doble Phenix Technologies HC-3 User manual

HC-3
USER’S MANUAL
PORTABLE HIGH CURRENT TEST SET
MODEL NUMBER HC-3
Version 4.2
Phenix Technologies, Inc.
75 Speicher Drive
Accident, Maryland 21520
Copyright © Phenix Technologies, Inc.
12/23/22

HC-3
TABLE OF CONTENTS
DESCRIPTION SECTION NUMBER
DANGER / GENERAL SAFETY PRECAUTIONS
INTRODUCTION
TECHNICAL SPECIFICATIONS 1
DEVICE WARNINGS 2
CONTROLS AND INDICATORS 3
BASIC APPROACH TO TESTING 4
CALIBRATION 5
PARTS LIST 6
PARTS ORDERING INFORMATION 7
RECOMMENDED SPARE PARTS 8
RETURNED MATERIAL 9
ELECTRICAL SCHEMATICS 10
CUSTOMER COMMENTS / SUGGESTIONS 11

HC-3
DANGER / WARNINGS
WARNING !!
Complete Grounding of this unit is necessary for the
safe operation of this equipment. Disconnect inputs
before ungrounding this equipment

HC-3
GENERAL SAFETY PRECAUTIONS
HIGH CURRENT
This equipment is capable of providing POTENTIALLY LETHAL VOLTAGES and /or
SEVERE BURNS!
Improper operation or test practices may result in injury or death to the operator or
surrounding personnel.
The operation of High Voltage test equipment should only be performed by personnel familiar
with HIGH VOLTAGE testing and safety procedures. The operator of this equipment must be
aware of all hazards associated with High Voltage testing. The operator is responsible for
himself and others in close proximity of the testing area.
Some General Safety Practices for working with High Voltage Test Equipment have been
listed below for your reference.
•Become familiar with your instrument before performing an actual test
•Know your work area, check that all circuits are de-energized and locked out.
•Never work alone; always work with another qualified worker.
•Mark off entire work area with barriers and warning tape.
•Make all personnel aware of your testing activities.
•Be aware of dangerous conditions that may arise from energizing a test specimen.
•Never modify test equipment, modifications to equipment could introduce an unknown
hazard or hinder a designed-in safety feature.
•DO NOT operate damaged equipment. Remove power, and do not use the equipment
until safe operation can be verified by service-trained personnel.
Phenix Technologies, Inc. assumes no liability for unsafe or improper use of test equipment.

HC-3
INTRODUCTION
The HC-3 is a portable high current test set built for field and shop use. Designed using the latest technology,
the HC-3 combines a variable high current output with appropriate controls and instrumentation for testing
thermal, magnetic, and solid-state motor overload relays, molded-case circuit breakers, and ground fault trip
devices. The HC-3 can be used in many other applications requiring a high current source.
The HC-3 provides a short duration output of up to 4000 amps through a typical 400 ampere molded-case
circuit breaker when an instantaneous trip element must be tested. Sufficient current is available for testing
time delay characteristics of motor overload relays and molded-case circuit breakers.
The unique auto-sensing feature makes the HC-3 easy to operate. Sensing leads, which operate on either
normally-open or normally-closed (non-energized) devices, are connected to the test object auxiliary or non-
energized contacts. The output current level can be easily pre-set. When the output is initiated, the pre-set
output current locks on and the timer starts. When the test set senses a change in state of the test object
auxiliary contacts (NO to NC or NC to NO), the current shuts off and the timer stops.
If set to sense current, unit will shut current off at approximately 9% (5% of range at 4000 amps) of range
switch setting of currentmeter when test object goes open. For instantaneous trip tests, the memory feature of
the currentmeter holds the peak current value until reset by the operator.

HC-3
1-1
SECTION 1: TECHNICAL SPECIFICATIONS
INPUT: 220-240 Volts, 50 Amps –Delay Circuit Breaker
50 Hz or 60 Hz (must be preset)
OUTPUT: 0-15 Volts, 0-333 Amps
0-10 Volts, 0-500 Amps
0-5 Volts, 0-1000 Amps
OVERLOAD: Short duration overloads are possible on each tap. The test set is capable of up to
5000+ amps, depending on the impedance of the test circuit.
DUTY CYCLE: Continuous at 100%
5 minutes ON/15 minutes OFF at 200%
1 minute ON/10 minutes OFF at 300%
10 seconds ON/5 minutes OFF at 400%
3 seconds ON/5 minutes OFF at 500%
INSTRUMENTATION: Currentmeter: 4 1/2 digit LCD
Ranges: 0-19.999/199.99/1999.9/5000+ amperes
Accuracy: +/- .5% F.S. to 2000 Amps, 1% F.S. 2000-5000 Amps
Timer: 6 digit LCD, in cycles or seconds
Ranges: 0-999999 cycles or 0-9999.99 seconds
Accuracy: +/- 0.1% reading
DIMENSIONS: 22 1/4" W x 22 1/4" D x 46" H; (266 lbs. with cables)
(565 mm W x 565 mm D x 1168 mm H; 121 kg)
OUTPUT LEADS: 8 ft. sense leads
2 ft. high current leads (Parallel 4/0)
6 ft. low current leads (10 Ga)
4 ft medium current leads (4 Ga)
ENVIRONMENTAL
AND ENCLOSURE
RATINGS: Not intended for wet locations
Indoor use only
IP Rating: IPX0
Temperature Rating: 10 –40 degrees Celsius
Humidity Rating: < 95%
Altitude Rating: <3300 ft. (1000m)
Pollution Degree: 2
Overvoltage Category: II

