Eti Pi-800 User manual

PRIMARY INJECTION CIRCUIT BREAKER

TEST SET

INSTRUCTION MANUAL

Models

PI-800 and PI-1600

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 PI-800 and PI-1600

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

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

Proposed Enhancements I-5

Advantages Compared to Other Test Sets I-6

Trademarks I-6

MAC-21 Specifications I-7

PI-800 Specifications I-8

PI-1600 Specifications I-9

SECTION II: DETAILED DESCRIPTION

Theory of Operation

High Current Test Sets II-1

PI-800 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

Electrical Test Instruments PI-800 and PI-1600

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

Multi-pole Molded Case Breakers IV-8

Low Voltage Power Breakers IV-11

Motor Overload Relays IV-15

Ratioing Current Transformers IV-17

SECTION V: SERVICE INFORMATION AND DOCUMENTATION

Maintenance and Calibration of PI-800/1600 V-1

Maintenance and Calibration of MAC-21 V-1

Parts List (PI-800) V-4

Parts List (PI-AUX) V-5

Warranty V-6

Overall Schematics END

Electrical Test Instruments PI-800 and PI-1600

Section I - General Information and Specifications

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

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 and PI-1600

Section I - General Information and Specifications

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

Page I-1

INTRODUCTION

A primary injection test set, such as the PI-800 and PI-1600, 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

The PI-800/1600 Circuit Breaker Test System incorporates modular design and

flexibility to provide unequaled capability in a portable package. The PI-800

used alone, on 120 or 240 VAC supplies, 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 mobil-

ity. Basic operation is very simple, and the proven MAC-21 provides optimal out-

put control and measurement.

The PI-800 is a versatile and technologically advanced portable primary injec-

tion test set capable of testing circuit breakers up to 800 amperes frame size. It

incorporates a special lightweight toroidal output transformer with dual prima-

ries to facilitate its use on power sources of 120 VAC as well as 240 VAC, 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 consists of a strong aluminum 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 portable cords

with a variety of connectors for 120 VAC, 208 VAC, or 240 VAC. Individual 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 re-

cessed side handles provide ease of mobility.

The MAC-21 is supplied in a separate rugged portable case, interlocks on top of

the PI-800, 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

Electrical Test Instruments PI-800 and PI-1600

Section I - General Information and Specifications

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

Page I-2

amperes at 2.1 VAC, which can be used for CT testing, heat runs of bus connec-

tions and limited testing of air drawout breakers. They have pressed-in 3/8"-16

stainless steel threaded inserts, which eliminates the need for nuts, and the con-

figuration 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 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 removable

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, the PI-800 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 by means of a single cable, which allows it to be placed

in the interlocking ridges of the PI-Aux for a three-piece stacked unit. The out-

puts 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 continuous 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 configu-

rations.

Optional stab mounting plates may be bolted to the PI-800 and the PI-Aux as

required to provide connection to standard 3 1/2" x 5" stab adapters, with a true

continuous output current rating of 1600 amperes at 5 VAC. Strong, easily re-

placeable stainless steel bolts allow maximum 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 stab adaptors, available as an option for the test

set, are designed to be used for both vertical and horizontal stabs, and are avail-

able for ½” and ¾” stab blades.

The test set may be plugged into any 60 Hz AC voltage source of 100-140 VAC

or 200-264 VAC, and will work on 50 Hz sources of 100-120 VAC or 200-220 VAC.

Voltage selection is provided by means of a simple selector switch on the PI-

800 front panel. An internal voltage sensor prevents the main power from being

turned on if the input voltage is incorrect. An optional lightweight Voltage Con-

verter Unit (AT-10) is available to allow the test set to be used to full capacity on

208 VAC or 480 VAC.

Electrical Test Instruments PI-800 and PI-1600

Section I - General Information and Specifications

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

Page I-3

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

PI-800 or PI-Aux to provide 7ranges of output for the PI-1600 combined 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.

Electrical Test Instruments PI-800 and PI-1600

Section I - General Information and Specifications

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

Page I-4

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.

