Introduction; General Description - ETI PI-800-GEN2 Instruction Manual

Electrical Test Instruments PI-800 GEN2 and PI-1600 GEN2

INTRODUCTION

A primary injection test set, such as the PI-800 GEN2 and PI-1600 GEN2, 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 mech-
anisms and breaker contacts.

GENERAL DESCRIPTION

The PI-800 GEN2/1600 Circuit Breaker Test System incorporates modular de-
sign and flexibility to provide unequaled capability in a portable package. The
PI-800 GEN2 used alone, generates continuous current of 400, 800, or 1600
amps at 4.2 kVA, with peak output to over 10x. The PI-Aux boosts total power to
9.8 kVA, and allows testing of drawout breakers and MCBs to 1600 A. The units
are housed in rugged interlocking suitcase-size enclosures. Each piece weighs
no more than 125 pounds, allowing one-person hand truck mobility. Basic oper-
ation is very simple, and the proven MAC-21 provides optimal output control and
measurement.
The PI-800 GEN2 is a versatile and technologically advanced portable primary
injection test set capable of testing circuit breakers up to 800 amperes frame
size. It incorporates a special lightweight toroidal output transformer with dual
primaries, and quad secondaries to provide optimal impedance matching to a
wide range of breaker sizes. Internal fan cooling allows maximum utilization of
the output transformer and faster recovery after overload conditions.
The PI-800 GEN2 consists of a strong stainless-steel frame, housed in a rugged
plastic and aluminum enclosure with removable sealed front and back lids for
maximum protection of controls and indicators, as well as storage for test leads,
manuals, etc. All controls, indicators, and input connections are on the front
panel. The versatile 50-amp input plugs may be connected to heavy duty port-
able cords with a variety of connectors for 120 VAC, 208 VAC, or 240 VAC. Indi-
vidual leads may also be used to connect to buswork. The output connections
are on the rear, along with an auxiliary Output ON indicator, configuration
switch, and air output from the fans, which can help cool cables and breakers.
Comfortable recessed side handles provide ease of mobility.
The MAC-21 is supplied in a separate rugged portable case, interlocks on top of
the PI-800 GEN2, and connects to a cable in the rear of the test set.
The eight-silver plated output bus connectors allow configuration for continu-
ous outputs of 800 amperes at 4.2 VAC, and 400 amperes at 8.4 VAC, for testing
molded case breakers with cables. They can also be connected for 1600 am-
peres at 2.1 VAC, which can be used for CT testing, heat runs of bus connections
and limited testing of air drawout breakers. They have pressed-in 3/8"-16 stain-
less steel threaded inserts, which eliminates the need for nuts, and the
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