ETI PI-800-GEN2 User manual

PRIMARY INJECTION CIRCUIT BREAKER
TEST SET
INSTRUCTION MANUAL
Models
PI-800-GEN2 and PI-1600-GEN2
Electrical Test Instruments, LLC
8430 Spires Way, Suite A
Frederick, MD 21701
www.etiprecision.com
p [phone]
f [phone]

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
I-1
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
Advantages Compared to Other Test Sets I-6
Trademarks I-6
MAC-21 Specifications I-7
PI-800 GEN2 Specifications I-8
PI-1600 Specifications I-9
SECTION II: DETAILED DESCRIPTION
Theory of Operation
High Current Test Sets II-1
PI-800 GEN2 Main Circuitry II-1
PI-AUX Boost Unit Circuitry II-3
Major Parts Identification and Operation II-3
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
Output Connection Diagram IV-2
Basic Guidelines and Suggestions IV-3
Duty Cycle Ratings IV-3
Single Pole Molded Case Breakers IV-5
Multi-pole Molded Case Breakers IV-8
Low Voltage Power Breakers IV-11
Motor Overload Relays IV-15

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
I-2
Ratioing Current Transformers IV-17
SECTION V: SERVICE INFORMATION AND DOCUMENTATION
Maintenance and Calibration of PI-800 GEN2/1600 V-1
Maintenance and Calibration of MAC-21 V-1
Parts List (PI-800 GEN2) V-4
Parts List (PI-AUX) V-5
Warranty V-6
Overall Schematics END

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
II-0
SECTION I
GENERAL INFORMATION and SPECIFICATIONS
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-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
2-1
INTRODUCTION
A primary injection test set, such as the PI-800 GEN2 and PI-1600 GEN2, 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 mech-
anisms and breaker contacts.
GENERAL DESCRIPTION
The PI-800 GEN2/1600 Circuit Breaker Test System incorporates modular de-
sign and flexibility to provide unequaled capability in a portable package. The
PI-800 GEN2 used alone, generates continuous current of 400, 800, or 1600
amps at 4.2 kVA, with peak output to over 10x. The PI-Aux boosts total power to
9.8 kVA, and allows testing of drawout breakers and MCBs to 1600 A. The units
are housed in rugged interlocking suitcase-size enclosures. Each piece weighs
no more than 125 pounds, allowing one-person hand truck mobility. Basic oper-
ation is very simple, and the proven MAC-21 provides optimal output control and
measurement.
The PI-800 GEN2 is a versatile and technologically advanced portable primary
injection test set capable of testing circuit breakers up to 800 amperes frame
size. It incorporates a special lightweight toroidal output transformer with dual
primaries, and quad secondaries to provide optimal impedance matching to a
wide range of breaker sizes. Internal fan cooling allows maximum utilization of
the output transformer and faster recovery after overload conditions.
The PI-800 GEN2 consists of a strong stainless-steel frame, housed in a rugged
plastic and aluminum enclosure with removable sealed front and back lids for
maximum protection of controls and indicators, as well as storage for test leads,
manuals, etc. All controls, indicators, and input connections are on the front
panel. The versatile 50-amp input plugs may be connected to heavy duty port-
able cords with a variety of connectors for 120 VAC, 208 VAC, or 240 VAC. Indi-
vidual leads may also be used to connect to buswork. The output connections
are on the rear, along with an auxiliary Output ON indicator, configuration
switch, and air output from the fans, which can help cool cables and breakers.
Comfortable recessed side handles provide ease of mobility.
The MAC-21 is supplied in a separate rugged portable case, interlocks on top of
the PI-800 GEN2, and connects to a cable in the rear of the test set.
The eight-silver plated output bus connectors allow configuration for continu-
ous outputs of 800 amperes at 4.2 VAC, and 400 amperes at 8.4 VAC, for testing
molded case breakers with cables. They can also be connected for 1600 am-
peres at 2.1 VAC, which can be used for CT testing, heat runs of bus connections
and limited testing of air drawout breakers. They have pressed-in 3/8"-16 stain-
less steel threaded inserts, which eliminates the need for nuts, and the

