Eti Pi-2500-g2 User manual

PRIMARY INJECTION CIRCUIT BREAKER

TEST SET

INSTRUCTION MANUAL

Models

PI-2500-G2 and PI-5000-G2

Electrical Test Instruments, LLC.

8430 Spires Way, Suite A-F

Fredrick, MD 21701

www.ETIPrecision.com

(410) 857-1880

Fax (410) 857-1387

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

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TABLE OF CONTENTS

SECTION I: GENERAL INFORMATION and SPECIFICATIONS

WARNING I-1

Introduction I-2

General Description I-2

Monitor and Controller MAC-21 I-5

PI2500-G2 Specifications I-6

PI5000-G2 Specifications I-7

SECTION II: DETAILED DESCRIPTION

High Current Test Sets II-1

PI-2500-G2 Main Circuitry II-1

PI-2500-G2 Control Circuitry II-1

AUX-5000-G2 Main Circuitry II-4

AUX-5000-G2 Control Circuitry II-5

PI-2500-G2 Control Panel Circuitry II-5

Indicator Control Panel II-7

Figure II-2: Retrofit Indicator Panel II-7

SECTION III: MAC-21 Monitor and Controller

MAC-21 Specifications III-1

MAC-21 Unit Circuitry III-2

MAC-21 Software III-2

MAC-21 Parts Identification and Operation III-4

MAC-21 Internal Parts III-8

Figure II-1: Front Panel III-9

Maintenance and Calibration of MAC-21 III-10

Parts List (MAC-21) III-12

Overall Schematic (MAC-21) III-13

SECTION IV: OPERATING INSTRUCTIONS

Pre-Test Installation and Setup IV-1

Basic Guidelines and Suggestions IV-3

Single Pole Molded Case Breakers IV-6

Multi-pole Molded Case Breakers IV-9

Low Voltage Power Breakers IV-12

Motor Overload Relays IV-17

Ratioing Current Transformers IV-19

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

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SECTION V: SERVICE INFORMATION AND DOCUMENTATION

Maintenance and Calibration of PI-4000B V-1

Maintenance and Calibration of MAC-21 V-1

Parts List (PI-2500-G2) V-2

Parts List (AUXI-5000-G2) V-4

Parts List (Indicator Control Panel) V-5

Parts List (MAC-21) V-6

Overall Schematic (PI-2500-G2) V-7

Overall Schematic (AUX-5000-G2) V-7

Overall Schematic (Indicator Control Panel) V-8

Overall Schematic (MAC-21) V-9

Warranty END

Additional Schematics END

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

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Page I-1

SECTION I

GENERAL INFORMATION

WARNING

WARNING - READ THIS ENTIRE MANUAL AND

THOROUGHLY FAMILIARIZE YOURSELF WITH THE UNIT

OPERATION PRIOR TO CONNECTING THE UNIT TO A

SOURCE OF POWER. HIGH CURRENT TEST SETS ARE

NORMALLY POWERED FROM HIGH CAPACITY 208 VOLT TO

575 VOLT SERVICES, AND IMPROPER CONNECTION OR

OPERATION COULD CAUSE DAMAGE TO THE TEST SET AND

EQUIPMENT UNDER TEST, AS WELL AS CREATE AN UNSAFE

CONDITION FOR PERSONS OPERATING THE SET.

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

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Page I-2

INTRODUCTION

A primary injection test set such as the PI-2500 and PI-5000 is a device with

high current, low voltage AC outputs for testing direct acting low voltage circuit

breakers. Current is injected through the main contacts of the breaker to simu-

late actual fault conditions, which tests the operation of CTs, solid state, thermal,

or electromechanical trip devices, and the actual trip mechanisms and breaker

contacts.

GENERAL DESCRIPTION –PI2500

The PI-2500 is a versatile and technologically advanced primary injection test

set capable of testing circuit breakers up to 2000 amperes frame size. It incor-

porates an improved low impedance output transformer with dual primaries to

facilitate its use on power sources of 480 VAC as well as 240 and 208 VAC, and

dual secondaries to provide optimal impedance matching to a wide range of

breaker sizes. High capacity internal fan cooling allows maximum utilization of

the output transformer and faster recovery after overload conditions.

It is housed in a rugged Steel frame enclosure with removable sides and top for

easy access to internal components. The sides are clear of protruding compo-

nents, and a full-width handle facilitates moving the unit. Locking swivel castors

on one end provide ease of mobility and allow the test set to be moved on rough

surfaces.

