Vanguard CT-6500 S2 User Manual

V

OPERATING INSTRUCTIONS

for the

CT-6500 Series 2

Digital Circuit Breaker Analyzer

anguard Instruments Company

TEL: [phone] May 2008
FAX: [phone] Rev 2

1520 South Hellman Avenue
Ontario, California 91761, USA

CT-6500 Series 2 Operating Instructions

SAFETY WARNINGS AND CAUTIONS

Only trained operators shall use the device. All circuit breakers under test shall be off line and
fully isolated.

DO NOT SERVICE OR TEST ALONE

Do not perform test procedures or service unless another person is also present who is
capable of rendering aid and resuscitation.

DO NOT MODIFY TEST EQUIPMENT

Due to the added risk of introducing additional or unknown hazards, do not install substitute
parts or perform any unauthorized modifications to any CT-6500 test unit. To ensure that all
designed safety features are maintained, it is recommended that repairs be performed only by
Vanguard Instruments Company’s factory personnel or by an authorized repair and service
center. Unauthorized modifications can cause serious safety hazards and will nullify the
manufacturer's warranty.

FOLLOW EXACT OPERATING PROCEDURES

Any deviation from the procedures described in the operator’s manual may create one or more
safety hazards, damage the CT-6500, the test circuit breaker or cause errors in the test
results. Vanguard Instruments Company, Incorporated assumes no liability for unsafe or
improper use of the CT-6500.

WARRANTY

The CT-6500’s warranty is only valid to the original purchaser to be free from defects in
material and workmanship for a period of one year. The warranty does not apply to normal
wear or damage from misuse, abuse, improper storage, installation, accident, unauthorized
repair or alterations.

I

CT-6500 Series 2 Operating Instructions

Table of Contents

1.0 Introduction ............................................................................................................................. 7

2.0 CT-6500 Description ............................................................................................................... 8

2.1 Contact Timing Channels ............................................................................................ 8

2.2 Analog Voltage Monitoring Channel ............................................................................ 8

2.3 Digital Voltage Monitoring Channel ............................................................................. 8

2.4 Trip/Close Current Monitoring ..................................................................................... 8

2.5 Travel Transducer Input Channels .............................................................................. 8

2.6 Breaker Initiate Capability ........................................................................................... 8

2.7 Built-in Thermal Printer ............................................................................................... 9

2.8 Computer Interface Capabilities .................................................................................. 9

2.9 Timing Records Storage Capabilities .......................................................................... 9

2.10 Diagnostic Capabilities .............................................................................................. 9

2.11 CT-6500 Display and Control Switches .................................................................... 9

3.0 Test Result Tabulation ............................................................................................................ 9

3.1 Timing Test Measurement Results ............................................................................. 9

3.2 Mechanical Measurement Results ............................................................................ 10

3.3 Analog Voltage Input Results .................................................................................... 10

3.4 Digital Voltage Input Results ..................................................................................... 10

3.5 Initiate Current Results.............................................................................................. 10

3.6 Slow-Close Test Results ........................................................................................... 11

4.0 Test Result Graphics ............................................................................................................ 11

4.1 Thermal Printer Graphic Printout .............................................................................. 11

5.0 CT-6500 Controls and Display .............................................................................................. 12

6.0 CT-6500 Analyzer Specifications .......................................................................................... 15

7.0 CT-6500 Special Features .................................................................................................... 17

7.1 CT-6500 Supplied Cables ......................................................................................... 17

7.2 CT-6500 Operating Voltages .................................................................................... 18

7.3 CT-6500 Main Power Switch & Circuit Breaker ........................................................ 18

7.4 Initiate Circuit Protection Fuses ................................................................................ 18

7.5 CT-6500 Printer and Printer Paper ........................................................................... 19

7.6 Replacing CT-6500 Thermal Paper .......................................................................... 19

7.7 CT-6500 Printer Paper Control ................................................................................. 19

7.8 CT-6500 LCD Contrast Control ................................................................................. 19

8.0 Test Hook-up Connections ................................................................................................... 20

8.1 Contact Cable Hookup .............................................................................................. 20

8.2 Initiate Cable Hookup ................................................................................................ 22

8.3 Analog Voltage Monitor Hookup ............................................................................... 23

8.4 Digital Voltage Monitor Hookup ................................................................................. 23

8.5 External Trigger Input ................................................................................................ 24

