Multi-Amp CB-832 Bedienungsanleitung

Part 12470

Rev. 2 3/25/99

INSTRUCTION MANUAL

For

HIGH CURRENT TEST SET

MODEL CB-832

It is essential that this instruction book be read thoroughly before putting the equipment in service.

Advanced Test Equipment Rentals

www.atecorp.com 800-404-ATEC (2832)

Part 12470

Rev. 2 3/25/99

IMPORTANT

The information and data contained within this instruction manual are proprietary with MULTI-

AMP Corporation. The equipment described herein may be protected by one or more U.S. letters

patent. MULTI-AMP specifically reserves to itself all rights to such proprietary information aswell

as all rights under any such patent, none of which is waived by the submission of this instruction

manual to anyone.

The recipient, if a Government agency, acknowledges that this instruction book and the equipment

described were procured with "Limited Rights" to technical data as described in ASPR 9-203 (b).

Part 12470

Rev. 2 3/25/99

TABLE OF CONTENTS

SECTION PAGE

I. INTRODUCTION ............................................................................................................. 1

A. Specifications.............................................................................................. Bulletin

B. General Information............................................................................................... 1

C. About This Manual................................................................................................ 1

D. Safety Precautions.................................................................................................. 2

II. THEORY OF OPERATION.............................................................................................. 3

A. Description of Controls.......................................................................................... 3

B. Selection of Output Terminal ................................................................................ 6

C. Selection of Output Leads...................................................................................... 6

D. Overload Capacity .................................................................................................. 7

III. TEST PROCEDURES....................................................................................................... 8

A. Maintenance of Motor Overload Relays................................................................ 8

1. Planned Maintenance Program................................................................. 10

2. Time Delay................................................................................................ 11

3. Instantaneous Element.............................................................................. 13

B. Maintenance of Molded Case Circuit Breakers........................................ 15

1. Planned Maintenance Program................................................................. 15

2. Thermal Element....................................................................................... 16

3. Instantaneous Element.............................................................................. 18

4. Ground Fault Element............................................................................... 19

IV. SERVICE DATA 21

A. Service and Repair Order Instructions.................................................................. 22

B. Preparation for Reshipment .................................................................................. 23

C. Operational Errors/Troubleshooting..................................................................... 23

D. Warranty ............................................................................................................... 25

V. SCHEMATICS................................................................................................................. 26

Part 12470

Rev. 2 3/25/99

SECTION I

INTRODUCTION

GENERAL INFORMATION

TheMulti-AmpModelCB-832is aself-containedtest setwhichincorporatesavariablehighcurrent

output and appropriate control circuitry and instrumentation for testingthermal ,magnetic, or solid-

state motor overload relays, molded-case circuit breakers and ground fault trip devices.

ABOUT THIS MANUAL

This manual provides the user with all of the necessary information for complete working

understanding of the CB-832 test set. It is divided into five main sections.

SECTION I Gives a description of the test set. Gives basic guidelines on the

different applications performed with it.

SECTION II Is a detailed guide to all the controls and operating modes of the CB-

832. This section is by far the most important for understandinghow

to use the test set.

SECTION III Contains selected test procedures for motor overload relays and

molded case circuit breakers.

SECTION IV This section contains a troubleshooting guide and service and repair

information.

SECTION V This section contains a schematic drawing of the test set.

Part 12470

Rev. 2 3/25/99

SAFETY PRECAUTIONS

Every consideration has been given to the designand constructionof the Multi-Amp ModelCB-832

Portable High Current Test Set to make it a safe piece of test equipment as well as one that is

accurate, reliable, and easy to use.

WARNING

The Model CB-832 is not designed for use on energized circuits. For the safety of the operator and

protection of the instrument, do not connect it to circuits that are energized. This includes circuits

that could become energized during the course of a test procedure utilizing this instrument.

It must be remembered that the test set is capable of producing voltageand currentlevelsthat can be

deadly if personnel come in contact with them.

For safe operation, it is absolutely essential that the technician properly and effectively ground

(earth) the test set. This is accomplished by connecting the input line cord to a properly grounded

receptacle.

