Full-Function Test Kit

Series 1 Software Version 1.60

Instruction Bulletin /

48049-183-06
Rev. 02, 05/2015
Retain for future use.

™
0
Full-Function Test Kit
Series 1 Software Version 1.60

ENGLISH
Instruction Bulletin
48049-183-06
Rev. 02, 05/2015
Retain for future use.

™
 Hazard Categories and Special Symbols
ENGLISH

Read these instructions carefully and look at the equipment to become familiar with
the device before trying to install, operate, service, or maintain it. The following
special messages may appear throughout this bulletin or on the equipment to warn
of hazards or to call attention to information that clarifies or simplifies a procedure.
The addition of either symbol to a “Danger” or “Warning” safety label indicates that
an electrical hazard exists which will result in personal injury if the instructions are
not followed.
This is the safety alert symbol. It is used to alert you to personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

NOTICE
NOTICE is used to address practices not related to physical injury. The safety
alert symbol is not used with this signal word.

NOTE: Provides additional information to clarify or simplify a procedure.

Please Note
Electrical equipment should be installed, operated, serviced, and maintained only
by qualified personnel. No responsibility is assumed by Schneider Electric for any
consequences arising out of the use of this material.
A qualified person is one who has skills and knowledge related to the construction,
installation, and operation of electrical equipment and has received safety training
to recognize and avoid the hazards involved.
 Full-Function Test Kit

FCC Notice

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This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to part fifteen of the FCC Rules. These limits are designed
to provide reasonable protection against harmful interference when the equipment
is operated in a commercial environment. This equipment generates, uses, and
can radiate radio frequency energy and, if not installed and used in accordance
with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required to correct the
interference at his own expense. This Class A digital apparatus complies with
Canadian ICES-003.

Full-Function Test Kit Software Version and Upgrade

Full-Function Test Kit (FFTK) software version 1.60 is programmed to work in both
Series 1 and Series 2 FFTK units. Software version 1.60 recognizes the hardware
and configures the program to work on either hardware version.
FFTK software version 1.60 is available for download from the Schneider Electric
internet site: www.schneider-electric.com/download.

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 5

 Full-Function Test Kit
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6 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Table of Contents Full-Function Test Kit

Table of Contents

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Table of Contents ............................................................................................. 7
Full-Function Test Kit Identification .................................................................. 9
Technical Specifications .......................................................................... 10
Determine Trip Unit Compatibility ............................................................ 10
Connections ................................................................................................... 11
Connect Power Cable .............................................................................. 11
Compact™ NS Circuit Breakers Equipped with STR Trip Units .............. 11
Micrologic™ and ET Trip Units ................................................................ 11
Power-On Test ............................................................................................... 12
Language Selection ....................................................................................... 13
From Full-Function Test Kit Title Screen ................................................. 13
From Select Test Kit Function Screen ..................................................... 14
Secondary Injection Testing ........................................................................... 15
Secondary Injection Test Setup Procedures ........................................... 15
Configure Circuit Breaker Parameters............................................... 16
Automatic Trip Curve Test (All Trip Units Except STR22ME) .................. 20
Configure Protection Parameters ...................................................... 20
Configure Automatic Trip Curve Test ................................................ 21
Save Test Files .................................................................................. 23
Automatic Trip Curve Test (STR22ME Trip Unit Only) ............................ 24
Configure Protection Parameters ...................................................... 24
Configure Automatic Trip Curve Test ................................................ 24
Save Test Files .................................................................................. 26
Manual Trip Curve Test (All Trip Units Except STR22ME) ...................... 27
Save Test Files .................................................................................. 29
Manual Trip Curve Test (STR22ME Trip Unit Only) ................................ 30
Save Test Files .................................................................................. 31
Mechanical Operation Trip Test ............................................................... 32
Zone-Selective Interlocking Test .................................................................... 33
Inhibit Functions ............................................................................................. 35
Ground-Fault Inhibit ................................................................................. 35
Thermal-Imaging Inhibit ........................................................................... 38
View, Delete and Print Saved Test Files ........................................................ 41
View Saved Test Files ............................................................................. 41
Delete Saved Test File ............................................................................ 43
Delete One Saved Test File .............................................................. 43
Delete All Saved Test Files................................................................ 44
Print Saved Test Files .............................................................................. 45
Configure Full-Function Test Kit Options ....................................................... 45
Language Selection ................................................................................. 45
Set Display Screen Backlight ................................................................... 46
Adjust Display Screen Contrast ............................................................... 46
Calibrate Display ...................................................................................... 46
Maintenance .................................................................................................. 47
Fuse Replacement ................................................................................... 47
Calibration ................................................................................................ 48
Cleaning ................................................................................................... 48

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 Full-Function Test Kit Table of Contents

Troubleshooting ............................................................................................. 48
General Errors ......................................................................................... 48
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Error Messages ....................................................................................... 52

Glossary ......................................................................................................... 53
ASIC (Application Specific Integrated Circuit) ................................... 53
Circuit Breaker Family ....................................................................... 53
Circuit Breaker Type .......................................................................... 53
Close and Latch................................................................................. 53
Earth-Leakage Delay (th)................................................................... 53
Earth-Leakage Pickup (Ih) ................................................................. 53
Ground-Fault Delay (tg) ..................................................................... 53
Ground-Fault Pickup (Ig) ................................................................... 53
In........................................................................................................ 53
Interrupt Rating .................................................................................. 53
LSIG/LSIV.......................................................................................... 53
Long-Time Ampere Rating................................................................. 53
Long-Time Delay (tr).......................................................................... 53
Long-Time Pickup (Ir) ........................................................................ 53
Selectivity........................................................................................... 54
Short-Time Delay (tsd)....................................................................... 54
Short-Time Pickup (Isd) ..................................................................... 54
Standard ............................................................................................ 54
Trip Unit ............................................................................................. 54
Trip Unit Family.................................................................................. 54
Trip Unit Type .................................................................................... 54

8 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Full-Function Test Kit Identification Full-Function Test Kit

Full-Function Test Kit Identification

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Figure 1 – Full-Function Test Kit and Case Contents

A F

D J

E 06134953
06134954

G
A—Power Cable Receptacle
B—Power Switch
C—Line Fuse Holder and Voltage Selector
D—RS232 Serial Connection Port
E—Trip Unit Test Cable Ten-Pin Port
F—Interface Screen
G—Keys
H—Two-Pin Test Cable (STR Trip Units)
I—Seven-Pin Test Cable (Micrologic™ Trip Units)
J—10 A Filtered Power Cable

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 Full-Function Test Kit Full-Function Test Kit Identification

Technical Specifications
Table 1 – Full-Function Test Kit Technical Specifications
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Parameters Value
2 A, 250 Vac, Fast-blow (Recommended Fuse:
120 Vac Applications
Bussman Part No. AGC-2)
Fuse
1 A, 250 Vac, Fast-blow (Recommended Fuse:
230 Vac Applications
Bussman Part No. AGC-1)
Nominal Operating Voltage 115–230 Vac
102–144 Vac
Operating Voltage Range
207–253 Vac
50 Hz
Operating Frequency
60 Hz
Operating Temperature -20–50 °C
Storage Temperature -20–60 °C
Nominal Voltage 24 Vdc
24 Vdc Power Tolerance 22.8–25.2 Vdc
Maximum Output Current 100 mA
Accuracy ±5 mS
Trip Time Measurement Resolution 1 mS
Range 0–3000 sec.
Accuracy (Percent Error in Amplitude +
±3%
Percent Error in Frequency)
Voltage Source
Nominal Frequency 60 Hz
Fault Signal
Amplitude Range 0.031–21.5 at 60 Hz Vrms
Accuracy ±3%
Current Source
Amplitude Range 0.020–2.3 Amperes dc
Installation Category (Overvoltage Category) Category II
Maximum Power Rating 100 W

Determine Trip Unit Compatibility

Refer to Table 2 to determine which tests and functions are applicable then follow
appropriate connection procedures. Read this instruction bulletin in its entirety
before initiating any test or function.
Table 2 – Trip Unit Compatibility

Test Functions Inhibit Functions

Test Ground- Thermal-
Trip Unit Family/Type Automatic Manual Mechanical ZSI
Cable Fault imaging
Trip Trip Operation Function
Inhibit Inhibit
STR22ME, STR22GE, STR22SE, 2-Pin
X X X
STR23SE, STR23SP, STR43ME Test
STR53UP, STR53UE Cable X X X
Non-Communicating ET 1.0M X X X
ET 1.0I X X X
ET1.0 7-Pin X X X
Micrologic 2.0, 3.0, 5.0 Test X X X
Micrologic 2.0A, 3.0A, 5.0A, 7.0A Cable X X X X X
Communicating Micrologic 5.0P, 5.0H, 7.0P, 7.0H X X X X X
Micrologic 6.0A, 6.0P, 6.0H X X X X X X

10 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Connections Full-Function Test Kit

Connections

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NOTE: Trip unit must be installed in circuit breaker in order to properly execute the
Full-Function Test Kit tests and inhibit functions.
The power cord, test cables, keys and instruction bulletin are located in the lid
compartment of the Full-Function Test Kit case.
Connect Power Cable
1. Connect socket end of power cord to the power cord receptacle on the Full-
Function Test Kit.
2. Plug other end of the power cord into a grounded outlet.
NOTE: If a Full-Function Test Kit is used in a noisy environment, the power cable
ground connection must be connected to same potential as the cradle of the circuit
breaker being tested.
Compact™ NS Circuit Breakers Equipped with STR Trip Units
1. Connect ten-pin test cable connector (A) to ten-pin port on Full-Function Test
Kit.
2. Connect two-pin test cable connector (B) to test port on STR trip units. Make
sure to observe correct polarity.
Figure 2 – Connection to STR Trip Units

I0 Ir Im
+ -

test

+ - B

test +-
+ -

Micrologic™ and ET Trip Units

NOTICE
HAZARD OF EQUIPMENT DAMAGE
Pins on a seven-pin test cable connector (see Fig. 3) can bend or break if forced.
Avoid using excess force when connecting to trip unit test port.
Failure to follow these instructions can result in equipment damage.

NOTE: Older ET1.0 trip units have the test port covered. Cut the label (A) as
shown to access the trip unit port.
1. Connect ten-pin test cable connector (B) to ten-pin port on Full-Function Test Kit.
2. Connect seven-pin test cable connector (C) to test port on Micrologic trip units.
a. To plug in, push in seven-pin connector and turn clockwise.
b. To unplug, push in seven-pin connector and turn counterclockwise.