8.6 Digital Transducer Connection .................................................................................. 25

9.0 Operating Procedures ........................................................................................................... 26

9.1 Timing a Circuit Breaker ............................................................................................ 27

9.1.1 Timing an OPEN Operation (With No Insertion Resistors) .................................... 28

9.1.2 Timing an OPEN Operation with Insertion Resistors ............................................. 29

9.1.3 Timing CLOSE-OPEN Operation Using Contact Channel #1 ................................ 30

9.1.4 Timing OPEN-CLOSE-OPEN Operation ................................................................ 32

II

CT-6500 Series 2 Operating Instructions

9.2 Printing Tabulated Timing Results Using the Thermal Printer .................................. 33

9.2.1 Tabulated Results Interpretation ............................................................................ 35

9.3 Get Graphic Timing Results Using the Thermal Printer ............................................ 36

9.4 Save Timing Test Records in the EEPROM ............................................................. 41

9.5 Printing Timing Test Record Directory Stored in the EEPROM ................................ 42

9.6 Recalling a Timing Test Record ................................................................................ 44

9.7 Deleting a Timing Test Record .................................................................................. 45

9.8 Test Record Description............................................................................................ 46

9.9 Computer Interface ................................................................................................... 48

9.10 Breaker Travel Analysis .......................................................................................... 49

9.10.1 Breaker Stroke ..................................................................................................... 49

9.10.2 Breaker Over-Travel Distance .............................................................................. 49

9.10.3 Breaker Bounce-Back Distance ........................................................................... 49

9.10.4 Contact Wipe........................................................................................................ 49

9.10.5 Breaker Velocity ................................................................................................... 49

9.10.6 Analysis Point Selections ..................................................................................... 49

9.10.7 Analysis Point No.1 (AP1) .................................................................................... 50

9.10.8 Analysis Point No. 2 (AP2) ................................................................................... 50

9.10.9 Set-Up Open Analysis Points ............................................................................... 52

9.11 Select English or Metric Measurement Unit. ........................................................... 54

9.12 Digital Rotary Transducer Selection ........................................................................ 54

9.13 Slow-Close Test ...................................................................................................... 55

9.14 Transducer Self-Test............................................................................................... 57

9.15 Check Cable Hookup .............................................................................................. 58

9.16 Set CT-6500 Time and Date ................................................................................... 59

9.17 Automatic Print Setting ............................................................................................ 60

9.18 Selecting 50 Hz or 60 Hz for Contact Time Reading .............................................. 61

9.19 CT-6500 Channel Configuration ............................................................................. 63

9.20 Print Test Record Data ............................................................................................ 64

9.21 Transducer Encoder Filter Setting .......................................................................... 65

9.22 Contact Filter Setting............................................................................................... 66

9.23 Running CT-6500s in Tandem ................................................................................ 68

10.0 CT-6500 Trouble Shooting Guide ....................................................................................... 69

III

CT-6500 Series 2 Operating Instructions

List of Figures

Figure 1.0 CT-6500 Control Panel .......................................................................................... 12

Figure 2.0 CT-6500 Operating Voltage Setting ....................................................................... 18

Figure 3.0 Contact Cable Connection ..................................................................................... 20

Figure 4.0 Series Contact Cable Connection .......................................................................... 21

Figure 5.0 DC Trip and DC Close, Initiate Circuit Cable Hook-Up .......................................... 22

Figure 6.0 DC Trip and AC Close, Initiate Circuit Cable Hook-Up .......................................... 22

Figure 7.0 Voltage Monitoring Cable Hook-Up ....................................................................... 23

Figure 8.0 External Trigger Cable Hook-Up ............................................................................ 24

Figure 9.0 Transducer Connection ......................................................................................... 25

Figure 10.0 CT-6500 Operating Steps .................................................................................... 26

Figure 11.0 Typical Tabulated Printout of an Open Operation From the Thermal Printer ....... 34

Figure 12.0 Typical Graphic Result Printed on Thermal Printer .............................................. 37

Figure 13.0 Expansion Graph From 0 to 300ms Printed on Thermal Printer .......................... 38

Figure 14.0 Graphical Interpretation of an Open Timing Shot ................................................ 39

Figure 15.0 Graphical Interpretation of a Close Timing Shot .................................................. 39

Figure 16.0 Graphical Interpretations of an Open-Close and a Close-Open Timing Shot ...... 40