CAUTION

The input voltage of this instrument is not selectable. All the units are shipped from the factory set

up for operation from either a nominal 115 volt or 230 volt source. If the unit is to be used on a

voltage source different than the nameplate specifies, major changesin thetest set arerequired. It is

necessary for the technician to contact the factory to obtain the necessary parts and instructions

before attempting to change the input voltage of the test set.

The CB-832 should be properly operated by qualified personnel who have familiarized themselves

with the test set and thoroughly read the instruction manual provided with it.

If questions arise concerning the care, operation, maintenance or application of the test set, contact

the Multi-Amp Corporation for assistance.

Part 12470

Rev. 2 3/25/99

SECTION II

THEORY OF OPERATION

DESCRIPTION OF CONTROLS

This section of the instruction manual describes thefunctionsof allthe variouscontrol switches, etc.

which are located on the control panel of the Model CB-832. All controls are clearly marked and

logically grouped so that continual reference to the instruction manualshouldnot benecessaryafter

the operator has become acquainted with the operation of the test set.

POWER ON/OFF Switch

Controls input power to the test set. The self-protected switch resets

after an overload, when placed in the OFF position. Displays will

light when the switch is ON.

MAIN FUSE

Protects power output circuit of CB-832 against overloads.

CONTROL FUSE

Protects instrumentation and control circuitry against overloads.

OUTPUT CONTROL

Variable autotransformer provides continuous non-stepped output

froma varietyof current-ratedterminals. Outputsystemiscontrolled

by a combination of timer STOP MODE and OUTPUT MODE

Switch positions.

OUTPUT ON Lamp

Lights whenever output control circuit is energized.

OUTPUT Terminals:

A combination of the COMMON terminal and any one of the three

current-designated terminals provides an output circuit. Refer to

other sections of the text for an explanation of the output

characteristics of these terminals.

NOTE: Thecurrentdesignationoftheseterminalshasno bearingontheactualcurrentoutput

capability of each. Much higher currents can be achieved depending on test circuit

impedance and duration of the test.

Part 12470

Rev. 2 3/25/99

OUTPUT MODE Switch

Initiates the output circuit in conjunction with the appropriate Timer

STOP MODE Switch position.

MOMENTARY

Momentary on position with spring return to OFF. Output will

remain energized as long as switch is held in MOMENTARY

position and is de-energized when released. Timerstartsand stops in

the same manner. Used for jogging the output circuit.

MAINTAIN

Maintained on position with spring return to OFF. Output will

remain energized until appropriate STOP MODE function occurs,

switch is moved to OFF position or current drops below threshold

requirement.

OFF

Test set input power remains energized but output current remains

de-energized and timer will not count.

AMMETER

LED displays show the numeral one in the left most position when

the meter is over-ranged.

RANGE SWITCH

Decimal of display shifts one digit to the right for each increase in

range selection.

DISPLAY MODE Switch

Selects either the NORMAL or MEMORY mode of the ammeter.

NORMAL

Ammeter updates reading continually as long as the output is

energized. Reading is lost when the output is de-energized.

MEMORY

Ammeter retains the highest peak value attained during current

output operation above 8% of the full scale of range selected.

Reading is retained until the output is reinitiated or RANGE

SWITCH position is changed.

TIMER

Automatically resets each time output is reinitiated.

CYCLES/SEC. Switch

Selects cycles or seconds mode.

Part 12470

Rev. 2 3/25/99

CYCLES Position

The timer counts in whole

cycles and uses the power

input line frequency as timing

reference.SEC. Position

The timer counts in two selectable increments and uses an internal

10kHz oscillator as timing reference.

.01/.001 Switch

Selects one of two counting increments available for the timer SEC.

mode.

NOTE: Changing the position of the CYCLE/SEC. Switch (or the .01/.001 Switch while in

the SEC. position) during timer operation will produce erroneous readings.

CONTACTS Binding Posts

Circuit controls output and timer in the normally open or normally

closed positions of the STOP MODE Switch.

NOTE: Do not connect CONTACTS binding posts to an energized circuit.

STOP MODE Switch

Selects either current actuated position to stop the current output and

timer, or either of the two external contact stop mode positions.

NORM. OPEN

With CONTACTS binding posts connected to normally open

contacts, output circuit will remain energizedand timerwill continue

to run until contacts close.

NORM. CLOSED

With CONTACTS binding posts connected to normally closed

external contacts, output circuit will remain energized and timer will

continue to run until contacts open.

