dynamic Fault or Timing Test to determine the 50-element pickup. If the relay
operates within the Max duration time (0.08 s) the Fault Timer will be less than Max
duration (0.08 s) which means that the test current is greater than the 50-element pickup.
If the relay does not operate, the Fault Time will be the same or slightly higher than the
Max duration (0.08 s).

The actual pickup test is very similar to the Static Fault test procedure. Setup your test
by entering the Manual Test Menu and press State [F10] until Fault is selected.
Operate the 50-element contact manually and ensure that the Input 2 display illuminates
and release. Set the fault current 10% higher than the setting (40 x 1.10 =44.0 A in our
example). Watch the Input 2 status and start a Dynamic Fault or Timing Test by
momentarily pressing the [FAULT] button. Is the Fault Timer less than Max duration?
If not, review the connections and settings to ensure that everything is correct.


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If the Fault Timer is less than Max duration, you are ready to start the pickup test.
Lower the current setting to 5% below the setting (40 x 0.95 =38A) and run the
Dynamic Fault by momentarily pressing the [FAULT] button. If the relay is set
correctly, the element will NOT pickup because the applied current is less than the
setting and the Fault Timer will be equal to or slightly greater than Max duration.
Increase the current by 0.5 Amps (38.5 A) and try again. Keep increasing and re-
applying the current until the relay operates which is displayed on the test set by a Fault
Timer less than the Max duration. You can reduce the change in current between tests
to obtain a more accurate result but remember that most organizations have a 5% error
tolerance which would be between 38 42 Amps for our example.

Fault Timer and Max duration are the
same =No Pickup.

Fault Timer is less that Max duration =
Pickup.
Figure 34


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F) Sequence of Events (SEQ)
It can be hard to keep track of events when you are distracted during a test and another
very useful feature is the built-in Sequence of Events recorder. You can view the
sequence of event of any test by pressing the Sequence of Events [F6] button at any time
during and after a test before the [RESET] button is pressed. Manual Test Sequence of
Events screen displays every state transition, input operation, and output operation
recorded or performed by the MTS-5000.

No Inputs operated = No Pickup

Input 1 operated 18.1 ms after the MTS-5000
entered the fault state
Figure 35
The default time reference in the SEQ is the moment the MTS-5000 enters the fault state
but you can choose your own reference by selecting the event and pressing Show Times
Relative to Selected Event [F2]. We can determine the time that the trip contact stayed
closed by selecting Evt# 3 and pressing Relative to Selected Event [F2] to find that the
time from Input Status 1 (Trip)ON to Input Status 1 (Trip)OFF is 148.4 ms. You can
also press Show Graphically [F7] to see a graphical representation of the fault.

Figure 36


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G) Instantaneous Overcurrent (50) Timing Tests
Any fixed time delay element such as the instantaneous overcurrent element should have
a timing test performed. The test magnitude should be 100% or greater of the rated
minimum pickup and the time delay for an instantaneous element should be less than 3
cycles or 0.05 seconds.

If the Dynamic Fault pickup method described earlier was used to perform the pickup
test, the timing test is performed by changing the magnitude of current to 110% x the
pickup setting and performing one more test. Our example pickup setting was 40.0 A
and our timing test would be performed by applying 44.0 A (40 x 1.10 =44.0 A) to the
relay. The time test result is displayed as the Fault Timer value and should be between
0 - 3 cycles or 0 0.05 s.


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4. Productivity Mode: 51: Time Overcurrent Relay Test Mode
The MTS-5000 can provide some simple automation for electro-mechanical relays using built-
in Productivity Modes. We can test the same CO-9 relay from our manual testing example
using the 51: Time Overcurrent Relay Test Mode.

Start using the productivity mode by pressing Productivity Modes [F2] from the MTS-5000
Main Menu. Use the arrow keys or dial to select 51: Time Overcurrent Relay Test Mode
and press [ENTER] or Accept New Choice [F2]. Select the model of relay you would like to
test. (CO for our example) Select the style of relay you wish to test (CO-9 Very Inverse for
our example).