The indicator control panel and MAC-21 are mounted in a hood on the top,

which provides protection during transportation. The auxiliary 120 VAC GFI pro-

tected outlet is conveniently located on the side of the Hood and protected by

a 4-ampere circuit breaker.

The output stab connectors are slotted to accommodate special breaker stab

adaptor plates as well as being able to connect to the AUX-5000 for increased

output capacity. The rugged silver-plated copper stab adaptors supplied with

the test set are designed to be used for both vertical and horizontal stabs and

have both ½” and ¾” output plates. Standard ½”-13 stainless steel hex head

bolts with matching nuts and washers are used to connect the output stab

plates, and they may be replaced easily.

A series adaptor bar allows the output to be configured for continuous current

of 1000 amps at 15 VAC for testing breakers that require connection via cables.

A configuration switch on the output faceplate adjusts the internal CT output

for proper readings in either configuration.

The test set may be plugged into any 60 Hz AC voltage source of 200-250 VAC

or 400-500 VAC, and will work on 50 Hz sources of 200-210 VAC or 400-420 VAC.

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

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Page I-3

The line voltage is displayed on the indicator control panel digital meter. An in-

put selector switch can be set for 208, 240, or 480 VAC inputs. An internal volt-

age sensor automatically ensures that the switch is set correctly before AC con-

trol power can be turned on, and monitors input voltage for compliance to spec-

ifications.

The Vernier uses a large wheel to adjust the output manually within the range

determined by the coarse tap, as well as a motorized control actuated by means

of a smart control switch. When the switch is pressed briefly, the Vernier moves

in a very small increment for fine control. When the switch is held, the Vernier

moves very quickly, so that the entire span may be traversed in less than five

seconds. The approximate Vernier position is displayed on an LED indicator bar

graph. For the PI-2500, the Vernier is always turned clockwise to increase out-

put.

The electronically controlled tap selection uses power contactors to set the

coarse tap. The unit powers up in the lowest tap position (1), and the setting may

be adjusted by means of a rocker switch on the indicator/control panel. If the

switch is held, the taps change at a rate of about two seconds per tap. Tap

change is not allowed when output is on. Note: Output taps 1-3 only for the PI-

2500. Output taps 4-9 are only operational when the AUX-5000 section is con-

nected to the PI-2500 section.

The indicator/control panel features two temperature indicators: one for the

output bus temperature, and the other for the overall system temperature. This

is determined by a combination of actual winding temperature, and a “virtual

temperature” which is derived from time and current duty cycle usage as mon-

itored by a “POD”, or Programmable Overload Device. Additional details are

available in a separate manual. If either temperature exceeds a safe operating

level, the interlock is asserted, and the output section is de-energized. Addi-

tional thermostatic sensors in the output transformer windings will also assert

the interlock if unsafe temperature levels are detected.

The output voltage of the test set is provided on the indicator/control panel for

monitoring by means of a separate digital voltmeter.

Primary catastrophic overload protection for the test set is accomplished with

input fuses having high interrupting current capacity. Overload of the output

system is sensed by means of the previously mentioned “POD” on the Vernier

autotransformer, and thermal sensors in the transformer winding. Thermal

switches are also installed in the transformer windings. The combination of

these devices allows full utilization of the overload capability of the test set and

eliminates costly and cumbersome fuse replacement required in other test sets.

The output of the test set is controlled by means of a proven SCR controller,

which drives A Thyristor assy. This provides precise initial phase angle control to

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

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Page I-4

reduce DC offset for inductive loads and more consistent pulse currents. The

phase angle is internally adjustable and is preset for optimal waveforms with

most breakers.

The measurement of output current and time is accomplished by means of the

proven MAC-21, which uses highly accurate A/D circuitry and intelligent firm-

ware to resolve true-RMS values of distorted waveforms. It also provides features

such as preset ON times for convenient jogging of output current without over-

heating the breaker or causing unwanted trips.

The entire test set has been designed for reliability, ruggedness, and ease of use.