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
2-2
configuration bars are slotted for quick and easy changing for various breaker
sizes.
The PI-Aux is a booster unit which connects to the PI-800 GEN2 and MAC-21 to
create a powerful two-piece test system for medium size air drawout and
molded case breakers up to 1600 amperes frame size. It also consists of a strong
aluminum frame, housed in a rugged plastic and aluminum enclosure with re-
movable sealed front and back lids. The output connections are on the rear,
along with an auxiliary Output ON indicator, and air output from the fans, which
can help cool cables and breakers. Comfortable recessed side handles provide
ease of mobility.
For the PI-1600 GEN2, the PI-800 GEN2 is placed in interlocking ridges on top
of the PI-Aux and interconnected by means of simple control and power cables.
The MAC-21 connects to the PI-800 GEN2 by means of a single cable, which al-
lows it to be placed in the interlocking ridges of the PI-Aux for a three-piece
stacked unit. The outputs are connected by means of two slotted bus bars, and
four connection plates. A series bar is supplied for continuous current of 800
amps at 10 VAC for testing smaller breakers that require connection via cables.
Larger breakers may be tested by connecting up to six cables in parallel, for con-
tinuous current of 1600 amps at 5 VAC. It is also possible to configure the output
for 400 amps at 20 VAC for connection to small breakers with long cables. A
selector switch adjusts the internal CT output for proper readings in each of the
three configurations.
stab mounting plates may be bolted to the PI-1600 GEN2 as required to provide
connection to standard Stabs, with a true continuous output current rating of
1600 amperes at 5 VAC. Strong, easily replaceable stainless steel bolts allow max-
imum torque to be applied without concern about breakage or rotation of
studs. The edges of the stab mounting plates provide solid mechanical bracing
to the output plates of the two units, and breakers may be racked in without
worrying about bending the buswork.
Standard silver-plated copper Stabs are designed to be used both vertically and
horizontally, they are available with ½” or ¾” blades.
The test set comes with 2 input voltage options.
Option A: 120, 208-240VAC
Option B: 208, 240, 277VAC
Voltage selection is provided by means of a simple selector switch on the PI-
800 GEN2 front panel. An internal voltage sensor prevents the main power from
being turned on if the input voltage is incorrect.
The vernier uses a simple knob to adjust the output manually within the range
determined by the coarse tap. Clockwise rotation always increases output,
which reduces confusion.
A convenient rotary switch selects the coarse tap. It activates relays in either the

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
2-3
PI-800 GEN2 or PI-Aux to provide 7 ranges of output for the PI-1600 GEN2 com-
bined unit.
The indicator/control panel features:
(1) An Input Voltage indicator, which lights whenever power is connected to
the test set
(2) A green Control Power ON switch/indicator, which also turns on the main
output power
(3) An amber Output ON indicator, which lights when output is initiated.
(4) A red Interlock Indicator, which lights if control power is off, or if an inter-
lock open condition exists. It also functions as an output shut-down
switch, which turns off main power.
(5) Three System Status LEDs, which provide information on the internal
temperature of the buswork, as well as duty cycle limitations of the ver-
nier.
(6) Three Output LEDs, which show overcurrent usage of the test set, from 1x
to 10x.
(7) A Bus Overtemperature indicator on the rear, which lights if any bus con-
nection overheats.
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 a Programmable Overload Detector (POD) on the
vernier autotransformer. The POD allows full utilization of the overload capabil-
ity of the test set and eliminates costly and cumbersome fuse replacement re-
quired in other test sets. It senses actual temperature of the output bus, as well
as duty cycle overload use of the vernier, and provides visual indication by
means of green, yellow, and red LEDs. It will shut down the test set output if
extreme overloads or overtemperatures are detected and will inhibit re-initia-
tion until there has been sufficient cooling time.
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
loads and more consistent pulse currents.
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 MAC-21 is also capable of reading Peak RMS current, which can help detect
waveform distortion on fast trips, as well as Last RMS current, which is useful for
pickup tests. Either value may be displayed after the test is completed. Nor-
mally, the MAC-21 displays the true RMS value of the entire waveform, regard-
less of duration.

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
2-4
The entire test set has been designed for reliability, ruggedness, reasonable
portability, and ease of use. Sophisticated electronics in the MAC-21 provide
state of the art accuracy and convenience, while simple connections allow for
easy disassembly for transportation or service.
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.
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 0.1 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.
The memory current displayed after a test indicates the true RMS value of the
entire pulse, no matter how long or short it was. Additionally, it is possible to
read the peak RMS value, which indicates the amount of DC offset or distor-
tion, or the last displayed average RMS reading, which is useful for pickup test-
ing.

