ETI PI-2500-G2 Instruction Manual
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ETI PI-2500-G2 Instruction Manual

Primary injection circuit breaker test set
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PRIMARY INJECTION CIRCUIT BREAKER
TEST SET
INSTRUCTION MANUAL
Models
PI-2500-G2 and PI-5000-G2
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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Summary of Contents for ETI PI-2500-G2

  • Page 1 PRIMARY INJECTION CIRCUIT BREAKER TEST SET INSTRUCTION MANUAL Models PI-2500-G2 and PI-5000-G2 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

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== TABLE OF CONTENTS SECTION I: GENERAL INFORMATION and SPECIFICATIONS WARNING Introduction General Description Monitor and Controller MAC-21 PI2500-G2 Specifications PI5000-G2 Specifications SECTION II: DETAILED DESCRIPTION High Current Test Sets II-1 PI-2500-G2 Main Circuitry...
  • Page 3 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== SECTION V: SERVICE INFORMATION AND DOCUMENTATION Maintenance and Calibration of PI-4000B Maintenance and Calibration of MAC-21 Parts List (PI-2500-G2) Parts List (AUXI-5000-G2) Parts List (Indicator Control Panel) Parts List (MAC-21) Overall Schematic (PI-2500-G2)

  • Page 4: Warning

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== 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 NORMALLY POWERED FROM HIGH CAPACITY 208 VOLT TO...

  • Page 5: Introduction

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== INTRODUCTION A primary injection test set such as the PI-2500 and PI-5000 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-...
  • Page 6 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== The line voltage is displayed on the indicator control panel digital meter. An in- put selector switch can be set for 208, 240, or 480 VAC inputs. An internal volt- age sensor automatically ensures that the switch is set correctly before AC con- trol power can be turned on, and monitors input voltage for compliance to spec- ifications.
  • Page 7 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== reduce DC offset for inductive loads and more consistent pulse currents. The phase angle is internally adjustable and is preset for optimal waveforms with most breakers. 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.

  • Page 8: Monitor And Controller Mac-21

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== amperes. The configuration switch on the PI2500 must be set to 4000 or 2000 for proper output readings. .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.

  • Page 9: Pi2500-G2 Specifications

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== PI-2500 SPECIFICATIONS INPUT SUPPLY: 208/240 or 480 VAC +/- 10% (Field switchable) SINGLE PHASE 60 HZ (50 Hz at 10% lower line voltages) 15 KVA (Continuous) at 12 KVA output (80% efficiency) OUTPUT CURRENT & OVERLOAD CAPABILITIES: 7.6V (Par)

  • Page 10: Pi5000-G2 Specifications

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 ============================================================================== PI-5000 SPECIFICATIONS INPUT SUPPLY: 208/240 or 480 VAC +/- 10% SINGLE PHASE 60 HZ (50 Hz at 10% lower line voltages) 45 KVA (Continuous) at 36 KVA output (80% efficiency) OUTPUT CURRENT & OVERLOAD CAPABILITIES: 7.6V (Par)

  • Page 11: Section Ii: Detailed Description

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section II – Detailed Description ============================================================================== SECTION II DETAILED DESCRIPTION ============================================================================== Copyright(C) 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved...

  • Page 12: High Current Test Sets

    Electrical Test Instruments PI-2500-G2 & PI-5000-G2 Section II - Detailed Description ============================================================================== 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:...
  • Page 13 Electrical Test Instruments PI-2500-G2 & PI-5000-G2 Section II - Detailed Description ============================================================================== Primary protection is provided by high capacity 400 ampere input fuses (F1 and F2). After that, the control section is protected by smaller 5 ampere fuses (F3 and F4), and the power section is isolated by means of high current contactors (K13 and K14).
  • Page 14 Electrical Test Instruments PI-2500-G2 & PI-5000-G2 Section II - Detailed Description ============================================================================== switched output voltage is supplied to distribution blocks DB1 and DB2. The Vernier autotransformer T1 and output transformer T2 are connected to in- put voltage selector switch S11. This allows for connection in series for 480 VAC, and parallel for 208/240 VAC.
  • Page 15 Electrical Test Instruments PI-2500-G2 & PI-5000-G2 Section II - Detailed Description ============================================================================== enhanced reliability and cooler operation due to single piece secondary bus conductors. It was designed so that it could provide three connection modes for 1000, 2000, and 4000 amps continuous current. Stab Adaptor Plates and se- ries bars are used for convenient output connection.
  • Page 16 Electrical Test Instruments PI-2500-G2 & PI-5000-G2 Section II - Detailed Description ============================================================================== PI-5000 connection: PI-2500 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: Indicator Control Panel

    Electrical Test Instruments PI-2500-G2 & PI-5000-G2 Section II - Detailed Description ============================================================================== rectified and filtered by the metering PC board and displayed on the panel me- ter. Output is inhibited during tap change or when an interlock condition exists. An interlock (INTLKB) will be asserted if either temperature readouts exceed an ad- justed setpoint.
  • Page 18 Electrical Test Instruments PI-2500-G2 & PI-5000-G2 Section II - Detailed Description ============================================================================== POD also calculates a “virtual” temperature based on overload duty cycle limits as indicated in the specifications. The ten bar graph LEDs correspond to tem- peratures of approximately 80 to 280 degrees F, with about 20 degrees per bar.
  • Page 19 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 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 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 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.
  • Page 22 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 23 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 24: Mac-21 Internal Parts Iii-8

    Electrical Test Instruments MAC-21 Section III – MAC-21 ============================================================================== remote initiate function (see below). A resistance of about 200 ohms or less will be in- terpreted as continuity. Although the signal is low power and transformer isolated, it is good practice to avoid touching any conductive surface connected to these termi- nals.

