Frequently Asked Questions

Product Information Using the ITS Specification & Ordering

Product Information

What is a Test Block?

The ITS Test Block is a modular arrangement of contacts that can be wired to measurement devices and circuits in a panel such as relays, meters and other instrumentation applications. The Test Block by itself is the equivalent of an FT switch with all contacts closed, and it feeds all currents and voltages to the device to which it is wired. In order to open circuits and isolate the device for testing, the user must insert the Test Plug.

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What is a Test Plug?

The ITS Test Plug is a modular arrangement of pins that are inserted into the Test Block in order to safely open secondary circuits and isolate the device that is to be tested. The Test Plug also provides the user with a direct connection for the test set and allows injections from the secondary side.

What is a Test Probe?

Test Probes are used to for safely opening individual and small groups of circuits. We currently have Test Probes with 1 to 4 pins that can be used to open current and voltage circuits.

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Can the Interface Test System replace the FT switch?

Yes. The ITS gives the end user the same ability to isolate and test meters, relays and other devices without having to disconnect the device and remove from the panel. However, our design and approach to achieving this function safely and efficiently is very different.

Will I need to cut/drill the panels in order to retro fit the ITS?

No. We have a retro-fit version of the ITS in a 10 or 11 pole configuration that replaces the standard 10 pole FT switch. This version allows the end user the ability to change technologies without having to modify the panel in any way.

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What conductive materials are used in the ITS Modules?

In the ITS Test Block module we use silver coated copper for the contacts, brass for the terminals and steel for the pressure springs. The ITS Test Plug modules have brass pins, zinc contact blocks and copper shorting bars. The high quality materials we use in our modules allow for an extremely low resistance of around 1 to 2 Milliohms.

What is the maximum amount of modules I can have in a Test Block & Test Plug?

The maximum number of modules is 21. When the module count gets to high in the Test Plug it can become difficult for one person to insert it smoothly into the Test Block.

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Do you provide entire test panels?

Yes. SecuControl can provide complete panel solutions of any size and cutout pattern. Please contact us via email or phone to specify an Interface Test System panel solution.

Using the ITS

Is there a chance I could insert the wrong plug into a test block?

No. Each module of the Interface Test System is keyed to match an opening of a specific test block arrangement. Even if the module counts were the same the pins could not be inserted into the openings unless each module was an exact match.

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Why would I use Test Probes instead of a Test Plug?

Test Plugs are best used in standard testing procedures that should be done the same way every time. Test Probes allow more experienced users to perform advanced testing procedures by opening individual and small groups of circuits.

Is it possible to have a �visible open� with the ITS?

Because the contacts of the ITS are designed to limit exposed metals for safety, the idea of being able to have a �visible open� is achieved in a different manner. The visual confirmation that a circuit is open in the ITS system is when a Test Plug or Test Probe is inserted into the Test Block. Any time a Test Plug is inserted into a matching Test Block, all circuits are open. When a single module Test Probe is inserted, just the one circuit is open.

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Can I re-close individual contacts once the test plug has been inserted?

Yes. When the test plug is inserted into the test block and all contacts are open, you can then re-close contacts by connecting the banana plugs together in the desired test plug module.

How do I short out CT circuits with the ITS?

The Interface Test System automatically shorts current circuits when the Test Plug is inserted into the Test Block. We install shorting bridges in the Test Plug that connect designated current modules so the customer never needs to worry about CT problems.

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What happens when I insert a complex plug assembly into a test block?

Each time a complex ITS Test Plug is inserted into a Test Block an �automatic operating sequence� takes place.

First, the long pins of the plug make contact and are inserted first. These modules are the trip signals and are opened first to ensure that the relay doesn't send out any false communications.

Second, the shorter pins begin to make contact and the current circuits are safely shorted.

Third, the test plug is fully inserted, all circuits have been safely opened and the relay is ready to receive secondary injections from the test set.

Why can I be sure that the contact is closed again when the pin has been pulled out?

Inside our Test Block Modules we have two sources of pressure that ensure our contacts are closed when the Test Plug has been pulled out. The contacts themselves are similar to �leaf springs� and are installed in such a way that they touch with a decent pressure. Each module also uses pressure springs on both sides that keep the contacts together and ensure a strong tight fit.

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Can I really do secondary injection testing while the relay is still in the panel?

Yes. The Interface Test System gives the user the ability to block all relay communications to the outside world. Secondary injections could then be sent to the relay through the ITS and no real false trip could be sent to the breaker.

Can I take a relay out of service with the ITS plug?

Yes. The need to de-energize entire panels to remove a relay is costly and time consuming. If relay testing brings undesired results and the relay must be replaced, the ITS can be used to safely remove the relay. With the Test Plug inserted the secondary circuits will be redirected until a new relay is installed.

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How does the ITS connect to my test set and which types of test sets do you support?

The ITS Test Plug allows for a direct connection to the test set using banana plugs which are already installed into recessed openings of the plug. This feature can provide great time savings in test preparations. We support any type of test set that has banana jack test leads.

Specification & Ordering

Why do I need to specify trip (DC signals) instead of just potential and current?

The Interface Test System has 3 basic types of modules: Trip, Potential and Current. In the test block each of these modules are physically the same but in the test plug they are each different. The trip modules in the test plug will have a longer pin length than both current and potential plug modules, so when the test plug is inserted the Trip circuits will be opened first. This ensures that the device is properly isolated and does not send out a false trip. We call this functionality the automatic operating sequence.

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What is the maximum number of modules I can have in a Test Block & Test Plug?

We recommend to our customers that they try to stay under 21 modules. When the module count gets to high in the Test Plug it can become difficult for one person to insert it smoothly into the Test Block.

How many modules can I fit in a 2U or 3U 19 inch panel?

The maximum number of modules in a panel depends on the number of Test Blocks. For 2 blocks in any arrangement the maximum number of modules is 34. A 3 block arrangement allows for a maximum of 33 and 4 blocks allows for 31.

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How many test plugs do I need for use with the test blocks we ordered?

Usually our customers will outfit each relay tech with a test plug and have one at the substation. It is also a good idea to equip the relay technicians with single and double pole test probes so they have the tools for more advanced testing procedures.

How can the ITS save me money when I plan a panel?

Because the ITS is a modular system there is no more wasting material and space on unused contacts. You will no longer be limited to a 10 or 14 pole setup. With this new freedom we encourage you to carefully look at the application and try to develop a standard setup for that particular type of relay. When you are able to develop standard ITS arrangements for your standard relays, the cost of ownership goes down considerably. ITS Test Plugs would be a one time purchase for the relay technicians and future orders for that relay type would consist only of Test Blocks.

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How can the ITS save me money in my testing procedures?

The ITS can save you money in your testing procedures by increasing efficiency, safety and overall ease of use. You will no longer need to worry about the order in which you open contacts or question how the test switch has been wired. With the ITS there is no room for error, and each time a Test Plug is inserted the automatic operating sequence takes place. This functionality will also greatly reduce training time with new relay technicians and will allow them to study what is most important about testing relays, the data!