URC B-292 User manual

AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
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Table of Contents
1.0 Introduction..........................................................................................................................1
2.0 Overview..............................................................................................................................1
3.0 Test Set Controls..................................................................................................................6
3.1 Power...................................................................................................................6
3.2 Time Display .......................................................................................................6
3.3 Timer Clear Push Button .....................................................................................6
3.4 Start Push Button and LED.................................................................................. 6
3.5 Stop Push Button ................................................................................................. 6
3.6 Test Current display.............................................................................................6
3.7 Current Preset Push Button..................................................................................7
3.8 Amp Coarse Adjust..............................................................................................7
3.9 Amp Fine Adjust..................................................................................................7
3.10 Phase Selector.................................................................................................... 7
3.11 Frequency Selector ............................................................................................7
3.12 Contrast Push Button.........................................................................................7
3.13 Ground Fault Type Selector Switch................................................................... 7
3.14 24V Fuse / Fuseholder....................................................................................... 7
4.0 Operation............................................................................................................................10
4.1 Connecting to AC-PRO or AC-PRO-II .............................................................10
4.1.1 AC-PRO-GR, Ground Return Trip Unit............................................... 10
4.2 Select the Frequency..........................................................................................10
4.3 Calculate Long Time (LT) Pick-Up Secondary Current.................................... 10
4.4 Long Time (LT) Pick-Up Test........................................................................... 11
4.5 Long Time (LT) Time Test................................................................................ 11
4.6 Calculate Short Time (ST) Pick-Up Secondary Current.................................... 12
4.7 Short Time (ST) Pick-Up Test...........................................................................12
4.8 Short Time (ST) Test.........................................................................................13
4.9 Calculate Instantaneous (I) Pick-Up Secondary Current...................................13
4.10 Instantaneous (I) Pick-Up Test ........................................................................14
4.11 Calculate Ground Fault (GF) Pick-Up Secondary Current.............................. 14
4.12 Ground Fault (GF) Pick-Up Test..................................................................... 15
4.13 Ground Fault (GF) Time Test.......................................................................... 15
4.14 AC-PRO Unbalance Testing............................................................................ 15
4.15 Calculate Neutral Overload (NOL) Pick-Up Secondary Current ....................16
4.16 Neutral Overload (NOL) Pick-Up Test............................................................16
4.17 Neutral Overload (NOL) Time Test ................................................................17
5.0 Quick-Trip®Testing........................................................................................................... 20
5.1 Calculate Quick-Trip Instantaneous (QT-I) Pick-Up Secondary Current..........20
5.2 Quick-Trip Instantaneous (QT-I) Pick-Up Test................................................. 20
5.3 Calculate Quick-Trip Ground Fault (QT-GF) Pick-Up Secondary Current ...... 21
5.4 Quick-Trip Ground Fault (QT-GF) Pick-Up Test .............................................21
6.0 Clearing Last Trip Data...................................................................................................... 22
7.0 Error/Fault Conditions .......................................................................................................22
7.1 Current Error......................................................................................................22
7.2 Thermal Limit.................................................................................................... 22
7.3 Unexpected GF Trip ..........................................................................................22
8.0 Specifications.....................................................................................................................22
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AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
www.utilityrelay.com
Figure 1: Test Set Exterior............................................................................................................ 2
Figure 2: Test Set Case Interior .................................................................................................... 3
Figure 3: Test Set Cables .............................................................................................................. 4
Figure 4: Control Panel Overview ................................................................................................5
Figure 5: AC-PRO Breaker Test Set Connections........................................................................8
Figure 6: AC-PRO-II Breaker Test Set Connections....................................................................9
Figure 7: AC-PRO Quick-Trip Testing Connections..................................................................18
Figure 8: AC-PRO-II Quick-Trip Testing Connections.............................................................. 19
Figure 9: AC-PRO Overload TCC..............................................................................................24
Figure 10: AC-PRO Unbalance TCC & Ground Fault TCC ......................................................25
Figure 11: AC-PRO Quick-Trip TCC.........................................................................................26
Figure 12: AC-PRO-II Overload TCC........................................................................................ 27
Figure 13: AC-PRO-II Ground Fault TCC .................................................................................28
Figure 14: AC-PRO-II Quick-Trip TCC.....................................................................................29
Figure 15: AC-PRO-II Neutral Overload TCC...........................................................................30
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AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
www.utilityrelay.com Page 1
1.0 Introduction
The Model B-292 Secondary Injection Test Set
is a single-phase test set specifically designed
for testing the operation of the AC-PRO and
AC-PRO-II microcontroller based trip units
manufactured by Utility Relay Company.
The earlier version test set with the “Red”
panel, can only be used to test the AC-PRO. It
cannot be used to test the AC-PRO-II.
The test set can test pick-up and time delays of
the various protection functions by driving
current into the trip unit on the secondary side
of the CT circuit.
The test set will test 60, 50, 40 or 25 Hertz
AC-PRO trip units. (The AC-PRO-II can be
set for either 50 Hertz or 60 Hertz).
The test set will test the AC-PRO or
AC-PRO-II trip system with the exception of
the CTs and associated wiring harness.
Important:
Secondary injection testing is not a
substitute for primary injection testing
that should be performed for any circuit
breaker retrofit.
2.0 Overview
The basic function of the test set is to deliver an
accurate level of AC current directly to the trip
unit under test and to verify the pick-up values
and times required for the AC-PRO or
AC-PRO-II to trip.
The technician running the test will operate the
Start (5), Stop (7), Clear (8) and Current Preset
(13) push buttons, adjust the Amp Coarse (14)
and Amp Fine (15) potentiometers (pots), and
adjust the Phase (11) and Frequency (16)
Selector switches. The two displays (6 & 12)
are used to indicate elapsed time in seconds and
test current in amps.
Note: Numbers in parentheses refer to the
labeled items in Figure 4.
Please reference the AC-PRO and
AC-PRO-II users manuals for complete
trip unit instructions.

AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
www.utilityrelay.com Page 2
Figure 1: Test Set Exterior
Copolymer Polypropylene
Compound
Chemical Resistant
Replaceable Steel-Axle Wheels
Padlock Provisions
Telescoping Handle
Large Handles
Rugged Construction for
protection during
operation, transport,
and shipping
Durable Latches

AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
www.utilityrelay.com Page 3
Figure 2: Test Set Case Interior
Interior Panel
Abbreviated
Instruction Manual
Long Time
Test Chart
Cable Storage

AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
www.utilityrelay.com Page 4
Figure 3: Test Set Cables
Power Cord
AC-PRO Test Set Harness
AC-PRO-II Test Set Harness
Labeled “For AC-PRO”
Labeled “For AC-PRO-II”
Note: different connector
AC-PRO Test Set Harness for
Breaker Test Port
Labeled “AC-PRO Test Set to
Breaker Test Port”

AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
www.utilityrelay.com Page 5
1Power Cable/Fuse Holder
Power cable connector with main fuse.
(120Vac 50/60Hz).
2Cooling Airflow Exhaust
Cooling air for the test set exits via this
filter opening (must not be blocked).
3Power ON/OFF Switch
4Start LED
Illuminates when test current
is flowing.
5Start Push Button
Starts test current flow and starts
the timer.
6Timer Display
Displays elapsed time of test current
flow in seconds.
7Stop Push Button
Stops test current flow and freezes
the timer.
8Clear Push Button
Resets the timer to zero.
9Contrast Push Button
Hold this button in until the desired
display contrast is reached.
10 Ground Fault Type Select Switch
Selects between Standard Residual GF
or Ground Return GF.
11 Phase Select Switch
Selects one of the phases (A,B,C) or
ground fault as the test current path.
12 Current Display
Displays measured true RMS current
and Current Preset value.
13 Current Preset Push Button
When held, the current display
indicates the setting of the Amp Coarse
and Fine pots but does not send current
to the trip unit.
14 Amp Coarse Pot
Used to make large adjustments
in current.
15 Amp Fine Pot
Used to make small adjustments
in current.
16 Frequency Select Switch
This switch selects the AC frequency;
25, 40, 50 or 60 Hertz for AC-PRO.
50 or 60 Hertz for AC-PRO-II.
17 Cooling Airflow Intake
Cooing air for the test set enters
via this filter opening (must not
be blocked).
18 AC-PRO or AC-PRO-II Test
Harness Connector
The trip unit connects to the test-set
with the supplied wire harness via
this connector.
19 24V Fuse / Fuseholder (fuse
is rated 1A/250V, 3AG slow
blow fuse)
Figure 4: Control Panel Overview
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1
13
14
16
18
17
8
11
9
7
15
4
3
5
12
6
10
19

AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
www.utilityrelay.com Page 6
3.0 Test Set Controls
A brief description of the operation of the
various test set controls is given below.
The numbers in parentheses refer to the labels
in Figure 4.
3.1 Power
Power to the test set is controlled with the
Power On-Off switch.
An AC cord is supplied with the test set. The
recommended AC power source is 120V AC at
either 50 or 60 Hz. The 120 VAC receptacle
also contains the 5 Amp, 250V, 5 x 20mm main
power fuse.
3.2 Time Display
The test set will measure the time elapsed while
current is being delivered to the trip unit, and
display the time on the Timer display.
The displayed time is in seconds with 1/100 of
a second resolution.
The time will stop accumulating when a
trip occurs or when the Stop (7) push button
is pushed.
The timer display is cleared when the Clear (8)
push button is pushed.
3.3 Timer Clear Push Button
The Clear (8) push button clears the
Timer display.
3.4 Start Push Button and LED
The Start push button starts the test current
flow to the trip unit and simultaneously starts
the Timer (6).
The green LED located above the Start push
button indicates test current flow.
3.5 Stop Push Button
The Stop push button stops the test current flow
and simultaneously freezes the Timer (6).
3.6 Test Current display
The Test Current display indicates the true
RMS test current in amps, going to the
AC-PRO or AC-PRO-II during a test.
To determine the equivalent CT
primary current:
1-Amp AC-PRO or AC-PRO-II…multiply
the test set current by the CT Primary rating
set in the trip unit.
For example:
If the CT primary rating is 600 and the test
current is 1.50 amps, then the equivalent
primary current is:
1.50 x 600 = 900 amps primary
0.5 Amp Example…multiply the test set
current by the CT Ratio (CT Primary
Rating ÷ CT Secondary Rating).
For example:
If the CT Primary Rating is 600, the CT
Secondary Rating is 0.5A, and the test
current is 0.75 amps, then the equivalent
primary current is:
0.75 x (600 ÷0.5) = 900 amps
Note: If CT Secondary Rating is different than 1.0 or
0.5, use the 0.5 example above and replace 0.5 with
the specific CT secondary rating.
3
6
8
5
4
7
12

AC-PRO®& AC-PRO-II®B-292 Secondary Injection Test Set Instruction Manual Rev 1.1
www.utilityrelay.com Page 7
3.7 Current Preset Push Button
While the Current Preset push button is pushed,
the test set will display the current setting (from
the Amp Coarse and Fine adjust pots) in the
Current (12) display without actually driving
any current to the trip unit.
The sum of the Amp Coarse (14) and Fine (15)
pots is displayed in the Current (12) display
and is continually updated while the Current
Preset switch is pushed.
After the current pots are adjusted to the
desired test current as seen on the display,
release the Current Preset push button.
The test set limits the current set point level to
12.00 amps.
3.8 Amp Coarse Adjust
The Amps Coarse adjustment quickly changes
the test current to the trip unit or the test
Current Preset, with clockwise rotation
increasing the value.
3.9 Amp Fine Adjust
The Amps Fine adjustment slowly changes
the test current to the trip unit or the test
Current Preset, with clockwise rotation
increasing the value.
3.10 Phase Selector
The Phase Select selector switch is used to
select which phase of the trip unit the test
current is driven into. It selects between
Phase A, Phase B, Phase C or Ground
Fault (Neutral).
3.11 Frequency Selector
The Frequency selector switch is used to select
the AC test current frequency. This is used to
select either 25, 40, 50 or 60 Hz for AC-PRO.
The selections for AC-PRO-II are 50 or 60
Hertz.
3.12 Contrast Push Button
The Contrast push button changes the contrast
of both the Timer (6) and Current (12) displays.
The push button should be pushed until the
desired contrast is seen in the displays.
3.13 Ground Fault Type Selector Switch
The GF Type Selector switch selects between
the standard "residual" ground fault trip unit
and the special "ground return" ground fault
trip unit.
For AC-PRO, the option label on the front of
the AC-PRO indicates if that trip unit is the
special factory-configured "ground return"
type, with a “GR” suffix in the trip unit part
number.
For AC-PRO-II, Ground Fault Type is a user
setting. It can be set to Residual (standard) or
Ground Return.
Push the GF Type Selector switch so the
correct type of ground fault is selected.
Note: When the GF Type Switch is set to
standard “residual” and Phase switch is set to
A, B, or C, current is injected into the phase
current input and returned through the neutral
current input (to result in zero GF current).
When the GF Type switch is set to “ground
return” and Phase Switch is set to A, B, or C,
current is injected into the Phase input only.
3.14 24V Fuse / Fuseholder
The main 24V fuse is accessible from the front
panel. The fuse is rated 1A/250V max, type
3AG slow blow fuse.
13
14
15
11
9
10
16
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