Eti Pi-6000 User manual

PRIMARY INJECTION CIRCUIT BREAKER

TEST SET

INSTRUCTION MANUAL

Model

PI-6000

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-6000

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TABLE OF CONTENTS

SECTION I: GENERAL INFORMATION and SPECIFICATIONS

WARNING II-1

Introduction II-2

General Description II-2

Monitor and Controller MAC-21 II-5

Proposed Enhancements II-5

Advantages Compared to Other Test Sets II-6

Trademarks II-6

PI6000 Specifications II-7

SECTION II: DETAILED DESCRIPTION

Theory of Operation

High Current Test Sets II-9

PI-6000 Main Circuitry II-9

PI-6000 Indicator Control Panel Circuitry II-12

Indicator Control Panel II-13

Figure II-2: Retrofit Indicator Panel II-14

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-4

Multi-pole Molded Case Breakers IV-7

Low Voltage Power Breakers IV-10

Motor Overload Relays IV-14

Ratioing Current Transformers IV-16

Electrical Test Instruments PI-6000

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SECTION V: SERVICE INFORMATION AND DOCUMENTATION

Maintenance and Calibration of PI-6000 V-1

Maintenance and Calibration of MAC-21 V-1

Parts List (PI-6000) V-4

Parts List (Indicator Control Panel) V-5

Parts List (MAC-21) V-6

Overall Schematic (PI-6000) V-7

Overall Schematic (Indicator Control Panel) V-8

Warranty END

Additional Schematics END

Electrical Test Instruments PI-6000

Section II –Detailed Description

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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-6000

Section II - Detailed Description

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Page II-1

INTRODUCTION

A primary injection test set such as the PI-6000 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 simulate 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

The PI-6000 is a versatile and technologically advanced primary injection test

set capable of testing circuit breakers up to 6000 amperes frame size. It

incorporates 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 enclosure with removable sides and top for easy

access to internal components. The sides are clear of protruding components,

and full-width handles with provisions for lifting hooks are on both ends.

Locking swivel castors on all four corners provide ease of mobility.

The indicator control panel and MAC-21 are mounted in a compact hood with a

hinged lid on the top, which provides maximum protection during

transportation and a large flat area on the top surface for convenient placement

of manuals, breaker curve books, and auxiliary instruments. A hinged access

panel in the back of the hood provides a storage area for manuals, contact leads,

fuses, and other small items. The auxiliary 120 VAC GFI protected outlet is

conveniently located on the side of the hood and protected by an 8-ampere

circuit breaker.

The output stab plates accommodate standard breaker stab adaptors. 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.

An optional series adaptor assembly allows the output to be configured for

continuous current of 2000 amps at 22 VAC for testing breakers that require

connection via cables. An automatic sensor 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

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Section II - Detailed Description

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Page II-2

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

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

internal voltage sensor automatically configures the AC control power for

nominal 240 or 480 VAC, and monitors input voltage for compliance to

specifications. The main output section may be configured by means of a

simple rotary switch on the power input panel, and an interlock allows the

power section to be energized only when properly configured for the applied

voltage.

The rheostat 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 rheostat moves

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

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

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

graph. For the PI-6000, the rheostat is always turned clockwise to increase

output.

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 one per second. Tap change is

not allowed when output is on.

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

monitored 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. Additional

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 rheostat

autotransformer, and thermal sensors in each winding and on the SCR. 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. This

provides precise initial phase angle control to reduce DC offset for inductive

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Section II - Detailed Description

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Page II-3

loads and more consistent pulse currents. The phase angle is internally

adjustable.

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

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

features such as preset ON times for convenient jogging of output current

without overheating 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

removable, allowing easy access to all internal components. A horizontal relay

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

service and maintenance. Two large front-mounted fans provide maximum

airflow to the transformer and output bus, and rear exhaust directs air flow away

from the operator. The cabinet is designed with no protruding components on

the sides, so it can be navigated through narrow doorways without problems.

The input jacks and voltage switch are protected by the heavy-duty full width

handles on both ends.

