URC I-AC-PRO-TS User manual

test set
URC
Utility Relay Company
i-ac-pro-ts ac-pro trip unit
instruction manual
Secondary Injection Test Set
for AC-PRO Trip Units
Chagrin Falls, OH 44023
Phone: [phone]
www.utilityrelay.com

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Table of Contents
Page
Section 1.0 Introduction...............................................................................................2
2.0 Overview ....................................................................................................2
3.0 B-291 Test Set Controls............................................................................2
3.1 Power..........................................................................................2
3.2 Time Display .............................................................................2
3.3 Timer Clear Push Button..........................................................2
3.4 Start Push Button and LED......................................................2
3.5 Stop Push Button.......................................................................3
3.6 Test Current Display.................................................................3
3.7 Current Preset Push Button.....................................................3
3.8 Amp Coarse Adjust...................................................................3
3.9 Amp Fine Adjust........................................................................3
3.10 Phase Selector ............................................................................3
3.11 Frequency Selector....................................................................4
3.12 Contrast Push Button................................................................4
4.0 Operation...................................................................................................4
4.1 Connecting to the AC-PRO .....................................................4
4.2 Select Frequency........................................................................4
4.3 Calculate Long Time (LT) Pick-Up Secondary Current.......5
4.4 Long Time (LT) Pick-Up Test..................................................5
4.5 Long Time (LT) Time Test.......................................................6
4.6 Calculate Short Time (ST) Pick-Up Secondary Current.......6
4.7 Short Time (ST) Pickup Test....................................................7
4.8 Short Time Test .........................................................................7
4.9 Calculate Instantaneous (I) Pick-Up Secondary Current......8
4.10 Instantaneous (I) Pickup Test...................................................8
4.11 Calculate Ground Fault (GF) Pick-Up Secondary Current..9
4.12 Ground Fault (GF) Pick-up Test..............................................9
4.13 Ground Fault Time Test ...........................................................10
4.14 Unbalance...................................................................................10
5.0 Error / Fault Conditions...........................................................................10
5.1 Current Error............................................................................10
5.2 Thermal Limit............................................................................10
Figure 1 Control Panel Overview........................................................................11
Figure 2 AC-PRO/Breaker Test Set Connections..............................................12
Ground Fault/Unbalance TCC .............................................................................13
Overload TCC .....................................................................................................14

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1.0 Introduction
The Model B-291 Secondary Injection Test Set
is a single-phase test set specifically designed
for testing the operation of the Utility Relay
Co., AC-PRO microcontroller based trip units.
The test set will test either the standard 1-Amp
or the special 1/2-Amp AC-PRO.
The test set can test pick-up and time delays of
the various protection functions by driving
current into the AC-PRO on the secondary side
of the current transformer circuit.
The test set will test the AC-PRO trip system
with the exception of the current transformers
and associated wiring harness. 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
AC-PRO trip unit under test and to measure the
pick-up values and times required for the AC-
PRO to trip. The technician running the test
will operate the Start, Stop, Clear and Current
Preset momentary push buttons, adjust the Amp
Coarse and Amp Fine potentiometers (pots),
and adjust the Phase and Frequency Selector
switches. The two displays are used to indicate
elapsed time in seconds and test current in
amps.
Reference the AC-PRO users manual for the
AC-PRO operating instructions.
3.0 B-291 Test Set Controls
3.1 Power
Power to the test set is controlled with the
manual “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, 5X20mm main power fuse.
3.2 Time Display
The B-291 test set will measure the time
elapsed while current is being delivered to the
AC-PRO, and display the time on the “Time
(seconds)” LCD display. The time will stop
accumulating when the AC-PRO trips or when
the Stop push button is pushed. The LCD time
display will display seconds with 1/100 of a
second resolution. The timer display is cleared
when the Clear push button is pushed.
3.3 Timer Clear Push Button
The “Clear” push button clears the time
display.
3.4 Start Push Button and LED
The “Start” push button starts the test current
flow to the AC-PRO and simultaneously starts
the timer. The green LED located above the
Start push button indicates test current flow.