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 11

 Full-Function Test Kit Power-On Test

Figure 3 – Connection to Micrologic and ET Trip Units

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A 2

Ii
4
Instan
5
6
taneou
s
7
8
1
10
3

2
x In
setting

ic 2.0
olog
Micr

Plug in 7-pin connector

C 2

3 1

Unplug 7-pin connector

Power-On Test
The Power-On Test, performed each time the Full-Function Test Kit power switch
is turned on, verifies memory has not been corrupted. It also confirms functionality
of interface screen.
A spinning Schneider Electric logo (Fig. 4) is displayed on interface screen during a
power-on test. If the logo continues to spin longer than ten seconds, the Full-
Function Test Kit has failed the power-on test.
Figure 4 – Power-On Test Screen

If the Full-Function Test Kit passes the test, the spinning logo screen will advance
to the Full-Function Test Kit title screen (Fig. 5).
Figure 5 – Full-Function Test Kit Title Screen

FULL-FUNCTION
TEST KIT
VERSION 1.60

LANGUAGE ENGLISH

NEXT

12 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Language Selection Full-Function Test Kit

When the Full-Function Test Kit title screen appears:

• If the LANGUAGE touch key or the NEXT touch key is pressed within 10

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seconds, the test kit will advance to the appropriate screen for the pressed
touch key.
• If the LANGUAGE touch key or the NEXT touch key is not pressed within 10
seconds, the Full-Function Test Kit will automatically go into calibration mode.
After calibration is complete, the test kit will return to the Full-Function Test Kit
Title Screen.
NOTE: Please refer to “Calibrate Display” on page 46 to perform the
calibration.
This procedure applies once each time the test kit is powered on.

Language Selection
The Full-Function Test Kit supports English, French, Spanish, German and Italian.
The language setting can be changed in two places, from the Full-Function Test Kit
Title screen and from the Select Test Kit Function screen.
From Full-Function Test Kit Title Screen
NOTE: Pressing a language touch key on the Select Language screen will
automatically change all Full-Function Test Kit language settings.

Figure 6 – Full-Function Test Kit Title Screen

1. From Full-Function Test Kit title
screen, press the Language
FULL-FUNCTION touch key
TEST KIT
VERSION 1.60

LANGUAGE ENGLISH

NEXT

Figure 7 – Select Language Screen

2. Select the appropriate language
SELECT LANGUAGE setting from the Select
ENGLISH FRANCAIS ESPANOL DEUTSCH Language screen. these
instructionswill return to the
ITALIANO
Full-Function Test Kit title
screen (Fig. 6).

CANCEL

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 13

 Full-Function Test Kit Language Selection

From Select Test Kit Function Screen

NOTE: Pressing the language touch key on the Select Language screen will
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automatically change all Full-Function Test Kit language settings.

Figure 8 – Select Test Kit Function Screen

1. From the Select Test Kit function
SELECT TEST KIT FUNCTION screen, press Configure Test Kit
TEST VIEW/DELETE Options touch key. The display
BREAKER TRIP TEST FILES
CONFIGURE TEST
will advance to the Configure
INHIBIT GROUND
FAULT PROTECTION KIT OPTIONS Test Kit Options screen (Fig. 9).
INHIBIT THERMAL
IMAGE PROTECTION
TEST
ZSI FUNCTION

Figure 9 – Configure Test Kit Options Screen

2. From the Configure Test Kit
CONFIGURE TEST KIT OPTIONS
Options screen press the
LANGUAGE ENGLISH Language touch key.
DISPLAY
70%
3. Select appropriate language
BACKLIGHT setting from the Select
DISPLAY
CONTRAST
65% Language screen (Fig. 7). The
display will return to the
HOME
Configure Test Kit Options
screen (Fig. 9).

14 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

Secondary Injection Testing

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Secondary Injection Test Setup Procedures

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E or CSA Z462.
• This equipment must only be installed and serviced by qualified electrical
personnel.
• Turn off all power supplying this equipment before working on or inside
equipment.
• Always use a properly rated voltage sensing device to confirm power is off.
• Replace all devices, doors and covers before turning on power to this
equipment.
Failure to follow these instructions will result in death or serious injury.

The following set-up procedures apply to automatic, manual and mechanical

secondary injection tests.
From the Select Test Kit Function screen press TEST BREAKER TRIP to advance
to the Configure Circuit Breaker Parameters screen.
Figure 10 – Select Test Kit Function Screen

SELECT TEST KIT FUNCTION

TEST VIEW/DELETE
BREAKER TRIP TEST FILES
INHIBIT GROUND CONFIGURE TEST
FAULT PROTECTION KIT OPTIONS
INHIBIT THERMAL
IMAGE PROTECTION
TEST
ZSI FUNCTION

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 15

 Full-Function Test Kit Secondary Injection Testing

Configure Circuit Breaker Parameters selected on the Configure Circuit Breaker Parameters screen determine
Parameters type and magnitude of the fault to be injected into the circuit breaker during the
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secondary injection test. Values must be selected for all parameters on the Configure
Circuit Breaker Parameters screen before advancing to the next screen.
1. Press the touch key beside each parameter name to select its value.

Figure 11 – Configure Circuit Breaker Parameters Screen

CONFIGURE CIRCUIT BREAKER PARAMETERS

TRIP UNIT
FAMILY STANDARD
TRIP UNIT INTERRUPT
TYPE RATING
BREAKER
FAMILY In
BREAKER
TYPE

HOME NEXT

See Figures 12 and 13 for examples of parameter value locations on the circuit
breaker labels and trip units. The parameter input sequence is controlled by the
Full-Function Test Kit according to the following hierarchy:
• TRIP UNIT FAMILY: select trip unit family (see Table 2 for compatibility)
• TRIP UNIT TYPE: select trip unit type (see Table 2 for compatibility)
• STANDARD: choose electrical standard for circuit breaker (UL, IEC, ANSI or
CCEE)
• BREAKER FAMILY: select circuit breaker family (Compact, Masterpact or
PowerPact)
• BREAKER TYPE: select type of circuit breaker (NS, NSJ, ET, NT, NW, M, P
or R)
NOTE: If testing a standard-width 4000 A ANSI circuit breaker, set STANDARD to
"ANSI" and BREAKER TYPE to "NW40B".
Parameters must be selected according to the hierarchy outlined above. An empty
touch key next to a parameter label indicates its value must be selected before
moving to the next parameter touch key. Parameter values displayed in reverse
video either have only one available option which cannot be altered or are
automatically determined by means of communication between the Full-Function
Test Kit and a communicating trip unit. If these preset values are incorrect, refer to
the trip unit instruction bulletin for more details.
NOTE: Verify that each parameter value is correct before continuing to the next
screen. Full-Function Test Kit records parameter values are entered from the most
recent secondary injection test performed.

16 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

Figure 12 – Circuit Breaker Label Examples for Configure Circuit Breaker Parameters Screen

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A

A C
C B
B
B
C

D
D

A—Circuit Breaker Family

B—Circuit Breaker Type
C—Interrupting Rating
D—Standard
E—Sensor Plug Rating (In)

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 Full-Function Test Kit Secondary Injection Testing

Figure 13 – Trip Unit Examples for Configure Circuit Breaker Parameters Screen
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Micrologic 5.0 Micrologic 6.0 P

B
B
A A
4260A
N 1 2 3
100

50

long time long time

Ir tr alarm alarm
.8 8 Ir .8 tr 8
.7 .9 (s) 4 12 (s) 4
.7 .9 12
.6 .95 2 16 .6 .95 2 16
.5 .98 1 20 .5 .98 1 20
.4 1 .5 24 .4 1 .5 24
x In @ 6 Ir x In @ 6 Ir
short time instantaneous short instantaneous
Isd tsd Ii
3
4
5 (s) . . . 6 8 10
Isd
4
tsd
(s) . . .
Ii
6 8 10
3 5
2.5 6 . .2 4 12 2.5 6 . . 4 12
2 8 . . 3 15 2 8 . . 3 15
1.5 10 . 2
0 2 off
1.5 10 . 0 2 off
x Ir on I t off x In 2
x Ir on I t off x In
setting delay setting delay
test
Ig tg
D
E (s) . . .
C G . .
B H . .
A J . 2
0
on I t off
ground fault

In=800A In=800A

A B
C C
STR 53 UP %Ir >Ir >Isd >Ig

Io Ir Isd Ii Ig
.8 .9 .9 .93 4 5 4 6 .5 .6
.7 1 .88 .95 3 6 3 8 .4 .7 > Ir
.6
.5 1
.85
.8
.98
1
2
7
7 2 9
9
.3
1
.8 A
tr
A—Trip Unit Family
1.5 1.5 .2
x In

tr
x Io

tsd
x Ir x In

tg
x In
tm
B—Trip Unit Series
test 8 .3 .3 .4 .4 In I1 I2 I3
+ -
2
4 (s).2
.1
.2
.1
(s) .3
.2
.3
.2
Ir Isd li C—Sensor Plug Rating
1 8 0 0 .1 .1

(s) @ 6 Ir on I t
2
off on I t
2
off

Figure 14 – Select Circuit Breaker Test Screen

SELECT CIRCUIT BREAKER TEST

AUTOMATICALLY
TEST TRIP CURVE
MANUALLY
TEST TRIP CURVE
TEST MECHANICAL
OPERATION

HOME BACK

2. Once all parameter values have been entered and confirmed on the Configure
Circuit Breaker Parameters screen (Fig. 11), press NEXT to advance to the
Select Circuit Breaker Test screen.

18 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

NOTE:

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• Parameter values displayed in reverse video either have only one available
option which cannot be altered or are automatically determined by means of
communication between the Full-Function Test Kit and a communicating trip unit.
For all trip units, the Full-Function Test Kit identifies trip unit family/type by
connection of either a two-pin or seven-pin test cable. For communicating
Micrologic trip units (see Table 2), the Full-Function Test Kit identifies the sensor
plug value and all available pickup and delay settings for LSIG protection for the
device being tested. In addition to reading these values, the Full-Function Test
Kit can read BREAKER FAMILY, BREAKER TYPE, INTERRUPT RATING and
STANDARD for Micrologic P and H trip units if these trip units have been
properly configured.
• Verify the values for the device parameters are correct before continuing with
test. The Full-Function Test Kit records values entered from previous
secondary injection test performed.
• For Micrologic trip units, the circuit breaker will be ZSI self-restrained for both
equipment ground-fault and short-time protection during secondary injection
testing.
• The contact wear counter on Micrologic P and H trip units will not increment
during secondary injection testing.
• All advanced protections, logging of trips, logging of alarms and activation of
alarms are disabled during secondary injection testing for Micrologic P and H trip
units. Refer to trip unit instruction bulletin for more information on these functions.
• The Full-Function Test Kit cannot disable thermal imaging on non-communicating
trip units (see Table 2). Therefore, a fifteen-minute delay must be observed from
the last long-time trip test performed until the next long-time trip test performed.
• The SDE counter, located in the circuit breaker communication module (BCM),
will increment each time a circuit breaker opens due to a fault secondary
injected by the Full-Function Test Kit. Refer to the trip unit instruction bulletin
for more information regarding this condition.
• The Full-Function Test Kit will only test residual equipment ground-fault
protection. Systems using modified differential ground fault (MDGF) and
ground source return cannot be tested.
• For Micrologic 7.0A, 7.0H and 7.0P trip units, the Full-Function Test Kit cannot
test earth leakage pickup and delay (VIGI) protection. The Full-Function Test
Kit will only test the LSI protection functions of the circuit breaker.
• For Micrologic A trip units only, performing a secondary injection test will reset
to zero the maximum recorded value on each phase. If necessary, record
maximum values before testing.