Sophisticated electronics in the indicator/control panel and the MAC-21 provide

state of the art accuracy and convenience, while simple connections allow for

easy removal and replacement for transportation or service. All covers are re-

movable, allowing easy access to all internal components. An internal relay

panel located just under the top panel contains most of the circuitry, facilitating

service and maintenance. The rear panel may be removed for access to input

fuses, control fuses, and the SCR board. A fan with air filter provides airflow to

the transformer and output bus. The cabinet is designed with no protruding

components on the sides, so it can be navigated through narrow doorways

without problems.

The reduced length and width of the test set allows it to be maneuvered in tight

spaces and it can be lowered into a shaft 26” x 30”, or a manhole 40” diameter.

Provisions have been made on the bottom of the frame for a lifting sling to be

attached without slipping from the corners.

GENERAL DESCRIPTION –PI5000

The PI-5000 is composed of the PI2500 as described above, and the AUX-5000

auxiliary output unit, which when combined gives the unit the capability of

testing 4000 ampere breakers, with essentially the same specifications as the

proven PI-4000B. The unit is smaller than the PI4000, so it can also be maneu-

vered easily in tight spaces or lowered into shafts and manholes that would

not be possible with a larger single piece unit.

The AUX-5000 is easily attached to the PI-2500 by means of Vertical bus bars

with stainless steel socket head cap bolts and sturdy nut plates. The AUX-5000

is simply rolled into place to mate with the PI-2500, and then the Bolts are

tightened.

The main electrical power and ground connections to the AUX-5000 are

housed in 1 amphenol connector.

The output of the AUX-5000 is identical to that of the PI-4000B, and accom-

modates standard breaker stabs, for continuous output of 4000 amperes. It

can also be configured in series mode for a continuous output of 2000

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Page I-5

amperes. The configuration switch on the PI2500 must be set to 4000 or 2000

for proper output readings.

.MONITOR AND CONTROLLER MAC-21

The MAC-21 microprocessor-based measurement and control unit features

digital readout of current and time enhanced by digital signal processing.

Pulse (memory) mode provides fast and accurate automatic evaluation of out-

put current pulses as short as one-half cycle.

The MAC-21 incorporates a precision A/D converter and special firmware for

true-RMS continuous and pulse current reading with much greater accuracy.

It also utilizes a sophisticated current sensing system for more reliable current

latch mode operation and better timing accuracy. An LED digital readout for

current in four ranges from 1000 A to 100 KA reduces the chance of operator

error.

An integral auto ranging timer with LED readout provides four digits in sec-

onds or cycles mode, with a resolution of 0.001 second or 0.5 cycle. A preset

function allows you to set a maximum ON time in seconds or cycles, for con-

venient "jogging" of output to desired current or setting time for heat runs and

long-time tests.

A current hold feature is also built in. When the desired current is displayed, a

simple touch of the MAINTAIN key activates the function, which automatically

adjusts the motorized Vernier to hold the current within 5 amperes.

The memory current displayed after a test indicates the true RMS value of the

entire pulse, no matter how long or short it was, except for instantaneous trip,

where the peak RMS value is used. After a test, it is possible to read the peak

RMS value, which indicates the amount of DC offset or distortion, or the last

displayed average RMS reading, which is useful for pickup testing.

The entire metering and control package are designed to be removed and re-

placed very easily, so that it may be transported separately.

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

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Page I-6

PI-2500 SPECIFICATIONS

INPUT SUPPLY:

208/240 or 480 VAC +/- 10% (Field switchable)

SINGLE PHASE

60 HZ (50 Hz at 10% lower line voltages)

15 KVA (Continuous) at 12 KVA output (80% efficiency)

OUTPUT CURRENT & OVERLOAD CAPABILITIES:

7.6V (Par)

15.2 V (Ser)

Ovld

Duty

Max ON Time

Min OFF

Time

Max Inp Curr

(@480/240)

2000 A

1000 A

100%

CONTINUOU

N/A

32 / 64

2800 A

1400 A

1.4x

50%

15 Minutes

45 / 90

4000 A

2000 A

25%

5 Minutes

15 Minutes

64 / 128

6000 A

3000 A

10%

1.5 Minutes

15 Minutes

96 / 192

8000 A

4000 A

45 Seconds

15 Minutes

128 / 256

10000 A

5000 A

4 Seconds

2 Minutes

160 / 320

14000 A*

7000 A*

1 Second

2 Minutes

224 / (448 *)

20000 A*

10000 A*

10x

0.2 Second

2 Minutes

320 / (640 *)