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3.5 Stop Push Button
The “Stop” push button stops the test current
flow and simultaneously freezes the timer.
3.6 Test Current display
The “Test Current (amps)” LCD display
indicates the true RMS test current in amps,
going to the AC-PRO during a test.
To determine the equivalent CT primary
current:
1-Amp AC-PRO…multiply the test set current
by the CT rating set in the trip unit.
Example: If the CT rating is 600 and the
test current is 1.50 amps, then the
equivalent primary current is
1.50 X 600 = 900 amps primary
1/2-Amp AC-PRO…multiply the test set
current by 2 and then multiply by the CT
rating set in the trip unit.
Example: If the CT rating is 600 and the
test current is 0.75 amps, then the
equivalent primary current is
0.75 X 2 X 600 = 900 amps primary
3.7 Current Preset Push Button
While the “Current Preset” push button is
pushed, the test set will display the current
setting (from Amp Coarse and Fine adjust pots)
in the Test Current LCD display without
actually driving any current to the AC-PRO.
The sum of the Amp Coarse and Fine pots is
displayed in the current LCD 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 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 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 AC-PRO the test
current is driven into. It selects between
Phase A, Phase B, Phase C or Ground Fault
(Neutral).

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3.11 Frequency Selector
The “Frequency (Hertz)”selector switch is used
to select the AC test current frequency. This is
used to select 25, 40, 50 or 60 Hz.
3.12 Contrast Push Button
The “contrast” push button changes the contrast
of both the timer and current LCD displays.
The switch should be pushed until the desired
contrast is seen in the displays
4.0 Operation
4.1 Connecting to the AC-PRO
The Test Harness makes the connections from
the test set to the AC-PRO (including power for
the AC-PRO). It also provides a connector for
connection to the breaker harness to allow the
AC-PRO to fire the breaker actuator and trip
the breaker. See Figure 2.
While the power switch is in the off position
(red led in switch off):
1) Connect the round connector on the
Test Harness to the connector on the
test set marked “AC-PRO”. Twist the
outer ring clockwise to fully seat and
lock the connector.
2) Remove the breaker wiring harness
from the “breaker harness” connector
on the AC-PRO (if installed on a
breaker).
3) Connect the female ten-position
terminal block connector on the Test
Harness to the AC-PRO.
4) Connect the small round connector on
the Test Harness to the “24 VAC
auxiliary power” connector on the AC-
PRO.
5) Connect the previously removed
breaker wiring harness connector to the
male ten-position terminal block on the
Test Harness (if installed on a breaker).
6) Once all connections are made the test
set power can be turned on. The AC-
PRO should also power up. (A short
current pulse to the selected AC-PRO
phase can occur on power-up or power-
down which may cause an
instantaneous trip.)
4.2 Select the Frequency
Select the desired frequency of operation using
the “Frequency (Hertz)” selector switch.
This must match the AC-PRO frequency.

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4.3 Calculate Long Time (LT) Pick-Up
Secondary Current
Calculate the secondary LT pick-up current
(LTSPU) as follows:
For 1-Amp AC-PRO:
LTSPU = LT Pick-UP
CT Rating
Example: If the CT rating is 1600 and the LT
pick-up 800 amps, then
LTSPU = 800 = 0.50 amp
1600
Example: If the CT rating is 1600 and the LT
pick-up 1600 amps, then
LTSPU = 1600 = 1.00 amp
1600
For 1/2-Amp AC-PRO:
LTSPU = LT Pick-Up X 1/2
CT Rating
Example: If the CT rating is 1600 and the LT
Pick-Up 800 amps, then
LTSPU = 800 X 1/2 = 0.25 amp
1600
Example: If the CT rating is 1600 and the LT
Pick-Up 1600 amps, then
LTSPU = 1600 X 1/2 = 0.50 amp
1600
4.4 Long Time (LT) Pick-Up Test
To test the LT pick-up:
1) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
until the display shows about 90% of
the LT pick-up current (LTSPU)
previously calculated.
2) Set the Phase selector to either Phase A,
B or C.
3) Push the Start button.
4) Increase the test current until the
display on the AC-PRO matches the LT
pick-up programmed in the AC-PRO.
The red pick-up LED on the AC-PRO
should be flickering or solidly on. The
test set current should be within ±10%
of LTSPU.
5) Push the Stop pushbutton.
6) If desired, test the other two phases in
the same way.