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 Full-Function Test Kit Secondary Injection Testing

Automatic Trip Curve Test (All Trip Units Except STR22ME)

This mode provides an automated test of the circuit breaker time-current curve,
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allowing the Full-Function Test Kit to verify long-time, short-time, instantaneous

and ground-fault functions. The Full-Function Test Kit injects secondary fault
signals based on trip unit and circuit breaker pickup and delay settings to measure
the amount of time delay before a trip signal is initiated. This data is automatically
compared to the circuit breaker time-current curve to determine if the device is
within tolerance. This comparison of data will determine which specific protection
functions passed or failed.
NOTE: Test points are chosen to minimize test time required to adequately test
each trip curve segment.
Configure Protection 1. Follow secondary injection test setup procedures.
Parameters 2. Choose or confirm the applicable LSIG circuit breaker protection settings on
Configure Protection Parameters screen:
— Io: derating value (STR trip units only).
— Ir: long-time pickup.
— tr: long-time delay.
— Idmtl: inverse definite mean time lag (refer to Micrologic P or H trip unit
instruction bulletin for more information.)
— Isd: short-time pickup.
— tsd: short-time delay.
— Ii: instantaneous trip.
— Ig: ground-fault pickup.
— tg: ground-fault delay.
NOTE: All applicable values for LSIG protection must be entered before
moving to Configure Automatic Trip Curve Test screen.
Figure 15 – Configure Protection Parameters Screen

CONFIGURE PROTECTION PARAMETERS

Ir 0.4 tsd
(40 A) 0.3 s ON

tr 0.5 s Ii 2
(200 A)
IDMTL OFF Ig 0.3
(30 A)
Isd 1.5 tg
(60 A) 0.1 s OFF

HOME BACK NEXT

3. Once all LSIG protection settings are confirmed, press NEXT to advance to
Configure Automatic Trip Curve Test screen.

20 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

Configure Automatic Trip The parameter touch keys on the Configure Automatic Trip Curve Test screen
Curve Test (Long-time, Short-time, Instantaneous and Ground Fault) represent specific

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segments of a trip unit time-current curve. Some segments may be disabled and
appear in reverse video or may not appear at all depending on type and individual
settings of the trip unit and circuit breaker being tested. Refer to Table 2 for
application compatibility. Applicable time-current curve segments can be enabled
or disabled by toggling the touch key next to the appropriate parameter touch key.
1. Select the time-current curve segments to be tested by toggling the appropriate
touch keys to ENABLED.
2. Press NEXT to proceed to the Automatic Trip Curve Test Alert screen.

Figure 16 – Configure Automatic Trip Figure 17 – Automatic Trip Curve

Curve Test Screen Test Alert Screen

CONFIGURE AUTOMATIC TRIP CURVE TEST AUTOMATIC TRIP CURVE TEST ALERT
LONG
ENABLED
TIME
SHORT THIS TEST WILL TRIP THE CIRCUIT
ENABLED
TIME BREAKER. THE CIRCUIT BREAKER SHOULD BE
INSTANT- CLOSED BEFORE STARTING THIS TEST.
ENABLED
ANEOUS
GROUND PROCEED WITH AUTOMATIC TRIP TEST?
ENABLED
FAULT

HOME BACK NEXT YES NO

NOTE: Circuit breaker must be in the closed position to guarantee correct test
results. A Full-Function Test Kit will automatically test a circuit breaker by
injecting appropriate current required to test each enabled section of the time-
current curve.
NOTE: Micrologic 5.0 trip units with a short-time delay setting of I2t ON will fail
the test on the short-time segment of the time-current curve. This failure may
be due to the thermal-imaging feature which causes circuit breakers to trip on
the long-time function. Refer to the trip unit instruction bulletin for more
information on thermal imaging.
To accurately test short-time segment of time-current curve for Micrologic 5.0
trip units with a short-time delay setting of I2t ON, wait 15 minutes after testing
the long-time segment of the time-current curve, then toggle the LONG TIME
time touch key on the Configure Automatic Trip Curve Test screen (Fig. 16) to
DISABLED and perform the test. The fifteen-minute wait period applies each
time the short-time segment of the time-current curve is tested since the
thermal imaging feature is operable regardless of the time-current curve
segment being tested.
3. Read alert message, verify circuit breaker is closed and press YES to initiate test.

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 Full-Function Test Kit Secondary Injection Testing

The Automatic Trip Curve Test screen displays a table with three columns:
• INJECTION CURRENT—shows magnitude of current, in amperes, during
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testing of each segment of the time-current curve.

• TRIP TIME—displays time, in seconds, until circuit breaker trips.
• STATUS—indicates testing progress for each protective function once all the
parameter values have been entered and confirmed on the Configure Circuit
Breaker Parameters screen (Fig. 11), Press NEXT to advance to the Select
Circuit Breaker Test screen.
Figure 18 – Automatic Trip Curve Test Screen

AUTOMATIC TRIP CURVE TEST

INJECTION TRIP STATUS
CURRENT TIME
LONG 53 A 3.188 s ENABLED
TIME
SHORT 130 A
TIME
INSTANT- 250 A
ANEOUS
GROUND 60 A
FAULT
CANCEL

CAUTION
HAZARD OF LOSS OF GROUND-FAULT PROTECTION
Equipment ground-fault protection will be disabled for up to two minutes if the test
cable is removed from the test port on a communicating Micrologic trip unit
without properly exiting the secondary injection testing function. Wait two minutes
before re-energizing circuit breaker.
Failure to follow these instructions could result in injury or equipment damage.

The following variables can appear in the status column:

NOTE: If the test cable is removed from the test port on a communicating
Micrologic trip unit without properly exiting the secondary injection testing
function, advanced protection, activation of alarms, logging of events, equipment
ground-fault protection and thermal imaging may be disabled for up to two
minutes after cable has been removed. Circuit breaker may also be ZSI
restrained for up to two minutes for equipment ground-fault and short-time
protection.
— INITIALIZING (blinking): initializing Full-Function Test Kit and trip unit.
— TESTING: injecting fault signal.
— TRIPPED: fault signal caused circuit breaker to trip.
— STOPPING (blinking): exiting test mode.
— STOPPED (user initiated): fault signal removed.
— PASSED: segment of time-current curve passed.
— FAILED: segment of time-current curve failed.
— ERROR: communication error occurred.

22 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

4. After each segment of the time-current curve is tested, close the circuit breaker
before continuing to the next segment of the time-current curve.

ENGLISH
The Full-Function Test Kit records the amount of time required to initiate a trip
signal for each time-current curve segment and automatically compares results
with the circuit breaker time-current curve points. After checking each time-current
curve segment, the STATUS column indicates which functions passed or failed.
NOTE: If performing another long-time trip test, a fifteen-minute delay must be
observed on non-communicating Micrologic, ET and STR trip units to allow
reset of the thermal memory.
Save Test Files 1. From the Automatic Trip Curve Test screen, press NEXT to advance to the
Save Test File screen. Results of up to fifty completed time-current curve tests
can be saved.
Figure 19 – Save Test File Screen

SAVE TEST FILE

FILE TEST–01
NAME
SAVE
MODE CREATE

HOME BACK NEXT

2. A default test file name is automatically provided in the FILE NAME touch key.
To change the default file name press the FILE NAME touch key to bring up a
keypad screen and enter a new file name.
3. Toggle the SAVE MODE touch key to indicate whether file is new (CREATE) or
replacing an existing file (OVERWRITE).
NOTE: If fifty files already exist it will be necessary to overwrite one of them. If no
files exist, the OVERWRITE option is not selectable.

4. Press NEXT to save the file and proceed to the TEST FILE STATUS screen.

Figure 20 – Test File Status Screen

TEST FILE STATUS

FILE
NAME TEST–01
SAVE CREATE
MODE
STATUS SAVED

HOME BACK

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 23

 Full-Function Test Kit Secondary Injection Testing

Automatic Trip Curve Test (STR22ME Trip Unit Only)

This mode provides an automated test of the circuit breaker time-current curve.
ENGLISH

This function allows the Full-Function Test Kit to verify long-time, short-time and
instantaneous functions. The Full-Function Test Kit injects secondary fault signals
based on the trip unit settings and measures the amount of time delay before a trip
signal is initiated. This data will then automatically be compared to the circuit
breaker time-current curve to determine if the device is within tolerance. This
comparison of data will determine which specific functions passed or failed.
Configure Protection 1. Follow secondary injection test setup procedures.
Parameters 2. Set trip unit long-time pickup to minimum value.

Figure 21 – Configure Protection Parameters Screen

CONFIGURE PROTECTION PARAMETERS

Ir 0.6

HOME BACK NEXT

NOTE: The Full-Function Test Kit cannot accurately detect when the circuit
breaker has tripped if the pickup setting is higher than the minimum value. If the
pickup setting is normally set higher than the minimum value, record the value so it
can be reset after testing is complete.
Configure Automatic Trip The parameter touch keys on the Configure Automatic Trip Curve Test screen
Curve Test (Long-time, Short-time and Instantaneous) represent specific segments of a trip
unit time-current curve. Some segments may be disabled and appear in reverse
video or may not appear at all depending on the type and individual settings of the
trip unit and circuit breaker being tested. Refer to Table 2 for application
compatibility. Applicable time-current curve segments can be enabled or disabled
by toggling the touch key next to the appropriate touch key label.
1. Select time-current curve segments to be tested by toggling appropriate touch
keys to ENABLED.
Figure 22 – Configure Automatic Trip Curve Test Screen

CONFIGURE AUTOMATIC TRIP CURVE TEST

LONG
ENABLED
TIME
SHORT
ENABLED
TIME
INSTANT-
ENABLED
ANEOUS

HOME BACK NEXT

2. Press NEXT to proceed to the Automatic Trip Curve Test Alert screen.
NOTE: The circuit breaker must be in the closed position to guarantee correct
test results. The Full-Function Test Kit will then automatically test the circuit
breaker by injecting the appropriate current required to test each enabled
section of the time-current curve.