The entire test set has been designed for reliability, ruggedness, reasonable

one-person portability, and ease of use. Sophisticated electronics in the MAC-21

provide state of the art accuracy and convenience, while simple connections al-

low for easy disassembly for transportation or service. In the unlikely case of fail-

ure of the MAC-21, in an emergency, it is possible to operate the test set without

it by using a clamp-on ammeter and a simple adapter for initiation.

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 0.1 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.

PROPOSED ENHANCEMENTS

The AT-10 Autotransformer unit also allows the test set to be used on 208 VAC

or 480 VAC at full capacity, and also provides a GFCI protected 120 VAC conven-

ience outlet with 4 amperes capacity for lamps, test equipment, and small

power tools.

Electrical Test Instruments PI-800 and PI-1600

Section I - General Information and Specifications

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

Page I-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 and PI-1600 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 volt-

ages 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.

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

Electrical Test Instruments PI-800 and PI-1600

Section I - General Information and Specifications

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

Page I-6

SPECIFICATIONS

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: +/- 0.005% 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 and PI-1600

Section I - General Information and Specifications

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

Page I-7

PI800

INPUT SUPPLY:

120 or 240 VAC + 10%, -15% (Switch Selectable), SINGLE PHASE

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

3.8 KVA (Continuous) at 3.4 KVA output (90% efficiency)

PI-800 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

100%

CONTINUOUS

N/A

16 / 32

1120 A

560 A

1.4x

50%

15 Minutes

23 / 46

1600 A

800 A

25%

5 Minutes

15 Minutes

32 / 64

2400 A

1200 A

10%

2.5 Minutes

20 Minutes

48 / 96

3200 A

1600 A

75 Seconds

20 Minutes

64 / 128

4000 A

2000 A

4 Seconds

2 Minutes

80 / 160

5600 A *

2800 A *

2 Seconds

2 Minutes

112 *

8000 A *

4000 A *

10x

0.6 Second

1 Minute

160 *

12500 A **

6250 A **

15x

0.5%

0.1 Seconds

1 Minute

240 *

*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

DIMENSIONS AND NET WEIGHT (Not including MAC-21)

Height: 11.5 in. (292 mm)

Width: 21.5 in. (546 mm)

Depth: 18.5 in. (470 mm), 22.5 in (572 mm) with lids

Weight: 125 lb. (57 kg)

STANDARD ACCESSORIES

Input power plugs only 2 each

Series/Parallel and Output buswork 1 set

Contacts leads 1 pair

Technical manual 1 copy

Electrical Test Instruments PI-800 and PI-1600

Section I - General Information and Specifications

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

Page I-8

PI-1600

INPUT SUPPLY:

240 VAC + 10%, -15%, SINGLE PHASE

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

8.8 KVA (Continuous) at 8.0 KVA output (90% efficiency)

(Note: Specifications include required PI-800 unit)

PI-1600 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

100%

CONTINUOUS

N/A

2250 A

1125 A

1.4x

50%

15 Minutes

3200 A

1600 A

25%

5 Minutes

15 Minutes

4800 A

2400 A

10%

2.5 Minutes

20 Minutes

111

6400 A

3200 A

75 Seconds

20 Minutes

148

8000 A

4000 A

4 Seconds

2 Minutes

185

11200 A

5600 A

2 Seconds

2 Minutes

259

16000 A

8000 A

10x

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

Additional Equipment Required

Requires a complete PI-800 (including MAC-21) for operation

See separate data sheet for specifications

DIMENSIONS AND NET WEIGHT (for PI-Aux Booster)

Height: 11.5 in. (292 mm)

Width: 21.5 in. (546 mm)

Depth: 18.5 in. (470 mm), 22.5 in (572 mm) with lids

Weight: 110 lb. (50 kg)

STANDARD ACCESSORIES

Connection bar 2 each

800-amp output connectors 4 each

Series connection bar 1 each

Technical manual 1 copy

Stab adaptor plates 4 each

Standard universal breaker stabs (1/2” horiz and vert) 2 each

Standard universal breaker stabs (3/4” horiz and vert) 2 each

OPTIONAL ACCESSORIES

Autotransformer 208/480 VAC model AT-10 (provides use on standard 208/480VAC)

Electrical Test Instruments PI-800 and PI-1600

Section I - General Information and Specifications

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

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 Main Unit Circuitry

Main power is applied to the PI-800 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 greater

Electrical Test Instruments MAC-21

Section III –MAC-21

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

Page III-1

than about 160 VAC, this relay energizes to indicate connection to a voltage of

208 to 264 VAC. The Input Select Error indicator DS2 lights if it senses an incor-

rect connection.

