ETI PI-4000B Instruction Manual
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ETI PI-4000B Instruction Manual

Primary injection circuit breaker
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PRIMARY INJECTION CIRCUIT BREAKER
TEST SET
INSTRUCTION MANUAL
Model
PI-4000B
Electrical Test Instruments, Inc.
1301 Avondale Road, Suite J
New Windsor, MD 21776
www.electricaltestinstruments.com
(410) 857-1880
Fax (410) 857-1387

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  • Page 1 PRIMARY INJECTION CIRCUIT BREAKER TEST SET INSTRUCTION MANUAL Model PI-4000B Electrical Test Instruments, Inc. 1301 Avondale Road, Suite J New Windsor, MD 21776 www.electricaltestinstruments.com (410) 857-1880 Fax (410) 857-1387...

  • Page 2: Table Of Contents

    II-7 SECTION II: DETAILED DESCRIPTION Theory of Operation High Current Test Sets II-9 PI-4000B Main Circuitry II-9 PI-4000B Indicator Control Panel Circuitry II-12 Indicator Control Panel II-13 Figure II-2: Retrofit Indicator Panel II-14 SECTION III: MAC-21 Monitor and Controller MAC-21 Specifications...
  • Page 3 Electrical Test Instruments PI-4000B ============================================================================== SECTION V: SERVICE INFORMATION AND DOCUMENTATION Maintenance and Calibration of PI-4000B Maintenance and Calibration of MAC-21 Parts List (PI-4000B) Parts List (Indicator Control Panel) Parts List (MAC-21) Overall Schematic (PI-4000B) Overall Schematic (Indicator Control Panel)
  • Page 4 Electrical Test Instruments PI-4000B Section II – Detailed Description ============================================================================== SECTION I GENERAL INFORMATION ============================================================================== Copyright(C) 1994-2004 Electrical Test Instruments, Inc. All Rights Reserved...

  • Page 5: Warning

    Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== SECTION I GENERAL INFORMATION WARNING WARNING - READ THIS ENTIRE MANUAL AND THOROUGHLY FAMILIARIZE YOURSELF WITH THE UNIT OPERATION PRIOR TO CONNECTING THE UNIT TO A SOURCE OF POWER. HIGH...

  • Page 6: Introduction

    ============================================================================== INTRODUCTION A primary injection test set such as the PI-4000B is a device with high current, low voltage AC outputs for testing direct acting low voltage circuit breakers. Current is injected through the main contacts of the breaker to simulate actual fault conditions, which tests the operation of CTs, solid state, thermal, or electromechanical trip devices, and the actual trip mechanisms and breaker contacts.
  • Page 7 When the switch is held, the vernier moves very quickly, so that the entire span may be traversed in less than five seconds. The approximate vernier position is displayed on an LED indicator bar graph. For the PI-4000B, the vernier is always turned clockwise to increase output.
  • Page 8 Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== protruding components on the sides, so it can be navigated through narrow doorways without problems. The input jacks and voltage switch are protected by the heavy duty full width handles on both ends.

  • Page 9: Monitor And Controller Mac-21

    Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== MONITOR AND CONTROLLER MAC-21 The MAC-21 microprocessor-based measurement and control unit features digital readout of current and time enhanced by digital signal processing. Pulse (memory) mode provides fast and accurate automatic evaluation of output current pulses as short as one half cycle.

  • Page 10: Advantages Compared To Other Test Sets

    The MAC-21 Monitor Ammeter Controller used in the PI-4000B 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.

  • Page 11: Pi4000B Specifications

    Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== PI4000B SPECIFICATIONS INPUT SUPPLY: 208/240 or 480 VAC +/- 10% (Field switchable) SINGLE PHASE 60 HZ (50 Hz at 10% lower line voltages) 45 KVA (Continuous) at 36 KVA output (80% efficiency) OUTPUT CURRENT &...

  • Page 12: Section Ii: Detailed Description

    Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== SECTION II DETAILED DESCRIPTION ============================================================================== Copyright(C) 1994-2004 Electrical Test Instruments, Inc. All Rights Reserved Page II-8...