*Available with 480 VAC input only; Max ON Times may be less at 208 or 240 VAC

DIMENSIONS AND NET WEIGHT

Height: 45 in. (1143 mm) (includes castors and hood)

Width: 30.0in. (762 mm)

Depth: 25.0 in. (635 mm)

Weight: 700 lb. (317 kg)

STANDARD ACCESSORIES

Stabs, (½” bus, horizontal or vertical) 1 set

Stabs, (¾” bus, horizontal or vertical) 1 set

Stab adaptor assembly 1 pair

Series bars 3 pcs

Input power plugs 3 pcs

Contacts leads 1 pair

Technical manual 1 copy

OPTIONAL ACCESSORIES

Remote initiate cable

Serial Interface Cable

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

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Page I-7

PI-5000 SPECIFICATIONS

INPUT SUPPLY:

208/240 or 480 VAC +/- 10%

SINGLE PHASE

60 HZ (50 Hz at 10% lower line voltages)

45 KVA (Continuous) at 36 KVA output (80% efficiency)

OUTPUT CURRENT & OVERLOAD CAPABILITIES:

7.6V (Par)

15.2 V (Ser)

Ovld

Duty

Max ON Time *

Min OFF Time

Max Inp Curr

(@480/240

4000 A

2000 A

100%

CONTINUOUS

N/A

96/192

5600 A

2800 A

1.4x

50%

15 Minutes

134/268

8000 A

4000 A

25%

5 Minutes

15 Minutes

192/384

12000 A

6000 A

10%

1.5 Minutes

15 Minutes

288/576

16000 A

8000 A

45 Seconds

15 Minutes

384/768

20000 A

10000 A

4 Seconds

2 Minutes

480/960

28000 A*

14000 A*

1 Second

2 Minutes

672/*

40000 A*

20000 A*

10x

0.2 Second

2 Minutes

960/*

*Available with 480 VAC input only; Max ON Times may be less at 208 or 240 VAC

DIMENSIONS AND NET WEIGHT PI-5000 AUX

Height: 32 in. (812 mm) (includes castors)

Width: 30.0 in. (762 mm)

Depth: 25.0 in. (635 mm)

Weight: 680 lb. (308 kg)

DIMENSIONS AND NET WEIGHT PI-5000 (Combined PI-2500 & PI-5000AUX)

Height: 45 in. (1143 mm) (includes castors and hood)

Width: 77.0 in. (1955 mm) (includes buss interconnects)

Depth: 25.0 in. (610 mm)

Weight: 1380 lb. (626 kg)

STANDARD ACCESSORIES

Stabs, (½” bus, horizontal or vertical) 1 set

Stabs, (¾” bus, horizontal or vertical) 1 set

Input power plugs 1 pair

Contacts leads 1 pair

Technical manual 1 copy

Remote initiate cable 1 each

OPTIONAL ACCESSORIES

Series bar

Serial Interface Cable

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

Section II –Detailed Description

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SECTION II

DETAILED DESCRIPTION

Electrical Test Instruments PI-2500-G2 & PI-5000-G2

Section II - Detailed Description

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Page II-1

SECTION II

DETAILED DESCRIPTION

THEORY OF OPERATION

High Current Test Sets

High current test sets generally consist of the following:

1. One or more coarse taps accomplished by:

(a) A tapped autotransformer providing several equal steps of volt-

age or

(b) A multi-section output transformer

2. A continuously variable Vernier adjustment between coarse taps by

means of:

(a) A variable autotransformer and boost transformer, or

(b) A variable autotransformer connected to a section of the out-

put transformer.

3. An output transformer with one or more isolated low voltage, high

current secondary.

4. Power control circuitry consisting of switches, relays, protective de-

vices, etc.

5. Current measurement circuitry consisting of sensors, current meter,

and timer.

In general, a primary voltage is selected by means of a combination of coarse

tap and Vernier adjustment. This voltage is stepped down by the output trans-

former to provide the desired current into the load impedance.

PI-2500 Main Unit Circuitry

Main power is applied to the PI-2500 by means of standard high current Cam-

Lok connectors, which are supplied for the customer to connect to the power

source with appropriate flexible leads. A ground connector is also provided for a

solid ground connection.