Figure 17.0 Printout of the Timing Shot Directory From the Thermal Printer .......................... 43

Figure 18.0 Typical Slow-Close Test Report .......................................................................... 56

Figure 19.0 Typical 50 Hz Tabulated Report .......................................................................... 62

Figure 20.0 Typical 60 Hz Tabulated Report .......................................................................... 62

Figure 21.0 CT-6500 Timing Data ........................................................................................... 64

Figure 22.0 Contact Filter Setting Illustration .......................................................................... 67

IV

CT-6500 Series 2 Operating Instructions

List of Tables

Table 1.0 CT-6500 Controls and Displays .............................................................................. 13

Table 2.0 CT-6500 Cable set .................................................................................................. 17

Table 3.0 Open Operation With No Insertion Resistors .......................................................... 28

Table 4.0 Open Operation With Insertion Resistor ................................................................. 29

Table 5.0 Close-Open Operation Using Contact Channel #1 ................................................. 31

Table 6.0 Open-Close-Open Operation Using Delay .............................................................. 32

Table 7.0 Printing Tabulated Results ...................................................................................... 33

Table 8.0 Plot Timing Chart .................................................................................................... 36

Table 9.0 Save Timing Test Record In EEPROM ................................................................... 41

Table 10.0 Print Timing Test Record Directory ....................................................................... 42

Table 11.0 Recalling a Timing Test Record ............................................................................ 44

Table 12.0 Deleting a Timing Record ..................................................................................... 45

Table 13.0 Entering Test Record Identification Header .......................................................... 46

Table 14.0 RS-232C Connector Pin Definition ....................................................................... 48

Table 15.0 Setting Up "OPEN" Analysis Points Using Distance ............................................. 52

Table 16.0 Select English or Metric Procedure ....................................................................... 54

Table 17.0 Select Rotary Transducer ..................................................................................... 54

Table 18.0 Performing a Slow-Close Test .............................................................................. 55

Table 19.0 Performing a Transducer Self Test ....................................................................... 57

Table 20.0 Checking the Cable Hookup ................................................................................. 58

Table 21.0 Set CT-6500 Time and Date ................................................................................. 59

Table 22.0 Automatic Print Setting ......................................................................................... 60

Table 23.0 Selecting 50Hz or 60 Hz for Contact Time Reading .............................................. 61

Table 24.0 Channel Configuration .......................................................................................... 63

Table 25.0 Print Test Record Data ......................................................................................... 64

Table 26.0 Set Transducer Filter ............................................................................................ 65

Table 27.0 Set Contact Filter .................................................................................................. 66

V

CT-6500 Series 2 Operating Instructions

Appendix

APPENDIX A ITE Circuit Breaker model 14.4K Timing Chart ................................................... 71

APPENDIX B CLOSE-OPEN Timing Chart for ITE Circuit Breaker Model 14.4K ..................... 72

APPENDIX C CLOSE-OPEN Tabulated Report for ITE Circuit Breaker Model 14.4K .............. 73

APPENDIX D OPEN-CLOSE Timing Chart for ITE Circuit Breaker Model 14.4K ..................... 74

APPENDIX E OPEN-CLOSE Tabulated Report for ITE Circuit Breaker Model 14.4K .............. 75

APPENDIX F SIEMENS TCP Breaker Velocity Calculation ...................................................... 76

APPENDIX G SIEMENS SPS2 Breaker Velocity Calculation ................................................... 77

APPENDIX H CT-6500 SIEMENS SPS2 Test Plan .................................................................. 78

APPENDIX I CT-6500 Transducer Illustration ........................................................................... 79

VI

CT-6500 Series 2 Operating Instructions

1.0 Introduction

The CT-6500 is the fifth generation microprocessor-based, digital time travel circuit breaker
analyzer developed by Vanguard Instruments Co. The CT-6500 can fully analyze a utility circuit
breaker’s performance by measuring: the contact time, stroke, velocity, over-travel, bounce-back
and contact wipe.
The circuit breaker contact motion analysis includes: Open, Close, Open-Close, Close-Open
and Open-Close-Open operations. A timing window of one second, ten second or twenty second
can be selected. The ten and twenty second windows allow timing of long timing events such as
circuit switcher contact activities.

The conventional Time-Travel test mode allows the user to fully analyze the circuit breaker
contact time and contact travel information. Additional circuit breaker information such as:
Operating-coil current reading, breaker DC coil power supply voltage reading are also
available.