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4.5 Long Time (LT) Time Test
To test the LT time delay trip:
1) The first step is to select a test current.
For example, three times the LT pick-up
(3X on the TCC in Figure 4). The
desired test current is then 3 X LTSPU.
Note, to accurately test the LT delay, the
test current must be at least 110% of the LT
pick-up.
2) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
until the display shows the test current
calculated in step 1.
3) Set the Phase selector to either Phase A,
B or C.
4) Push the Clear button to reset the timer
to zero.
5) Push the Start button and quickly make
any minor adjustments required to the
Amp Fine pot. The red pick-up LED on
the AC-PRO should be on and the AC-
PRO should display OVERLOAD.
6) When the AC-PRO trips, the test set
current will stop and the timer will
freeze and display the total trip time.
7) Compare the trip time with the TCC
(Figure 4) for the LT time band setting
in the AC-PRO.
8) Verify that the AC-PRO saved the
proper last trip data.
9) Repeat for the other two phases if
desired.
4.6 Calculate Short Time (ST) Pick-Up
Secondary Current
Calculate the ST secondary pick-up current
(STSPU) as follows:
For 1-Amp AC-PRO:
STSPU = ST Pick-Up
CT Rating
Example: If the CT rating is 1600 and the ST
pick-up 6400 amps, then
STSPU = 6400 = 4.00 amp
1600
For 1/2-Amp AC-PRO:
STSPU = ST Pick-Up X 1/2
CT Rating
Example: If the CT rating is 1600 and the ST
pick-up 6400 amps, then
STSPU = 6400 X 1/2 = 2.00 amp
1600

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4.7 Short Time (ST) Pick-Up Test
To test the ST pick-up:
1) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
to 90% of the calculated STSPU.
2) Set the Phase selector to either Phase a,
B or C.
3) Push the Start button but leave the test
current on only long enough to see if a
ST trip occurs. If the current is left on
long enough a LT trip will occur.
A ST trip should NOT occur.
4) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
to 110% of the calculated STSPU.
5) Push the Start button.
A ST trip should occur. The test set
current will stop and the timer will
freeze displaying the trip time.
6) Verify that the AC-PRO saved the
proper last trip data.
7) Repeat for the other two phases if
desired.
4.8 Short Time (ST) Test
To test the ST time delay trip:
1) The first step is to select a test current.
For example, 150% of the ST pick-up.
The desired test current is then 1.5 X
STSPU.
Note, to accurately test the ST delay, the
test current must be at least 110% of the ST
pick-up.
2) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
until the display shows the test current
calculated in step 1.
3) Set the Phase selector to either Phase A,
B or C.
4) Push the Clear button to reset the timer
to zero.
5) Push the Start button.
6) When the AC-PRO trips, the test set
current will stop and the timer will
freeze displaying the trip time.
7) Compare the trip time with the TCC
(Figure 4) for the ST time band setting
in the AC-PRO.
8) Verify that the AC-PRO saved the
proper last trip data.
9) Repeat for the other two phases if
desired.

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4.9 Calculate Instantaneous (I) Pick-Up
Secondary Current
Calculate the I secondary pick-up current (ISPU)
as follows:
For 1-Amp AC-PRO:
ISPU = I Pick-Up
CT Rating
Example: If the CT rating is 1600 and the I
pick-up 9600 amps, then
ISPU = 9600 = 6.00 amp
1600
For 1/2-Amp AC-PRO:
ISPU = I Pick-Up X 1/2
CT Rating
Example: If the CT rating is 1600 and the I
pick-up 9600 amps, then
STSPU = 9600 X 1/2 = 3.00 amp
1600
4.10 Instantaneous (I) Pick-Up Test
To test the I pick-up:
1) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
to 90% of the calculated ISPU.
2) Set the Phase selector to either Phase A,
B or C.
3) Push the Start button but leave the test
current on only long enough to see if an
I trip occurs. If the current is left on
long enough a LT or ST trip will occur.
If ST is on, it is best to temporarily turn
it off.
An I trip should NOT occur.
4) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
to 110% of the calculated ISPU.
5) Push the Start button.
An I trip should occur. The test set
current will stop and the timer will
freeze displaying the trip time.
6) Verify that the AC-PRO saved the
proper last trip data.
7) Repeat for the other two phases if
desired.

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4.11Calculate Ground Fault (GF) Pick-Up
Secondary Current
Calculate the GF secondary pick-up current
(GFSPU) as follows:
For 1-Amp AC-PRO:
GFSPU = GF Pick-Up
CT Rating
Example: If the CT rating is 1600 and the GF
pick-up 1200 amps, then
GFSPU = 1200 = 0.75 amp
1600
For 1/2-Amp AC-PRO:
GFSPU = GF Pick-Up X 1/2
CT Rating
Example: If the CT rating is 1600 and the GF
pick-up 1200 amps, then
GFSPU = 1200 X 1/2 = 0.38 amp
1600
For AC-PRO with Special 2-Amp Neutral
Input:
GFSPU = GF Pick-Up X 2
CT Rating
Example: If the CT rating is 1600 and the GF
pick-up 1200 amps, then
GFSPU = 1200 X 2 = 1.50 amp
1600
4.12 Ground Fault (GF) Pick-Up Test
To test the GF pick-up:
1) Set the phase selector switch to GF.
2) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
to 90% of the calculated GFSPU.
3) Push the Start button but leave the test
current on only long enough to see if a
GF trip occurs.
A GF trip should NOT occur.
4) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
to 110% of the calculated GFSPU.
5) Push the Start button.
A GF trip should occur. The test set
current will stop and the timer will
freeze displaying the trip time.
6) Verify that the AC-PRO saved the
proper last trip data.