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
2-5
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 gener-
ate 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.
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 im-
proved 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 pro-
vide 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 measure-
ment 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-800 GEN2 and PI-1600
GEN2 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 without external transformers.
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.
SPECIFICATIONS

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
2-6
MAC-21 Monitor Ammeter Controller
CURRENT RANGES: 0-1000 A / 5 kA / 25 kA / 100 kA
CURRENT ACCURACY: +/- 0.5% of reading + 0.5% Full Scale (Continu-
ous)
+/- 1% of reading + 1% Full Scale (Pulse)
TIMER RANGES: 0-9999.999 Seconds / 0-9999.9 Cycles
TIMER ACCURACY: +/- 0.5% of reading +/- 1 count
DIMENSIONS & WEIGHT: Height:8.5 in. (216 mm)
Width: 19.5 in (495 mm)
Depth: 13.0 in. (330 mm),
23.0 in (584 mm) with lids
Weight: 15 lb. (6.8 kg)

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
2-7
PI800 GEN2
OPTION A INPUT SUPPLY:
120 or 240 VAC + 10%, -15% (Switch Selectable), SINGLE PHASE
60 HZ (50 Hz at 10% lower maximum line voltages)
4.2 KVA (Continuous) at 3.8 KVA output (90% efficiency)
PI-800 GEN2 OUTPUT CURRENT & OVERLOAD CAPABILITIES:
4.2V (S/P)
8.4 V
(Ser)
Ovld
Duty
Max ON Time
*
Min OFF
Time
Max Inp Curr
(@240/120)
800 A
400 A
1x
100%
CONTINUOUS
N/A
18
/
36
1120 A
560 A
1.4x
50%
15 Minutes
15 Minutes
25
/
50
1600 A
800 A
2x
25%
5 Minutes
15 Minutes
36
/
72
2400 A
1200 A
3x
10%
2.5 Minutes
20 Minutes
50
/
100
3200 A
1600 A
4x
6%
75 Seconds
20 Minutes
72
/
144
4000 A
2000 A
5x
4%
4 Seconds
2 Minutes
90
/
180
5600 A *
2800 A *
7x
2%
2 Seconds
2 Minutes
126
*
8000 A *
4000 A *
10x
1%
0.6 Second
1 Minute
180
*
*Available with 240 VAC input only; Max ON Times may be less at 120 VAC
**Maximum output current possible into short circuit with very low source impedance
OPTION B INPUT SUPPLY:
208, 240 or 277 VAC + 10%, -15% (Switch Selectable), SINGLE PHASE
60 HZ (50 Hz at 10% lower maximum line voltages)
4.2 KVA (Continuous) at 3.8 KVA output (90% efficiency)
PI-800 GEN2 OUTPUT CURRENT & OVERLOAD CAPABILITIES:
4.2V (S/P)
8.4 V
(Ser)
Ovld
Duty
Max ON Time
*
Min OFF
Time
Max Inp Curr
(@
277
/
240/208
)
800 A
400 A
1x
100%
CONTINUOUS
N/A
16 /
18 / 21
1120 A
560 A
1.4x
50%
15 Minutes
15 Minutes
22
/
25 / 29
1600 A
800 A
2x
25%
5 Minutes
15 Minutes
31
/
36 / 42
2400 A
1200 A
3x
10%
2.5 Minutes
20 Minutes
43
/
50 / 58
3200 A
1600 A
4x
6%
75 Seconds
20 Minutes
62
/
72 / 83
4000 A
2000 A
5x
4%
4 Seconds
2 Minutes
78
/
90 / 104
5600 A *
2800 A *
7x
2%
2 Seconds
2 Minutes
109
/ 126 / 146
8000 A *
4000 A *
10x
1%
0.6 Second
1 Minute
155
/ 180 / 208
**Maximum output current possible into short circuit with very low source impedance