The CT-6500 is available with the following configurations:

CT-6500-3:

- Three Contact-Input channels

- Three Digital Travel Transducer Input channels

- One Analog Voltage Monitor Input channel

- One Digital Voltage Monitor Input channel

- One Trip/Close Current Monitor channel

CT-6500-6:

- Six Contact-Input channels

- Three Digital Travel Transducer Input channels

- One Analog Voltage Monitor Input channel

- One Digital Voltage Monitor Input channel

- One Trip/Close Current Monitor channel

CT-6500-12:

- Twelve Contact-Input channels

- Three Digital Travel Transducer Input channels

- One Analog Voltage Monitor Input channel

- One Digital Voltage Monitor Input channel

- One Trip/Close Current Monitor channel
There are two different modes of operation for the CT-6500 which are Stand Alone Mode and

Computer Control Mode. The manual will focus on the Stand Alone Mode. The Computer Control
Mode is covered under the Circuit Breaker Analyzer Software Series 2 manual.

7

CT-6500 Series 2 Operating Instructions

2.0 CT-6500 Description

2.1 Contact Timing Channels

A breaker's interruption of contacts are timed with the dry-contact input channels. Each contact
channel can detect the main contacts and the insertion resistor contact times in milliseconds and
cycles.
The CT-6500 applies a test voltage of 35Vdc to each of the contact channels thus allowing an
analog to digital converter (A/D) to determine if a close, an open or an insertion resistor was the
state of the contact. The CT-6500 records into the memory 20,000 readings from the A/Ds and
the transducer position counters. The contact time, circuit breaker stroke and velocity is then
derived from the data that was stored in the memory.

NOTE

The CT-6500 can detect insertion resistors ranging from 10 to 7,000 Ohms.
Resistances over 7,000 Ohms are detected as an open contact.

2.2 Analog Voltage Monitoring Channel

One analog voltage, input channel, “V1” is dedicated to monitoring the breaker's DC power
supply or coil voltages from 0 to 255Vdc or peak Vac.

NOTE

Maximum input voltage is 300Vdc or peak Vac. Recording voltage readings are from 0
to 255Vdc.

2.3 Digital Voltage Monitoring Channel

One digital voltage, input channel, “V2” monitors the status voltage as “ON” or “OFF.” Voltages
from 30 to 255Vdc are considered as “ON” status. Voltages less than 30Vdc are considered as
“OFF” status.

2.4 Trip/Close Current Monitoring

A built-in, hall-effect, current sensor measures the trip and close coil current levels and
duration. The coil current waveform can be graphically plotted onto a printout. The coil current
reading is also printed in the tabulated report. The CT-6500 initiate circuit is capable of carrying
up to 30 amperes. Maximum coil current reading is 20 amperes.

2.5 Travel Transducer Input Channels

Each CT-6500 has three digital transducer input channels. The CT-6500 uses up-down
counters to sense the breaker’s transducer reading. The CT-6500 travel transducer employs
optical encoders to send quadrature signals to the CT-6500’s counters. With the use of digital
transducers and counters, the need to set up or calibrate the transducers is eliminated.
The CT-6500 will interface with a linear, a rotary and other special transducers developed by
Vanguard Instruments Company. Please refer to Appendix I for more details.

2.6 Breaker Initiate Capability

A built-in, solid-state, initiate device allows the user to operate the circuit breaker from the CT-

6500. Operational modes include: Open, Close, Open-Close, Close-Open and Open-Close­Open. The multiple operations of: Open-Close, Close-Open and Open-Close-Open can be
initiated with a programmable delay time or by sensing the breaker's contact state.
The solid-state switching implemented in the initiate circuitry allows the CT-6500 to switch a

8

CT-6500 Series 2 Operating Instructions

breaker's AC or DC control circuit. . The CT-6500 initiate circuit is capable of carrying up to 30
amperes. Separate 5 Ampere, fast-blow fuses protect each trip and close circuits. An interlock
“ARM” switch action is required by the operator to operate the initiate circuit.

2.7 Built-in Thermal Printer

The breaker's contact analysis results can be printed in both tabular and graphical formats by
a built-in, 4.5 inch wide, thermal printer. Refer to paragraph 7.5 for ordering thermal paper.

2.8 Computer Interface Capabilities

Built-in, RS-232C and USB ports allow the CT-6500 to be interfaced with an IBM-compatible
personal computer. A Windows XP Circuit Breaker Analyzer software is supplied with each CT-

6500. The software allows the user to:

- Control CT-6500 from a personal computer.

