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OPERATING MANUAL

PRIMARY CURRENT INJECTOR

MODEL: PCT-20

WARNING

 TAKE DUE PRECAUTIONS TO PREVENT ACCIDENTS.

 THIS MANUAL SHOULD BE PLACED WITHIN THE REACH

OF THE OPERATOR.

UDEYRAJ ELECTRICALS PRIVATE LIMITED

212-A, Hind Saurashtra Industrial Estate,
85-86 [Link] Road, Marol Naka, Andheri (E),
Mumbai-400 059. INDIA

Email : udeyraj@[Link] Website; [Link]

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 OPERATING MANUAL

‘UDEY’
PRIMARY CURRENT INJECTOR
Model: PCT-20

1. FEATURES Page 3

2. APPLICATIONS Page 3

3. DESCRIPTION Page 4

4. CONTROL PANEL LEGEND Page 5

5. SPECIFICATION Page 7

6. OPERATING INSTRUCTIONS Page 8

7. SERVICE & REPAIRS Page 10

8. MAXIMIZING THE CURRENT OUTPUT Page 11

The information contained in this booklet is up-to date at the time of publication and due to
our constant endeavor to keep abreast with modern methods and to our continuous research
programme, it may be altered at any time without previous notification.

COPY RIGHT 1995. UDEYRAJ ELECTRICALS PRIVATE LIMITED

Reproduction of matter in any form or language strictly forbidden.

Issued for limited and specific purpose only.
Rev: 04-2014
UDEYRAJ ELECTRICALS PRIVATE LIMITED
212-A, Hind Saurashtra Industrial Estate,
85-86 [Link] Road, Marol Naka, Andheri (E),
Mumbai-400 059. INDIA

Email : / udeyraj@[Link] Website; [Link]

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 INSTRUCTION MANUAL

PRIMARY CURRENT INJECTOR

PCT-20

1. FEATURES:

 All outputs continuously variable.

 Built - in crystal time base multi- range DIGITAL TIMER.

 True RMS digital metering of outputs.

 Compact rugged design - Fully tropicalized.

 Auto-switch off in all modes of operation.

 All current outputs fully isolated and distortion free.

 Suitable for testing thermal devices

 All controls and metering centralized.

2. APPLICATIONS

Maintenance, commissioning and routine testing of protective devices and systems by means
of primary current injection, timing tests on protective relays- both magnetic and thermal
types, current transformer ratio testing etc.

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3. Description

The PCT-20 comprises of two units: 1) a control unit and 2) a loading unit. Thus making the
tester simple to use, compact and portable. The control unit offers a current output of 0-10
Volt at 50 Amp or 0-5 Volt at 100 Amp. Additionally, a separate voltage output of 0-250 V AC
is available for testing voltage operated relays coils or checking the magnetization
characteristics of current transformers.

Current and voltage outputs are varied from the output controller. The high output current is
supplied through nut bolts to the low inductance lead set (available optionally).The voltage
output has a separate pair of terminals. Each set has a built-in multi range timer.

All current and voltage levels are displayed on digital meters. The elapsed time is measured
by the timer and is displayed on 4 digit LED display.

Circuit protection is by circuit breaker in input. Controlled switching ensures that, in the event
of power failure or timer cut off operating, the output cannot be re-energized until the controls
are reset, thereby offering protection to the equipment and the operator.
The mains supply for the tester is 240 volts, plus 10 % minus 6 %.

The control unit houses all necessary controls and metering for the complete equipment. The
top panel has legend printed for all controls and indicators.

Automatic control has been provided such that the selected output can be switched off once
the device under test has operated. The automatic control can be switched in and out of
circuit for the selected output, this enables setting up tests to be performed.

The control unit is provided with a crystal time base timer for timing relays whose contacts are
either normally open or normally closed.

The control unit is housed in a robust sheet steel cabinet and with fold away handles. The
loading units are housed in robust cases complete with fold away handles.
It is important to note that on all outputs, a duty cycles applies. Low voltage outputs of 5, 10
and 3 and 6 volts are isolated from mains supply. For full details please refer to
SPECIFICATIONS on page 7.

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4.0 CONTROL PANEL LEGEND:
Legend drawing above shows the control and indicator elements on the panel and their
function is briefly described below.

PRIMARY CURRENT INJECTOR PCT Series

LO ADING UNIT O UT PUT CO NT RO L UNIT

OUTPUT CONTRO L

MAINS ON:
For mains supply there is a socket at the back of the control unit. The input power is switched
on and off by miniature circuit breaker switch. A power on indicator lamp is provided. The test
set is earthed through the 3 core power supply cord.

OUTPUT
These are push buttons to switch output ‘ON’ and ‘OFF’.