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4.13 Ground Fault (GF) Time Test
To test the GF time delay trip:
1) The first step is to select a test current.
For example, 150% of the GF pick-up.
The desired test current is then 1.5 X
GFSPU.
Note, to accurately test the GF delay, the
test current must be at least 110% of the GF
pick-up.
2) Hold down the Current Preset while
adjusting the Amp Coarse and Fine pots
until the display shows the test current
calculated in step 1.
3) Set the Phase selector to GF.
4) Push the Clear button to reset the timer
to zero.
5) Push the Start button.
6) When the AC-PRO trips, the test set
current will stop and the timer will
freeze displaying the trip time.
7) Compare the trip time with the TCC
(Figure 4) for the GF time band setting
in the AC-PRO.
8) Verify that the AC-PRO saved the
proper last trip data.
4.14 Unbalance Testing
The Unbalance can not be tested with this test
set.
5.0 Error/fault Conditions
5.1 Current Error
The test set monitors the current level while a
test is in progress. Should the current level be
outside of the expected range, a current error
will occur and the test set will stop current flow
and display “Current Error”.
To clear the current error the Clear push button
must be pressed. After this, normal operation
on the test set should be restored.
The most likely causes are:
1) The trip unit is not powered up.
2) There are loose connections in the test
cable.
5.2 Thermal Limit
As a protective feature, the test set will stop
delivering current and display a “Thermal
limit” message if high levels of test current
remain for a prolonged time period. The
timeout for the thermal limit shutdown begins
when any test current exceeds eight amps.
If a thermal limit occurs it must be cleared by
pressing the “Clear” push button. The test set
will not allow a test to be restarted for about
five seconds. Before restarting the test, verify
that there are no loose connections.

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1 POWER CABLE/FUSE HOLDER
Power cable connector with main fuse.
(120Vac 50/60Hz).
2 COOLING AIR-FLOW EXHAUST
Cooling air for the test set exits via this
filter opening. (Must not be blocked)
3 POWER ON/OFF SWITCH
4 START LED
Illuminated when test current flowing.
5 START PUSH BUTTON
Starts test current flow and starts the
timer.
6 TIMER DISPLAY
Displays elapsed time of test current
flow in seconds.
7 STOP PUSH BUTTON
Stops test current flow and freeze the
timer.
8 CLEAR PUSH BUTTON
Resets the timer to zero.
9 CONTRAST PUSH BUTTON
Hold this input in until the desired
display contrast is reached.
10 PHASE SELECT SWITCH
Selects one of the phases (A,B,C) or
ground fault as the test current path.
11 CURRENT DISPLAY
Displays measured true RMS current
and Current Preset value.
12 CURRENT PRESET PUSH BUTTON
When held, the current display
indicates the current setting of the Amp
Coarse and Fine pots.
13 AMP COARSE POT
This is used to make large adjustments
in current.
14 AMP FINE POT
This is used to make small adjustments
in current.
15 FREQUENCY SELECT SWITCH
This switch selects the AC frequency.
25, 40, 50 or 60 Hertz.
16 COOLING AIR-FLOW INTAKE
Cooing air for the test set enters via
this filter opening. (Must not be
blocked).
17 AC-PRO TEST HARNESS
CONNECTOR
The AC-PRO connects to the test-set
with the supplied wire harness via this
connector.
Figure 1
Control Panel Overview
2
1
12 13 15
17 16
8 1097 1443
5
11
6

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A) TEST SET HARNESS.
B) TEST SET HARNESS POWER PLUG TO AC-PRO.
C) TEST SET HARNESS MAIN CONNECTOR TO AC- PRO.
D) TEST SET HARNESS ACTUATOR CONNECTOR.
E) CIRCUIT BREAKER WIRING HARNESS (PREVIOUSLY CONNECTED TO THE AC-PRO).
Figure 2
AC-PRO / Breaker Test Set Connections
A
B
C
E
D
AC-PRO on breaker

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