Electrical Test Instruments PI-2500-G2 & PI-5000-G2

Section II - Detailed Description

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Page II-2

Primary protection is provided by high capacity 400 ampere input fuses (F1 and

F2). After that, the control section is protected by smaller 5 ampere fuses (F3 and

F4), and the power section is isolated by means of high current contactors (K13

and K14).

Transformer T6, protected by fuse F6, steps down the primary voltage by a factor

of ½, and is connected to a wide range switching power supply in the indicator

control panel to provide 12 VDC. The dual primary of transformer T6 steps it

down by a factor of 1/2, and T10 steps it down by another factor of ½, and this

voltage is sensed by a voltage relay circuit and read on the control panel LED

meter. When the primary voltage is between about 200 and 270 VAC, this circuit

allows operation in 208 or 240 VAC mode. If the voltage is between about 420

and 520 VAC, operation is allowed in 480 VAC mode. Control power cannot be

turned on if the voltage is outside these bounds.

Another transformer, T9, supplies nominal 104, 120 or 240 VAC power to the con-

trol panel, which has an internal 12 VDC power supply which powers other por-

tions of the control circuitry of the control PCB.

When the input voltage selector switch S1 is the 208 or 240 V position, relay K6

is energized, setting the primary windings of transformer T4 in parallel. This also

energizes relay K1 on the voltage sensor PCB and provides an interlock and in-

put selector error indication. The voltage sensor PCB rapidly flashes the Input

Select Error LED on the control panel for 5 seconds during startup, and then

turns off if input voltage is within bounds as determined by the input selector

switch position. If line voltage is incorrect, the Input Select Error LED will flash,

and control power cannot be turned on. If control power is energized, brief volt-

age sags or surges will flash the LED as a warning. If such voltage excursions

persist for longer than about 0.2 seconds, the control power will drop out.

Binding post BP1 is provided for separate connection to an earth ground, to

check for ground integrity. When there is continuity from this point to chassis

ground, a relay on the control PCB is energized, and enables the interlock for

control power. If ground integrity is not sensed, the Ground Open LED DS1 will

light. A separate lead should be connected to the external equipment ground

system to verify that the main grounding cable is intact. Do not defeat this

safety feature by jumpering the ground binding post to the test set frame.

When the control power switch in the indicator control panel is pressed, and all

voltage interlocks are OK, relay K7 is energized, which provides 120 VAC control

power to the auxiliary GFI outlet, protected by 4 ampere circuit breaker CB1. A

relay on the control PCB provides 120 VAC control power to the entire test set,

including the fans and the main contactors. In 208 V input mode.

If all power interlocks are OK, the Main Power switch in the indicator control

panel may be pressed to activate main contactors K13-14. This provides high cur-

rent power to the test set output circuitry through the SCR controller. The

Electrical Test Instruments PI-2500-G2 & PI-5000-G2

Section II - Detailed Description

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Page II-3

switched output voltage is supplied to distribution blocks DB1 and DB2.

The Vernier autotransformer T1 and output transformer T2 are connected to in-

put voltage selector switch S11. This allows for connection in series for 480 VAC,

and parallel for 208/240 VAC. Vernier T1 is connected directly to the first primary

of T2, so that clockwise rotation produces an output voltage of about 0-1.5 VAC.

Relays K3, K4, and K5 connect the second primary windings for fixed outputs of

0, 1.25, or 2.50 VAC for taps 1, 2 and 3. This provides three (3) overlapping output

ranges up to 3.75. 7.5 or 15 VAC, depending on how the four secondary windings

are connected.

Output current is detected by means of an air core CT around all four main bus-

ses. The configuration switch can be set to 1000, 2000, or 4000, which divides

the signal by a factor of 4, 2, or 1. Calibration of all three modes is accomplished

with potentiometers on the switch assembly under the output face plate.

The output section is energized when a signal is applied to the trigger board of

the SCR controller. The initial phase angle is determined by a zero-crossing de-

tector in the trigger PCB, and a delay which is normally preset to 70 degrees.

The Vernier autotransformer may be adjusted manually by means of a hand-

wheel, or by activating the motor drive. Increasing output is clockwise for all

taps.

When the SCR board is energized, 12 VDC is applied to the control panel which

is used for output ON detection and indication.

Thermistor TH2 senses the temperature of the output bus, and TH1 reads the

temperature of the first primary of output transformer T1. These normally have

a resistance of 10 K ohms at room temperature, and lower values as the temper-

ature increases.