‘SET / TEST’ MODE

This is a selector switch for selecting setting up or testing,
With this switch in the ‘SET’ position, the injected current available at the output terminals
may be set using the ‘OUTPUT CONTROL’. The test set’s timer is disabled in this position.
With the switch in ‘TEST’ position, the output previously set up is applied by pressing
‘OUTPUT ON’ push button in a complete test in which the device under test operates
normally and the out put from the tester is tripped off at the appropriate time. The test set’s
timer is in operation in this position.

OUTPUT SELECTOR
This is a selector switch to select output from a) 250 V b) 50A/100 A and c) Loading unit.

OUTPUT CONTROL
This is a torodial auto transformer for varying the output continuously.

LV OUTPUT TERMINALS: COM, 50A/10 V & 100A/5V

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Ac low voltage output is available at the three terminals marked ‘COM’, ‘50A/10V’ and
‘100A/5V’.This is isolated from mains supply and is controlled by “OUTPUT CONTROL”.

AMPERE METER [Control unit] 100 A

This is a digital ampere meter with display of 100 A and reads the low voltage (5 & 10 V)
output load current.

LV OUTPUT 0-3V/2000 A & 0-6 V/1000A

AC CURRENT OUTPUT: [From loading unit]
Each of the isolated two outputs (0-3 V and 0-6 V) are available at brass bolts marked ‘1’, ‘2’,
‘3’, and ‘4’. These outputs are controlled by ‘OUTPUT CONTROL’.

AMPERE METER 0-1000-2000 A [O/P from Loading unit}

This is a digital ampere meter with display of 1000 / 2000 A and reads the low voltage 3 and 6
volt output load current when control unit is used with the loading unit. This output is also
controlled by ‘OUTPUT CONTROL’.

LOADING UNIT O/P CONNECTION

This is 1000/2000 A meter range selector. For 1000 Amp output keep this switch in
‘SERIES (1000 A)’ position. For 2000 Amp output keep this switch in
‘PARALLEL (2000 A)’ position.

0-250V/20A OUTPUT TERMINALS

These are terminals from where continuously variable ac voltage of 0-250 V is available and
this output is also controlled by ‘OUTPUT CONTROL’.

VOLT METER
This is a digital voltmeter with display of 250 V and displays the output voltage of 0-250 Volts
at terminals marked ‘0-250V’.

TIME INTERVAL METER

This is time interval meter and measures time taken by the contacts to operate. This is multi
range with ranges from 0.0001 to 9999 seconds. ‘RANGE’ switch selects the range. ‘MODE’
switch selects the type of contacts ‘NC’ or ‘NO’ under test. ‘RESET’ push button resets the
timer display to zero. Terminals marked ‘CONTACTS’ are terminals for connecting the
contacts of the device under test.

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5. SPECIFICATION:

Model PCT-20
Supply 240 Volt AC, 50 HZ, Single phase.
Power 6 kVA
Output : AC : Loading unit 2000 Amps / 0-3V & 1000 Amps / 0-6V
Output : AC : Control unit 100 Amps / 0-5 V & 50 Amps / 0-10 V
Output : AC: Control unit 0-250V / 20 Amps

RATING : 5 Minutes ON / 15 Minutes OFF. Continuous rating does not

exceed 50% of the rated output.

METERING : 1) Digital ampere meter: Display of 1000-2000 Amp.

2) Digital ampere meter: Display of 100 Amp.
3) Digital volt meter: Display of 250 Volts.
Accuracy: ± 1% ±3 digits.

DIGITAL TIMER : 4digit, solid state crystal base timer system. Multi range from
.0001 to 9999 seconds.
Accuracy: ± 0.5 % ± 2 counts

TIMER CONTROL : The timer automatically starts when the output is initiated and
CIRCUITS automatically stops when the device under test operates.
START SIGNAL: Internal.
STOP SIGNAL : Via-either normally open or normally closed external
contacts.

AUTO-CUT-OFF : Cuts off output on operation of device under test.

OPERATION : Circuit breaker in input, mains on indicator, contractor controlled push

buttons for current output on or off, contact mode selector and reset
switch.
‘SET/TEST’ switch to set up test current level.

CONSTRUCTION : Two piece unit. Sheet steel cabinets powder coated and with lifting
handles.

ACCESSORIES : 1. Operating Manual 1 number.

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(supplied) 2. 2 meter long 3 core mains cable 1 set.
3. 2 meter long inter-connecting cable 2 pairs.
(optional) 4. 2 meter long high current test lead [280 mm²] 1 pair.
5. 2 meter long high current test lead [10 mm²] 1 pair.
6. 2 meter long contact connection test lead 1 pair.

6. OPERATING INSTRUCTIONS:

PRELIMINARY PROCEDURE FOR OPERATING

Ensure that the tester is properly earthed.
Ensure that the ‘MAINS ON’ switch is in off position.
Ensure that the ‘OUTPUT CONTROL’ regulator is at its minimum position. (knob to turned
fully anti-clockwise).

