suretest® circuit analyzer
SURETEST® CIRCUIT ANALYZER
PGT-61-164
User Manual
Table of Contents
PROSTAT® PGT-61-164 SURETEST® CIRCUIT ANALYZER
Section
Topic
Page
I.
Introduction
4
II.
General Operation
4
III.
Menu Navigation
5
IV.
GFCI Test Button
5
V
Testing Procedure
5
VI.
GFCI Testing
9
General Specifications
11
Copyright © 2011 by Prostat® Corporation. All rights reserved. Printed in the United States of America. No part of this
manual may be used or reproduced in any manner whatsoever without written permission. For information contact
Prostat Corporation, 1072 Tower Lane, Bensenville, IL 60106 USA
Prostat is the registered trademark of Prostat® Corporation
PGT-61-164 SureTest® Circuit Analyzer
WARNING
To maintain stated accuracies during repeated use, allow 20 seconds between insertions to adequately dissipate any heat buildup during the load testing.
I. Introduction
Utilizing patented technology, the SureTest circuit analyzer “look behind walls” to identify wiring problems
that can lead to personal shock hazards, electrical fires, or equipment performance issues. Personal shock
hazards stem from poor grounding, false grounds, and/or no ground fault protection. Electrical fires are
primarily caused from arc faults and high resistance points that lead to glowing connections in the circuit
wiring. And, equipment performance issues arise due to insufficient voltage available under load, poor
impedance, and high ground-to-neutral voltage. In fact, it’s estimated that 80% of power quality performance issues are related to the faulty wiring issues stated above.
Product Features
•
•
•
•
•
•
•
•
True RMS
Measures voltage drop under 12, 15 and 20-amp loads
Measures voltage: Line, Ground-to-Neutral, Peak, Frequency
Measures Hot, Neutral and Ground conductor impedances
Identifies proper wiring in 3-wire receptacles
Identifies false (bootleg) grounds
Tests GFCI’s for proper operation
Includes two 12 inch extension cord
II. General Operation
The PGT-61-164 SureTest Circuit Analyzer takes only seconds to test each outlet and circuit under a full
load. This test tool checks for various wiring conditions including: correct wiring, polarity reversal and no
ground per UL-1436. A simple menu gives access to measurements of line voltage, voltage drop under a
full load condition, ground-neutral voltage and line impedances. The ground fault circuit interrupter (GFCI)
test is performed separately, in accordance with UL-1436 and will disrupt the electrical supply if a functional GFCI is present.
WARNING
Do not use on outputs from UPS system, light dimmers or square wave generating
equipment, as damage to the analyzer will occur.
SureTest Circuit Analyzer
1. Menu Structure
2. Navigation Buttons
3. GFCI Test Button
4. AFCI Test Button (Not included on the 61164)
4
Rev. B / March 5, 2015
PGT-61-164 SureTest® Circuit Analyzer
III. Menu Navigation
The microprocessor’s top priorities are to take live measurements and then analyze the data. Hence, the
microchip occasionally will not recognize the keypad buttons being rapidly depressed, while it’s executing
these changes.
The measurements taken by the SureTest Model 61-164 are broken into five main menus positioned down
the left side of the display: Wiring Configuration (• • •), Voltage ( V ), Voltage Drop ( VD ), ASCC, and Impedance ( Z ). To navigate to each of the main menus, use the down arrow button ( ↓ ).
The Wiring Configuration (• • •) screen indicates correct wiring, reverse polarity, hot/ground reversal and
no ground conditions by sequencing the three balls. The label on the back of the product explains the wiring sequence indications.
The Voltage ( V ) menu displays the True RMS line voltage in real-time. This main menu has a sub-menu
positioned horizontally at the bottom of the screen that displays the line voltage (RMS HN), ground-toground voltage (RMS GN), Peak Voltage (PEAK), and Frequency ( HZ ). To navigate through the submenu,
use the side arrow button ( → ).
The Voltage Drop ( VD ) screen dual displays percent voltage drop with a 15 amp load along with the
resultant loaded voltage ( VL ). This main menu has a submenu, which also displays the percent voltage
drop and loaded voltage with 20 amp and 12 loads. To navigate through the submenu, use the side arrow
button ( → ).