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
2-8
PI-1600 GEN2
Option A INPUT SUPPLY:
240 VAC + 10%, -15%, SINGLE PHASE
60 HZ (50 Hz at 10% lower maximum line voltages)
9.8 KVA (Continuous) at 8.8 KVA output (90% efficiency)
(Note: Specifications include required PI-800 GEN2 unit)
PI-1600 GEN2 OUTPUT CURRENT & OVERLOAD CAPABILITIES:
5.0V (Par)
10 V (Ser)
Ovld
Duty
Max ON Time
*
Min OFF
Time
Max Inp Curr
(@240V)
1600 A
800 A
1x
100%
CONTINUOUS
N/A
37
2250 A
1125 A
1.4x
50%
15 Minutes
15 Minutes
52
3200 A
1600 A
2x
25%
5 Minutes
15 Minutes
74
4800 A
2400 A
3x
10%
2.5 Minutes
20 Minutes
111
6400 A
3200 A
4x
6%
75 Seconds
20 Minutes
148
8000 A
4000 A
5x
4%
4 Seconds
2 Minutes
185
11200 A
5600 A
7x
2%
2 Seconds
2 Minutes
259
16000 A
8000 A
10x
1%
0.6 Second
1 Minute
370
25000 A **
12500 A **
15x
0.5%
0.1 Seconds
1 Minute
555 **
**Maximum output current possible into short circuit with very low source impedance
Option B INPUT SUPPLY:
208, 240 or 277VAC + 10%, -15%, SINGLE PHASE
60 HZ (50 Hz at 10% lower maximum line voltages)
9.8 KVA (Continuous) at 8.8 KVA output (90% efficiency)
(Note: Specifications include required PI-800 GEN2 unit)
PI-1600 GEN2 OUTPUT CURRENT & OVERLOAD CAPABILITIES:
5.0V (Par)
10 V (Ser)
Ovld
Duty
Max ON Time
*
Min OFF
Time
Max Inp Curr
(@
208V/
240V
/277V
)
1600 A
800 A
1x
100%
CONTINUOUS
N/A
43 / 38 / 32
2250 A
1125 A
1.4x
50%
15 Minutes
15 Minutes
61 / 53 / 45
3200 A
1600 A
2x
25%
5 Minutes
15 Minutes
86 / 75 / 65
4800 A
2400 A
3x
10%
2.5 Minutes
20 Minutes
129 / 112 / 97
6400 A
3200 A
4x
6%
75 Seconds
20 Minutes
173 / 150 / 129
8000 A
4000 A
5x
4%
4 Seconds
2 Minutes
216 / 187 / 161
11200 A
5600 A
7x
2%
2 Seconds
2 Minutes
303 / 262 / 226
16000 A
8000 A
10x
1%
0.6 Second
1 Minute
433 / 375 / 323
25000 A **
12500 A **
15x
0.5%
0.1 Seconds
1 Minute
555 **
**Maximum output current possible into short circuit with very low source impedance
Additional Equipment Required
Requires a complete PI-800 GEN2 (including MAC-21) for operation
See separate data sheet for specifications

Electrical Test Instruments PI-800 and PI-1600
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-800 GEN2 Main Unit Circuitry
Main power is applied to the PI-800 GEN2 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 60 ampere input fuses F1 and
F2. After that, the control section is protected by smaller 2 ampere fuses F3 and
F4, and the power section is isolated by means of a high current contactor K1.
The input is connected, through voltage selector switch S1, to a wide range
switching power supply to provide 12 VDC to the control circuitry and fans. Input
voltage is sensed by voltage relay K8, and when the primary voltage is Correct
this relay energizes. The Input Select Error indicator DS2 lights if it senses an

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
III-1
incorrect connection.
The input voltage selector switch S1 sets the primary windings of transformer.
When the control power switch S3 on the front panel is pressed, and all voltage
interlocks are OK, relay K4 is energized, which provides 120 VAC control power
to the entire test set.
If all power interlocks are OK, a second set of contacts on S3 activate the main
contactor K1. This provides high current power to the test set output circuitry
through the SCR controller.
The dual vernier autotransformer T1 and T2, and output transformers T5 and T6,
are connected to input voltage selector switch S1. This allows for connection in
series for 240 VAC, and parallel for 120 VAC. Verniers T1 and T2 are connected
through paralleling transformer T3 and the POD, directly to the primaries of out-
put transformer T4, so that clockwise rotation produces an output voltage of
about 0-0.84 VAC for each secondary turn. Relays K2 and K3, energized by tap
switch S2, connect the primary windings of T5 and T6 to main power, for fixed
outputs of 0, 0.78, or 1.56 VAC for taps 1, 2 and 3, for a maximum of 2.40 VAC per
turn. The outputs may be connected in series for 4.8 and 9.6 VAC.
Output current is detected by means of air core CTs L1-L4 on each main bus.
Switch S7 on the calibration board is set to correspond to the output configura-
tion of 400, 800, or 1600 amps. Calibration of each mode is accomplished with
potentiometers on the calibration board 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 output of the SCR is distributed to T1 and T2, and output transformers T5
and T6 through the tap relays. This voltage is also supplied on connector J6 for
the PI-Aux Boost Unit.
The Vernier autotransformer is adjusted manually by means of a knob. Increas-
ing output is clockwise for all taps.
When T1 and T2 are energized, neon lamp DS14 on the rear panel and lamp DS2
on the front panel are Lit. This provides a visual indication from the front and
rear when output is on.
Thermistor TH1 senses the temperature of the output bus. This normally has a
resistance of 10 K ohms at room temperature, and lower values as the temper-
ature increases. This value is read by the POD and used to compute and display
the virtual temperature of the test set on LEDs DS10-DS12.
The output of the adjustable Vernier assembly in the PI-800 GEN2 is monitored
directly by means of the Programmable Overload Monitor (POD). The overall
system status is displayed on LEDs DS10-DS12, and the peak output current is
displayed on LEDs DS7-DS9. An interlock relay shuts down the output of the
test set if abnormal conditions are detected. More details are in the appendix.
The POD interlock may be defeated by holding switch S5 on.