  • Page 13: Theory Of Operation

    PI-4000B Main Unit Circuitry Main power is applied to the PI-4000B 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.
  • Page 14 Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== energized, setting the primary windings of transformer T4 in parallel. This also energizes relay K1 on the voltage sensor PCB, and provides an interlock and input selector error indication. The voltage sensor PCB rapidly flashes the Input Select Error LED on the control panel for 5 seconds during startup, and then turns off if input voltage is within bounds as determined by the input selector switch position.
  • Page 15 Catastrophic protection is provided by fuses F7 through F16. The adjustable vernier assembly in the PI-4000B consists of a stack of four 120 VAC decks, with each series connected pair connected to a 240 VAC primary on T2A. Minor...

  • Page 16: Pi-4000B Indicator Control Panel Circuitry

    Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== PI-4000 Indicator Control Panel Circuitry The power for the control panel is provided by the INV/2 circuit, which is the main input voltage divided by 2. This voltage, ranging from 104 VAC to 240 VAC, powers a wide range switching power supply, which supplies 12 VDC to the rest of the circuitry.
  • Page 17 Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== Output Voltage binding posts: These binding posts are connected to output stabs 1 and 4, and may be used to monitor voltage on the breaker with a DMM. Thermal Status - Bus: This multicolor bar graph indicates approximate temperature of the output bus.
  • Page 18 Electrical Test Instruments PI-4000B Section II - Detailed Description ============================================================================== Figure II-2 – Indicator Control Panel Indicator Control Panel Control Main Thermal Input Voltage Output Status Power Power Coarse Tap Vernier READY Input Stab Selector INTERLOCK Vernier Voltage Error Electrical Test Instruments, Inc.
  • Page 19 Electrical Test Instruments PI-4000B Section II – Detailed Description ============================================================================== MEMORY AMMETER CONTROLLER MAC-21 INSTRUCTION MANUAL Firmware Version 3.06 and above Electrical Test Instruments, Inc. 1301 Avondale Road, Suite J New Windsor, MD 21776 www.etiinc.com (410) 857-1880 Fax (410) 857-1387...

  • Page 20: Mac-21 Specifications Iii-1

    Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== 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 >...
  • Page 21 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== MAJOR PARTS IDENTIFICATION AND OPERATION MAC-21 Control Panel TIME DISPLAY: This 4 digit LED display normally indicates the elapsed time of a current pulse. In SECONDS mode, it displays time up to 9.999 seconds, then autoranges to 99.99 seconds, 999.9 seconds, and 9999 seconds.
  • Page 22 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== RESET key: This key resets the displays on the MAC-21, and arms the pulse reading system. The LED on the key indicates that the system is reset and armed. RESET also takes the unit out of PRESET ADJUST mode.
  • Page 23 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== 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 timebase. 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 timebase, or 1.0 cycles with the CYCLES timebase.
  • Page 24 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== change state. CONTACTS/REMOTE jacks: These jacks provide a low-power AC signal which detects continuity in N.O. and N.C. modes, or is used with a pushbutton cord switch for remote initiate function (see below). A resistance of about 200 ohms or less will be interpreted as continuity.

  • Page 25: Mac-21 Internal Parts Iii-8

    Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== MAC-21 Internal Parts INPUT CONNECTOR: This connector, located on the upper rear corner of the MAC-21, provides 120 VAC control power, and connects to the air core CT (current sensor), and initiate circuitry of the test set.
  • Page 26 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== Figure II-2: MAC-21 Front Panel ============================================================================== Copyright(C) 1994-2004 Electrical Test Instruments, Inc. All Rights Reserved Page III-7...

  • Page 27: Maintenance And Calibration Of Mac-21

    Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== SERVICE INFORMATION AND DOCUMENTATION MAINTENANCE AND CALIBRATION OF THE MAC-21 The MAC-21 is manufactured using solid state components that should not require extensive maintenance. However, the accuracy of the MAC-21 is critical to the testing of circuit breakers, and is dependent upon the output of an air-core current sensing coil, which could change due to movement caused by shock or vibration encountered in transporting the test set.
  • Page 28 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== 8. Check calibration at 200, 400, 600, and 1000 Amperes. 9. Adjust the current to zero, and press RESET key. 10. Raise the current slowly, until the timer begins to run. This is the Current Latch Threshold, which should be about 10% of range.
  • Page 29 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== PARTS LIST (MAC-21): The overall schematic is on the following pages. The parts list is provided below. Please refer to both when ordering replacement parts. ITEM QTY DESCRIPTION Part Number 1 MAC-21 Contact/LED Harness S-B369 1 MAC-21 Rear Panel Harness S-B368...
  • Page 30 Electrical Test Instruments MAC-21 Retrofit Package Section III – MAC-21 =============================================================================================================== Connections (MAC-21): ============================================================================================================= Copyright(C) 1994-2003 Electrical Test Instruments, Inc. All Rights Reserved...