The input voltage selector switch S1 sets the primary windings of transformer

T4 in parallel in the 120 V position, and in series in the 240 V position. 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 so equipped, this also powers the auxiliary GFI outlet in the MAC-21,

protected by a 4-ampere circuit breaker.

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, 120 VAC is supplied to neon lamp DS14 on the

rear panel, and 20 VAC is supplied to lamp DS2 on the front panel. 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.

Electrical Test Instruments MAC-21

Section III –MAC-21

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

Page III-2

The output of the adjustable Vernier assembly in the PI-800 is monitored di-

rectly by means of the Programmable Overload Monitor (POD). The overall sys-

tem status is displayed on LEDs DS10-DS12, and the peak output current is dis-

played 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.

The coil of interlock relay K1 is connected to overtemperature fuses in the cores

of the output transformers T4-T6, and also to thermal switches TS1-TS8

mounted on each output bus terminal. If any terminal exceeds about 150 de-

grees C, a thermal switch will open and trip the interlock, and will be displayed

on Bus Overtemperature lamp DS13.

PI-Aux Boost Unit Circuitry

The PI-Aux Boost Unit connects to the PI-800 to form the PI-1600. SCR con-

trolled voltage from the PI-800 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. The interlock circuit is connected through

transformer core overtemperature fuses S1-S4, and bus overtemperature

switches TS1-TS8. If any of these devices opens, the Bus Overtemperature lamp

DS3 lights.

MAJOR PARTS IDENTIFICATION AND OPERATION

PI-800 Front Panel

Input Jacks J3 and J4: These 50 ampere male jacks are to be connected to main

power of 120 or 240 VAC by means of female plugs.

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 (120 or 240 VAC) on which the test set

is to be used. The center OFF position disconnects the test set from the input

voltage, although 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.

Electrical Test Instruments MAC-21

Section III –MAC-21

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

Page III-3

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. 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

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 interlock

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 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 ener-

gized 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

Electrical Test Instruments MAC-21

Section III –MAC-21

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

Page III-4

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.

Electrical Test Instruments MAC-21

Section III –MAC-21

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

Page III-5

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-6

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:

+/- 0.005 sec +/- 0.005% 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

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

Page III-7

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

This manual suits for next models

Table of contents

Other ETI Test Equipment manuals

ETI

ETI PI-5000 User manual

ETI

ETI 822-950 User manual

ETI

ETI pH Pal Plus User manual

ETI

ETI IR-500 User manual

ETI

ETI PI-800-GEN2 User manual

ETI

ETI Dry-Well 3101 User manual

ETI

ETI PI-6000 User manual

ETI

ETI UAL/CL2 Operation instructions

ETI

ETI 813-513 User manual

ETI

ETI PI-2500-G2 User manual

ETI

ETI PI-4000B User manual

ETI

ETI PI-2500 User manual

Popular Test Equipment manuals by other brands

Maico

Maico WS 170 L Operating and maintenance instructions

Pentair

Pentair TRACETEK operating instructions

GW Instek

GW Instek GDS-3000 Series user manual

ISA

ISA T1000 PLUS user manual

View

View Glazier Test Tool Guide

PCE Instruments

PCE Instruments PCE-SC 42 manual

Klein Tools

Klein Tools VDV Scout Pro 3 instruction manual

Northmeter

Northmeter PowerBay-SSM user manual

Proceq

Proceq Zonotip Service manual

PIE

PIE 530 operating instructions

Ripley

Ripley Miller DLS355 user guide

pico Technology

pico Technology PicoScope 2000 Series user guide

Simpson

Simpson 42115 operating instructions

Fluke

Fluke 741B Specifications

G.R.A.S.

G.R.A.S. 43AE instruction manual

Sartorius

Sartorius Sartocheck 3 plus operating instructions

Keysight

Keysight DCA-X Series quick start guide

Sealey

Sealey VS0275 instructions

ETI PI-800 User manual

Popular Test Equipment manuals by other brands