ETI PI-6000 Instruction Manual
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ETI PI-6000 Instruction Manual

Primary injection circuit breaker test set
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PRIMARY INJECTION CIRCUIT BREAKER
TEST SET
INSTRUCTION MANUAL
Model
PI-6000
Electrical Test Instruments, LLC
8430 Spires Way, Suite A-F
Fredrick, MD 21701
www.ETIPrecision.com
(410) 857-1880
Fax (410) 857-1387

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  • Page 1 PRIMARY INJECTION CIRCUIT BREAKER TEST SET INSTRUCTION MANUAL Model PI-6000 Electrical Test Instruments, LLC 8430 Spires Way, Suite A-F Fredrick, MD 21701 www.ETIPrecision.com (410) 857-1880 Fax (410) 857-1387...

  • Page 2: Table Of Contents

    SECTION II: DETAILED DESCRIPTION Theory of Operation High Current Test Sets II-9 PI-6000 Main Circuitry II-9 PI-6000 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-6000 ============================================================================== SECTION V: SERVICE INFORMATION AND DOCUMENTATION Maintenance and Calibration of PI-6000 Maintenance and Calibration of MAC-21 Parts List (PI-6000) Parts List (Indicator Control Panel) Parts List (MAC-21) Overall Schematic (PI-6000) Overall Schematic (Indicator Control Panel)

  • Page 4: Warning

    Electrical Test Instruments PI-6000 Section II – Detailed Description ============================================================================== SECTION I GENERAL INFORMATION WARNING WARNING READ THIS ENTIRE MANUAL THOROUGHLY FAMILIARIZE YOURSELF WITH THE UNIT OPERATION PRIOR TO CONNECTING THE UNIT TO A SOURCE OF POWER. HIGH CURRENT TEST SETS ARE...

  • Page 5: Introduction

    ============================================================================== INTRODUCTION A primary injection test set such as the PI-6000 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...
  • Page 6 The approximate rheostat position is displayed on an LED indicator bar graph. For the PI-6000, the rheostat is always turned clockwise to increase output.
  • Page 7 Electrical Test Instruments PI-6000 Section II - Detailed Description ============================================================================== loads and more consistent pulse currents. The phase angle is internally adjustable. 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 firmware to resolve true-RMS values of distorted waveforms.

  • Page 8: Monitor And Controller Mac-21

    Electrical Test Instruments PI-6000 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 9: Trademarks

    The MAC-21 Monitor Ammeter Controller used in the PI-6000 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 10: Pi6000 Specifications

    Electrical Test Instruments PI-6000 Section II - Detailed Description ============================================================================== PI-6000 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 11: Section Ii: Detailed Description

    PI-6000 Main Unit Circuitry Main power is applied to the PI-6000 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 12 Electrical Test Instruments PI-6000 Section II - Detailed Description ============================================================================== control panel to provide 12 VDC. Transformer T6, protected by fuse F5, steps it down by a factor of ¼, and this voltage is sensed by a voltage relay circuit. When the primary voltage is between about 200 and 270 VAC, this circuit allows operation in 240 VAC mode.
  • Page 13 Catastrophic protection is provided by fuses F7 through F16. The adjustable rheostat assembly in the PI-6000 consists of a stack of four 120 VAC decks, with each series connected pair connected to a 240 VAC primary on T2A.
  • Page 14 Electrical Test Instruments PI-6000 Section II - Detailed Description ============================================================================== stainless-steel output bolts should rarely require replacement but may be serviced by simply removing the sixteen screws on the phenolic output faceplate, and then removing one of four bolt retainers. The standard hex head bolts may then be pushed through and replaced.

  • Page 15: Pi-6000 Indicator Control Panel Circuitry

    Section II - Detailed Description ============================================================================== PI-6000 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 16 Electrical Test Instruments PI-6000 Section II - Detailed Description ============================================================================== Main Power READY switch: This green switch turns on the main power to the output section of the test set, and its green lamp lights when ON. Main Power INTERLOCK switch: This red switch turns off the main power to the test set.
  • Page 17 Electrical Test Instruments PI-6000 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 18 Electrical Test Instruments PI-6000 Section II – Detailed Description ============================================================================== 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...

  • Page 19: 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 20 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 auto ranges to 99.99 seconds, 999.9 seconds, and 9999 seconds.
  • Page 21 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== takes the unit out of PRESET ADJUST mode. MAINTAIN key: This key toggle the MAINTAIN mode for initiation; its LED indicates that this mode is enabled. When in MAINTAIN mode, the INITIATE key need only be pressed briefly to turn output on.
  • Page 22 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== SECONDS key: This key normally selects the SECONDS time base. If the PRESET mode is selected, this key is used to LOWER the preset time limit by decrements of 1.000 second (5.000 seconds above 10.00) with the SECONDS time base, or 1.0 cycles with the CYCLES time base.
  • Page 23 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== remote initiate function (see below). A resistance of about 200 ohms or less will be interpreted as continuity. Although the signal is low power and transformer isolated, it is good practice to avoid touching any conductive surface connected to these terminals.

  • Page 24: 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 25: 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 26 Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== important, because waveform distortion is more prevalent at lower levels. 7. If the MAC-21 reading differs from the standard by more than rated accuracy, adjust the gain potentiometer on the analog board for proper reading.
  • Page 27 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 28 Electrical Test Instruments MAC-21 Retrofit Package Section III – MAC-21 =============================================================================================================== Connections (MAC-21): ============================================================================================================= Copyright(C) 1994-2003 Electrical Test Instruments, LLC All Rights Reserved...