  • 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 re- quire 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 ============================================================================== there may be a problem in the test setup. 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 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) 1994-2021 Electrical Test Instruments, LLC All Rights Reserved...
  • Page 29 Electrical Test Instruments MAC-21 Retrofit Package Section III – MAC-21 =============================================================================================================== ============================================================================================================= Copyright(C) 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved...

  • Page 30: Section Iv: Operating Instructions

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section IV - Operating Instructions ============================================================================== SECTION IV OPERATING INSTRUCTIONS ============================================================================== Copyright(C) 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved...

  • Page 31: Pre-Test Installation And Setup

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== SECTION IV OPERATING INSTRUCTIONS PRE-TEST INSTALLATION AND SET-UP (PI2500) 1. The following components of the test set should be available and in good condition: a) PI-2500 Main Unit...
  • Page 32 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== f) When all parts are properly assembled, the bolt pattern should match standard stabs g) Make sure selector switch is set to 2000 4. Alternate 1000-amp output mode a) Connect series bars and stab adaptor assemblies per instructions for 2000-amp mode above.
  • Page 33 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== 9. When the bus connectors are nearly touching, verify that the bus bars of the AUX5000 fit just over the bus bars of the PI2500. It may be necessary to adjust the two units slightly while pushing together.
  • Page 34 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== contactor(s) should energize, and green lamp should light. 13. Connect breaker under test to appropriate output tap, using stabs or ca- bles and series bar as required.

  • Page 35: Basic Guidelines And Suggestions

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== BASIC GUIDELINES AND SUGGESTIONS 1. Best timing and current accuracy will be obtained with the MAC-21 in cur- rent latch (C.L.) mode. 2. Current Latch modes are preferred for most testing purposes. Exceptions...

  • Page 36: Single Pole Molded Case Breakers

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== SINGLE POLE MOLDED CASE CIRCUIT BREAKERS Timing Test Consult breaker manufacturer's literature to determine any necessary pre- cautions and expected test results. A test current of three times the rating of the breaker should be used for this test.
  • Page 37 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== Pick-Up of Instantaneous Element Consult breaker manufacturer's literature to determine any necessary pre- cautions and expected test results. Check the breaker's instantaneous set- ting. Pickup should occur at about that current.
  • Page 38 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== 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 39: Multi-Pole Molded Case Breakers

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== MULTI-POLE MOLDED CASE CIRCUIT BREAKERS Timing Test Consult breaker manufacturer's literature to determine any necessary pre- cautions and expected test results. A test current of three times the rating of the breaker should be used for this test.
  • Page 40 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== manufacturer's time range for the value of test current chosen. All poles of the breaker need not trip in exactly the same amount of time. 20. Shut down test set, disconnect breaker, and prepare for subsequent test- ing or relocation according to steps 18 through 22 in pre-test installation and setup outlined above.
  • Page 41 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== Instantaneous Trip Time Test Perform Instantaneous Pickup Test as outlined above. Adjust controls to obtain current above pickup, at approximate desired multiple of rating. Close breaker under test.

  • Page 42: Low Voltage Power Breakers

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== 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 43 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== Consult breaker manufacturer's literature to determine any necessary pre- cautions and expected test results. A test current of three times the rating of the breaker should be used for this test.
  • Page 44 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== 20. Shut down test set, disconnect breaker, and prepare for subsequent test- ing or relocation according to steps 18 through 22 in pre-test installation and setup outlined above.
  • Page 45 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== testing or relocation according to steps 18 through 22 in pre-test installa- tion and setup outlined above. Pick-Up of the Instantaneous Unit Consult breaker manufacturer's literature to determine any necessary pre- cautions and expected test results.
  • Page 46 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== Instantaneous Trip Time Test Perform Instantaneous Pickup Test as outlined above. Adjust controls to obtain current above pickup, at approximate desired multiple of rating. Close breaker under test.

  • Page 47: Motor Overload Relays

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== MOTOR OVERLOAD RELAYS The motor overload relay is designed to provide overload protection for a mo- tor; therefore, it offers only one time/current characteristic, which is essentially a long-time delay.
  • Page 48 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== 12. Press RESET button. 13. Set MAC-21 to N.C. mode. Set MAINTAIN on. 14. Press and release INITIATE button; OUTPUT ON light should glow, timer should operate, and current should indicate on display.

  • Page 49: Ratioing Current Transformers

    Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== 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 50 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== SECTION V SERVICE INFORMATION AND DOCUMENTATION ============================================================================== Copyright(C) 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved...
  • Page 51 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== SECTION V SERVICE INFORMATION AND DOCUMENTATION MAINTENANCE AND CALIBRATION OF THE PI-2500 and PI-5000 The PI-2500 and PI-5000 require only minimal maintenance. Mechanical components such as casters and hinges may need periodic lubrication. External surfaces should be kept clean, and screws on access panels should be checked for tightness.
  • Page 52 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== PARTS LIST (PI-2500): The overall schematic is on the following pages. The parts list is provided below. Please refer to both when ordering replacement parts. ITEM...
  • Page 53 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== OVERALL SCHEMATIC (PI-2500) ============================================================================== Copyright(C) 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved Page V-3...
  • Page 54 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== ============================================================================== Copyright(C) 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved Page V-4...
  • Page 55 Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Section V - Service Information and Documentation ============================================================================== ============================================================================== Copyright(C) 1994-2021 Electrical Test Instruments, LLC. All Rights Reserved Page V-5...
  • Page 56 Retrofit Package Electrical Test Instruments PI-2500-G2 and PI-5000-G2 Electrical Test Instruments Section V - Service Information and Documentation Section V - 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.

This manual is also suitable for:

Pi-5000-g2

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