24 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

3. Read alert message, verify circuit breaker is closed and press YES to initiate test.
Figure 23 – Automatic Trip Curve Test Alert Screen

ENGLISH
AUTOMATIC TRIP CURVE TEST ALERT

THIS TEST WILL TRIP THE CIRCUIT

BREAKER. THE CIRCUIT BREAKER SHOULD BE
CLOSED BEFORE STARTING THIS TEST.

PROCEED WITH AUTOMATIC TRIP TEST?

YES NO

The Automatic Trip Curve Test screen displays a table with three columns:
• INJECTION CURRENT—shows magnitude of current, in amperes, during
testing of each segment of the time-current curve.
• TRIP TIME—displays time, in seconds, until circuit breaker trips.
• STATUS—indicates testing progress for each protective function. The following
variables can appear in the status column:
— INITIALIZING (blinking): initializing Full-Function Test Kit and trip unit.
— TESTING: injecting fault signal.
— TRIPPED: fault signal caused circuit breaker to trip.
— STOPPING (blinking): exiting test mode.
— STOPPED (user initiated): fault signal removed.
— PASSED: segment of time-current curve passed.
— FAILED: segment of time-current curve failed.
— ERROR: communication error occurred.

Figure 24 – Automatic Trip Curve Test Screen

AUTOMATIC TRIP CURVE TEST

INJECTION TRIP STATUS
CURRENT TIME
LONG 810 A 0.000 s INITIAL-
TIME IZING
SHORT 1710 A
TIME
INSTANT- 2813 A
ANEOUS

CANCEL

4. After each segment of the time-current curve is tested, close circuit breaker
before continuing to next segment of time-current curve
The Full-Function Test Kit records the amount of time required to initiate the trip
signal for each time-current curve segment and automatically compares results
with the circuit breaker time-current curve points. After checking each time-current
curve segment, the STATUS column indicates which functions passed or failed.
NOTE: If performing another long-time trip test, a fifteen-minute delay must be
observed on non-communicating Micrologic, ET and STR trip units to allow reset of
thermal memory.
5. Restore trip unit long-time pickup setting to original value.

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 25

 Full-Function Test Kit Secondary Injection Testing

Save Test Files 1. From the Automatic Trip Curve Test screen, press NEXT to advance to the
Save Test File screen. Results of up to fifty completed time-current curve tests
ENGLISH

can be saved.
Figure 25 – Save Test File Screen

SAVE TEST FILE

FILE TEST–01
NAME
SAVE
MODE CREATE

HOME BACK NEXT

2. A default test file name is automatically provided in the FILE NAME touch key.
To change the default file name press the FILE NAME touch key to bring up the
keypad screen and enter a new file name.
3. Toggle the SAVE MODE touch key to indicate whether file is new (CREATE) or
replacing an existing file (OVERWRITE).
NOTE: If fifty files already exist it will be necessary to overwrite one of them. If no
files exist, the OVERWRITE option is not selectable.
4. Press NEXT to save file and proceed to the TEST FILE STATUS screen.
Figure 26 – Test File Status Screen

TEST FILE STATUS

FILE
NAME TEST–01
SAVE CREATE
MODE
STATUS SAVED

HOME BACK

26 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

Manual Trip Curve Test (All Trip Units Except STR22ME)

This test allows manual current injection specifications regardless of trip unit settings.

ENGLISH
The Full-Function Test Kit monitors and displays the trip time associated with the
selected current. Trip times reported by the Full-Function Test Kit must be manually
compared to a published trip unit time-current curve for the trip unit being tested.
1. Follow secondary injection test setup procedures.
2. From the Configure Manual Trip Curve Test screen, press INJECTION
CURRENT touch key to advance to the Select Injection Current screen.
Figure 27 – Configure Manual Trip Curve Test Screen

CONFIGURE MANUAL TRIP CURVE TEST

INJECTION
CURRENT 30 A
TRIP LONG
TYPE TIME

HOME BACK NEXT

3. Use numerical keypad to type in the desired fault current in amperes.

4. Press ENTER to return to the Configure Manual Trip Curve Test screen.
Figure 28 – Select Injection Current Screen

SELECT INJECTION CURRENT

1 2 3

4 5 6
6000 A
7 8 9

0 DEL ENTER

CANCEL

5. From the Configure Manual Trip Curve Test screen, scroll the TRIP TYPE
touch key to select the segment of the time-current curve to be tested
(Long-time, Short-time, Instantaneous or Ground-fault).
NOTE: Make sure the TRIP TYPE value matches the exact segment of the time-
current curve to be tested. If incorrect value is selected for the fault injected, the
circuit breaker may trip too fast or too slow. When performing secondary injection
testing on all STR trip units, injected fault signal is dc current. The amplitude of the
dc signal will either simulate RMS value or peak value depending on the TRIP
TYPE option selected. If LONG TIME is selected, the signal injected will simulate
the RMS value of an actual fault signal seen at the iron core CT secondary
windings. If INSTANTANEOUS is selected, the signal injected simulates peak
value of an actual fault signal seen at the iron core CT secondary windings.

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 27

 Full-Function Test Kit Secondary Injection Testing

6. Press NEXT to proceed to the Manual Trip Curve Test Alert screen.
Figure 29 – Manual Trip Curve Test Alert Screen
ENGLISH

MANUAL TRIP CURVE TEST ALERT

THIS TEST WILL TRIP THE CIRCUIT

BREAKER. THE CIRCUIT BREAKER SHOULD BE
CLOSED BEFORE STARTING THIS TEST.

PROCEED WITH MANUAL TRIP TEST?

YES NO

7. Read the alert message, verify the circuit breaker is closed and press YES to
initiate the test.
The Manual Trip Curve Test screen displays a table with three columns:
— INJECTION CURRENT—shows magnitude of current, in amperes, during
testing of each segment of time-current curve.
— TRIP TIME—displays time, in seconds, until circuit breaker trips.
— STATUS—indicates testing progress for each protective function.

Figure 30 – Manual Trip Curve Test Screen

MANUAL TRIP CURVE TEST

INJECTION TRIP STATUS
CURRENT TIME
SHORT 6000 A 0.4125 s INITIAL-
TESTING
TIME IZING

CANCEL

CAUTION
HAZARD OF LOSS OF GROUND-FAULT PROTECTION
Equipment ground-fault protection will be disabled for up to two minutes if the test
cable is removed from the test port on a communicating Micrologic trip unit
without properly exiting the secondary injection testing function. Wait two minutes
before re-energizing the circuit breaker.
Failure to follow these instructions may result in injury or equipment damage.

The following variables can appear in status column:

NOTE: If test cable is removed from test port on a communicating Micrologic
trip unit without properly exiting secondary injection testing function, advanced
protection, activation of alarms, logging of events, equipment ground-fault
protection and thermal imaging may be disabled for up to two minutes after

28 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

cable has been removed. Circuit breaker may also be ZSI restrained for up to
two minutes for equipment ground-fault and short-time protection.

ENGLISH
— INITIALIZING (blinking): initializing Full-Function Test Kit and trip unit.
— TESTING: injecting fault signal.
— STOPPING (blinking): exiting test mode.
— STOPPED (user initiated): fault signal removed.
— TRIPPED: fault signal caused circuit breaker to trip.
— ERROR: communication error occurred.
NOTE: The Full-Function Test Kit records the amount of time required to
initiate a trip signal for each time-current curve segment.
8. Once the circuit breaker trips, compare the value recorded in the TRIP TIME
column with published time-current curve for the circuit breaker being tested.

Save Test Files 1. From the Manual Trip Curve Test screen, press NEXT to advance to the Save
Test File screen. Results of up to fifty completed time-current curve tests can
be saved.
Figure 31 – Save Test File Screen

SAVE TEST FILE

FILE TEST–01
NAME
SAVE
MODE CREATE

HOME BACK NEXT

2. A default test file name is automatically provided in the FILE NAME touch key.
To change the default file name press the FILE NAME touch key to bring up the
keypad screen and enter a new file name.
3. Toggle the SAVE MODE touch key to indicate whether file is new (CREATE) or
replacing an existing file (OVERWRITE).
NOTE: If fifty files already exist it will be necessary to overwrite one of them. If no
files exist, OVERWRITE option is not selectable.
4. Press NEXT to save file and proceed to the TEST FILE STATUS screen.

Figure 32 – Test File Status Screen

TEST FILE STATUS

FILE
NAME TEST–01
SAVE CREATE
MODE
STATUS SAVED

HOME BACK

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 29

 Full-Function Test Kit Secondary Injection Testing

Manual Trip Curve Test (STR22ME Trip Unit Only)

The Full-Function Test Kit monitors and displays the trip time associated with the
ENGLISH

selected current. Trip times reported by the Full-Function Test Kit must be manually
compared to a published trip unit time-current curve for the trip unit being tested.
1. Follow secondary injection test setup procedures.
2. Set the trip unit long-time pickup to minimum value.
NOTE: The Full-Function Test Kit cannot accurately detect when the circuit
breaker has tripped if the pickup setting is higher than the minimum value. If the
pickup setting is normally set higher than the minimum value, record the value so it
can be reset after testing is complete.
3. From Configure Manual Trip Curve Test screen, press the INJECTION
CURRENT touch key to advance to the Select Injection Current screen.
Figure 33 – Configure Manual Trip Curve Test Screen

CONFIGURE MANUAL TRIP CURVE TEST

INJECTION
CURRENT 30 A
TRIP LONG
TYPE TIME

HOME BACK NEXT

4. Use numerical keypad to type in the primary current in amperes.

5. Press ENTER to return to the Configure Manual Trip Curve Test screen.
Figure 34 – Select Injection Current Screen

SELECT INJECTION CURRENT

1 2 3

4 5 6
30 A
7 8 9

0 DEL ENTER

CANCEL

6. From the Configure Manual Trip Curve Test screen, scroll the TRIP TYPE
touch key to select the fault type (Long-time, Short-time or Instantaneous).
NOTE: Make sure the TRIP TYPE value matches the exact segment of the time-
current curve to be tested. If an incorrect value is selected for the fault injected, the
circuit breaker may trip too fast or too slow. When performing secondary injection
testing on all STR trip units, the injected fault signal is dc current. The amplitude of
the dc signal will either simulate RMS value or peak value depending on the TRIP
TYPE option selected. If LONG TIME is selected, the signal injected will simulate
the RMS value of an actual fault signal seen at the iron core CT secondary
windings. If INSTANTANEOUS is selected, the signal injected simulates the peak
value of an actual fault signal seen at the iron core CT secondary windings.