HC-3
2-1
SECTION 2: DEVICE WARNINGS
1. For safe operation, it is important that the unit be plugged into a properly grounded receptacle.
2. This unit is NOT designed for use to test energized circuits.
3. WARNING: Due to leakage current within the solid-state circuitry, it is STRONGLY RECOMMENDED to
turn control power off when changing the output leads.
4. NEVER connect sense jacks to energized contacts or terminals being injected by test unit.
5. Maintain a minimum of 6 inches between all inlet and exhaust vets and obstructions.

HC-3
3-1
SECTION 3: CONTROLS AND INDICATORS
The following is a listing of the controls, switches, and lamps on the control panels and a description of their
functions. Refer to Figures 1 through 3 below.
Refer to Figure 1
Refer to Figure 2
Refer to Figure 3

HC-3
3-2
CONTROLS AND INDICATORS
Figure 1. HC-3 Controls
1. INPUT Input cable plugs in here to provide input power.
2. MAIN POWER This controls the input power to the control and the power section and provides power
circuit protection.
3. OUTPUT Protects the variable transformer.
4. F1, F2 Fuses to protect the control circuitry and power supplies.
2
3
4
1

HC-3
3-3
CONTROLS AND INDICATORS
Figure 2. HC-3 Controls and Indicators
5. HC ON When pressed, this allows current to flow from the unit (provided that the
output is shorted as through a closed breaker). If this output current exceeds
approximately 9% (5% of 4000A range) of the selected output current range,
the output will be maintained when the switch is released. Also, the TIMER
will begin to run at this point.
6. HC OFF When this is pressed, the output current will cease to flow from the unit.
7. JOG This switch is used when it is desired to preset output current to a specific
level. When pressed, the output current will begin to flow as it would when
HC ON is pressed. The difference is that the TIMER will not begin running in
this mode, and the output current will cease to flow when the switch is
released, regardless of its magnitude.
8. CURRENT CONTROL Controls current level from minimum to maximum of output tap when HC ON
or JOG is activated. Use with JOG to preset current level through test object.
5
6
7
13
12
14
9
8
10
11

HC-3
3-4
CONTROLS AND INDICATORS
9. TRIP/RESET This switch serves several purposes.
1) When in CONTACTS mode, the lamp will illuminate to indicate that the non-
energized contacts of the test specimen connected to the SENSE INPUTS has
changed states.
2) When in CURRENT mode, the lamp will illuminate to indicate that the output
current has dropped below the 9% level (5% of 4000A range).
3) When pressed, the TIMER will be reset to zero.
4) When the CURRENTMETER MEM/CONT is set to the MEM mode, pressing reset
will release currentmeter from its highest registered reading. If the output current
is not at zero, the present output reading will be maintained until either the output
level increases, or the reset is pressed again.
5) When illuminated, it must be pressed to reset controls for further operation.
10. SENSE SWITCH This can be set to CONTACTS or CURRENT mode. When placed in CONTACTS
mode, the unit will react to a change in condition of the SENSE INPUTS (Normally
Open to Normally Closed, or Normally Closed to Normally Open). Upon a change in
condition, the TIMER will stop running and the output current will cease to flow. The
TRIP lamp will illuminate as an indication to the operator of a change in condition.
In CONTACTS mode, sense leads must be properly connected to non-energized
contacts operated by the test specimen or the timer will not shut off when the
test specimen goes open. If the sense leads are not used, the sense switch
must be in CURRENT position for proper functioning.
When the SENSE switch is set to the CURRENT mode, the unit will react to the
output current dropping below approximately 9% (5% of 4000A range) of the level of
the selected current range.
11. SENSE INPUTS These are connected to an auxiliary set of contacts (non-energized) regardless if they
are normally open or closed. When RESET is pressed, the unit will remember its
state. If the state changes, the unit will react to this change if the SENSE switch is set
to CONTACTS.
Please do not attempt to connect these to the same set of contacts which you
intend to energize or energized auxiliary contacts. This may cause damage to
the unit.
12. CURRENTMETER This displays the RMS value of the output current level of the unit. There are four
ranges available:
2 Amp 1.9999
20 Amp 19.999
200 Amp 199.99
4000 Amp 4000+
WARNING: Please note that there is no correlation between the currentmeter
range switch setting and the rating of the taps.

