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Electrical Test Instruments PI-6000
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TABLE OF CONTENTS

SECTION I: GENERAL INFORMATION and SPECIFICATIONS

WARNING

II-1

Introduction

II-2

General Description

II-2

Monitor and Controller MAC-21

II-5

Proposed Enhancements

II-5

Advantages Compared to Other Test Sets

II-6

Trademarks

II-6

PI6000 Specifications

II-7

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

III-1

MAC-21 Unit Circuitry

III-2

MAC-21 Software

III-2

MAC-21 Parts Identification and Operation

III-4

MAC-21 Internal Parts

III-8

Figure II-1: Front Panel

III-9

Maintenance and Calibration of MAC-21

III-10

Parts List (MAC-21)

III-12

Overall Schematic (MAC-21)

III-13

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

IV-14

Ratioing Current Transformers

IV-16

Содержание PI-6000

Страница 1: ...RIMARY 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 410 857 138...

Страница 2: ...ntrol 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 III 1 MAC 21 Unit Circuitry III 2 M...

Страница 3: ...ERVICE INFORMATION AND DOCUMENTATION Maintenance and Calibration of PI 6000 V 1 Maintenance and Calibration of MAC 21 V 1 Parts List PI 6000 V 4 Parts List Indicator Control Panel V 5 Parts List MAC 2...

Страница 4: ...AD THIS ENTIRE MANUAL AND 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 V...

Страница 5: ...lear of protruding components and full width handles with provisions for lifting hooks are on both ends Locking swivel castors on all four corners provide ease of mobility The indicator control panel...

Страница 6: ...ans of a rocker switch on the indicator control panel If the switch is held the taps change at a rate of about one per second Tap change is not allowed when output is on The indicator control panel fe...

Страница 7: ...reliability ruggedness and ease of use Sophisticated electronics in the indicator control panel and the MAC 21 provide state of the art accuracy and convenience while simple connections allow for eas...

Страница 8: ...played a simple touch of the MAINTAIN key activates the function which automatically adjusts the motorized rheostat to hold the current within 5 amperes The memory current displayed after a test indic...

Страница 9: ...easurement circuitry was essentially analog and did not provide accurate true RMS readings The Phenix Technologies HC 30 and HC 100 used a PC compatible computer and real time data analysis software t...

Страница 10: ...0 A 3x 10 1 5 Minutes 15 Minutes 415 830 24000 A 12000 A 4x 6 45 Seconds 15 Minutes 582 1164 30000 A 15000 A 5x 4 4 Seconds 2 Minutes 776 1552 36000 A 18000 A 7x 2 2 Seconds 2 Minutes 1208 60000 A 300...

Страница 11: ...etc 5 Current measurement circuitry consisting of sensors current meter and timer In general a primary voltage is selected by means of a combination of coarse tap and rheostat adjustment This voltage...

Страница 12: ...there is continuity from this point to chassis ground relay K2 on the voltage sensor PCB is energized and enables the interlock for control power If ground integrity is not sensed the Ground Open LED...

Страница 13: ...equipped with an electrical interlocks to avoid damage if all three are simultaneously energized Catastrophic protection is provided by fuses F7 through F16 The adjustable rheostat assembly in the PI...

Страница 14: ...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...

Страница 15: ...utput of the test set is ON 12 VAC will be applied to DS5 and also will be sensed by the PC board which will inhibit tap change The INV 4A and B signals provide a voltage equal to the input voltage Th...

Страница 16: ...perature of the output section and other conditions as determined by the POD A thermistor in the winding of the first section of the output transformer provides actual temperature but the POD also cal...

Страница 17: ...Test Instruments LLC All Rights Reserved Page II 13 Figure II 2 Indicator Control Panel Thermal Status Bus Vernier ON Stab Voltage READY INTERLOCK ON OFF Output Main Control Coarse Tap Vernier Power I...

Страница 18: ...C 1994 2019 Electrical Test Instruments LLC All Rights Reserved MEMORY AMMETER CONTROLLER MAC 21 INSTRUCTION MANUAL Firmware Version 3 06 and above Electrical Test Instruments LLC 1301 Avondale Road S...

Страница 19: ...0 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 0 01 sec TIMER RANGES 0 9 999 0 99 99 0 999 9 0 9999 Seconds 0 999 9 0 9999...

Страница 20: ...S value displayed in CONTINUOUS mode This is useful for pickup tests It may not be accurate for times less than 1 second INITIATE key This key is used to turn ON the output of the test set The LED in...

Страница 21: ...osts indicates that the protective device under test is in its normal non tripped mode and ready to accept current This mode may be used for testing multi pole breakers by connecting the CONTACTS bind...

Страница 22: ...et In MEMORY mode LED on the current display will read the continuous output current until the test is complete At this time the LED will flash and the display will read the computed true RMS value of...

Страница 23: ...abled in MAINTAIN mode unless a preset value is set in CYCLES time base SERIAL port This standard serial port may be connected to a printer computer or other device to print or store time and current...

Страница 24: ...rovides 120 VAC control power and connects to the air core CT current sensor and initiate circuitry of the test set The wiring of this connector is essentially compatible with that of the EIL Accu Amp...

Страница 25: ...e it is being transported and subject to shock and vibration The standard rack mount hardware and twist lock connector make it simple to remove the MAC 21 and carry it separately Field calibration of...