CURRENT

Timer will initiate only when the output circuit is completed and a

threshold current of approximately 8% offull scale of ammeter range

selected is exceeded. Timer will continue to run until output circuit

opens, current drops below threshold level or output is de-energized.

Part 12470

Rev. 2 3/25/99

SELECTION OF OUTPUT TERMINAL

Three output terminals at various voltage and current ratings are provided to adapt the CB-832 to a

wide variety of test circuit impedances.

TheMulti-AmpModelCB-832circuitbreakertestset hasthreecurrentoutputterminalstoprovidea

wide range of current-voltage capabilities. The terminal with the lower current rating provides an

output with the highest voltage for testing devices of low current requirements but with high

impedance characteristics. This tap also has the highest output resolution capable of fine current

adjustments. The highest current rated output terminal provides high current availabilityfor testing

devices of high current requirements of relatively low impedance. This tap offers the highest

resolution for voltage applications. Should the current required for the device to be tested exceed

the ability of the lowest tap or the impedance of the device to be tested require more voltage to

"push" the current than is available from the highest current tap, the medium range current tap can

be utilized to provide the current or voltage necessary to perform the desired test. Selection of the

output terminal depends entirely on the characteristics of the device to be tested, therefore, proper

selection will require some experimentation and will be easier as familiarity increases.

NOTE: There is no relationship between the ammeter ranges and the ratings of the output

terminal. All ammeter ranges can be used in conjunction with any of the output

terminals.

SELECTION OF OUTPUT LEADS

Model CB-832 is equipped with output connecting bars for attachment of the high current testleads

provided or any others suitable for the test application.

The following information on the selection of output leads will provide the user with a guide for

choosing the proper test leads for his application.

Due to the voltage drop from the inductive reactance of the test circuit, a significant loss of

current will result for each inch of test lead. Therefore, when choosing test leads, the length

and size of leads chosen will determinethe maximumavailable test current. It isworthwhile

to sacrifice cross section of test leads for the sake of reducing length. Everyinch of lead that

can be eliminated provides worthwhile increase in available test current. Heating is not a

significant problem in testing, even though the leads become hot. Paralleling of sufficient

cables provides highertest currents. Each cable can befittedwitha compressionlug oneach

end, then bolted to the output terminals or stab board of the test set and the breaker.

The two cables between the test set and the breaker should be twisted together or bundled

with tape or cord to maintain the close proximity, which minimizes inductive reactance.

OVERLOAD CAPACITY

Part 12470

Rev. 2 3/25/99

Model CB-832 is rated at 1.75 kVA output and is equippedwith three output terminals, each capable

of supplying its rated current. The current rating of these output terminals may be exceeded for

short durations provided the voltage rating is sufficient to "push" the desired current through the

device under test and the connecting test leads. The overload capacity, represented by multiples of

rated current, versus TIME ON and TIME OFF are given below.

%Rated Maximum Minimum

Current Time ON Time OFF

100 (1x) 30 minutes 30 minutes

200 (2x) 3 minutes 8 minutes

300 (3x) 30 seconds 4 minutes

400 (4x) 7 seconds 2 minutes

Model CB-832 also can be used continuously for any reasonable length of time at 70.7% of the

current rating of the output terminal.

EXAMPLE:

Consider the terminal rated at 500 amperes:

a. 500 amperes may be drawn at any voltage from 0-3.5 volts for 15 minutes provided

the test set is subsequently de-energized for 30 minutes.

b. 353.5 amperes (70.7% of 500 amperes) may be continuously drawn at any voltage

from 0-3.5 volts for any reasonable length of time.

c. Thefollowingoverloadcurrentsmaybe drawnat anyvoltagefromzeroto maximum

volts for the Time ON indicated, followed by the indicated Time OFF. The

maximum output voltage available when the current rating of the output terminal is

exceeded (overloaded) will be less than the rated value due to the regulation of the

transformer in the test set. For example, when drawing 750 amperes from the 500

ampere terminal, the maximum voltage available is approximately 2.9 volts.

500 Ampere Time ON Time OFF

750 amperes 6 minutes 13 minutes

1000 amperes 3 minutes 8 minutes

It should be noted that because of the impedance of the device under test and the connecting test

leads, the maximum practical test current available from the terminal rated 500 amperes is

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