30 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Secondary Injection Testing Full-Function Test Kit

7. Press NEXT to proceed to the Manual Trip Curve Test Alert screen.
8. Read the alert message, verify the circuit breaker is closed and press YES to

ENGLISH
initiate test.

Figure 35 – Manual Trip Curve Test Alert Screen

MANUAL TRIP CURVE TEST ALERT

THIS TEST WILL TRIP THE CIRCUIT

BREAKER. THE CIRCUIT BREAKER SHOULD BE
CLOSED BEFORE STARTING THIS TEST.

PROCEED WITH MANUAL TRIP TEST?

YES NO

The Manual Trip Curve Test screen displays a table with three columns:
• INJECTION CURRENT—shows magnitude of current, in amperes, during
testing of each segment of time-current curve.
• TRIP TIME—displays time, in seconds, until circuit breaker trips.
• STATUS—indicates testing progress for each protective function.

The following variables can appear in the status column:

— INITIALIZING (blinking): initializing Full-Function Test Kit and trip unit.
— TESTING: injecting fault signal.
— STOPPING (blinking): exiting test mode.
— STOPPED (user initiated): fault signal removed.
— TRIPPED: fault signal caused circuit breaker to trip.
— ERROR: communication error occurred.
The Full-Function Test Kit records the amount of time required to initiate a trip
signal for each time-current curve segment.
9. Once the circuit breaker trips, compare the value recorded in the TRIP TIME
column with published time-current curve for the circuit breaker being tested.
Save Test Files 1. From the Manual Trip Curve Test screen, press NEXT to advance to the Save
Test File screen. Results of up to fifty completed time-current curve tests can
be saved.
Figure 36 – Save Test File Screen

SAVE TEST FILE

FILE TEST–01
NAME
SAVE
MODE CREATE

HOME BACK NEXT

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 31

 Full-Function Test Kit Secondary Injection Testing

2. A default test file name is automatically provided in the FILE NAME touch key.
To change the default file name press the FILE NAME touch key to bring up the
ENGLISH

keypad screen and enter a new file name.

3. Toggle the SAVE MODE touch key to indicate whether file is new (CREATE) or
replacing an existing file (OVERWRITE).
NOTE: If fifty files already exist it will be necessary to overwrite one of them. If no
files exist, the OVERWRITE option is not selectable.
4. Press NEXT to save file and proceed to the TEST FILE STATUS screen.

Figure 37 – Test File Status Screen

TEST FILE STATUS

FILE
NAME TEST–01
SAVE CREATE
MODE
STATUS SAVED

HOME BACK

Mechanical Operation Trip Test

This test verifies trip unit short-circuit protection. The Full-Function Test Kit supplies
power to the trip unit while injecting a secondary fault signal large enough to cause
tripping and opening of the circuit breaker.
1. Follow secondary injection test setup procedures.
2. Make sure circuit breaker is in closed position.
3. From the Mechanical Operation Trip Test Alert screen read the alert message,
verify the circuit breaker is closed and press YES to initiate test.
Figure 38 – Mechanical Operation Trip Test Alert Screen

MECHANICAL OPERATION TRIP TEST ALERT

THIS TEST WILL TRIP THE CIRCUIT

BREAKER. THE CIRCUIT BREAKER SHOULD BE
CLOSED BEFORE STARTING THIS TEST.

PROCEED WITH MANUAL TRIP TEST?

YES NO

4. The Full-Function Test Kit injects a fault.

5. Once the Full-Function Test Kit has removed the fault, it displays a message
indicating test is complete.
6. Verify circuit breaker tripped.

32 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Zone-Selective Interlocking Test Full-Function Test Kit

Zone-Selective Interlocking Test

ENGLISH
This test verifies field wiring between multiple circuit breakers connected in a Zone-
Selective Interlocking (ZSI) system (see Table 2). While connected to a
downstream trip unit, the Full-Function Test Kit causes the trip unit to transmit a
ZSI test signal to all connected upstream trip units.
NOTE: Trip units on upstream circuit breakers must support ZSI.
NOTE: Advanced protection and alarms in Micrologic P and H trip units will be
disabled. Refer to the trip unit instruction bulletin for advanced protection features.
NOTE: If the test cable is removed from the test port on a communicating
Micrologic trip unit without properly exiting the ZSI test, advanced protection,
activation of alarms and logging of events may be disabled for up to two minutes
after the cable has been removed. Circuit breaker may also be ZSI restrained for
up to two minutes for the equipment ground-fault and short-time protection.
1. Press the TEST ZSI FUNCTION on the Select Test Kit Functions screen.
Figure 39 – Select Test Kit Function Screen

SELECT TEST KIT FUNCTION

TEST VIEW/DELETE
BREAKER TRIP TEST FILES
INHIBIT GROUND CONFIGURE TEST
FAULT PROTECTION KIT OPTIONS
INHIBIT THERMAL
IMAGE PROTECTION
TEST
ZSI FUNCTION

2. Read the alert message and press YES to initiate ZSI test.
Figure 40 – ZSI Test Alert Screen

ZSI TEST ALERT

PROCEED WITH ZSI TEST?

YES NO

3. The STATUS display on the ZSI Test screen will flash INITIALIZING.
Figure 41 – ZSI Test Initializing Screen

ZSI TEST

INITIAL-
STATUS
IZING

CANCEL

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 33

 Full-Function Test Kit Zone-Selective Interlocking Test

4. While the STATUS display flashes TESTING, the ZSI test is in progress. Check
that the Isd/Ii and/or Ig trip indicator LEDs are flashing on the upstream circuit
ENGLISH

breakers. A second Full-Function Test Kit or a Hand-Held Test Kit can be used
to power upstream trip unit(s), if necessary.
• If ground-fault protection only is configured for ZSI, the Ig trip indicator LED will
flash.
• If short-time protection only is configured for ZSI, the Isd/Ii trip indicator LED
will flash.
• If both ground-fault and short-time protection are configured for ZSI, both Ig
and Isd/Ii trip indicator LEDs will flash.

Figure 42 – ZSI Test Testing Enabled Screen

ZSI TEST

STATUS TESTING

CANCEL

5. Press CANCEL to terminate the ZSI test.

6. The STATUS display will flash STOPPING to indicate the Full-Function Test Kit
is exiting test mode.
Figure 43 – ZSI Test Stopping Screen

ZSI TEST

STATUS STOPPING

7. Once STOPPED appears in the STATUS display, the ZSI test is complete.
Figure 44 – ZSI Test Testing Stopped Screen

ZSI TEST

STATUS STOPPED

HOME

34 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Inhibit Functions Full-Function Test Kit

Inhibit Functions

ENGLISH
Inhibit functions are only available during long-time, short-time, instantaneous and
ground-fault (LSIG) primary-injection testing of communicating Micrologic trip units
(see Table 2). For Micrologic P and H trip units, the inhibit functions disables
advanced protection, alarms and logging of events. Refer to the trip unit instruction
bulletin for advanced protection features.
Ground-Fault Inhibit

CAUTION
HAZARD OF LOSS OF GROUND-FAULT PROTECTION
Equipment ground-fault protection will be disabled for up to two minutes if the test
cable is removed from the test port on a communicating Micrologic trip unit
without properly exiting the ground-fault inhibit function. Wait two minutes before
re-energizing circuit breaker.
Failure to follow these instructions can result in injury or equipment damage.

The ground-fault inhibit function allows user to temporarily disable equipment

ground-fault protection on Micrologic communicating trip units. This allows the user
to perform LSI time-current curve testing using single-phase primary injection.
NOTE: If the test cable is removed from the test port on a communicating
Micrologic trip unit without properly exiting the ground-fault inhibit function,
advanced protection, activation of alarms, logging of events, equipment ground-
fault protection and thermal imaging may be disabled for up to two minutes after
the cable has been removed. Circuit breaker may also be ZSI restrained for up to
two minutes for equipment ground-fault and short-time protection.
NOTE: The contact wear counter on Micrologic P and H trip units will not increment
while the ground fault is being inhibited.
NOTE: For communicating Micrologic trip units, activating the ground-fault inhibit
will automatically activate the thermal-imaging inhibit and enable the zone-selective
interlocking (ZSI) self-restraint. Therefore, a fifteen-minute waiting period between
long-time trip tests does not need to be observed to obtain accurate results.
To execute the ground-fault inhibit function:
1. Press INHIBIT GROUND FAULT PROTECTION on the Select Test Kit Function
screen.
Figure 45 – Select Test Kit Function Screen

SELECT TEST KIT FUNCTION

TEST VIEW/DELETE
BREAKER TRIP TEST FILES
INHIBIT GROUND CONFIGURE TEST
FAULT PROTECTION KIT OPTIONS
INHIBIT THERMAL
IMAGE PROTECTION
TEST
ZSI FUNCTION

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 35

 Full-Function Test Kit Inhibit Functions

2. Read the alert message and press YES to inhibit ground fault.
Figure 46 – Ground-Fault Inhibit Alert Screen
ENGLISH

GROUND-FAULT INHIBIT ALERT

THIS FEATURE WILL TEMPORARILY DISABLE

GROUND-FAULT PROTECTION
FOR DURATION OF TEST.

PROCEED WITH GROUND-FAULT INHIBIT?

YES NO

3. The STATUS display on the Ground-Fault Inhibit screen will flash

INITIALIZING for communicating Micrologic trip units
the thth

Figure 47 – Ground-Fault Inhibit Initializing Screen

GROUND-FAULT INHIBIT

INITIAL-
STATUS
IZING

CANCEL

4. Once the STATUS display flashes TESTING, the ground-fault and thermal imaging
are being inhibited and the circuit breaker is ready for primary injection testing.
Figure 48 – Ground-Fault Inhibit Enabled Screen

GROUND-FAULT INHIBIT

STATUS TESTING

CANCEL

NOTE: Each time the circuit breaker trips, the ground-fault inhibit function must be
stopped and restarted before performing another primary injection test.

36 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Inhibit Functions Full-Function Test Kit

5. When primary injection testing is completed, press CANCEL to stop the

ground-fault inhibit function. The STATUS display will flash STOPPING to

ENGLISH
indicate test exit communication between Full-Function Test Kit and trip unit.
Figure 49 – Ground-Fault Inhibit Stopping Screen

GROUND-FAULT INHIBIT

STATUS STOPPING

6. Once STOPPED appears in the STATUS display, test exit communication is

complete.