The ASCC screen displays the Available Short-Circuit Current that the branch circuit can deliver through
the breaker during a bolted fault (dead-short) condition.
The Impedance ( Z ) main menu displays the impedance in ohms ( Ω ) of the hot conductor. This main
menu has a sub-menu positioned horizontally at the bottom of the screen that also displays the neutral
( N ) and ground ( G ) conductor impedances. To navigate through the submenu, use the side arrow button
( → ). Note that testing the ground impedance will trip a GFCI protected circuit.
IV. GFCI Test Button
Depressing this button displays the GFCI main menu. Two tests can be performed
in this menu: GFCI and EPD. The GFCI tests Ground Fault Circuit Interrupting
devices by faulting 6-9mA from hot-to-ground per UL-1436. The EPD tests those
breakers, which have an Equipment Protective Device feature that trips the
breaker if a ground fault of greater than 30mA is detected. Pressing the side arrow button ( → ) navigates
between these two sets. Once the desired test is highlighted, depress the GFCI test button on the keypad
to activate the test.
V. Testing Procedure
Wiring Verification
Immediately after being inserted into a receptacle, the SureTest displays the
IDEAL logo while it performs a battery of tests. The first test result displayed is
the wiring condition. The SureTest checks for the following conditions and indicates the test result on the display.
Rev. B / March 5, 2015
5
PGT-61-164 SureTest® Circuit Analyzer
Wiring Condition
Display Indication
H
G
N
Correct Wiring
No Ground
Polarity Reversal
Open/Hot Neutral
False Ground
○
○
҉
●
○
●
○
●
○
○
҉
●
Legend
○ On
● Off
҉ Flashing
If the wiring condition is other than normal, the SureTest is limited on its measurements that can be performed. If a no ground condition exists, only the line voltage and voltage drop measurement are available.
In a hot/ground reversal, open neutral or open hot condition, the unit will not have any power so the
display will be blank.
Notes:
1) Will not detect two hot wires in a circuit.
2) Will not detect a combination of defects.
3) Will not detect reversal of grounded and grounding conductors.
False Ground Indication
NEC article 250-23(a) only allows for a neutral to ground bond to occur at the main panel. The SureTest
suggests any improper neutral-to-ground bonds within 15-20 feet upstream (towards the panel) of the
tester. If this bond improperly occurs in the branch circuit through a bootleg ground via a jumper wire at
the outlet device or inadvertent contact of the ground wire to the neutral connection, the SureTest indicates a false ground condition. Note that if the SureTest is within 15-20 feet of the main panel, the unit
will indicate a false ground condition on a properly wired circuit due to its close proximity to the proper
ground-neutral bond in the main panel.
Voltage Measurements
The line voltage measurement should be 120 VAC +/-10% fluctuation at 60 Hz. The peak voltage should be
1.414 times the rms line voltage reading for a clean sine waveform. Ground-to-neutral voltage should be
less than 2 VAC. In a single-phase circuit, a higher ground-neutral voltage indicates excessive current leakage between the neutral and ground conductors. In a 3-phase circuit with a shared neutral, a high groundneutral voltage could indicate an unbalanced load between the three phases or harmonic distortion on
the shared neutral. Excessive ground-neutral voltage may result in inconsistent or intermittent equipment
performance.
Troubleshooting Tips for Voltage Issues
WARNING
Do not exceed the unit’s maximum voltage rating of 250VAC!
6
Rev. B / March 5, 2015
PGT-61-164 SureTest® Circuit Analyzer
MEASUREMENT
Line Voltage
120 VAC
220 VAC
EXPECTED
RESULT
108-132
VAC
198-242
VAC
PROBLEM
POSSIBLE CAUSES
High/low
Too much load on
theload on circuit
High Resistance connection within the
circuit or at the panel
Supply voltage too
high/low
Current leaking from
neutral to ground
Neutral-Ground
Voltage
< 2 VAC
Voltage
High G-N
>2 VAC
Peak Voltage
120 VAC
220 VAC
153-185
VAC
280-342
VAC
High/Low
Peak voltage
Frequency
60 HZ
High/Low
Frequency
Unbalanced 3-phase
system
Triplen harmonics
returning on neutral
in 3-phase system
Supply voltage
Too high/low
High Peak Loads on
line caused by electronic equipment on
line
Supply frequency
Too high/low
POSSIBLE SOLUTIONS
Redistribute loads on the circuit
Locate high resistance connection/
device and repair/replace
Consult Power company
Idenify source of leakage; multiple
bonding points, equipment or
devices
Check load balance and redistribute load
Oversize neutral to impedance.