HC-3
3-5
CONTROLS AND INDICATORS
13. MEM/CONT When set to the CONT (continuous) mode, the meter will continuously update to
display the output current level. When placed in the MEM (memory) mode, the meter
will retain the highest output current level achieved. If the level again exceeds this
value, the meter will be updated. If you are below the highest level, pressing RESET
will update the meter to the present level of output.
Please note that the MEM mode of operation will only maintain the reading for a short
time before the reading starts to decay.
14. TIMER The timer will begin counting when HC ON is pressed and the current surpasses the
9% or 5% level. The timer will stop when the current drops below the 9% or 5% level
in the SENSE CURRENT mode. When in the SENSE CONTACTS mode, the timer
will stop when a change in the SENSE INPUTS is detected.
The timer can be set to read CYCLES or SECONDS.
Figure 3: Output Taps
15. OUTPUT TAPS These is the connection points for each of the transformer taps. Use only one tap at a
time. Current ratings shown are continuous operation ratings. Each tap is capable of
overcurrent for a short time. Check specifications page for duty cycles ratings.
16. COMMON TAPS This is the common connect point for the transformer. This tap must be used in all
testing connections.
15
16

HC-3
4-1
SECTION 4: BASIC APPROACH TO TESTING
The HC3 is a continuously variable high current source, the magnitudes of which are dependent on the output
tap which is selected. Please refer to the Technical Data and Specifications for the voltage and current ratings
of the taps. The test object should be connected between one of the output taps and the common tap.
The output current is controlled by use of the CURRENT CONTROL knob on the control panel. By turning the
knob in the clockwise direction, the current is raised. By turning the knob in the counterclockwise direction, the
output magnitude is decreased.
The RMS value of the output current is displayed on the CURRENTMETER. If the MEM/CONT switch is in the
CONT (for CONTinuous) position, the meter displays the real-time value of the output. If the MEM/CONT
switch is in the MEM (for MEMory) position, the highest value of the output current is displayed.
When a breaker is to be tested, the operator may select the SENSE CONTACTS mode or the SENSE
CURRENT mode of operation. If an auxiliary set of non-energized contacts are available, the SENSE
CONTACTS mode may be selected. By pressing JOG or RESET the state of the contacts (be it normally
open or normally closed) are remembered by the unit. The operator may then preset the output current to the
desired level by use of the JOG switch. When this is done, by pressing HC ON and assuming that the current
level exceeds approximately 9% of the CURRENTMETER range selected (4% on 5000A range), the current
will continue flowing after the switch is released and the TIMER will begin to run.
When the contacts connected to the SENSE INPUTS change state, the TIMER will stop running and the
output current will cease to flow. The TRIP lamp will illuminate as an indication to the operator. If the
MEM/CONT switch is in the MEM mode, the highest output current achieved will be displayed on the
CURRENTMETER. The operator should note this level before the readings begin to decay. Pressing RESET
will zero the TIMER and CURRENTMETER readings and prepare the unit for operation again.
When the SENSE switch is set to the CURRENT mode, the SENSE INPUTS are not used. This position was
meant mainly for single pole breakers in which the SENSE INPUTS cannot be used. In this mode initiation of
the test is the same as in SENSE CONTACTS mode. The difference is the completion of the test. When the
output current falls below 9% or 4% of range (as when the contacts of the breaker open), the TIMER stops
running and the output current turns off. The TRIP lamp illuminates as an indication to the operator.

HC-3
5-1
SECTION 5: CALIBRATION
TIMER The timer is run from a precision programmable oscillator and should never require
calibration.
CURRENTMETER The calibration of the currentmeter should be checked annually. To do this, place the
MEM/CONT switch in the CONT position. Place the range switch in the lowest range.
With nothing connected to the output and the CURRENT CONTROL knob in its fully
counterclockwise position (zero position), adjust R75 until the
CURRENTMETER reads zero.
Short output from the lowest current tap to the common tap with adequately rated
cable. With appropriate test equipment (RMS), raise the output current to 80% of the
range and adjust the corresponding calibration potentiometer to agree with your
standard. Repeat this process for each current range using the tap with the closest
higher current rating than the metering range.
Low R84
Med-L R85
Med-H R69
High R73

HC-3
6-1
SECTION 6: ELECTRICAL SCHEMATICS
Drawing Number Description
1. 9304531 HC-3 Electrical Schematic