Figure 37


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The MTS-5000 reconfigures itself to be a CO-9 relay tester and applies a Manual Test Type
by default. However, we are looking for automation so press Test Type [F7] to switch to the
Automatic Test Type. The MTS-5000 cannot properly test a relay without the relay settings
and test points and we can enter those by pressing Configure Test Parameters [F4].

Figure 38
The MTS-5000 will open the Configure Test Settings Menu where you can enter the Tap and
Time Dial settings using the arrow keys, keypad or dial. Notice that the Reset Time changes
automatically when the time dial is changed. The Reset Time determines the amount of time
that the MTS-5000 will wait between tests and is slightly longer than the calculated time it will
take the relay disc to move from the trip position to the reset position. This setting is blue so it
can be changed. However if the new setting is faster than the calculated setting, you must
manually reset the relay disc within that time between every test. Set the Tap and Time Dial to
match the relay settings. (Tap =5 and Time Dial =4 in our example.

Press Configure Automatic Time Test [F8] to set up the timing test parameters. Number of
Test Points determines the number of timing tests the MTS-5000 will perform. Change this
setting to 3 for our example and notice that the last two timing test settings are now gray,
indicating that they cannot be changed.

Figure 39


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Press the Down Arrow [] button to select the Test 1 xTap/Amps/Op. Time row to set up the
first timing test. The first column is a Multiple of Tap setting which is set at 2 to match our
manual timing test plan. Notice that the next two columns automatically change to match the
new multiple of tap. Also notice that the values are blue which means that they can be changed
as well. Press the arrow keys to select the Test 2 xTap/Amps/Op. Time row and the second
column that represents the test current. Change this value to 20.000 A and the xTap value will
change to 4.000 and the time will change accordingly.

Figure 40
Use the arrow keys and keypad to change the Test 2 xTap/Amps/Op. Time row xTap value to
6.000. The MTs-5000 uses a formula to determine the Op. Time value and may not be accurate
at the extreme ranges of the curve. If previous test sheets, coordination study, or engineers
instructions indicate a different time, the value can be changed. Change the Test 2
xTap/Amps/Op. Time row Op.Time value to 0.83 s.

Figure 41


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The relay and test set connections are the same as the manual test as shown in figure 42.
1 2 3 4
1 2 3 4
I1 I2 I3
MAX
0.4A
MAX
250V
51-A ICS IIT
51
1
51
10
ICS
51
2
51-A
51
9
51
8

Figure 42
Press Back to Test Menu [F1] to start testing. Always look at the [F10] key before starting any
test. The default Auto Test [F10] is a Pickup test and the instruction to start this test is located
between the meter display and Adjusting Fault 1. Press PREFAULT to run test.

Figure 43


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Pressing [PREFAULT] will start the Pickup test by applying 1.5x the pickup setting (7.50 A in
our example) and waiting until the relay trip contact operates Inputs 1. The test set will
automatically lower the current until the trip contact opens and records the drop-out value. The
current will immediately raise the current until the contacts close again and record the pickup
value. The Tone is turned on by default and can be switched Off by pressing Tone [F5].

The pickup and drop-out values are displayed on the display after the test is finished. You can
view and save a report of the test by pressing Test Report [F6].

Figure 44
After the Pickup test results are satisfactory, you can start the timing test by pressing Auto Test
[F10] to select Op. Time. Notice the graph of the expected results and the instructions just
under it. Pressing [PREFAULT] will start the Timing Tests. The MTS-5000 will wait for the
Reset Time defined in Configure Test Parameters and then start the first timing test. After the
first timing test is completed, the MTS-5000 will wait for the Reset Time again before
starting the next test. If the Reset Time was changed to a smaller value, make sure the disc is
in the fully reset position before the Waiting for relay reset display reaches 100%. The MTS-
5000 will repeat this process until all timing tests are completed.

Figure 45


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After all of the tests are completed, the MTS-5000 displays the results as Xs on the graph so
you can see the shape of the curve to help you when adjusting the time. The results are also
displayed as text under the graph. You can also press Test Report [F6] to review or save a test
report.