Reduce harmonic effect via filter or
other methods
Consult power company
Evaluate number of electronic
devices on circuit and redistribute
if necessary
Consult power
Company
Voltage Drop (VD) Measurements
The SureTest measures the line voltage, applies a load on the circuit, measures the loaded voltage, then
calculates the voltage drop. Results are displayed for 12A, 15A, and 20A loads. The National Electrical
Code recommends 5% as the maximum voltage drop for branch circuits for reasonable efficiency (NEC
article 210-19, FPN 4). And, the voltage under load ( VL ) should not drop below 108VAC for reliable equipment operation.
A good branch circuit should start out with less than 5% voltage drop at the furthest receptacle from the
panel at the end of the cable run. Then, each receptacle tested in sequence towards the panel should
show a steady decrease in voltage drop. If the voltage drop is above 5% and does not noticeably decrease,
as you get closer to the first device on the circuit, then the problem is between the device and the panel,
and the circuit breaker connections. High resistance points can usually be identified as hot spots using an
infrared thermometer or by measuring the voltage across the breaker. If the voltage drop exceeds 5% but
noticeably decreases as you nearer the panel, the circuit may have undersized wire, too long of a cable
run, or too much current on the circuit. Check the wire to ensure that it is sized per code and measure the
current on the branch circuit. If a voltage drop reading changes significantly from one receptacle to the
next, then the problem is a high impedance point at or between two receptacles. It is usually located at a
termination point, such as a bad splice or loose wire connection, but it might also be a bad receptacle.
Rev. B / March 5, 2015
7
PGT-61-164 SureTest® Circuit Analyzer
Troubleshooting Tips for Voltage Drop
MEASUREMENT
Voltage Drop
EXPECTED
RESULT
<5%
PROBLEM
POSSIBLE CAUSES
Too much load on
theload on circuit
Undersized wire for
High Volt- length of run
age Drop
High resistance connection within the
circuit or al the panel
POSSIBLE SOLUTIONS
Redistribute loads on the circuit
Check code requirement and rewire if necessary
Locate high resistance connection/
device and repair/replace
ASCC Measurement
The SureTest calculates the Available Short-Circuit Current (ASCC) that the branch circuit can deliver
through the breaker during a bolted fault (dead-short) condition.
The ASCC is calculated by dividing the line voltage by the circuit’s line impedance (hot + neutral). Depressing the side arrow (→) displays the worst-case scenario where all three conductors (hot, neutral, ground)
are shorted together – the neutral and ground provide a lower impedance via a parallel return path. Note
that this second test will trip a GFCI. See the following equations for clarification.
ASCC1 = Line Voltage (VHN)/ (Hot Ω + Neu Ω)
ASCC2 = Line Voltage (VHN)/ (Hot Ω + 1/(1/ Neu Ω + 1/Grd Ω)
Impedance (Z) Measurements
If the voltage drop measurement exceeds 5%, analyze the hot and neutral impedances. If one is significantly higher than the other, the problem is with the conductor with the much higher impedance. Then,
check all connections on that conductor back to the panel. If both impedance appear high, the source
can be undersized wire for the length of run, a bad device, or poor connections at the pigtails, devices, or
panel.
The ground impedance measured should be less than 1 ohm as a rule of thumb to ensure that fault current has a sufficient path back to the panel. IEEE states the ground impedance should be less than 0.25
ohms to ensure the ground conductor can safely return any fault current which could damage equipment
on the circuit. Surge suppression systems require a good ground to adequately protect equipment from
transient overvoltages. Note that a small amount of current is applied to the ground conductor to accurately measure its impedance. By the inherent nature of this test, a GFCI protected circuit will trip unless
the device is temporarily removed from the circuit.