Figure 50 – Ground-Fault Inhibit Disabled Screen

GROUND-FAULT INHIBIT

STATUS STOPPED

HOME

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 37

 Full-Function Test Kit Inhibit Functions

Thermal-Imaging Inhibit
Thermal-imaging provides continuous temperature rise status of the circuit breaker
ENGLISH

cabling, both before and after a device trips. Under normal conditions a fifteen-
minute delay is required following a device tripping to allow the system to cool
before returning to normal functionality. The thermal-imaging inhibit function
inhibits thermal imaging thus overriding the fifteen-minute delay and allowing for
multiple consecutive primary injection tests.
NOTE: If the test cable is removed from the test port on the Micrologic
communicating trip unit without properly exiting the thermal-imaging inhibit
function, advanced protection, activation of alarms, logging of events and thermal
imaging may be disabled for up to two minutes after the cable has been removed.
Circuit breaker may also be ZSI restrained for up to two minutes for short-time
protection.
NOTE: The contact wear counter on Micrologic P and H trip units will not increment
while thermal imaging is inhibited.
NOTE: Activating thermal-imaging inhibit will enable zone-selective interlocking
(ZSI) self-restraint. Therefore, a fifteen-minute waiting period between long-time
trip tests does not need to be observed to obtain accurate results.
To execute thermal-imaging inhibit function:
1. Press INHIBIT THERMAL IMAGE PROTECTION on the Select Test Kit
Function screen.
Figure 51 – Select Test Kit Function Screen

SELECT TEST KIT FUNCTION

TEST VIEW/DELETE
BREAKER TRIP TEST FILES
INHIBIT GROUND CONFIGURE TEST
FAULT PROTECTION KIT OPTIONS
INHIBIT THERMAL
IMAGE PROTECTION
TEST
ZSI FUNCTION

2. Read the alert message and press YES to inhibit thermal imaging.
Figure 52 – Thermal-Image Inhibit Alert Screen

THERMAL-IMAGE INHIBIT ALERT

THIS FEATURE WILL TEMPORARILY DISABLE

THERMAL-IMAGE PROTECTION
FOR DURATION OF TEST.

PROCEED WITH THERMAL-IMAGE INHIBIT?

YES NO

38 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Inhibit Functions Full-Function Test Kit

3. The STATUS display on the Thermal-Image Inhibit screen will flash INITIALIZING.
Figure 53 – Thermal-Image Inhibit Initializing Screen

ENGLISH
THERMAL-IMAGE INHIBIT

INITIAL-
STATUS
IZING

CANCEL

4. Once the STATUS display flashes TESTING, thermal imaging is being inhibited
and the circuit breaker is ready for primary injection testing.
Figure 54 – Thermal-Image Inhibit Enabled Screen

THERMAL-IMAGE INHIBIT

STATUS TESTING

CANCEL

NOTE: Each time the circuit breaker trips, the thermal-image inhibit function must
be stopped and restarted before performing another primary injection test.
5. When primary injection testing is completed, press CANCEL to stop the thermal-
imaging inhibit function. The STATUS display will flash STOPPING to indicate
test exit communication between the Full-Function Test Kit and the trip unit.
Figure 55 – Thermal-Image Inhibit Stopping Screen

THERMAL-IMAGE INHIBIT

STATUS STOPPING

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 39

 Full-Function Test Kit Inhibit Functions

6. Once STOPPED appears in the STATUS display, test exit communication is

complete.
ENGLISH

Figure 56 – Thermal-Image Inhibit Disabled Screen

THERMAL-IMAGE INHIBIT

STATUS STOPPED

HOME

40 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

View, Delete and Print Saved Test Files Full-Function Test Kit

View, Delete and Print Saved Test Files

ENGLISH
NOTE: The View/Delete Test Files touch key will not appear on the Select Test Kit
Function screen until at least one test file is saved.
View Saved Test Files
1. From the Select Test Kit Functions screen, press VIEW/DELETE TEST FILES.
The interface screen will advance to the Select Test File Function screen.
Figure 57 – Select Test Kit Function Screen

SELECT TEST KIT FUNCTION

TEST VIEW/DELETE
BREAKER TRIP TEST FILES
INHIBIT GROUND CONFIGURE TEST
FAULT PROTECTION KIT OPTIONS
INHIBIT THERMAL
IMAGE PROTECTION
TEST
ZSI FUNCTION

2. To view results of a previous trip test, from the Select Test File Function screen
press VIEW TEST FILE.
Figure 58 – Select Test File Function Screen

SELECT TEST FILE FUNCTION

VIEW
TEST FILE
DELETE
TEST FILE
DELETE
ALL TEST FILES

HOME

3. From the Select Test File screen, press the desired test file name touch key.
The display will advance to the Circuit Breaker Parameters screen to show
settings entered for this particular saved test.
Parameter display fields are neither selectable nor modifiable when viewing
saved files.
Figure 59 – Select Test File Screen

SELECT TEST FILE

TEST–00 TEST–01

CANCEL

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 41

 Full-Function Test Kit View, Delete and Print Saved Test Files

4. Press NEXT on the Circuit Breaker Parameters screen to advance to the

Protection Parameters screen and view protection settings entered for this
ENGLISH

particular saved test.

Figure 60 – Circuit Breaker Parameters Screen

CIRCUIT BREAKER PARAMETERS

BREAKER MASTER- INTERRUPT
FAMILY PACT RATING N
BREAKER NW25
TYPE STANDARD IEC
TRIP UNIT MICRO- In
FAMILY LOGIC 1200 A
TRIP UNIT 6.0 A
TYPE

HOME BACK NEXT

5. Press NEXT on the Protection Parameters screen to advance to the Trip Curve
Test screen and view test results for this particular saved test.
Figure 61 – Protection Parameters Screen

PROTECTION PARAMETERS
Ir 0.4 tsd
(480 A) 0.4 s OFF

tr 1s Ii 3
(3600 A)
IDMTL OFF Ig 0.2
(240 A)
Isd 10 tg
(4800 A) 0.1 s OFF

HOME BACK NEXT

The screen title will read Automatic Trip Curve Test, Manual Trip Curve Test or
Mechanical Trip Curve Test depending on original test type of this particular
saved test.
Figure 62 – Automatic Trip Curve Test Screen

AUTOMATIC TRIP CURVE TEST

INJECTION TRIP STATUS
CURRENT TIME
LONG 3360 A 0.620 s PASSED
TIME
INSTANT- 4500 A 0.036 s PASSED
ANEOUS
GROUND 480 A 0.085 s PASSED
FAULT

HOME BACK

42 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

View, Delete and Print Saved Test Files Full-Function Test Kit

Delete Saved Test File

To delete one or all saved test files, press VIEW/DELETE TEST FILES on the

ENGLISH
Select Test Kit Functions screen. The display will advance to the Select Test File
Function screen.

Figure 63 – Select Test Kit Function Screen

SELECT TEST KIT FUNCTION

TEST VIEW/DELETE
BREAKER TRIP TEST FILES
INHIBIT GROUND CONFIGURE TEST
FAULT PROTECTION KIT OPTIONS
INHIBIT THERMAL
IMAGE PROTECTION
TEST
ZSI FUNCTION

Delete One Saved Test File 1. To delete one or all saved test files, press VIEW/DELETE TEST FILES on the
Select Test Kit Functions screen. The display will advance to the Select Test
File Function screen.

Figure 64 – Select Test File Function Screen

SELECT TEST FILE FUNCTION

VIEW
TEST FILE
DELETE
TEST FILE
DELETE
ALL TEST FILES

HOME

2. From the Select Test File screen, press desired test file name touch key for
deletion. The display will advance to the File Delete Alert screen.

Figure 65 – Select Test File Screen

SELECT TEST FILE

TEST–00 TEST–01

CANCEL

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 43

 Full-Function Test Kit View, Delete and Print Saved Test Files

3. Read the alert message. Once YES is pressed the action cannot be reversed.
ENGLISH

— Press YES to delete the selected test file and proceed to the Select Test
File Function screen.
— Press NO to cancel the test file deletion procedure and return to the Select
Test File Function screen.

Figure 66 – File Delete Alert Screen

FILE DELETE ALERT

THE FILE(S) WILL BE PERMANENTLY

DELETED.

PROCEED WITH FILE DELETE?

YES NO

Delete All Saved Test Files 1. To delete all saved test files, from the Select Test File Function screen press
DELETE ALL TEST FILES. The display will advance to the File Delete Alert
screen.

Figure 67 – Select Test File Function Screen

SELECT TEST FILE FUNCTION

VIEW
TEST FILE
DELETE
TEST FILE
DELETE
ALL TEST FILES

HOME

2. Read the alert message. Once YES is pressed action cannot be reversed.
— Press YES to delete all saved test files and proceed to the Select Test File
Function screen.
— Press NO to cancel test file deletion procedure and return to the Select Test
File Function screen.

Figure 68 – File Delete Alert Screen

FILE DELETE ALERT

THE FILE(S) WILL BE PERMANENTLY

DELETED.

PROCEED WITH FILE DELETE?

YES NO

44 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Configure Full-Function Test Kit Options Full-Function Test Kit

Print Saved Test Files

Saved test files can be uploaded to a personal computer and printed using the Full-

ENGLISH
Function Test Kit Report Generator. Order CD part number FFTKRPT-V1-0 and
follow the test report printing instructions in the instruction bulletin shipped with the
Full-Function Test Kit Report Generator.

Configure Full-Function Test Kit Options

From the Select Test Kit Function screen press Configure Test Kit Options. The
display will advance to the Configure Test Kit Options screen.

Figure 69 – Select Test Kit Function Screen

SELECT TEST KIT FUNCTION

TEST VIEW/DELETE
BREAKER TRIP TEST FILES
INHIBIT GROUND CONFIGURE TEST
FAULT PROTECTION KIT OPTIONS
INHIBIT THERMAL
IMAGE PROTECTION
TEST
ZSI FUNCTION

Language Selection
NOTE: Pressing a language touch key on the Select Language screen will
automatically change all Full-Function Test Kit language settings.
1. On the Configure Test Kit Options screen press the Language touch key.

Figure 70 – Configure Test Kit Options Screen

CONFIGURE TEST KIT OPTIONS

LANGUAGE ENGLISH
DISPLAY
70%
BACKLIGHT
DISPLAY
65%
CONTRAST
CALIBRATE CALIBRATE
DISPLAY DISPLAY

HOME

2. Select the appropriate language setting from the Select Language screen. The
display will return to the Configure Test Kit Options screen.
Figure 71 – Select Language Screen

SELECT LANGUAGE
ENGLISH FRANCAIS ESPANOL DEUTSCH

ITALIANO

CANCEL

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 45

 Full-Function Test Kit Configure Full-Function Test Kit Options

Set Display Screen Backlight

Scroll the DISPLAY BACKLIGHT touch key on the Configure Test Kit Options
ENGLISH

screen (Fig. 71) to desired setting. The value range for the DISPLAY BACKLIGHT
touch key decreases from 100% to 30% in increments of 10 percent.
Adjust Display Screen Contrast
Scroll the DISPLAY CONTRAST touch key on the Configure Test Kit Options
screen (Fig. 71) to desired setting. The value range for the DISPLAY CONTRAST
touch key decreases from 80% to 35% in increments of 5 percent.
Calibrate Display
Press the calibrate display touch key on the Configure Test Kit Options screen
(Fig. 71). Verify no trip units are connected. A new screen will appear requesting
the user to touch the crosshairs on the screen. Once this is complete, the test kit
will calibrate and return to the Configure Test Kit Options screen.

