INSTRUCTIONS

GEK-49803

TEST PLUGS
FOR
MOLDED CASE DRAWOUT RELAYS
TYPES
I2XCA1IAI (4 Contacts)
12XCA11A2 (4 Contacts,Hard Wired)
12XCA28AI (28 Contacts)

GENERAL

ELECTRIC

GEK-498fl3
TEST PLUGS
FOR
MOLDED CASE DRAWOUT RELAYS
TYPES
12XCAI 1A1
1 2XCA1 1A2
12XCA2SA1
APPLICATION
The type XCA test plugs are used to test fourteen and twnety-eight point molded case drawout r&:ys.
The 12XCA11A1 dual test probe, Fig. 1, enables power to be applied to selected relay points from either
a separate source or the source that feeds the equipment. The 12XCA11A2 dual test probe, Fig. 2, is hard
wired and is used primarily for selected CT current measurements. The 12XCA28A1 test plug, Fig. 3, engages
all fourteen relay points and enables power to be applied to the relay from either a separate source or
the source that feeds the equipment.

RATINGS
Continuous
Vol tage

Current

One Second Surge

Current, Syninietrical

12XCAI1A1

600 VAC

15 Amps

240 Amps

12XCA11A2

600 VAC

15 Amps

240 Amps

12XCA28A1

600 VAC

15 Amps
15 Amps

240 Amps-banana plug connected

350 Amps-test clip connected

CONSTRUCTION
12XCA11A1
The 12XCA11A1 test probe, Fig. 1, is a two point, four contact test probe. It can be inserted into
relay point pairs 1 and 2, 3 and 4, 5 and 6, etc. of the fourteen or twentyeight point molded case
drawout relays after the relay connection plug is removed. The test probes construction is keyed to
prevent accidental inverted insertion and insertion into incorrect relay point pairs 2 and 3, 4 and 5;
etc. Access to this test probe is through four standard size banana jacks on its rear face. A CT shorting
plug (018485461) is also supplied which can be used to short circuit the current transformer circuits
when testing the relay.
,

This test probe is a riveted assembly and as such is not intended to be serviced. The internal part
arrangement is shown in Fig. 4. The accompanying shorting plug consists of an encapsulated assembly of
two banana plugs connected by a bus strip. The banana plugs are spaced to fit the case side test probe
jacks but they will not fit the 12XCA28A1 test probe.

These instructions do not purport to cover

all details or variations in equipment nor to provide
for
everq possible contingency to be met in connection with
installation, operation or maintenance.
Should
further information be dosired or should particu
lar problems arise which are not covered suffici
ently for
the purchasers purposes, the matter should be referre
d to the General Electric Company.
To the extent required the products described herein
meet applicable ANSI, IEEE and NEMA standards;
but not such assurance is given with respect to local
codes and ordinances because they vary greatly
.

GEK-49803
12XCA11A2
The 12XCAIIA2 test probe, Fig. 2, is a two point, four contact, hard wired test probe. It can be e
inserted into any current transformer circuit of the fourteen or twentyeight point, molded case, draw
out relays after the relay connection plug is removed. The test probe construction is keyed to prevent
accidental inverted insertion and insertion into incorrect relay point pairs 2 and 3; I and 5, etc.
Two of the terminals of the probe consist of spade logs on six foot long test leads hard wired to the brus
strips which enter the even-numbered relay points. The other two contacts are hard wired together.

This test probe is a bolted assembly which can be serviced for broken test leads should the need
arise. Fig. 5 shows an interval view.
1 2XCA28A1
The l.2XCA28A1 test plug, Fig. 3, is a fourteen point, twentyeight contact test plug. It can be
inserted into any fourteen or twenty-eight point molded case, drawout relay after the relay connection
plug has been removed. The test plug construction is keyed to prevent accidental inverted insertion. The
terminals of the test plug consist of fourteen concentric binding posts. The larger, outside, red ter
minals provide access to the case terminal points while the smaller, black terminals provide connection
to the relay connection points. In addition, the center of the black relay terminals contains a standard
size banana jack. The concentric binding posts are numbered on the nameplate so that numbers 1 thru 14
are right side up arid apply when the plug is used in the bottom of the relay case. If the relay has a
connection system in the top of the case, inversion of the test plug will be required before it can be
inserted. In this case, nameplate terminal numbers 15 thru 28 will appear upright and are applicable.
Accessory links, Fig. 6, are furnished with each 12XCA28A1 test plug and include through-connection and
short-circuiting links and test clips. These accessory links can also be used with the XLA12 and XLAI3
test devices.
This test plug is a bolted assembly. The twentyeight brush strips are insulated from each other
and terminate via internal wiring on one of the fourteen concentric binding posts, Fig. 7. All the
brush strips on the relay side of the plug terminate on the inner binding posts (black thumb nuts). All
the brushes on the case side of the plug terminate on the outer binding posts (red thumb nuts).
The 12XCA28A1 can be opened for servicing by first removing the five flat head, thread cutting screws
which secure the nameplate, then the four machine screws located on the inside face of the housing.
Further binding post disassembly is achieved by removing the hex nut which secures the relay side lead
wire to the terminal post assembly of interest. The inner (black) binding post can then be unscrewed
from the captive square nut which also releases the outer (red) binding post assembly from its hexagonal
recess. Reverse the procedure for reassembly but only finger tighten the inner binding post assembly
in its captive square nut. However, fully tighten the hex nut behind that, thus securing the concentric
terminal assembly. When reattaching the nameplate, restart the thread cutting screws in the previously
cut threads by turning the screws counterclockwise until they drop into their previously cut threads; then
tighten to about four inchpounds torque.
TESTING
Routine testing of fourteen or twentyeight point, molded case, drawout relays can be accomplished
by removing the relay cover and substituting the desired test plug for the connection plug.
CAUTION: BEFORE ANY OF THE TEST PROBES OR TEST PLUG ARE INSERTED INTO A RELAY, THEY SHOULD BE CARE
FULLY INSPECTED TO INSURE THAT PROPER CONNECTIONS ARE MADE TO THEM AND THAT THESE CONNECTIONS ARE TIGHT.
IT IS ESPECIALLY IMPORTANT THAT RELAYS WHICH RECEIVE CURRENT FROM CT SECONDARIES HAVE THESE CASE SIDE
TEST TERMINALS SHORT CIRCUITED BEFORE THE TEST PLUG IS INSERTED.
12XCA11A1
This test probe can be used to provide convenient, standard banana jack connections t.o both relay
and case terminals in point pairs such as points 1 and 2, 3 and 4, etc. It is supplied with a red CT
shorting plug which can be inserted into the two case side banana jacks before the probe is inserted
into a relay CT circuit so that the required short circuit is maintained on the CT. Several of these two
point probes can be used in a relay at the same time, Fig. 8. They are keyed to prevent accidental in
version and incorrect point selection.

