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ETI PI-5000 Instruction Manual

Primary injection circuit breaker test set
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PRIMARY INJECTION CIRCUIT BREAKER
TEST SET
INSTRUCTION MANUAL
Models
PI-2500 and PI-5000
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 Models PI-2500 and PI-5000 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 and PI-5000 ============================================================================== TABLE OF CONTENTS SECTION I: GENERAL INFORMATION and SPECIFICATIONS WARNING Introduction General Description Monitor and Controller MAC-20 Proposed Enhancements Advantages Compared to Other Test Sets Trademarks PI2500 Specifications PI5000 Specifications MAC-20 Specifications SECTION II: DETAILED DESCRIPTION...
  • Page 3 Electrical Test Instruments PI-2500 and PI-5000 ============================================================================== SECTION IV: OPERATING INSTRUCTIONS Pre-Test Installation and Setup IV-1 Basic Guidelines and Suggestions IV-3 Single Pole Molded Case Breakers IV-4 Multi-pole Molded Case Breakers IV-7 Low Voltage Power Breakers IV-10 Motor Overload Relays...
  • Page 4 Electrical Test Instruments PI-2500 and PI-5000 Section II – Detailed Description ============================================================================== SECTION I GENERAL INFORMATION ============================================================================== Copyright(C) 1994-2008 Electrical Test Instruments, LLC. All Rights Reserved...

  • Page 5: Warning

    Electrical Test Instruments PI-2500 & PI-5000 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 6: Introduction

    ============================================================================== 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 7 Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== The test set may be plugged into any 60 Hz AC voltage source of 200-250 VAC or 400-500 VAC, and will work on 50 Hz sources of 200-210 VAC or 400-420 VAC.
  • Page 8 GENERAL DESCRIPTION – PI5000 The PI-5000 is composed of the PI2500 as described above, and the AUX-5000 auxiliary output unit, which when combined gives the unit the capability of testing 4000 ampere breakers, with essentially the same specifications as the proven PI-4000B.
  • Page 9 2000 am- peres. The configuration switch on the PI2500 must be set to 4000 or 2000 for proper output readings. The combined unit, known as the PI-5000, can only be used on 480 VAC. ============================================================================== Copyright(C) 1994-2008 Electrical Test Instruments, LLC.

  • Page 10: Monitor And Controller Mac-20

    Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== MONITOR AND CONTROLLER MAC-20 The MAC-20 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 out- put current pulses as short as one-half cycle.

  • Page 11: Pi2500 Specifications

    Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== 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 &...

  • Page 12: Pi5000 Specifications

    Width: 30.0 in. (762 mm) Depth: 25.0 in. (635 mm) Weight: 585 lb. (218kg) DIMENSIONS AND NET WEIGHT PI-5000 (Combined PI-2500 & PI-5000AUX) Height: 41 in. (1041 mm) (includes castors and hood) Width: 48.0 in. (1219 mm) Depth: 25.0 in. (610 mm) Weight: 1100 lb.

  • Page 13: Section Ii: Detailed Description

    Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== SECTION II DETAILED DESCRIPTION ============================================================================== Copyright(C) 1994-2008 Electrical Test Instruments, LLC. All Rights Reserved Page II-9...

  • Page 14: Theory Of Operation

    Electrical Test Instruments PI-2500 & PI-5000 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 15 Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== control panel to provide 12 VDC. The dual primary of transformer T6 steps it down by a factor of 1/2, and T10 steps it down by another factor of ½, and this voltage is sensed by a voltage relay circuit and read on the control panel LED meter.
  • Page 16 Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== current power to the test set output circuitry through the SCR controller. The 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.
  • Page 17 Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== voltage balance on the series connected pairs, and also provide a resistive load to stabilize the SCR controller at low output settings. The secondary currents from T4 and T5 are monitored by the Programmable Overload Device (POD), which also measures actual temperature in the primary winding of T1A.
  • Page 18 Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== Illustration of PI-2500 Stab Plate Assembly: AUX5000 Main Unit Circuitry The AUX-5000 auxiliary unit connects to a 480 VAC supply and ground by means of standard input jacks. Primary protection is provided by 200-amp fuses F1 and F2.