HC-3

HC-3
7-1
SECTION 7: HC-3 PARTS LIST
Qty
Phenix
Stock #
Item
Description
INPUT PANEL
1
1153311
Cable, Input Connector
1
1153310
Panel, Input Connector
2
1603602
*F1, F2
Fuse, 1.5A, 250V, Fast Acting Fuse –User
Replaceable
2
1603920
F1, F2
Fuse Holder
2
1601327
CB1, CB2
25 Amp 2 Pole Circuit Breaker
CONTROLS
2
1351100
JACKS-SENSE
Binding Post, Black
1
1892206
CT1
Current Transformer
4
1420143
*HC ON, HC OFF,
JOG, RESET
Lamp, 6.3V
1
1422151
HC OFF
Lens, Green
2
1422150
HC ON, JOG
Lens, Red
1
1422148
RESET
Lens, Blue
1
1422152
RESET
Lens, Yellow
1
1506405
M1
Current Meter, 4 ½ Digit
2
1606110
MOV1, 2
Movistor V275LA40A
1
1590110
P.S. 5V
Power Supply, 5 Volt
1
31136100
PCB1361
PCB1361: HC CNTRLS AND PWR ASSY
1
31122305
PCB1223
PCB1223 ASSY FOR HC 0.3,1,2,3
2
1151955
J1, J2
JUMPER-JAX ROHS
2
1741990
R200,201
Resistor, 1K, 10W
1
1721700
R206
Resistor, 910 Ohm, .5W, 1%
1
1712175
R207
Resistor, 8.2 Kohm, .5W, 1%
3
1860120
SW1,3,4,5
Switch, HC ON, OFF, JOG, RESET
3
1865010
SW2,8,9
Mem/Cont, Cycles/Seconds, Current/Contacts
1
1355310
SW6
Knob, Current Range SW
1
1863042
SW6
Switch, Current Range
1
1505420
Timer
Timer, Red Lion, Sub Cub D, SCUB-D2-00/A
1
1505421
Timer Bezel Kit, HWK-60-000/D
REGULATOR/OUTPUT
1
1700375
SSR1
Relay, Solid State
1
1890239
T1
Transformer, Variable
1
2350124
Fan 1
Cooling Fan
1
1077300
Cord Set, Fan
1
38601678
T2
Output Transformer, IA1-1678
MISCELLANEOUS/MECHANICAL
1
2371045
Latch, Cover
2
2109525
Glides, Cart
2
2109500
Bumpers, Cover

HC-3
8-1
SECTION 8: PARTS ORDERING INFORMATION
Replacement parts are available from Phenix Technologies, Inc.
Changes to Phenix Technologies' products are sometimes made to accommodate improved components as
they become available, and to give you the benefit of the latest technical improvements developed in our
Engineering Department. It is, therefore, important when ordering parts to include the serial number of the unit
as well as the part number of the replacement part.
When your purchase order is received at our office, a representative of Phenix Technologies will contact you
to confirm the current price of the part being ordered. If a part you order has been replaced with a new or
improved part, an Applications Engineer will contact you concerning any change in part number.
Send orders for replacement parts to:
Service Department
Phenix Technologies, Inc.
75 Speicher Drive
Accident, Maryland 21520
Ph: 1 [phone]
Fax: [phone]
E- mail: [e-mail]

HC-3
9-1
SECTION 9: RECOMMENDED SPARE PARTS
Phenix Technologies recommends that the customer purchase and stock the following parts for normal
maintenance of the unit. The recommended quantity should be sufficient to support the unit during normal
operation.
If the unit will be operated at an isolated site for an extended period or will be subjected to unusual stresses, a
larger quantity of parts should be stocked as spares. In such cases, contact Phenix Technologies for a
recommendation.
Current prices may be obtained by contacting the Service Department at Phenix Technologies.
Qty
Part
Number
Item
Description
2
1603602
F1, F2
Fuse, 1.5A, 250V, Fast Acting Fuse –User
Replaceable
4
1420143
*HC ON, HC OFF,
JOG, RESET
Lamp, 6.3V
4
1860120
SW1,3,4,5
Switch, HC ON, OFF, JOG, RESET
1
1506405
M1
Current Meter, 4 ½ Digit
1
31144100
Timer
PCB1441: HC COUNTER W/ DISPLAY

HC-3
10-1
SECTION 10: RETURNED MATERIAL
If for any reason it should become necessary to return this equipment to the factory, the Service Department of
Phenix Technologies, Inc. must be given the following information:
Name Plate Information
Model Number
Serial Number
Reason for Return
Cause of Defect
If Phenix Technologies, Inc. deems return of the part appropriate, it will then issue an "Authorization for
Return."
If return is not deemed advisable, other inspection arrangements will be made.
NOTE: Material received at this plant without the proper authorization shall be held as
"Customer's Property" with no service until such time as the proper steps have been taken.
Your cooperation is requested in order to ensure prompt service.