  • Page 31: Section Iv: Operating Instructions

    Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== WARRANTY Electrical Test Instruments, Inc., will for two years after date of purchase of any Electrical Test Instruments product, correct any defect in workmanship or material. Such corrective measures will be limited to repairing or replacing the unit, at Electrical Test Instruments' option.

  • Page 32: Pre-Test Installation And Setup

    Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== SECTION IV OPERATING INSTRUCTIONS PRE-TEST INSTALLATION AND SET-UP 1. The following components of the test set should be available and in good condition: a) PI-4000B Main Unit b) MAC-21 c) Stab set to match breaker to be tested...
  • Page 33 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== is set for this voltage. Input selector error LED should light if incorrect. 12. Verify that Ground Open LED is not lit. Control power cannot be turned on if ground integrity is not sensed.

  • Page 34: Basic Guidelines And Suggestions

    Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== BASIC GUIDELINES AND SUGGESTIONS 1. Best timing and current accuracy will be obtained with the MAC-21 in current latch (C.L.) mode. 2. Current Latch modes are preferred for most testing purposes. Exceptions are: a) Non-series-connected devices such as motor overload relays or shunt-trip breakers.

  • Page 35: Single Pole Molded Case Breakers

    Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== SINGLE POLE MOLDED CASE CIRCUIT BREAKERS Timing Test 1. Consult breaker manufacturer's literature to determine any necessary precautions and expected test results. A test current of three times the rating of the breaker should be used for this test.
  • Page 36 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== Pick-Up of Instantaneous Element 1. Consult breaker manufacturer's literature to determine any necessary precautions and expected test results. Check the breaker's instantaneous setting. Pickup should occur at about that current.
  • Page 37 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== Instantaneous Trip Time Test 1. Perform Instantaneous Pickup Test as outlined above. 2. Adjust controls to obtain current above pickup, at approximate desired multiple of rating. 3. Close breaker under test.

  • Page 38: Multi-Pole Molded Case Breakers

    Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== MULTI-POLE MOLDED CASE CIRCUIT BREAKERS Timing Test 1. Consult breaker manufacturer's literature to determine any necessary precautions and expected test results. A test current of three times the rating of the breaker should be used for this test.
  • Page 39 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== relocation according to steps 18 through 22 in pre-test installation and setup outlined above. Pick-Up of Instantaneous Element 1. Consult manufacturer's literature to determine any necessary precautions and expected test results. Check the breaker's instantaneous setting. Pickup should occur at about that current.
  • Page 40 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== 4. Press the INITIATE button. Breaker should trip instantaneously. 5. Read and record timer and ammeter readings as instantaneous trip time and current. 6. Repeat the above test for the other poles of the circuit breaker.

  • Page 41: Low Voltage Power Breakers

    Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== LOW VOLTAGE POWER CIRCUIT BREAKERS Nearly all low voltage power circuit breakers are multi-pole devices. The trip units may be either magnetic with a dash pot or solid state electronic devices. Test procedures would be the same for either type.
  • Page 42 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== 4. Setup MAC-21 for C.L. Maint (MAINTAIN on). 5. Set MAC-21 RANGE to lowest range that is greater than desired test current. 6. Set TIMEBASE to CYCLES. 7. Press PRESET key. Adjust preset time to 5.0 cycles. This value may be set higher or lower, depending on trip characteristics of breaker.
  • Page 43 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== Set up of controls is the same as for timing test L.T.D. Consult breaker manufacturer's literature to determine any necessary precautions and expected test results. 1. Follow steps 1 through 8 under Timing Test Long Time Delay.
  • Page 44 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== 6. Press PRESET key. Adjust preset time to 5.0 cycles. This value may be set higher or lower, depending on trip characteristics of breaker. 7. Press PRESET again to return to normal mode.