46 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Maintenance Full-Function Test Kit

Maintenance

ENGLISH
NOTE: There are no repairable or adjustable parts inside the Full-Function Test Kit.
Fuse Replacement

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E or CSA Z462.
• This equipment must only be installed and serviced by qualified electrical
personnel.
• Turn off all power supplying this equipment before working on or inside
equipment.
• Always use a properly rated voltage sensing device to confirm power is off.
• Replace all devices, doors and covers before turning on power to this
equipment.
• Select proper type and value for replacement fuse(s).
• Make sure two fuses are installed at all times in line-fuse holder.
• Select proper system voltage for Full-Function Test Kit.
Failure to follow these instructions will result in death or serious injury.

1. Turn off the power switch and unplug the power cable from the Full-Function Test
Kit.
2. Carefully pry open the line-fuse holder cover (A) using a screwdriver.
3. Remove the line-fuse holder (B) from the power switch module.
4. Replace fuses (C) as required. See Table 1 for fuse recommendations.
5. Make sure both fuses are installed in the line-fuse holder and insert the line-
fuse holder into the power switch module.
6. Close the line-fuse holder cover. Make sure the correct system voltage value
on the voltage selector appears in the window.

Figure 72 – Fuse Replacement

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 47

 Full-Function Test Kit Troubleshooting

Calibration
The Full-Function Test Kit does not require periodic calibration. The Full-Function
ENGLISH

Test Kit performs a self-check of the microprocessor-generated fault signal before

the signal is injected into the trip unit. If the fault signal is out of tolerance, the
interface screen displays an error message and will not allow continuation of the test.
Cleaning

NOTICE
HAZARD OF EQUIPMENT DAMAGE
Avoid corrosive or abrasive agents when cleaning the Full-Function Test Kit
interface screen.
Failure to follow these instructions can result in equipment damage.

Use a soft cloth moistened with a diluted window-cleaning solution to clean the
Full-Function Test Kit case and interface screen.

Troubleshooting
General Errors
Condition Probable Causes Solutions
Circuit breaker trips faster than minimum trip Secondary injected fault into trip unit has Make sure circuit breaker is always in closed
band for instantaneous protection when exceeded one or more of the following circuit position before beginning secondary injection of
performing automatic trip curve test on short- breaker protection levels: each fault. This will eliminate tripping due to close
time or instantaneous segments of time-current • Instantaneous override and latch protection.
curve and/or HARDWARE appears in status • Close and latch Does long-time segment of time-current curve
cell on Automatic Trip Curve Test screen.
• Selectivity pass when performing automatic trip curve test?
A. YES
For communicating Micrologic trip units, if AP
trip indicator LED on trip unit comes on when
testing short-time or instantaneous segments
of time-current curve, then circuit breaker has
tripped on instantaneous override, close and
latch or selectivity protection functions.
For non-communicating Micrologic trip units,
no trip indicator LED is available. Check that
peak value for signal being injected does not
exceed instantaneous override or selectivity
protection levels. See published time-current
curves.
B. NO
Contact local field office.
STR or ET trip units trip faster than published 1. Incorrect trip unit settings entered. 1. Check trip unit settings.
time-current curves when performing manual 2. Fault type selection (LSIG) set to 2. Check fault type setting.
trip curve test. instantaneous when type of fault to be
tested is long-time or short-time.
3. Fifteen-minute waiting period not observed 3. Contact local field office.
between long-time tests.
Continued on next page

48 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Troubleshooting Full-Function Test Kit

General Errors (continued)

ENGLISH
Condition Probable Causes Solutions
Circuit breaker trips up to twice as long as While performing primary injection using either Terminate primary injection test completely,
expected when performing primary injection ground-fault or thermal-image inhibit function, start ground-fault or thermal-image inhibit
test. interface screen displayed Communications function and then start primary injection test.
Error. In response ground fault or thermal imaging
was re-inhibited without stopping primary injection
causing circuit breaker to trip long when long-time
segment of time-current curve tested.
Circuit breaker trips earlier than expected Ground-fault inhibit function or thermal-imaging Stop and then restart either ground-fault inhibit
during primary-injection test with either ground- inhibit function was not disabled and then function or thermal-imaging inhibit function after
fault inhibit function or thermal-imaging inhibit restarted after circuit breaker tripped during each circuit breaker tripping event.
function enabled. previous primary-injection test.
Circuit breaker trips faster than short-time Fault level being secondary injected into the trip If at any time there is variation in amplitude of
delay, but slower than maximum trip band for unit is near tripping levels for instantaneous signal exceeding pickup levels for
instantaneous protection when instantaneous override, close and latch or selectivity instantaneous override, close and latch or
protection on Micrologic trip units is turned off. protection functions. selectivity protection functions, circuit breaker
For communicating Micrologic trip units, AP trip will trip.
indicator LED on trip unit illuminated.
When choosing segments of time-current curve 1. Trip unit being tested does not support 1. Refer to Table 2 to determine if test is
to be tested using automatic trip curve test, short-time protection. applicable to trip unit.
short-time segment of time-current curve 2. Short-time protection available, but trip unit 2. Adjust trip unit dial settings.
cannot be enabled. dial settings have been altered to disable
short-time protection.
When performing automatic trip curve test on Incorrect In value entered. Make sure correct In value entered.
STR trip units, current injected for long-time,
short-time, instantaneous and ground fault
should not cause circuit breaker to trip. But
circuit breaker does trip and Full-Function Test
Kit reports trip unit passes all segments of the
time-current curve.
STR53UE or STR53UP trip units trip faster than Short-time pickup setting less than ground-fault Test ground-fault protection by either dialing
published time-current curves when performing pickup setting causing trip unit to trip on short- down ground-fault pickup or dialing up short-
automatic trip curve test. time protection. time pickup so that short-time pickup is greater
than ground-fault pickup.
For STR22ME trip unit, long-time, short-time or Long-time pickup value (Ir) not set to correct Set Ir to minimum position before performing
instantaneous segment of published time- position. tests.
current curves fails when performing automatic
trip curve test.
STR22ME trip unit reports “Timed Out” status Long-time pickup value (Ir) not set to correct Set Ir to minimum position before performing
for Trip Time cell when performing manual trip position. tests.
curve test.
Continued on next page

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 49

 Full-Function Test Kit Troubleshooting

General Errors (continued)

ENGLISH

Condition Probable Causes Solutions

1. ZSI test cannot be performed.
Isd/Ii and/or Ig LED not flashing on upstream 1. Upstream circuit breaker not wired for ZSI
circuit breaker when performing ZSI test. configuration.
2. Connect and turn on auxiliary 24 V power
2. Trip unit on upstream circuit breaker does
source to upstream circuit breaker. A
not have power applied to it.
second Full-Function Test Kit or a Hand-
held Test Kit can be used for this purpose.
3. Check that pins of seven-pin test cable have
3. Interface screen displayed Communications
not been bent, pushed in, pulled out or
Error.
otherwise damaged, thereby compromising
connection between Full-Function Test Kit
and trip unit.
4. Upstream circuit breaker not wired for short-
4. Refer to Table 2 to determine if test is
time ZSI restraint.
applicable to trip unit type.
5. Upstream circuit breaker not wired for
5. Refer to Table 2 to determine if test is
ground-fault ZSI restraint.
applicable to trip unit type.
6. Micrologic 3.0 trip unit connected to Full-
6. Refer to Table 2 to determine if test is
Function Test Kit. (Micrologic 3.0 trip unit
applicable to trip unit type.
does not provide short-time or ground-fault
protection.) If both upstream and downstream trip units are
powered and trip indicator LEDs are not
flashing, verify wiring between devices.
A. Terminal Z1 from downstream trip unit must
be connected to terminal Z3 of upstream trip
unit.
B. Terminal Z2 of downstream trip unit must be
connected to terminals Z4 (for short time)
and Z5 (for ground fault) of upstream trip
unit.
If wiring is correct and trip indicators still do not
flash while Full-Function Test Kit is initiating ZSI
test, then verify trip unit is not self-restrained.
Use an ohmmeter to verify terminal Z3 is not
shorted to terminals Z4 and/or Z5. All devices
are factory-shipped in self-restrained
configuration with Z3 shorted to Z4 and Z5.
If system includes Restraint Interface Module
(RIM), push-to-test button will also send a ZSI
test signal to upstream device(s). Refer to the
RIM instruction bulletin for correct wiring and
operation instructions.
Continued on next page

50 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Troubleshooting Full-Function Test Kit

General Errors (continued)

ENGLISH
Condition Probable Causes Solutions
STR 43ME trip unit does not trip according to STR43ME trip unit will trip in same time NA
long-time delay setting. whether long-time delay is set to hot or cold
setting for class rating. For example, if tr is set
to 20 hot, circuit breaker will trip in same time
as if tr is set to 20 cold. If circuit breaker is set to
10 hot it will trip in same time as if setting was
10 cold, etc. The purpose of hot and cold
settings on long-time delay is for systems with
different profiles for motor starting. Hot and cold
settings offer two motor cooling time constants
associated with motor starting class.
The first class of motor protection allows for short
cooling time constant. This provides maximum
continuity of service and satisfactory motor
protection and is used mainly for motors that start
and stop frequently. It allows for frequent inrush
currents without building toward trip condition.
The second class of motor protection allows for
long cooling time constant (four times the short
cooling time constant). This setting provides
maximum motor protection.