  • Page 19: Pi-2500 Indicator Control Panel Circuitry

    Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== 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 20 Electrical Test Instruments PI-2500 & PI-5000 Section II - Detailed Description ============================================================================== to the test set. 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.
  • Page 21 Electrical Test Instruments PI-2500 & PI-5000 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 22 Electrical Test Instruments PI-2500 and PI-5000 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 23 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 24: Major Parts Identification And Operation

    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 25 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 26 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 27 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 28: Mac-20 Internal Parts

    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 29: 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 30 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 accu- racy, adjust the gain potentiometer on the analog board for proper read- ing.
  • Page 31 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 32 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 33 Electrical Test Instruments MAC-20 Retrofit Package Section III – MAC-20 =============================================================================================================== ============================================================================================================= Copyright(C) 1994-2008 Electrical Test Instruments, LLC. All Rights Reserved...

  • Page 34: Section Iv: Operating Instructions

    Electrical Test Instruments PI-2500 and PI-5000 Section IV - Operating Instructions ============================================================================== SECTION IV OPERATING INSTRUCTIONS ============================================================================== Copyright(C) 1994-2004 Electrical Test Instruments, LLC. All Rights Reserved...

  • Page 35: Pre-Test Installation And Setup

    Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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 b) Series bars (three pieces) c) Stab adapter plate assemblies (one set of four) d) Allen wrench (hex) to match socket head bolts...
  • Page 36 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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 37 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 8. 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 38 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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. 14. Make sure that breaker is CLOSED. 15.

  • Page 39: Basic Guidelines And Suggestions

    Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== BASIC GUIDELINES AND SUGGESTIONS 1. Best timing and current accuracy will be obtained with the MAC-20 in cur- rent 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 40: Single Pole Molded Case Breakers

    Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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 41 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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. 2.
  • Page 42 Electrical Test Instruments PI-2500 and PI5000 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. 4.

  • Page 43: Multi-Pole Molded Case Breakers

    Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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 44 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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 45 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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. 4.

  • Page 46: Low Voltage Power Breakers

    Electrical Test Instruments PI-2500 and PI5000 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 47 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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. 2.
  • Page 48 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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. Timing Test, Short Time Delay Note: The breaker's trip time for short time delay will always be less than 30 cy- cles and may be as low as 4-5 cycles.
  • Page 49 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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 50 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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. 4.

  • Page 51: Motor Overload Relays

    Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 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. 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 52 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== 12. Press RESET button. 13. Set MAC-20 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. 15.

  • Page 53: Ratioing Current Transformers

    Electrical Test Instruments PI-2500 and PI5000 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 54: Section V: Service Information And Documentation

    Electrical Test Instruments PI-2500 and PI-5000 Section V - Service Information and Documentation ===================================================================================== SECTION V SERVICE INFORMATION AND DOCUMENTATION ===================================================================================== Copyright(C) 1994-2008 Electrical Test Instruments, LLC. All Rights Reserved...
  • Page 55 Vernier brushes should be inspected for signs of wear or overheating and cleaned or replaced as required. Calibration of the PI-2500 and PI-5000 requires accurate current measurement in 1000A, 2000A, and 4000A connections. Adjustment may be accomplished by means of the potentiometers accessible through the PI-2500 output face plate.

  • Page 56: Parts List (Pi-2500

    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 DESCRIPTION REF DES ETI Number Contactor, 3PST, 90A K1-K2 M-C378 Contactor, 3PST, 40A K3-K4...

  • Page 57: Overall Schematic (Pi-2500

    Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== OVERALL SCHEMATIC (PI-2500) ============================================================================== Copyright(C) 1994-2008 Electrical Test Instruments, LLC. All Rights Reserved Page IV-3...
  • Page 58 PI-2500 and PI-5000 Electrical Test Instruments Section VI - Service Information and Documentation ============================================================================== ============================================================================== Copyright(C) 1994-2008 Electrical Test Instruments, LLC. All Rights Reserved...
  • Page 59 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== ============================================================================== Copyright(C) 1994-2008 Electrical Test Instruments, LLC. All Rights Reserved Page IV-1...
  • Page 60 Electrical Test Instruments PI-2500 and PI5000 Section IV - Operating Instructions ============================================================================== ============================================================================== Copyright(C) 1994-2008 Electrical Test Instruments, LLC. All Rights Reserved Page IV-2...
  • Page 61 Retrofit Package Electrical Test Instruments PI-2500 and PI5000 Electrical Test Instruments Section V - Service Information and Documentation Section IV - Operating Instructions ============================================================================== ============================================================================== 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-2500Pi-5000auxPi-5000 gen2Pi-2500 gen2

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