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Section II - Detailed Description

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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

output 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

seconds 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

convenient "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 rheostat 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 metering and control package are designed to be removed and replaced

very easily, so that it may be transported separately.

ADVANTAGES COMPARED TO OTHER TEST SETS

Several changes have been made in the design of high current test sets since

early models such as the EIL BTS-50, many of which are important for safety and

convenience of operation.

The oldest test sets, made by companies such as Multi-Amp and EIL, used large

variable autotransformers and high current step-down transformers to

generate high current output. Tapped autotransformers provided coarse steps

for several ranges of output current, as well as selectable input voltage. These

old test sets used large, heavy iron-core CTs to measure output current with iron

vane analog meters, often with pointer preset mechanisms to read current

pulses. Times were displayed on electromechanical timers, suitable only for long

time measurement.

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Section II - Detailed Description

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Page II-5

Later test sets were improved by the use of air core current sensors, and various

electronic instruments to measure current and time. These devices include the

Duffers current meter, which was essentially peak responding, and the

improved Accu-Amp, which used analog true-RMS circuitry and sample/hold

technology. Similar circuitry was incorporated in the Multi-Amp Mem-Amp.

A major change in transformer design, incorporating multiple primary cores

and dual secondary busses, provided greater efficiency and lower overall weight

and size, but required a single input voltage.

The PLC-2000 used in the EIL PS-250 and PS-600 used a microprocessor to

provide some advanced functions such as auto jog and current hold, as well as

data collection and printout, but it was hard to use. Moreover, its current

measurement circuitry was essentially analog, and did not provide accurate

true RMS readings.

The Phenix Technologies’ HC-30 and HC-100 used a PC compatible computer

and real time data analysis software to provide some improvement, but it was

also hard to use and suffered from reliability problems due to its complexity.

The MAC-21 Monitor Ammeter Controller used in the PI-6000 has been used

with great success in many retrofits of older test sets. It has been refined to be

highly accurate, reliable, and easy to use. The overall design of the test set

incorporates advanced features which allow use on several input voltages and

allows for very fast adjustment of output current. Other important advantages

are simple current hold operation, and multi-mode memory current display.

The PI-6000 has been improved with a high efficiency C-core transformer that

produces much higher output current at lower input current, due to low

impedance.

TRADEMARKS

1. "Duffers" refers to a device manufactured by Duffers Corporation

2. "Accu-Amp" is a trademark for a device originally made by EIL Instruments,

Inc.

3. "SmartCore" is a trademark of ZWorld Engineering, Davis, CA.

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Section II - Detailed Description

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Page II-6

PI-6000 SPECIFICATIONS

INPUT SUPPLY:

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

SINGLE PHASE

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

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

OUTPUT CURRENT & OVERLOAD CAPABILITIES:

11.5V (Par)

23 V (Ser)

Ovld

Duty

Max ON Time

Min OFF

Time

Max Inp Curr

(@480/240)

6000 A

3000 A

100%

CONTINUOUS

N/A

121 / 242

8400 A

4200 A

1.4x

50%

15 Minutes

175 / 350

12000 A

6000 A

25%

5 Minutes

15 Minutes

260 / 520

18000 A

9000 A

10%

1.5 Minutes

15 Minutes

415 / 830

24000 A

12000 A

45 Seconds

15 Minutes

582 / 1164

30000 A

15000 A

4 Seconds

2 Minutes

776 / 1552

36000 A *

18000 A *

2 Seconds

2 Minutes

1208 / ***

60000 A *

30000 A

10x

1 Second

2 Minutes

1982 / ***

*Available with 480 VAC input only; **** Not available 240Volt input:

Max ON Times may be less at 208 or 240 VAC

DIMENSIONS AND NET WEIGHT (Est.)