- Retrieve timing records stored in the CT-6500.

- Transfer circuit breaker test plans to CT-6500.

- Recall timing records from a hard drive for reanalysis at an office PC.

2.9 Timing Records Storage Capabilities

The CT-6500 uses Electrically Erasable Programmable Read-Only-Memory (EEPROM) to
store timing-shot data. Unlike other media, EEPROMs are immune to temperature, shock and
humidity. Stored shots can be recalled to reanalyze the test data, to reprint test reports or to
transfer data to a personal computer for record keeping. Up to 100 timing records can be stored
in the EEPROMs. The number of test records stored in the EEPROMs may vary depending upon
the size of the records.

2.10 Diagnostic Capabilities

The CT-6500 is designed with self-diagnostic capability to check the integrity of the electronics.
Self testing of the contact cable hook-up and transducers permits the user to examine the CT­6500‘s components whenever verification is required.

2.11 CT-6500 Display and Control Switches

An alphanumeric keypad enables the users to operate the CT-6500 and to enter the breaker’s
nameplate data such as: the substation name, breaker model and other descriptions. A 4-line by
20-character LCD readout displays user messages and menus. The LCD is back-lighted to allow
messages to be viewed in low light conditions.

3.0 Test Result Tabulation

3.1 Timing Test Measurement Results

In the Time Travel Mode, each CT-6500 contact channel provides the following test results:

- Contact Close time

- Contact Open time

- Insertion Resistor Contact Open and Close times

- Contact Bounce time

- Resistor On time

- Contact Spread time

9

CT-6500 Series 2 Operating Instructions

NOTE

The CT-6500 can detect insertion resistors ranging from 10 to 7,000 Ohms.
Resistances over 7,000 Ohms are detected as an open contact.

3.2 Mechanical Measurement Results

In the Time Travel Mode, the digital transducer channels provide the following test results:

- CB contact stroke

- CB contact over travel

- CB Contact bounce back

- CB Contact wipe

- CB Contact velocity
Breaker contact speed calculations are based upon a contact's travel distance over a period of

time, which is defined by the manufacturer's specifications.

NOTE

When the resistor type transducer channel is used, the test results are shown as
transducer channel 1.
CB contact mechanical measurement can be shown in “English” or “Metric” units.

3.3 Analog Voltage Input Results

The analog voltage, input channel, “V1” measures the breaker's DC control voltage during an
operation. Printed voltage readings include nominal voltage (when the supply voltage has no
load) and minimum voltage (when the supply voltage is under load or when a coil is energized).
The “V1” connection allows the user to monitor the DC power supply’s voltage fluctuations during
a breaker operation. This feature is effective in detecting breaker power supply problems, which
normally can not be seen by using a voltmeter.

NOTE

Printed voltage readings can range from 0 to 255Vdc.

3.4 Digital Voltage Input Results

The digital voltage, input channel, “V2” monitors the voltage status as “ON” or “OFF”
conditions and graphs the result. A voltage level above 30Vdc is considered as the “ON” state.
The input channel is dedicated to monitor the breaker’s auxiliary switch action during a breaker
operation.

NOTE

The input voltage ranges from 0 to 300Vdc or peak ac.

3.5 Initiate Current Results

The CT-6500 not only plots the trip or close current waveforms, but also prints the steady-state
current readings of the trip and close coils during an operation. A typical circuit breaker timing
report is shown in Figure 11.0.

10

CT-6500 Series 2 Operating Instructions

3.6 Slow-Close Test Results

A Slow-Close test determines the contact touch distance and penetration by using the travel
transducer and dry contact channels. See section 9.13 for Slow-Close test Procedure.

4.0 Test Result Graphics

4.1 Thermal Printer Graphic Printout

A 4.5 inch wide, built-in, thermal printer can output graphic waveforms of the contact channels,
travel curves and actuator-coil currents. Using the Zoom Graphics Mode, the user can enlarge
the graphical outputs by specifying the timing zone. Typical graphical results are shown in
Figures 12.0 and 13.0.

11

CT-6500 Series 2 Operating Instructions

5.0 CT-6500 Controls and Display

Before using the CT-6500, users should become familiar with all of the controls and display
indications. The keypad and display are used to operate the CT-6500. Figure 1.0 represents the
control panel and the numbered lines pointing to each control and indicator refer to Table 1.0,
which describes the function of each control and indicator.