Circuit breaker does not trip on ground fault 1. Incorrect two-pin test cable polarity. 1. Reverse polarity on two-pin test cable
when testing STR53UE or STR53UP trip units. connection.
2. Trip unit does not provide ground-fault 2. Refer to Table 2 to determine if test is
protection. applicable to trip unit.
Circuit breaker installed with Micrologic 6.0A, 1. Fault level injected not high enough to cause 1. Inject higher fault current.
Micrologic 6.0H or Micrologic 6.0P trip unit does trip on ground-fault protection.
not trip when performing ground-fault test. 2. Circuit breaker connected in modified 2. Refer to Table 2 to determine if test is
differential ground-fault (MDGF) or source- applicable to trip unit.
ground return configuration.
Full-Function Test Kit displays “Timed Out” in 1. Maximum time reached for injecting fault level 1. Check if any test cable pins are pushed in or
Status cell when performing mechanical without detecting circuit breaker has tripped. bent.
operation trip test. 2. Full-Function Test Kit is damaged. 2. Contact local field office.
Full function test kit displays “FAILED” when Overlapping of the short time and long time Wait at least ten seconds after long time test
performing short time test right after long time test curves. before performing short time test.
in automatic mode for Micrologic A/P/H trip units.
1. Full-Function Test Kit has not detected circuit 1. Check if any test cable pins are pushed in or
Full-Function Test Kit reports “Timed Out” in breaker has tripped. Full-Function Test Kit bent.
Status cell when performing manual trip curve has a time out limit for maximum amount of
test. time it can inject a given fault level.
2. Full-Function Test Kit is damaged. 2. Contact local field office.
When performing automatic trip curve test, Full- 1. Full-Function Test Kit has not detected 1. Check if any test cable pins are pushed in or
Function Test Kit reports failure, circuit breaker circuit breaker has tripped. Full-Function bent.
does not trip and no trip time is displayed. Test Kit has time out limit for maximum
amount of time it can inject given fault level.
It removes fault if duration is 20% greater
than maximum trip band for any given fault.
2. Full-Function Test Kit is damaged. 2. Contact local field office.
When power switch is turned on, Full-Function Object in contact with interface screen when Turn off power switch, remove any objects in
Test Kit beeps twice with two different tones power switch turned on. contact with interface screen and turn power
and nothing is displayed on interface screen. switch on.
Spinning Schneider logo remains on the 1. Voltage selector set for 230 Vac but 115 Vac 1. Change voltage selector to 115 Vac.
interface screen longer than fifteen seconds applied.
when powering Full-Function Test Kit. 2. Full-Function Test Kit is damaged. 2. Contact local field office.
Continued on next page

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 51

 Full-Function Test Kit Troubleshooting

General Errors (continued)

ENGLISH

Condition Probable Causes Solutions

Interface screen and fan do not turn on when 1. Voltage selector set for 115 Vac but 230 Vac 1. Change voltage selector to 230 Vac.
power is applied to Full-Function Test Kit. applied.
2. Incorrect fuse size. 2. Make sure correct fuse being used.
3. Full-Function Test Kit is damaged. 3. Contact local field office.
Interface screen is locked or out of calibration Locked up or loss of interface screen calibration If the Full-Function Test Kit Title screen has
and does not respond to the touch keys version 1.20 displayed:
properly. • Restart the test kit. When the test kit title
screen shows up, wait for ten seconds to let
the test kit go into calibration mode to calibrate
the interface screen. Refer to “Calibrate
Display” on page 46 to perform the calibration.
• Contact the local field office
If the Full-Function Test Kit Title screen has
version other than 1.20 displayed, contact the
local field office.

Error Messages
Message Probable Causes Solutions
Trip unit disconnected from test kit. Operation 1. Test cable removed from trip unit. 1. Check if any pins are pushed in or bent.
aborted. 2. Test cable pins not making good contact 2. Make sure test cable is making good
between Full-Function Test Kit and trip unit. connection at trip unit and Full-Function Test
Kit connectors.
Test kit power supply overload detected. Current source on-time, time-out or over- Reduce interface screen backlight or turn off
Operation aborted. temperature. Full-Function Test Kit and allow it to cool.
Communication error detected. Communication error between Full-Function Press CANCEL. If error persists make sure pins
Test Kit and trip unit. on seven-pin test cable are not pushed in or
bent. Make sure Full-Function Test Kit earth
ground connection is at same potential as earth
ground connection of circuit breaker chassis.
If drawout circuit breaker is being tested and
error persists, rack circuit breaker out into
disconnect position.
Test kit calibration error. Test aborted. Contact Full-Function Test Kit has determined it cannot Contact local field office.
local field office. reliably secondary inject a fault signal into trip
unit to test circuit breaker.
Fatal error detected. All operations halted. Full-Function Test Kit internal failure. Press CANCEL to reboot. If error persists,
Contact field office if problem persists. contact local field office.
Error detected when determining if the trip unit 1. Damaged test cable. 1. Check if any pins are pushed in or bent.
is connected to the test kit. Operation aborted. 2. Damaged Full-Function Test Kit. 2. Contact local field office
3. Damaged trip unit. 3. Contact local field office

Error detected when determining if the trip unit 1. If testing STR22ME trip unit, long-time 1. Set STR22ME trip unit long-time pickup
has tripped. Operation aborted. pickup is not set to minimum value. value to minimum value.
2. Damaged trip unit. 2. Contact local field office
3. Damaged circuit breaker. 3. Contact local field office
Level of injection current out of test kit range. Value entered for Injection Current on Limit maximum current to be tested to 20 x In.
Configure Manual Trip Curve Test screen too Limit minimum current to be tested to 0.3 x In.
high or too low for Full-Function Test Kit to test.
Level of injection current out of trip unit range. Value entered for Injection Current on Limit maximum current to be tested to 20 x In.
Configure Manual Trip Curve Test screen Limit minimum current to be tested to 0.3 x In.
exceeds maximum value trip unit can handle
via secondary injection testing.
Non-volatile memory error detected. Contact Information being accessed from Full-Function Press CANCEL to reboot. If error persists,
local field office if problem persists. Operation Test Kit memory is corrupted. contact local field office.
aborted.

52 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Glossary Full-Function Test Kit

Glossary

ENGLISH
ASIC (Application Specific Electronic device located inside Micrologic electronic trip units that senses
Integrated Circuit) overload, short circuit, ground-fault or earth-leakage conditions and activates
mechanical mechanism for tripping circuit breaker.
Circuit Breaker Family Circuit breaker series being tested. Full-Function Test Kit tests Compact,
Masterpact or Powerpact circuit breakers. Verify circuit breaker family by referring
to circuit breaker label (Fig. 12) or instruction bulletin when configuring circuit
breaker parameters for secondary injection testing.
Circuit Breaker Type Specific type of circuit breaker within circuit breaker family. Verify circuit breaker
type by referring to circuit breaker label (Fig. 12) or instruction bulletin when
configuring circuit breaker parameters for secondary injection testing.
Close and Latch Rating used to describe level of root mean square (RMS) current a circuit breaker
is capable of closing into and carrying in a closed position for a specific amount of
time (usually up to 30 cycles).
Earth-Leakage Delay (th) Full-Function Test Kit DOES NOT test this function.
Earth-Leakage Pickup (Ih) Full-Function Test Kit DOES NOT test this function.
Ground-Fault Delay (tg) Length of time ground-fault timer runs before initiating trip signal (i.e., determines
amount of time circuit breaker will wait before initiating trip signal).
There are two choices for ground-fault delay characteristics:
• I2t ON—Delay characteristic which results in inverse-time delay that
coordinates best with zero sequence ground-fault relays used in conjunction
with thermal magnetic circuit breakers and fusible switches.
• I2t OFF—Delay characteristic which results in constant delay that coordinates
best with electronic trip circuit breakers with ground-fault option.
Ground-Fault Pickup (Ig) Ground-fault current level at which ground-fault delay timer starts (i.e., sets ground-
fault current level at which trip unit begins timing).
In Sensor rating; 100% full-load circuit breaker rating.
Instantaneous Override: Rating used to describe level of root mean square (RMS) current
that will cause circuit breaker to trip without an adjustable delay.

Interrupt Rating Defines maximum circuit breaker withstand rating depending on circuit breaker
standard. Verify interrupt rating by referring to circuit breaker label when
configuring circuit breaker parameters for secondary injection testing.
LSIG/LSIV Abbreviations for electronic trip unit protection features.
L—Long-time pickup and delay
S—Short-time pickup and delay
I—Instantaneous pickup
G—Ground-fault pickup and delay
V—Earth-leakage pickup and delay (VIGI)
Long-Time Ampere Rating Circuit breaker current-carrying capacity or “handle rating.”
Long-Time Delay (tr) Time period long-time delay timer runs before initiating a trip signal (i.e., length of
time circuit breaker will carry sustained, low-level overload before initiating trip
signal).
Long-Time Pickup (Ir) Current level at which long-time delay timer starts.

48049-183-06 © 2001–2015 Schneider Electric All Rights Reserved 53

 Full-Function Test Kit Glossary

Selectivity General term used to describe interaction among multiple circuit breakers where
circuit breaker nearest fault will open and circuit breakers closer to source will
ENGLISH

remain closed to carry remaining load.

Short-Time Delay (tsd) Time period the short-time delay timer runs before initiating trip signal (i.e., short-
time delay allows circuit breaker to carry or withstand low-level or high-level short-
circuit currents, up to published withstand ratings, with intentional time delay before
tripping). There are two choices for short-time delay characteristics:
• I2t ON—Delay characteristic which results in inverse-time delay that most
closely parallels time-current characteristics of fuses.
• I2t OFF—Delay characteristic which results in constant delay that coordinates
best with thermal-magnetic and electronic trip circuit breakers.
Short-Time Pickup (Isd) Current level at which short-time delay timer starts (i.e., current at which short-time
function recognizes overcurrent).
Standard Electrical standard by which circuit breaker is certified. Standards for Full-Function
Test Kit are UL, IEC, ANSI or CCEE. Some circuit breakers may be certified under
multiple standards. Use appropriate standard for application and location. Selecting
incorrect standard can produce inaccurate test results. Verify standard by referring
to circuit breaker label when configuring circuit breaker parameters for secondary
injection testing.
Trip Unit Electronic device that controls circuit breaker protection pickup and delay points.
Trip unit, along with circuit breaker mechanical trip mechanism, is primary
component tested by Full-Function Test Kit.
Trip Unit Family Series of trip unit being tested. Full-Function Test Kit tests Micrologic, ET and STR
trip units. Verify trip unit family by referring to trip unit face (Fig. 13) or instruction
bulletin and Table 2 when configuring circuit breaker parameters for secondary
injection testing.
Trip Unit Type Specific type of trip unit within trip unit family. Verify trip unit type by referring to trip
unit face (Fig. 13) or instruction bulletin and Table 2 when configuring circuit
breaker parameters for secondary injection testing.

54 © 2001–2015 Schneider Electric All Rights Reserved 48049-183-06

Schneider Electric USA, Inc.
800 Federal Street
Andover, MA 01810 USA
888-778-2733
www.schneider-electric.us
Standards, specifications, and designs may
change, so please ask for confirmation that
the information in this publication is current.

Schneider Electric, Square D, Compact and

Micrologic are owned by
Schneider Electric Industries SAS or its
affiliated companies. All other trademarks are
the property of their respective owners.

© 2001–2015 Schneider Electric

All Rights Reserved
48049-183-06, Rev. 02, 05/2015
Replaces 48049-183-06 Rev. 01, 12/2009