Height: 45 in. (1140 mm) (includes castors and hood)

Width: 48.0 in. (1219 mm)

Depth: 27.0 in. (686 mm)

Weight: 850 lb. (386 kg)

STANDARD ACCESSORIES

Stabs, BS-50HV (½” bus, horizontal or vertical) 2 each

Stabs, BS-75HV (¾” bus, horizontal or vertical) 2 each

Input power plugs only 2 each

Contacts leads 1 pair

Technical manual 1 copy

OPTIONAL ACCESSORIES

Series bar PN: M-I213

Adjustable Stab System, custom PN: OP-114

MAC Report Generator Software PN: OP-112

Electrical Test Instruments PI-6000

Section II - Detailed Description

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Page II-7

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

voltage or

(b) A multi-section output transformer

2. A continuously variable rheostat 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

output transformer.

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

current secondary.

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

devices, 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 rheostat adjustment. This voltage is stepped down by the output

transformer to provide the desired current into the load impedance.

PI-6000 Main Unit Circuitry

Main power is applied to the PI-6000 by means of standard high current plug

and socket connectors, which are supplied for the customer to connect to the

power source with appropriate flexible leads. A ground terminal with wing nut

and washers is provided for a solid ground connection.

Primary protection is provided by high capacity 200 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 T3, 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

Electrical Test Instruments PI-6000

Section II - Detailed Description

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Page II-8

control panel to provide 12 VDC. Transformer T6, protected by fuse F5, steps it

down by a factor of ¼, and this voltage is sensed by a voltage relay circuit. When

the primary voltage is between about 200 and 270 VAC, this circuit allows

operation in 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.

When the input voltage selector switch S11 is the 208/240 V position, relay K9 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

input 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

voltage 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, relay K2 on the voltage sensor 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 K10 is energized, which provides 120 VAC control

power to the entire test set, including the fans and the auxiliary GFI outlet,

protected by 8 ampere circuit breaker CB1.

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

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

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

The rheostat autotransformer T1 and output transformer T2 are connected to

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

and parallel for 208/240 VAC. Rheostat 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 K1, K2, and K3 connect the second primary windings for fixed

outputs of 0, 1.25, or 2.50 VAC for taps 1, 2 and 3. For subsequent taps, the large

sections T2C, T2D, and T2E are added to the circuit, while the second section

alternates between 1.25 and 2.5 VAC, for a series of nine (9) overlapping output

ranges up to 11.5 VAC.

Electrical Test Instruments PI-6000

Section II - Detailed Description

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Page II-9

Output current is detected by means of an air core CT around both main busses.

When the series bar is attached to the output, a switch is actuated, which

divides the signal by a factor of 2. Calibration of series and parallel modes is

accomplished with potentiometers on the S/P calibration/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

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

The rheostat autotransformer may be adjusted manually by means of a

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

all taps.

When T1 is energized, 120 VAC is applied to the primary of T5. This provides a

voltage of about 12 VAC which is used for output ON detection in the indicator

control panel.

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

temperature of the first primary of T2. These normally have a resistance of 10 K

ohms at room temperature, and lower values as the temperature increases.

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

K1, K2, and K3 are equipped with an electrical interlocks to avoid damage if all

three are simultaneously energized. Catastrophic protection is provided by

fuses F7 through F16.

The adjustable rheostat assembly in the PI-6000 consists of a stack of four 120

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

T2A. Minor voltage imbalance up to about 2 VAC is corrected by means of

paralleling transformer T7, and actual current in each primary circuit is

monitored by means of 50:5 current transformers T10 and T11. 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 T10 and T11 are monitored by the Programmable

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

primary winding of T2A. 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.

The voltage on the coil of interlock relays K13 and K14 is monitored by interlock

detector relay K7. If the voltage drops to a point where the relays would drop

out, this module turns off the signal to the SCR trigger board, so as to turn off

main output current before the interlock relays actually open.

The PI-6000 features a very efficient low impedance output transformer with

enhanced reliability and cooler operation due to output plates brazed directly

to the secondary bus conductors. The high strength and corrosion resistant

Electrical Test Instruments PI-6000

Section II - Detailed Description

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Page II-10

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 replaced. The bolt retainers for the

upper bolts in the lower plates are also the air core CTs.

Electrical Test Instruments PI-6000

Section II - Detailed Description

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Page II-11

PI-6000 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

circuitry for rheostat 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.

Otherwise, 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 VAC 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

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

meter.

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

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

adjusted setpoint.