Figure 1.0 CT-6500 Control Panel

12

CT-6500 Series 2 Operating Instructions

Table 1.0 CT-6500 Controls and Displays

Fig. 1.0

Index

no.

1-11 &

31
12

13, 16,

19
14

15

17

PANEL MARKING FUNCTIONAL DESCRIPTION

CONTACT INPUT

Female connectors for the contact channels.

(C1–C12)

0-300V

V1

D1, D2, D3

TRANSDUCER INPUT

0-300V

V2

0-300V

TRIGGER

GROUND

3-pin connector. V1 voltage input channel is dedicated to
monitor circuit breaker DC power supply or coil voltages.
Voltage sensing range is from 0-255 volts, dc or peak
ac.

16-pin connectors. Digital travel transducer input
channels.

3-pin connector. V2 voltage input channel is dedicated to
detect voltage on/off status (present or absent) of an A/B
switch. Voltage input ranges from 0-300 volts, dc or
peak ac.

3-pin connector. Triggers voltage input for external
trigger application. Voltage levels ranging from 30 to 300
V, dc or peak ac.

Safety, ground terminal. 5/16-18 thread stud, with wing
nut.

18

20

21

22

23

24

120/240Vac, 2A, 50-60Hz

Fuse: 250V 3A, Fast Blow

INITIATE

OPEN

250V, 5A FAST-BLOW

CLOSE

250V, 5A FAST-BLOW

“PUSH” TO ARM

(Printer; No panel marking)

3-wire power plug. 3 Ampere, AC fuses. The ON/OFF
switch is a 2-pole rocker.

4-pin connector used for the switching circuit for
operating the circuit breaker under test.

Open circuit fuse: 5 Ampere, 250V, Fast-Blow.

Close circuit fuse: 5 Ampere, 250V, Fast-Blow.

Spring-loaded, pushbutton switch. Press and hold to
complete the Trip or Close circuits for breaker tests.

Thermal printer. Microprocessor controlled printer that
uses specially treated, 4.5 inch wide paper.

13

CT-6500 Series 2 Operating Instructions

Table 1.0 CT-6500 Controls and Displays (Continued)

Fig. 1.0

Index no.

25
26

27

28

PANEL MARKING FUNCTIONAL DESCRIPTION

RS-232C

1-9, 0, ENTER, START,

STOP, CLEAR,
↑ PAPER LCD,

RS-232C serial computer interface port.
16 button keypad. The keys are momentary-contact,

pushbutton switches. Allows users to make menu
selections, enter alphanumeric data, adjust the LCD
contrast and reposition the printer paper.

↓ PAPER LCD

(Display; no panel marking)

4-line by 20-character, backlit LCD. Displays menus,
options, prompts and test result data.

USB

Computer interface, USB Port.

14

CT-6500 Series 2 Operating Instructions

6.0 CT-6500 Analyzer Specifications

PHYSICAL SPECIFICATIONS 16” W by 11”H by 14”D (40.6 cm x 29.9 cm x 35.6 cm)

Weight: 25lbs (11.3Kg).

INPUT POWER 8 Amperes, 90-120Vac or 200-240Vac (selectable), 50/60 Hz.

DRY-CONTACT INPUT 3 or 6 or 12 contact channels. All contact inputs are grounded until testing

is started. Each contact detects main and insertion resistor contacts.

TIMING WINDOW Selectable between: 1, 10, or 20 second.

TIMING RESOLUTION ±50 microseconds at 1 second duration.

±0.5 millisecond at 10 second duration.
±1.0 millisecond at 20 second duration.

TIMING ACCURACY 0.05% of reading, ±50 micro-seconds at 1-second duration.

CONTACT DETECTION RANGE CLOSED: less than 20 Ohms.
RANGE OPEN: greater than 10,000 Ohms.

RESISTOR DETECTION RANGE Ranges from 50 to 5,000 Ohms.

EXTERNAL TRIGGER INPUT Open/Close: 30 to 300Vdc, peak Vac.

VOLTAGE SENSING INPUTS V1: analog input, 0-255V dc or peak ac. Sensitivity: ±1V;

V2: voltage detector (present/absent).Input: 30-300V, dc or peak ac.

BREAKER OPERATION Open, Close, Open-Close, Close-Open, and Open-Close-Open.