8
Rev. B / March 5, 2015
PGT-61-164 SureTest® Circuit Analyzer
EXPECTED PROBLEM
POSSIBLE CAUSES
RESULT
<0.48Ω/
Too much load on
foot of 14
branch circuit
AWG wire
<0.03Ω/
High
Undersized wire for
Hot and Neutral foot of 12 Conductor
length of run
Impedance
AWG wire impedance
<0.01Ω/
High resistance confoot of 10
nection within the
AWG wire
circuit or at the panel
< 1Ω to
Undersized wire for
protect
length of run
High
people
Ground Impedground
ance
<0.25Ω to impedance High resistance conprotect
nection within the
equipment
circuit or at the panel
MEASUREMENT
POSSIBLE SOLUTIONS
Redistribute loads on the circuit
Check code requirements and rewire if necessary
Locate high resistance connection/
device and repair/replace
Check code requirements and rewire if necessary
Locate high resistance connection/
device and repair/replace
VI. GFCI Testing
To test the GFCI device, the SureTest creates an imbalance between the hot and neutral conductors by
leaking a small amount of current from hot to ground using a fixed value resistor. The trip current should
not be less than 6mA or greater than 9mA per UL-1436. A functional GFCI should sense a imbalance and
disconnect the power. The SureTest displays the actual trip current in milliamps and trip time in milliseconds.
To conduct a GFCI test, press the GFCI button to enter the GFCI main menu. The GFCI symbol in the display
should be highlighted as the default test. If EPD is lit, then use the side arrow (→) to highlight the GFCI
symbol. Then, press the GFCI button to activate the test. The actual current being leaked to ground is displayed. The TEST icon and hourglass symbol appear on the display to let the user know that the GFCI test
is being performed. The GFCI device should trip within the UL established guideline causing the display
to blank out with the loss of power. When the FDCI device is reset, the unit displays the actual trip time
that the GFCI took to respond to the current imbalance and open the circuit. Pressing the down arrow
button (↓) returns it to the wiring verification mode. If the GFCI fails to trip, the SureTest terminates the
test after 6.5 seconds. Further inspection should determine whether the GFCI circuitry is faulty, the FDCI is
installed incorrectly, or if the circuit is protected by a GFCI device.
UL Guideline for trip time:
T = ( 20 ) 1.43 where: T = milliseconds (ms)
I I = milliamps (mA)
Notes:
1) In order to test a GFCI in a 2-wire system (no ground), the #61-175 ground continuity adapter (sold
separately) must be used. Connect the alligator clip on the adapter to a ground source, such as to a metal,
water or gas pipe.
2) All appliances or equipment on the ground circuit being tested should be unplugged to help avoid erroneous reading.
Rev. B / March 5, 2015
9
PGT-61-164 SureTest® Circuit Analyzer
In addition to performing a GFCI test for evaluating personal protection from shock hazards, the SureTest
can also conduct testing to ensure equipment protection from ground faults exceeding 30mA. The method of operation is the same as the GFCI test noted in the first paragraph above but uses a different resistor
to create a 30mA leakage current from hot-to-ground. To conduct an EPD test on a Equipment Protective
Device, press the GFCI button to enter the GFCI main menu. The GFCI symbol in the display should be
highlighted as the default test. Press the side arrow (→) button to highlight the EPD symbol. Then, press
the GFCI button to activate the test. The actual current being leaked to ground is displayed. The TEST icon
and hourglass symbol appear on the display to let the user know that the EPD test is being performed.
The EPD should trip causing the display to blank out with the loss of power. When the EPD is reset and
power is restored, the unit displays the actual trip time that the EPD took to respond to the current imbalance and open the circuit. Pressing the down arrow button (↓) returns it to the wiring verification mode.
If the EPD fails to trip, the SureTest terminates the test after 6.5 seconds. Further inspection should determine whether the EPD circuitry is faulty, the EPD is installed incorrectly, or if the circuit is protected by an
EPD.