The rheostat 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 binding posts BP1 and BP2.

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.

Electrical Test Instruments PI-6000

Section II - Detailed Description

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Page II-12

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 binding posts: These binding posts are connected to output

stabs 1 and 4 and may be used to monitor voltage on the breaker with a DMM.

Thermal Status - Bus: This multicolor bar graph indicates approximate

temperature 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

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

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

temperatures 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.

Rheostat Indicator Bar Graph: This ten-segment red LED indicates approximate

rheostat position. 0 or 1 segment lit indicates minimum position, and 9 or 10

segments lit indicates maximum position.

Rheostat Adjust Switch: This rocker switch adjusts the rheostat position.

Pressing it briefly UP or DOWN causes the rheostat to move by a very small

increment, for fine control. Holding it for about a second will cause the rheostat

to move very quickly, for rapid rough adjustment.

Electrical Test Instruments PI-6000

Section II - Detailed Description

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Page II-13

Figure II-2 –Indicator Control Panel

Thermal

Status

Bus

Vernier

Down

Stab

Voltage

READY

INTERLOCK

OFF

Output

MainControl

Coarse Tap Vernier

Power

Input Voltage

50%

100%

Electrical Test Instruments, Inc.

Indicator Control Panel

Power

Input

Selector

Error

Electrical Test Instruments PI-6000

Section II –Detailed Description

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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

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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

Electrical Test Instruments MAC-21

Section III –MAC-21

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Page III-2

MAJOR PARTS IDENTIFICATION AND OPERATION

MAC-21 Control Panel

TIME DISPLAY: This 4-digit LED display normally indicates the elapsed time of a

current pulse. In SECONDS mode, it displays time up to 9.999 seconds, then auto

ranges to 99.99 seconds, 999.9 seconds, and 9999 seconds. In CYCLES mode, it reads

time (based on 60 Hz), up to 999.9 cycles, then auto ranges to 9999 cycles. If time

exceeds maximum display capacity (10,000 seconds or 10,000 cycles), the display will

read "OVER". In PRESET mode, the display indicates the maximum time of initiation

(ON time), in either cycles or seconds. A reading of zero disables the PRESET function

and allows any time.

CURRENT DISPLAY: This 4-digit LED display indicates the output current. In

CONTINUOUS mode, as well as in MEMORY mode before and during a test, the

display indicates true-RMS output current in real time. After completion of a test, in

MEMORY mode, the display shows the true-RMS value as computed over the entire

length of the pulse. This mode is indicated by a flashing LED on the MEMORY key. If a

reading exceeds the maximum value for the selected range, the display will read

"OVER".

This display is also used When the time base is in SECONDS mode, press the

STOP key to display the last average RMS value displayed in CONTINUOUS mode. This

is useful for pickup tests. It may not be accurate for times less than 1 second.

INITIATE key: This key is used to turn ON the output of the test set. The LED in the key

indicates that the MAC-21 is attempting to turn the output ON, but other conditions

(such as interlocks) could keep the output from actually turning on. In MOMENTARY

mode, the key must be held to keep output current on. In MAINTAIN mode, once

current is detected, the output will stay on until the breaker trips, or the STOP or

RESET button are pressed. The MAC-21 must be RESET in order to initiate output, and

in N.C. or N.O. contact modes, the contact status (continuity) must indicate that the

breaker is closed. If the output on time exceeded the PRESET time, as indicated by

flashing of the PRESET key LED, the INITIATE key will automatically reset the MAC-21

and turn the output on.

STOP key: This key is used to turn the output of the test set OFF. Its LED indicates

that output is not being turned on by the MAC-21, but other conditions could cause

output voltage to be ON. Use of this key is usually necessary only when in MAINTAIN

mode, and it is necessary to abort the test before the breaker trips. NOTE: It is

important to realize that the interlock system of the circuit breaker test set may also

turn the output off, but it will turn back ON when the interlock condition is cleared (in

N.O. and N.C. modes only).

RESET key: This key reset the displays on the MAC-21, and arms the pulse reading

system. The LED on the key indicates that the system is reset and armed. RESET also

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