BREAKER INITIATE CAPACITY 30A/250V ac/dc max (100A inrush).

INITIATE CURRENT READING One, Non-contact, hall-effect sensor ranging from 0-20 Amperes, DC to 5 kHz.
RANGE

TRAVEL TRANSDUCER 3 travel-transducer channels. Linear motion from 0.0 to 30.0 inches (±0.01) inch.
INPUT Rotary ranges from 0 to 360
BREAKER SLOW-CLOSE Measures “Slow-Close” the contact point distance (hard copy printout).
TEST

DISPLAY Back-lit LCD screen, 4-lines by 20-characters, sunlight viewable.

PRINTOUT Both graphic contact-travel waveforms & tabulated results are printed on 4.5 inch

thermal paper.

STORAGE CAPABILITIES Store up to 100 timing records.

COMPUTER INTERFACE RS-232C Port, USB Port.

PC SOFTWARE (included) Furnished Circuit Breaker Analyzer PC software. Windows XP and Windows Vista

compatible. Th e analysis softw are can be installed on an IBM-compatible computer
for graphical display, numerical reports and database utility for office use.

SAFETY Designed to meet UL 61010A-1 Certification and CAN/CSA C22.2 No 1010.1-92.

o

(± 0.36º).

15

CT-6500 Series 2 Operating Instructions

ENVIROMENT Operating: -10°C to 50°C (+15°F to +122°F).

Storage: -30°C to 70°C (-22°F to +158°F).

OPTIONS Hard shipping case for CT-6500.
Hard shipping case for Travel Transducers.

WARRANTY One year warranty on parts and labor.

16

7.0 CT-6500 Special Features

7.1 CT-6500 Supplied Cables

ITEM DESCRIPTION QTY

1 GND Cable 1
2 Power Cord 1
3 Contact Cable 3 or 6 or 12
4 Contact Extension Cable 3 or 6 or 12
5 Transducer cable 1
6 Voltage & Trigger Leads 3
7 Voltage & Trigger Extension cables 3
8 Initiate Lead 1

9 Initiate Extension Cable 1
10 USB Cable 1
11 RS-232C Cable 1

CT-6500 Series 2 Operating Instructions

Table 2.0 CT-6500 Cable set

17

CT-6500 Series 2 Operating Instructions

7.2 CT-6500 Operating Voltages

The CT-6500 operating voltage is selectable between 110-120Vac, 50/60 Hz or 220-240Vac,
50/60 Hz. Operating voltage is set by the voltage selection switch as shown in Figure 2.0.
To change the voltage setting, remove the CT-6500 from the case, locate the voltage setting
switch and set the new operating voltage.

Figure 2.0 CT-6500 Operating Voltage Setting

7.3 CT-6500 Main Power Switch & Circuit Breaker

The CT-6500 uses an AC input module that contains the AC receptacle, power switch and
fuse holder. A 3AG, 250Vac, 3 ampere, fast-blow type fuse is recommend.

7.4 Initiate Circuit Protection Fuses

The OPEN and CLOSE initiate circuits are protected by 5 Ampere fuses (3AG, 250Vac, fast­blow types).

18

CT-6500 Series 2 Operating Instructions

7.5 CT-6500 Printer and Printer Paper

The built-in, thermal printer uses 4.5 inch wide, thermal paper for printing test results. To
maintain the highest, quality printing and to avoid paper jamming, it is highly recommended
that the thermal paper be supplied by the factory. Additional paper can be ordered from either
of the two sources listed below:

Vanguard Instruments Co, Inc.
1520 S. Hellman Ave.
Ontario, CA 91761
Tel: [phone]
Fax: [phone]
Part Number: TP-4 Paper

BG Instrument Co.
13607 E. Trent Avenue
Spokane, WA 99216
Tel: [phone]
Fax: [phone]
Part Number: TP-4 paper

7.6 Replacing CT-6500 Thermal Paper

The roll of thermal paper resides inside a pocket underneath the printer cover. To replace
the paper, follow the steps below:

- Remove the printer cover.

- Remove the leftover thermal paper roll from the paper holder.

- Unroll the new thermal paper.

- Feed the thermal paper into the slot between the paper pocket and the rubber

roller. The printer will automatically pull the paper under the thermal head.

7.7 CT-6500 Printer Paper Control

To advance the paper from the printer, press and release the “↑ PAPER LCD” button. To
retract the thermal paper from the printer, press and release the “↓ PAPER LCD” button.