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
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III-2
PI-Aux Boost Unit Circuitry
The PI-Aux Boost Unit connects to the PI-800 GEN2 to form the PI-1600 GEN2.
SCR controlled voltage from the PI-800 GEN2 is distributed to the four tap relays
K1-K4, which provide power to the primaries of T1-T4 when energized. Output
ON indicators DS1 and DS2 light when voltage is applied to the main input. Fans
B1 and B2 are powered from the 12VDC supply.
MAJOR PARTS IDENTIFICATION AND OPERATION
PI-800 GEN2 Front Panel
Input Jacks J3 and J4: These 50 ampere male jacks are to be connected to main
power.
Ground Terminal J2: This ¼” steel lug with wingnut is used to connect the frame
of the test set to a solid earth ground.
Input Voltage Lamp DS1: This amber neon lamp glows whenever voltage above
about 90 volts is present on the input jacks.
Input Selector Switch S1: This three-position switch is used to select the proper
input configuration for the mains voltage on which the test set is to be used.
The center OFF position disconnects the test set from the input voltage, alt-
hough the Input Voltage lamp still indicates the presence of voltage.
Control Power ON switch S3: This green switch turns on 120 VAC control power
to the test set, and its green lamp lights when ON. It also resets the output in-
terlock and energizes the interlock contactor K1 if all interlocks are clear.
Interlock/Stop switch S4: This red switch turns off the main output of the test
set by deenergizing contactor K1. Its lamp lights when there is an interlock con-
dition.
Output ON lamp DS5: This yellow lamp turns on when test set output is ON.
Interlock Bypass Switch S5: This yellow switch, when held ON, bypasses the POD
interlock. This should be used only if there is a defect in the POD circuitry. Dam-
age to the test set may result if abused.
Tap Selector Switch S2: This seven-position switch is used to select the desired
coarse output tap. Positions 4-7 are used only for the PI-1600 GEN2. Never
change output tap while output is on. The output is deenergized between taps,
but damage to the test set may result if output is not turned off before changing
taps.
System Status LEDs DS10-DS12: These multicolor LEDs indicate approximate in-
ternal temperature of the test set. The Green LED indicates normal tempera-
ture. A Green + Yellow LED indicates slight heating, and a Yellow LED indicates

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
III-3
moderate heating. A Yellow+ Red LED indicates significant heating, and heavy
testing should be postponed until unit cools to Yellow. A Red LED indicates se-
vere overheating, and the unit will soon trip the interlock. Allow the test set to
cool to Red + Yellow range before testing. Temperature indication is a combina-
tion of actual bus temperature and “virtual temperature” as determined by duty
cycle usage. The virtual temperature will be reset if test set power is turned off,
but actual temperature will be indicated.
Output LEDs DS7-DS9: These multicolor LEDs indicate approximate overload
current of the test set. The Green LED indicates current up to about 1x, where
the test set may be used continuously. Green + Yellow indicates about 2x, and
Yellow indicates 3x. The test set may be used for up to about 5 minutes ON time
at 3x, followed by at least 5 minutes cooling. Yellow + Red is about 4-7x, and Red
is about 8-10x. These overloads may be sustained for only about 5 seconds or
less. Red + Yellow + Green indicates a severe overload which will trip the inter-
lock within 0.5 seconds. The output LEDs hold their reading for several seconds.
If interlock is tripped, the Red LED will flash until clear.
Vernier Adjust Knob: This knob adjusts the output Vernier. Clockwise rotation
increases output in all tap positions.
Aux Unit Power Jack J6: This female three position jack is used to supply main
power to the PI-AUX Booster Unit for the PI-1600 GEN2 configuration. Voltage
may be present on this connector anytime the interlock contactor is closed. A
safety cover or other means should be used to prevent inadvertent contact with
energized conductors when the PI-AUX unit is not connected.
Aux Unit Control Jack J1: This female 14 position jack is used to supply 120 VAC
control signals and 12 VDC power to the PI-AUX Booster Unit for the PI-1600
GEN2 configuration. Voltage may be present on this connector anytime the in-
terlock contactor is closed. A safety cover or other means should be used to pre-
vent inadvertent contact with energized conductors when the PI-AUX unit is
not connected.