Relays K1 through K6 are energized through the indicator control panel and the

control PCB.

The adjustable Vernier assembly T2 in the PI-2500 consists of a stack of four 120

VAC decks, with each series connected pair connected to a 240 VAC primary on

T1A. Minor voltage imbalance up to about 2 VAC is corrected by means of paral-

leling transformer T3, and actual current in each primary circuit is monitored by

means of 50:5 current transformers T4 and T5. Resistors R1 through R4 ensure

voltage balance on the series connected pairs, and also provide a resistive load

to stabilize the SCR controller at low output settings.

The secondary currents from T4 and T5 are monitored by the Programmable

Overload Device (POD), which also measures actual temperature in the primary

winding of T1A. The overall system status is displayed on the bar graph of the

indicator control panel, and an interlock relay shuts down the output of the test

set if abnormal conditions are detected. More details are in a separate manual.

The PI-2500 features a very efficient low impedance output transformer with

Electrical Test Instruments PI-2500-G2 & PI-5000-G2

Section II - Detailed Description

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Page II-4

enhanced reliability and cooler operation due to single piece secondary bus

conductors. It was designed so that it could provide three connection modes

for 1000, 2000, and 4000 amps continuous current. Stab Adaptor Plates and se-

ries bars are used for convenient output connection. The output bus connectors

are slotted so that the hardware can be loosened and removed or replaced eas-

ily.

Illustration of PI-2500 Stab Plate Assembly:

AUX5000 Main Unit Circuitry

The AUX-5000 auxiliary unit connects to the 2500 one amphenol connector and

4 buss bars. Primary protection is provided by 200-amp fuses F1 and F2. Main

power is supplied to the output section by power contactors K1 and K2, which

are energized main power in the PI2500 is turned on.

The control connector to the PI5000 provide ACHI and ACLO power for the fan,

control signals and power for the contactors, interlocks, and sense leads for the

output bus voltage from terminal 1 to 4.

The secondary windings of the transformer, consisting of two pairs of bus bars,

are bolted to the secondary bus bars of the mating PI-2500. The combined units

form a transformer which is nearly identical to the PI4000B.

The high strength and corrosion resistant stainless-steel output bolts should

rarely require replacement but may be serviced by simply removing the sixteen

screws on the phenolic output faceplate, and then removing one of four bolt

retainers. The standard hex head bolts may then be pushed through and re-

placed.

Electrical Test Instruments PI-2500-G2 & PI-5000-G2

Section II - Detailed Description

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Page II-5

PI-5000 connection:

PI-2500 Indicator Control Panel Circuitry

The power for the control panel is provided by the INV/2 circuit, which is the

main input voltage divided by 2. This voltage, ranging from 104 VAC to 240 VAC,

powers a wide range switching power supply, which supplies 12 VDC to the rest

of the circuitry. When the CTL ON switch S1 is pressed, DS1 lights and relay K4 is

energized, and latches on if voltage interlocks are OK and the external control

relay energizes. K4 also provides 12 VDC power to the PC board, which has cir-

cuitry for Vernier position display and adjustment, tap selection and display, and

temperature readings. Pressing S2 turns control power off.

If any external interlock is open, as sensed by K1, indicator DS4 will light. Other-

wise, K2 will energize, which energizes K2 and allow operation of S3. When MAIN

ON switch S3 is pressed, relay K3 energizes, MAIN READY lamp DS3 lights, and

power is provided to external main contactor. If it operates, K3 is latched on

through its auxiliary contact.

If the output of the test set is ON, 12 VDC will be applied to DS5, and also will be

sensed by the PC board, which will inhibit tap change.

The INV/4A and B signals provide a voltage equal to ¼ the input voltage. This is

Electrical Test Instruments PI-2500-G2 & PI-5000-G2

Section II - Detailed Description

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Page II-6

rectified and filtered by the metering PC board and displayed on the panel me-

ter.

Output is inhibited during tap change or when an interlock condition exists. An

interlock (INTLKB) will be asserted if either temperature readouts exceed an ad-

justed setpoint.

The Vernier position signal is supplied to the PC board and displayed as a 0-

100% reading on a ten segment LED bar graph. The signal is about 1.0 to 4.0

VDC.

The bus temperature is from a 10 K ohm thermistor. System temperature is a

variable voltage from the POD, as discussed elsewhere. Circuitry in the PC board

converts these signals to voltages which are displayed on multicolor bar graphs.