7.8 CT-6500 LCD Contrast Control

To darken the LCD screen, press and hold the “↑ PAPER LCD” button to decrease the
contrast of the LCD screen, press and hold the “↓ PAPER LCD” until the desired contrast is
reached.

- Place the paper roll into the paper holder.

- Lift the thermal head and align the thermal paper if necessary.

- Replace the printer cover back.

NOTE

The paper should feed from the bottom of the roll.
The thermal paper will show a colored stripe in the margin to indicate that the roll
is about to run out of paper.

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CT-6500 Series 2 Operating Instructions

8.0 Test Hook-up Connections

8.1 Contact Cable Hookup

A typical, contact cable connection to a circuit breaker is shown in Figure 3.0. Red and black
clips are connected across the circuit breaker contact phase A, B and C.
A typical circuit breaker with series contacts is shown in Figure 4.0. In the below example,
the circuit breaker has 2 contacts in series per phase. Contact timing channel 1 and 2 are
used in the illustration.

NOTE

It is advisable to ground one side of the contacts for most testing purposes. If a breaker
is floating or ungrounded, ensure that the contact channel inputs are protected against
static discharge.

Figure 3.0 Contact Cable Connection

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CT-6500 Series 2 Operating Instructions

Figure 4.0 Series Contact Cable Connection

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CT-6500 Series 2 Operating Instructions

8.2 Initiate Cable Hookup

The CT-6500 will trip or close breakers through a solid-state device, which will operate on any
AC or DC control voltage ranging from 10 to 300 Volts. Both the trip and close circuits are
protected by 5 Ampere fuses.
A typical DC trip and DC close, control circuit test hookup is shown in Figure 5.0.
A typical DC trip and AC close, control circuit test hookup is shown in Figure 6.0.

Figure 5.0 DC Trip and DC Close, Initiate Circuit Cable Hook-Up

Figure 6.0 DC Trip and AC Close, Initiate Circuit Cable Hook-Up

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CT-6500 Series 2 Operating Instructions

8.3 Analog Voltage Monitor Hookup

The analog voltage input, “V1” permits the user to monitor a breaker's DC control voltage
during an operation. The analog voltage input will record the nominal DC voltage at no load and
the minimum DC voltage while the Trip or Close coil is energized.
The nominal and minimal voltage readings will be printed on a tabulated report. Analog
waveforms will also be plotted in a graphical format. Thus, the user is able to see the breaker's
DC control voltage "dip" under load conditions. Problems, such as a poor connection or an
excessive voltage drop, during the circuit breaker operation can be easily detected.
A typical voltage monitoring hook up scheme is shown on Figure 7.0.

NOTE

The maximum voltage that can be recorded is 255 Vdc.

Figure 7.0 Voltage Monitoring Cable Hook-Up

8.4 Digital Voltage Monitor Hookup

The digital, voltage input channel, “V2” permits the user to monitor the voltage status as “ON”
or “OFF” states. The voltage “ON” or “OFF” states will be plotted on the graphical report. A typical
hook up is shown in Figure 7.0.

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CT-6500 Series 2 Operating Instructions

8.5 External Trigger Input

The External Trigger Mode enables the user to start recording data when the CT-6500 senses
a voltage. A typical application for the External Trigger Mode is to time a circuit breaker in a close
operation and to start timing only when the close coil is energized, thus bypassing the 52X relay
delay time.
Since the 52X relay carries the close coil current, the user will need to connect the CT-6500’s
initiate cable to the close terminal shown in Figure 5.0. The CT-6500 will energize the 52X relay
to start the close operation, which will then start the timing when the CT-6500 senses the voltage
across the closing coil. See Figure 8.0 for a typical test hookup. Another application for external
trigger is to start timing the breaker when the user trips or closes the breaker remotely.

NOTE

Minimum trigger voltage is set for 30 Vac/dc. Maximum, continuous voltage is limited to
300 Vac/dc. Different trigger voltages can be set at the factory, based upon specific
requests.
The CT-6500 will start looking for the external trigger voltage when the message,
“AWAITING TRIGGER…” is shown on the LCD screen. The external trigger voltage
needs to be sensed by the CT-6500 within 15 seconds after the initiate sequence has
begun. The CT-6500 will return to the main menu if no voltage is sensed.

Figure 8.0 External Trigger Cable Hook-Up

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