Figure 46
5. Productivity Mode: 50: Instantaneous Overcurrent Relay
Test Mode
The MTS-5000 can provide some simple automation for electro-mechanical relays using built-
in Productivity Modes. We can test the same CO-9 relay from our manual testing example
using the 50: Instantaneous Overcurrent Relay Test Mode.

Start using the productivity mode by pressing Productivity Modes [F2] from the MTS-5000
Main Menu. Use the arrow keys or dial to select 50: Instantaneous Overcurrent Relay Test
Mode and press [ENTER] or Accept New Choice [F2].

Figure 47


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All instantaneous overcurrent relays operate in the same manner so there is no need to choose
the style of relay as in the 51 productivity mode. All of the relay and test settings are on the
front display screen but it may be difficult to read. You can press Configure Test Parameters
[F4] to set up the tests with a larger display. Dont forget to press Configure Automatic Pickup
Test [F7] and Configure Automatic Timing Test [F8] to set up all test parameters.

Figure 48
The first setting is called Max Duration and is exactly the same setting we discussed in the
Instantaneous Overcurrent (50) Pickup Testing Using Dynamic Fault section of this
publication. Instantaneous overcurrent elements should typically operate within 3 cycles or
0.05 ms and this setting should be approximately 0.1 s. Notice that when this setting is
changed, the Max Cycles setting also changes. These two settings are linked and represent the
same time with different units. The Pickup test will apply a test current until the relay operates
or the Max Duration timer is exceeded, whichever comes first. If the Max Duration expires,
the test set will raise the test current to the next level and repeat until the relay operates or the
maximum current magnitude is reached.

The next setting is Pickup Level which defines the expected pickup of the relay. The MTS-
5000 will use this number to determine percent error of the result and the baseline for all tests.
This setting would be 35.000 A for our example.


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When you try to apply 35 A to this setting, a warning message will appear to inform you that
the setting is greater than the MTS-5000 can produce through channel Ia=I1. Instantaneous
overcurrent element settings are often greater than 30 A so a shortcut has been added. You can
parallel all three current channels by pressing Parallel All Currents [F8]. Remember that all
current outputs must be paralleled together!

Start level defines the magnitude of current for the first test. A setting of 95% would apply
33.25 A (0.95 x 35 A) for the first test.

Max level defines the maximum amount of current to be applied. A setting of 105% would
apply 36.75 A (1.05 x 35 A) as the last test if the relay did not operate for lower current levels.

Step defines the amount of change between tests. A setting of 1% will change the applied
current magnitude 0.35 A (0.01 x 35 A) between steps. A larger Step setting will provide a less
accurate pickup result. A smaller setting will provide a more accurate result but increase the
amount of steps and time to find the pickup. Remember that most companies have a 5%
tolerance and a 1% Step is a good balance.

The Input Number setting defines which input will be used to determine pickup. Setting this
input as 2 matches the connection diagram from our previous example.
1 2 3 4
1 2 3 4
I1 I2 I3
MAX
0.4A
MAX
250V
51-A ICS IIT
51
1
51
10
ICS
51
2
50-A
51
9
51
8
51-A
51
3

Figure 49


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All productivity modes that include an automatic function have an instruction to run the test
above the Adjusting Fault 1 purple dialog box. The instruction in this case is Press
PREFAULT to run test. Press prefault to run the Pickup test defined by Test Type [F9] and
the MTS-5000 will apply the Start Level magnitude of current and wait for a trip signal from
the relay. If a trip is detected, the test will stop and the result will be displayed on the front
panel. If a pickup is not detected, the MTS-5000 will stop the test after the Max Duration
timer expires, increase the current magnitude by the Step setting and try again. If a trip is not
detected before the Max Level magnitude of current is applied, the test set will stop after the
Max Level is applied and no trip is detected.

Press Test Report [F6] to view the test report after a successful pickup test is recorded.

Figure 50
Run a timing test by pressing Test Type [F9] to select Timing. Test Level is the magnitude of
current to apply during the timing test and should be at lease 110%. Follow the instruction on
the screen, Press PREFAULT to run test to run the timing test. The test result will displayed
on the screen and you can view and save the test result by pressing Press Test Report [F6].

Figure 51

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