ABREVIATIONS USED:
CU : Control unit
LU : Loading unit
DUT : Device under test.
TIM : Time interval meter.
NO : Normally open.
NC : Normally closed
COM : Common
LV : Low voltage

6.1 OUTPUT from CU: 0-10 V/ 50 A, 0-5 V/100 A and 0-250 V/ 20A.

Connect the control unit to mains supply thru the cable with industrial plug.

Connect the DUT under test to terminals marked as under:

a) 0-250 V or
b) ‘LV OUTPUT’. The output is between ‘COM’ and ’50 A’ or ‘100A’
terminals.

Keep the output selector switch in ‘250 V’ or ‘50/100 A’ position, depending upon the output
chosen.

For measuring operating time of the contacts of DUT, connect the contacts to ‘CONTACTS’
terminals of ‘TIM’. Depending upon the nature of the contact (normally open or normally
closed), keep the mode switch in ‘NO’ or ‘NC’ position. Select the range in seconds.

Switch on mains supply thru the switch ‘MAINS ON’ and an indicator lights up. Mains is now
supplied to the tester.

Put the ‘SET/TEST’ in ‘SET’ position. Press the output on push button and move the
‘OUTPUT CONTROL’ knob slowly in clockwise direction observing the respective ampere/volt
meter. After having reached the value required or on operation of the DUT, stop rotating the
knob and switch off output by pressing ‘OUTPUT OFF’ push button.

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Do not move the output control knob.

Bring ‘SET/TEST’ switch to ‘TEST’ position. Now press ‘OUTPUT ON ’ press button and the
current is now applied to the DUT. The DUT operates and the time taken to operate is
displayed on the 4 digit digital display of the ‘TIM’ and supply to the DUT is automatically cut
off. Reset the ‘TIM’.

6.2 OUTPUT from LU interconnected to CU

Interconnect LU to CU by the two pairs of leads provided. One lead is for carrying the voltage
to the primary of the loading unit and the other lead is for bringing the signal to the control
unit.
Select output in CU to ‘Loading unit.
Connect the DUT under test to output brass studs of the LU as under:

For 1000 Amp, short studs ‘3’ to ‘4’. Output leads are connected to studs ‘1’ and
‘2’.
For 2000 Amp, short studs ‘1’ to ‘3’ and ‘2’ to ‘4’. Output leads are connected to
studs ‘1’ & ‘2’.
Loading unit output connection selector
Depending upon the output selected bring this switch to a) Series 1000 A or
b) Parallel 2000 A.
For measuring operating time of the contacts of DUT, connect the contacts to ‘CONTACTS’
terminals of ‘TIM’. Depending upon the nature of the contact (normally open or normally
closed), keep the mode switch in ‘NO’ or ‘NC’ position. Select the range in seconds.
Switch on mains supply thru the switch ‘MAINS ON’ and an indicator lights up. Mains is now
supplied to the tester.
Put the ‘SET/TEST’ in ‘SET’ position. Press the output on push button and. move the
‘OUTPUT CONTROL’ knob slowly in clockwise direction observing the respective meter. After
having reached the value required or on operation of the DUT, stop rotating the knob and
switch off output by pressing ‘OUTPUT OFF’ push button. Do not move the output control
knob.
Bring ‘SET/TEST’ switch to ‘TEST’ position. Now press ‘OUTPUT-ON ’ press button and the
current is now applied to the DUT. The DUT operates and the time taken to operate is
displayed on the 4 digit digital display of the ‘TIM’ and supply to the DUT is automatically cut
off. Reset the ‘TIM’.

Disconnect Mains supply.

Remarks:

a) By keeping the ‘SET/TEST’ switch in “SET’ position, the system can be used as high
current source as the auto-cut off function and TIM do not operate.

b) The output of 0-3 V, 0-6 V, 0-10 V and 0-5 V is isolated from mains supply.

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 c) The output of 0-250 V / 20 A is not isolated from mains supply. Primary current
injection systems have a very high current, low voltage output, and to get
maximum output current it is necessary to minimize the impedance to the load.
Firstly, tie the feed and return cables from the loading unit to the load together-
this will minimize the loop inductance. The larger the area enclosed by the
output loop, the higher the inductance and hence the lower current will be.
Using the shortest possible output cables will also help to maximize the output
current.

7.0 SERVICING /REPAIRS.

No user serviceable parts inside. Hence refer servicing to qualified service personnel.
The components used are standard components and available easily all over the
world. Manufacturer’s repair and service division is as under:
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UDEYRAJ ELECTRICALS PRIVATE LIMITED

208- A Hind Saurashtra Indl. Estate
85/86 M. Vasanji Road, Marol Naka, Andheri (East)
MUMBAI - 400 059. India.
Phone : 022 66916181 Fax : 022 6694 2787
Email : info@[Link] / udeyraj@[Link] Website: [Link]

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