When the signal exceeds that which lights one red bar, the interlock is tripped.

The output voltage of the test set is supplied at jacks J1 and J2.

Indicator Control Panel

Input Voltage Meter: This LED panel meter indicates the approximate input

voltage applied to the test set.

Control Power ON switch: This green switch turns on 120 VAC control power to

the test set, and its green lamp lights when ON.

Control Power OFF switch: This red switch turns off the 120 VAC control power

to the test set.

Main Power READY switch: This green switch turns on the main power to the

output section of the test set, and its green lamp lights when ON.

Main Power INTERLOCK switch: This red switch turns off the main power to the

test set. It lights if an interlock condition is detected.

Output ON indicator: This yellow lamp lights when output voltage is ON.

Output Voltage jacks: These banana jacks are connected to output stabs 1 and

8 in the PI2500, and stabs 1 and 4 in the AUX-5000 and may be used to monitor

voltage on the breaker with a DMM.

Thermal Status - Bus: This multicolor bar graph indicates approximate temper-

ature of the output bus. Green bars indicate normal temperature. Yellow bars

indicate significant heating, and heavy testing should be postponed until unit

cools. Red bars indicate overheating, and unit must cool to yellow range before

testing. Output initiation will be inhibited if second red bar lights. Excessive

temperature may indicate poor output connections.

Thermal Status - System: This indicates temperature of the output section, and

other conditions, as determined by the POD. A thermistor in the winding of the

first section of the output transformer provides actual temperature, but the

Electrical Test Instruments PI-2500-G2 & PI-5000-G2

Section II - Detailed Description

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Page II-7

POD also calculates a “virtual” temperature based on overload duty cycle limits

as indicated in the specifications. The ten bar graph LEDs correspond to tem-

peratures of approximately 80 to 280 degrees F, with about 20 degrees per bar.

Testing is allowed up to a reading of two red bars but will then be inhibited until

temperature cools to no more than four yellow bars.

Coarse Tap Switch: This rocker switch selects the coarse tap. The unit powers up

in tap 1. Pressing the switch briefly UP or DOWN will raise or lower the tap by

one. Holding it will change taps about one per second.

Coarse Tap Indicator: This seven-segment red LED indicates tap position from 1

to 9.

Vernier Indicator Bar graph: This ten-segment red LED indicates approximate

Vernier position. 0 or 1 segment lit indicates minimum position, and 9 or 10 seg-

ments lit indicates maximum position.

Vernier Adjust Switch: This rocker switch adjusts the Vernier position. Pressing

it briefly UP or DOWN causes the Vernier to move by a very small increment, for

fine control. Holding it for about a second will cause the Vernier to move very

quickly, for rapid fine adjustment.

Figure II-2 –Indicator Control Panel

Electrical Test Instruments PI-2500-G2 and PI-5000-G2

Section II –Detailed Description

==============================================================================

MEMORY AMMETER CONTROLLER

MAC-21

INSTRUCTION MANUAL

Firmware Version 3.06 and above

Electrical Test Instruments, LLC

1301 Avondale Road, Suite J

New Windsor, MD 21776

www.ETIPrecision.com

(410) 857-1880

Fax (410) 857-1387

Electrical Test Instruments MAC-21

Section III –MAC-21

==============================================================================

Page III-1

MAC-21 Specifications

INPUT POWER:

120 VAC, SINGLE PHASE

50/60 HZ, 20 VA Max

CURRENT RANGES:

0-1,000 / 5,000 / 25,000 / 100,000 Amperes

CURRENT ACCURACY:

+/- 0.5% Reading + 0.5% Range + 1 Digit (Continuous)

+/- 1.0% Reading + 1.0% Range + 1 Digit (Pulse > 0.01 sec)

TIMER RANGES:

0-9.999 / 0-99.99 / 0-999.9 / 0-9999 Seconds

0-999.9 / 0-9999 Cycles

TIMER ACCURACY:

+/- 0.5% of reading +/- 1 count

DIMENSIONS AND NET WEIGHT

Height: 7.0 in. (178 mm)

Width: 19.0 in. (483 mm)

Depth: 2.0 in. (51 mm)

Weight: 3.7 lb. (1.68 kg)

STANDARD ACCESSORIES

Remote Initiate cable 1 S-B143

Contact Leads 1 pair S-A108

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