MEASUREMENT
GFCI Test
EXPECTED
RESULT
PROBLEM
POSSIBLE CAUSES
GFCI
doesn’t GFCI maybe installed
trip within
GFCI trips proper trip improperly
within trip
time
time
GFCI
doesn’t GFCI may be defective
trip
POSSIBLE SOLUTIONS
Check wiring for proper installation
in accordance with manufacturer’s
instructions and NEC
Check wiring and ground. Replace
GFCI if necessary
Estimated Load on Line (ELL) Meassurement
The PGT-61-164 SureTest® mow estimates the load on a branch circuit to provide an indication of how
much capacity in the circuit remains or to quicly check if the circuit is dedicated. This function is a rough
estimate (no stated accuracy), as accurately measuring circuit current has to be done with a clamp meter
at the electrical panel. The proprietary way in which these calculations are made allows the user to plug
the unit into an outlet and quickly determine the current load on that branch circuit.
Both the distance of the SureTest® from the load and branch circuit impedance will affect the accuracy.
Best accuracy is obtained by positioning the SureTest® in the same outlet as the largest load on line;
otherwise, try to position the SureTest® between the load(s) and the electrical panel. The maximum amperage reported by the tester is 15A.
Maintenance
Clean case with a damp cloth and mild detergent. Do not use abrasives or solvents.
10
Rev. B / March 5, 2015
PGT-61-164 SureTest® Circuit Analyzer
PGT-61-164 SureTest® Circuit Analyzer Specifications
General Specifications
Display:
Display update for Volt:
Over-range indication on
all functions:
128x64 OLED with backlight
Less than 2.5 times second
Display “OL”
Operating Environment
Relative Humidity:
Storage Environment:
Case Construction:
Altitude:
Dimensions:
Weight:
Safety:
32°F to 122°F (0°C to 50°C) at <80% Rh
32°F to 122°F (0°C to 50°C) at <80% Rh
ABS UL 94 V/0/5VA Rated
6561.7 ft. (2000m)
6.4” (L) x 3” (W) x 1.4” (D)
162mm (L) x 76mm (W) x 36mm (D)
9.4 oz (267 g)
UL61010B-1, Cat III-300V
UL-1436 for AFCI, GFCI & Outlet
Accessories:
Includes 12” plug adapter and instruction manual
Double Insulation
Instrument has been evaluated and complies with insulation category III, (Overvoltage category III) Pollution degree 2 in accordance with IEC-644. Indoor use.
Measurement Specifications
All specifications are at 23°C ± 5°C at less than 80% relative humidity
Accuracy is stated as ± ((% of range) + (counts))
AC converter is true rms sensing
MEASUREMENT
Line Voltage
Peak Line Voltage
Frequency
% Voltage Drop
Voltage Loaded
Neutral-Ground V
Impedance – Hot Neutral, & Ground
GFCI Trip Time
GFCI Trip Current
EPD Trip Current
Rev. B / March 5, 2015
RANGE
85.0 – 250.0 VAC
121.0 – 354.0 VAC
45.0 – 65.0 Hz
0.1% - 99.9%
10.0 – 250.0 VAC
0.0 – 10.0 VAC
0.0 Ω - 3.00 Ω
1.0 > 3 Ω
1mS to 6.500S counter
6.0 – 9.0 mA
30.0 – 37.0 mA
RESOLUTION
0.1 V
0.1 V
0.1 Hz
0.1 %
0.1 V
0.1 V
0.01 Ω
1 mS
0.1 mA
0.1 mA
ACCURACY
1.0% ± .2 V
1.0% ± .2 V
1.0% ± .2 V
2.5% ± .2 %
2.5% ± .2 %
2.5% ± .2 %
2.5% ± .02 Ω
Unspecified
1.0% ± .2mS
1.0% ± .2 mA
1.0% ± .2 mA
11
PGT-61-164 SureTest® Circuit Analyzer
NOTES
12
Rev. B / March 5, 2015
PGT-61-164 SureTest® Circuit Analyzer
NOTES
Rev. B / March 5, 2015
13
PGT-61-164 SureTest® Circuit Analyzer
NOTES
14
Rev. B / March 5, 2015
Specifications are subject to change without notice.
All Prostat trademarks and trade names are the property of Prostat Corporation.
All other trademarks and trade names are the property of their respective companies.
P R O F E S S I O N A L
S T A T I C
C O N T R O L
P R O D U C T S
Prostat Corporation
Corporate Headquarters • 1072 Tower Lane • Bensenville, IL 60106 • 630-238-8883 • Fax: 630-238-9717 • 1-855-STATIC1 • www.prostatcorp.com
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