  • Page 45: Motor Overload Relays

    Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== MOTOR OVERLOAD RELAYS The motor overload relay is designed to provide overload protection for a motor; therefore, it offers only one time/current characteristic, which is essentially a long time delay. It may be multi-pole, however, most relays are single pole. In the case of a multi- pole device each pole is tested individually as in the case of a multi-pole direct acting circuit breaker.
  • Page 46 Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== 15. When the relay control circuit contacts open, the test set output should deenergize and the timer should stop. 16. Read and record the test value of current and the time of the test. Compare the results to the manufacturer's specifications.

  • Page 47: Ratioing Current Transformers

    Electrical Test Instruments PI-4000B Section IV - Operating Instructions ============================================================================== RATIOING CURRENT TRANSFORMERS To conduct a ratio test on a current transformer, a good multi-range bench ammeter is required in addition to the breaker test set. The breaker test set supplies primary current to the transformer and the bench ammeter is used to read the transformer secondary current.
  • Page 48 Electrical Test Instruments PI-4000B Section V - Service Information and Documentation ============================================================================== SECTION V SERVICE INFORMATION AND DOCUMENTATION ============================================================================== Copyright(C) 1994-2004 Electrical Test Instruments, Inc. All Rights Reserved...
  • Page 49 Vernier brushes should be inspected for signs of wear or overheating, and cleaned or replaced as required. Calibration of the PI-4000B requires accurate current measurement in both series and parallel connection. Adjustment may be accomplished by means of the potentiometers accessible through the output stab plate.
  • Page 50 Electrical Test Instruments PI-4000B Section V - Service Information and Documentation ============================================================================== test set if it is being transported under conditions of extreme shock and vibration. The standard rack-mount hardware and twist-lock connector make it simple to remove the Indicator Control Panel and MAC-21 and carry or ship them separately. Suggested periodic maintenance consists of the following: 1.
  • Page 51 Electrical Test Instruments PI-4000B Section V - Service Information and Documentation ============================================================================== 15. Set Timer Timebase to SECONDS. Press Master Reset Switch. Set N.O. mode. Using a timing standard, initiate for exactly ninety (90) seconds. Timer should read 90.00 Seconds, +/- 0.01 Seconds. (Note: actual reading may vary because of inability to control and measure pulse length.)
  • Page 52 Electrical Test Instruments PI-4000B Section V - Service Information and Documentation ============================================================================== PARTS LIST (PI-4000B): The overall schematic is on the following pages. The parts list is provided below. Please refer to both when ordering replacement parts. ITEM QTY DESCRIPTION...
  • Page 53 Electrical Test Instruments PI-4000B Section V - Service Information and Documentation ============================================================================== Ser/Par switch/cal Ass’y S-B121 Thermistor, 10k TH1,TH2 M-B226 Input Voltage Selector Switch M-C234 Nut, Hex, SS, ½”-13 M-B228 Bolt, hex, SS, ½”-13x2”, F/T M-C251 Vernier Wheel Assembly, 3/8”...
  • Page 54 Electrical Test Instruments PI-4000B Section V - Service Information and Documentation ============================================================================== PARTS LIST (MAC-21): The overall schematic is on the following pages. The parts list is provided below. Please refer to both when ordering replacement parts. ITEM QTY DESCRIPTION...
  • Page 55 Electrical Test Instruments PI-4000B Section V - Service Information and Documentation ========================================================================================================= OVERALL SCHEMATIC (PI-4000B) ============================================================================================================= Copyright(C) 1994-2004 Electrical Test Instruments, Inc. All Rights Reserved Page V-7...
  • Page 56 Electrical Test Instruments PI-4000B Section V - Service Information and Documentation ============================================================================== OVERALL SCHEMATIC (Indicator Control Panel) ============================================================================= Copyright(C) 1994-2004 Electrical Test Instruments, Inc. All Rights Reserved Page V-8...
  • Page 57 PI-4000B Electrical Test Instruments Section IV - Service Information and Documentation ============================================================================== WARRANTY Electrical Test Instruments, Inc., will for one year after date of purchase of any Electrical Test Instruments product, correct any defect in workmanship or material. Such corrective measures will be limited to repairing or replacing the unit, at Electrical Test Instrument’s option.

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