GEK-49803
12XCA11A2
This hard wired test probe is designed for convenient testing of the current
cults connected to a fourteen or twentyeight point, molded case drawout relay.
only be connected to an ammeter before it is inserted into a relay CT circuit in
CT current, Fig. 9. Several of these two point probes can be used in a relay at
are keyed to prevent accidental inversion and incorrect point pair selection.

flowing in the CT cir

Its terminal lugs need
order to measure the
the same time. They

12XCA28AI
Several pieces of hardware are supplied with this test plug; Fig. 6. The U-shaped link is used to
make through connections, relay stud to case terminal. Two sizes of corrugated end links are provided
so that standard test clips can be used if desired. These links are also provided with a hole so thdt a
secure bolted connection may be obtained. The long, open end link is used to short-circuit any current
transformers and any normally closed contacts. This link must be inserted under the red thumb nuts
before the test plug is inserted in the relay unit. The holes in the ends of the relay terminal studs
are banana jacks, sized to receive standard banana plugs. They are a convenience when connecting to the
relay side studs.
A conventional representation of test connections used in wiring diagrams is shown in Fig. 10.
outline of this plug is shown in Fig. 13.

An

More specific testing information can be obtained by referring to the appropriate relay instruction
book.
SHIPP 1MG-UNPACKING
Type 12XCA test plugs are shipped in individual cartons.
plug in the individual carton.

All accessory hardware is packed with the

Immediately upon receipt of the test plug, an examination should be made for any damage sustained in
transit. f injury or rough handling is evident a damage claim should be filed at once with the trans
portation company and the nearest General Electric Sales Office should be notified.
RENEWAL PARTS
Orders for renewal parts should be addressed to the nearest Sales Office of the General Electric
Company giving the name of part wanted, quantity required and complete nameplate data.

GEK-49803

CT SHORTING
PLUG

Fig. 1 (8043331) 12XCA11A1 Dual Test Probe with CT Shorting Plug

Fig. 2 (8043330) 12XCA11A2

i-lard Wired Dual Test Probe

EK-498O3

Fig. 3 (8043325) 12XCA281U

Test Plug

Fig. 4 (d043327) Sectional View of 12XCA11A1 Dual Test Probe and Shorting Plug

GEK-49803

Fig. 5 (8043329) Sectional View of 12XCA11A2 Test Probe

1y

1/
j/)

Fig. 6 (8043265) Accessory Links for the XCA and XLA Test Plugs
8

-o

-.f
CD

><

C
-4

CD

rt

CD

I.)

BLACK

THUMB

NUT
(RELAY SIDE)

SLEEVE

(CASE SIDE)

INSULATING

CASE
SIDE
LEADS

RELAY
SIDE
LEADS

CONTACT

EINGERS

C
C

G)

GE K- 49803

Fig. 8 (804334?) Relay Testing with Two 12XCAI1A1 Test Probes

10

Note Use of CT Shorting Plug in CT Circuit

GEK-49803

Fig. 9 (8043341) Relay CT Current Measurement with a 12XCA11A2 Test Probe

11

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In

CD
I,

C-,
0

=
to

If,

I
(0

p3

C-,

p3

-.,

CD

CD

C,
0

17

7
9

II

12
LI

I,

INDICATES RELAY
CONNECTION (BLACK)

INDICATES JUMPER
BETWEEN RELAY
CONNECTIONS

INDiCATES STUD
CONNECTION (RED)

INDICATES SHORT
CIRCUITING- LINK

3
9

INDICATES THROUGH
CONNECTION LINK

co

GEK-498O3

400
10MM

4.250
108MM

L750
44MM

.166
4MMD IA
(4 PLACES)

.312
8MM

Fig. 11 (0269A1831-1) Outline of the 12XCA11A1 Test Probe

13

.5W
tI3MM

GEK-49803

L500
i MM

-n

4.250
108MM

#18 STRANDED
RUBBER COVEEED
WIRE
G FEET
OR 1829MM
LONG.
BLACK

D
TERMINAL LUG
50 STUD.
ECR?
MM

Fig. 12 (0269A1832-1) Outline of the 12XCA11A2 Test Probe

14

GEK-49803

JIIf)

.s

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(J
CD
_I

(s.,

T
F

Ui
0
C)
CJ CL

>-

Oj

-J

Z1

ft

UI
--

Fig. 13

01d4B5491-?) Outline of the 12XCA28A1 Test Plug

15

GE Power Management
215 Anderson Avenue
Markham, Ontario
Canada L6E 1B3
Tel: (905) 294-6222
Fax: (905) 201-2098
www.ge.comlindsys!pm