Страница 26: ...imer begins to run This is the Current Latch Threshold which should be about 10 of 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 th...

Страница 27: ...umber 1 1 MAC 21 Contact LED Harness S B369 2 1 MAC 21 Rear Panel Harness S B368 3 1 MAC 21 Metal Cage M D464 4 1 MAC 21 Main PCB M C492 5 1 MAC 21 Membrane Switch Panel M D462 6 6 LOCKWASHER INT TOOT...

Страница 29: ...2 Additional requirements for testing are as follows a Breakers to be tested b Manufacturers curve data c Test log and or report forms See examples at end of section d Basic hand tools wrench screwdri...

Страница 30: ...wer switch Green lamp should light control panel should power up to tap 1 and MAC 21 should power up Fans should run 14 If Interlock lamp is not lit press Main Power Ready switch Main contactor should...

Страница 31: ...he test set is powered up 4 Always choose an ammeter range that allows the test current to be read in the area from 20 to 80 of the maximum This provides greatest accuracy of readings least chance of...

Страница 32: ...ss PRESET again to return to normal mode 8 Select MEMORY mode 9 Repeatedly jog the INITIATE button while adjusting the OUTPUT CONTROL higher until the desired test current is read on the ammeter If in...

Страница 33: ...ASE to CYCLES 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 8 Sel...

Страница 34: ...re 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 2 Follow steps 1 through 16 in pre test install...

Страница 35: ...to cool Note it is acceptable if all poles of the breaker trip within 15 of the manufacturer s time range for the value of test current chosen All poles of the breaker need not trip in exactly the sa...

Страница 36: ...ecord ammeter reading as instantaneous pick up of the breaker 13 Repeat the above test for the other poles of the circuit breaker 14 Shut down test set disconnect breaker and prepare for subsequent te...

Страница 37: ...ers include timing test on L T D timing test on S T D and instantaneous pick up It is recommended that the magnitude of test current for the L T D timing test be 3 times coil rating or transformer tap...

Страница 38: ...urn to normal mode 9 Select MEMORY mode 10 Repeatedly jog the INITIATE button while adjusting the OUTPUT CONTROL higher until the desired test current is read on the ammeter If insufficient current is...

Страница 39: ...in timing if a test current of 1500 2000 or 2500 amperes is used Set up of controls is the same as for timing test L T D Consult breaker manufacturer s literature to determine any necessary precautio...

Страница 40: ...he setting to its minimum value At the end of the test restore the instantaneous setting to its specified value 2 Follow steps 1 through 16 in pre test installation and setup as required to set up the...

Страница 41: ...oles of the circuit breaker 7 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...

Страница 42: ...rving the CONTINUITY lamp 11 Repeatedly jog the INITIATE button while adjusting the OUTPUT CONTROL higher until the desired test current is read on the ammeter If insufficient current is obtained at m...

Страница 43: ...n ends of the circuit until the resultant arc is extinguished Under these conditions personal injury and or damage to the current transformer under test are probable 1 Follow steps 1 through 16 in pre...

Страница 44: ...ructions Copyright C 1994 2019 Electrical Test Instruments LLC All Rights Reserved Page IV 15 9 Shut down test set disconnect CT and prepare for subsequent testing or relocation according to steps 18...

Страница 45: ...rag and checked for signs of bearing wear by spinning Rheostat brushes should be inspected for signs of wear or overheating and cleaned or replaced as required Calibration of the PI 6000 requires accu...

Страница 46: ...testing 3 Connect the calibration standard to the desired output tap If cables are used it is recommended that they be twisted so as to minimize radiation and pickup of stray magnetic fields 4 Apply p...

Страница 47: ...han 6 cycles 0 1 Sec duration The meter should read the same value within 2 that was set in step 11 above 14 Check pulse reading operation in this manner for currents of 200 400 600 and 1000 Amperes a...

Страница 48: ...eostat assembly T1A B C D S B315 22 1 Transformer output T2 M D205 23 1 Transformer isolation 50VA T6 M E116 24 1 Transformer isolation 1100VA T8 M E115 25 1 Transformer 120V 12VCT T4 M C161 26 1 MOV...

Страница 49: ...igital Panel Meter M1 M C524 3 1 Relay DPDT 120VAC K1 M C147 4 3 Relay DPDT 12 VDC K2 4 M C149 5 4 Switch pushbutton lighted S1 S4 M C110 6 1 Indicator DS4 M C111 7 2 Lens Red XS2 XDS2 M C112 8 2 Lens...

Страница 50: ...nd Documentation Copyright C 1994 2019 Electrical Test Instruments LLC All Rights Reserved Page V 5 PARTS LIST MAC 21 The overall schematic is on the following pages The parts list is provided below P...

Страница 51: ...Electrical Test Instruments PI 6000 Section V Service Information and Documentation Copyright C 1994 2004 Electrical Test Instruments Inc All Rights Reserved Page V 7 OVERALL SCHEMATIC PI 6000...

Страница 52: ...trical Test Instruments PI 6000 Section V Service Information and Documentation Copyright C 1994 2019 Electrical Test Instruments LLC All Rights Reserved Page V 8 OVERALL SCHEMATIC Indicator Control P...

Страница 53: ...y shall not apply to equipment which has been subjected to negligence accident or damage by operation maintenance or storage or to non normal use or service This limited warranty does not cover reimbu...

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