  • Page 29: Section Iv: Operating Instructions

    Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== SECTION IV OPERATING INSTRUCTIONS PRE-TEST INSTALLATION AND SET-UP The following components of the test set should be available and in good condition: a) PI-6000 Main Unit b) MAC-21 c) Stab set to match breaker to be tested...
  • Page 30 Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== Connect power source to input, using connectors supplied. 10. Turn on power at source, if turned off in step 8 above. 11. Input Voltage meter should indicate actual line voltage. Verify that voltage selector is set for this voltage.

  • Page 31: Basic Guidelines And Suggestions

    Electrical Test Instruments PI-6000 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...

  • Page 32: Single Pole Molded Case Breakers

    Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== SINGLE POLE MOLDED CASE CIRCUIT BREAKERS Timing Test 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 33 Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== 18. Shut down test set, disconnect breaker, and prepare for subsequent testing or relocation according to steps 18 through 22 in pre-test installation and setup outlined above. Pick-Up of Instantaneous Element Consult breaker manufacturer's literature to determine any necessary precautions and expected test results.

  • Page 34: Multi-Pole Molded Case Breakers

    Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== Instantaneous Trip Time Test 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 35 Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== 11. Press RESET button. 12. Set TIMEBASE to SECONDS. 13. Select MAINTAIN mode. 14. If desired, N.C. mode may be used; connect contacts leads to an unused pole of the breaker.
  • Page 36 Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== 9. Repeatedly jog the INITIATE button, while adjusting the OUTPUT CONTROL higher, until the circuit breaker trips instantaneously. This is the approximate pickup point. If insufficient current is obtained at maximum position of the rheostat, set the OUTPUT TAP control to the next higher tap, return the rheostat to zero, and continue.

  • Page 37: Low Voltage Power Breakers

    Electrical Test Instruments PI-6000 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.
  • Page 38 Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== Timing Test, Long Time Delay 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-6000 Section IV - Operating Instructions ============================================================================== 19. Repeat the above tests for the other poles of the breaker, allowing time for breaker to cool. Note: Results are acceptable if all poles of the breaker trip within the manufacturer's time range for the value of test current chosen.
  • Page 40 Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== 10. Repeat the above tests for the other poles of the breaker, allowing time for breaker to cool. Note: Results are acceptable if all poles of the breaker trip within the manufacturer's time range for the value of test current chosen.

  • Page 41: Motor Overload Relays

    Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== 13. Repeat the above test for the other poles of the circuit breaker. 14. If trip settings were modified for test purposes, restore them to their original values. 15. Shut down test set, disconnect breaker, and prepare for subsequent testing or relocation according to steps 18 through 22 in pre-test installation and setup outlined above.
  • Page 42 Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== precautions and the expected timing test results. The test current should be 3 to 4 times the rating of the relay operating coil or heater. 2. Follow steps 1 through 16 in pre-test installation and setup, as required, to set up the breaker test set.

  • Page 43: Ratioing Current Transformers

    Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== testing or relocation according to steps 18 through 22 in pre-test installation and setup outlined above. 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.
  • Page 44 Electrical Test Instruments PI-6000 Section IV - Operating Instructions ============================================================================== 9. Shut down test set, disconnect CT, and prepare for subsequent testing or relocation according to steps 18 through 22 in pre-test installation and setup outlined above. ============================================================================== Copyright(C) 1994-2019...
  • Page 45 Rheostat brushes should be inspected for signs of wear or overheating and cleaned or replaced as required. Calibration of the PI-6000 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. The outer pot is for parallel connection, and the inner pot is for series.
  • Page 46 Electrical Test Instruments PI-6000 Section V - Service Information and Documentation ============================================================================== The inherently delicate nature of electronic circuitry and metering make it generally inadvisable to leave the Indicator Control Panel and MAC-21 fastened into the breaker test set if it is being transported under conditions of extreme shock and vibration.
  • Page 47 Electrical Test Instruments PI-6000 Section V - Service Information and Documentation ============================================================================== Latch Threshold, which should be about 5% of full-scale range. 11. Set the current at 50% of full scale (500 A) and stop the current. 12. Set the MAC-21 to MEMORY mode and press the RESET Switch.
  • Page 48 Electrical Test Instruments PI-6000 Section V - Service Information and Documentation ============================================================================== PARTS LIST (PI-6000): The overall schematic is on the following pages. The parts list is provided below. Please refer to both when ordering replacement parts. ITEM DESCRIPTION REF DES...
  • Page 49 Electrical Test Instruments PI-6000 Section V - Service Information and Documentation ============================================================================== PARTS LIST (Indicator Control Panel): 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 50 Electrical Test Instruments PI-6000 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. See Mac Section...
  • Page 51 Electrical Test Instruments PI-6000 Section V - Service Information and Documentation ========================================================================================================= OVERALL SCHEMATIC (PI-6000) ============================================================================================================= Copyright(C) 1994-2004 Electrical Test Instruments, Inc. All Rights Reserved Page V-7...
  • Page 52 Electrical Test Instruments PI-6000 Section V - Service Information and Documentation ============================================================================== OVERALL SCHEMATIC (Indicator Control Panel) ============================================================================= Copyright(C) 1994-2019 Electrical Test Instruments, LLC All Rights Reserved Page V-8...
  • Page 53 Retrofit Package Electrical Test Instruments PI-6000 Electrical Test Instruments Section V - Service Information and Documentation Section IV - Service Information and Documentation ============================================================================== ============================================================================== WARRANTY Electrical Test Instruments, LLC, will correct any defect in workmanship or material for two years after date of purchase of any Electrical Test Instruments product.

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