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
III-4
MEMORY AMMETER CONTROLLER
MAC-21
INSTRUCTION MANUAL
Firmware Version 3.06 and above
Electrical Test Instruments, LLC
8430 Spires Way, Suite A
Frederick, MD 21701
www.etiprecision.com
p [phone]
f [phone]

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
III-5
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 PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
III-6
MAJOR PARTS IDENTIFICATION AND OPERATION
MAC-21 Control Panel
TIME DISPLAY: This 4-digit LED display normally indicates the elapsed time of a cur-
rent 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 dis-
play 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 cur-
rent 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 im-
portant 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 sys-
tem. The LED on the key indicates that the system is reset and armed. RESET also
takes the unit out of PRESET ADJUST mode.
MAINTAIN key: This key toggle the MAINTAIN mode for initiation; its LED indicates

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2
Copyright© 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved
III-7
that this mode is enabled. When in MAINTAIN mode, the INITIATE key need only be
pressed briefly to turn output on. MAINTAIN must be set in order to read pulse cur-
rent when output is initiated by means other than the MAC-21.
For test sets with motorized vernier, the MAINTAIN key may be pressed while output
is ON to provide automatic current hold. The LED in the MAINTAIN key will blink while
this mode is set, and the vernier motor will be activated whenever the current varies
more than 5 amperes from the value displayed when the key was pressed. The key
may be pressed again to return to normal mode. STOP or RESET will also discontinue
current hold.
N.O. key: This key is used to set the Normally Open contacts mode. In this mode, lack
of continuity on the CONTACTS binding posts indicates that the protective device un-
der test is in its normal (non-tripped) mode, and ready to accept current. In N.O.
mode, after the INITIATE key is pressed, the timer starts when current (about 3% of
range) is detected. The timer stops when the STOP key is pressed, or continuity is
sensed at the CONTACTS binding posts. Timing accuracy in this mode is typically +/-
0.01 seconds.
N.C. key: This key is used to set the Normally Closed contacts mode. In this mode,
continuity on the CONTACTS binding posts indicates that the protective device under
test is in its normal (non-tripped) mode, and ready to accept current. This mode may
be used for testing multi-pole breakers by connecting the CONTACTS binding posts
to an unused pole. In N.C. mode, the timer starts as soon as current (about 3% of
range) is detected after the INITIATE key is pressed and stops when the STOP key is
pressed or a break in continuity is sensed at the CONTACTS binding posts. Timing ac-
curacy in this mode is typically +/- 0.01 seconds.
C.L. key combination: When the N.O. and N.C. keys are pressed simultaneously, both
LEDs light, indicating C.L. mode (Current Latch). This is the normal power-up default
mode for the test set, and is recommended for all tests, unless there is a good reason
for using contacts to sense trip. In this mode, current is continuously sampled, and
when it exceeds approximately 10% of the current range value, the timer starts, and
calculation of pulse current begins. When current stops (or drops below a dynamically
determined threshold value), the timer stops running, and the final value for pulse
current is calculated and displayed. If the output was initiated by the MAC-21, it is
turned OFF. NOTE: in C.L. mode only, the contacts jacks may be used for remote initi-
ation (see below).
PRESET key: This key toggle the PRESET ADJUST mode, indicated by illumination of
its LED. When PRESET ADJUST is active, the adjacent SECONDS and CYCLES keys re-
spectively lower and raise the preset time in seconds or cycles, depending on the
time base that was selected. Both keys may be pressed simultaneously to reset the
time limit to zero, which disables the time limit function. When not in PRESET mode,
the LED will flash if the displayed time exceeds the preset limit.
SECONDS key: This key normally selects the SECONDS time base. If the PRESET
mode is selected, this key is used to LOWER the preset time limit by decrements of
1.000 second (5.000 seconds above 10.00) with the SECONDS time base, or 1.0 cycles
with the CYCLES time base. If it is held, the reading will decrease at a rate of about 5
intervals per second. If a preset time limit was set in SECONDS mode, the output will