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IDEAL SureTest 61-165 - User Manual

IDEAL SureTest 61-165
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Branch Circuit Testing
Branch circuit wiring and testing practices are primarily code driven with little thought as
to why such stringent requirements are necessary. But these practices are necessary to
ensure safe and efficient branch circuits. Hidden problems within a branch circuit can
result in fire, electrocutions and equipment failure.
Fires
Based on the National Fire Protection Association (NFPA) and the US Consumer
Product Safety Commission data, there was an estimated 406,000 residential structural
fires in 1997, resulting in an estimated 3,390 civilian deaths and 17,775 injuries.
Approximately 9% of the structural fires and 7% of the deaths were determined to be the
result of the electrical distribution system. Residential fires were by far the biggest
problem, accounting for 97% of all structural fires and 87% of deaths.
1
The most common cause of residential electrical fires is problems within the branch
circuit wiring. These problems resulted in 14,600 fires, 420 injuries and 110 deaths in
1997.
2
1
Fact Sheet on Fire in the US and Canada, National Fire Protection Agency (NFPA) 1997
2
1997 Residential Fire Loss, Consumer Product Safety Commission, 1997
250136040,300Total
10
350
160
320
420
Injuries
104,600
Other
309,900
Lamp, light Fix.
104,900
Switch, Outlet
906,300
Cord, Plug
11014,600
Installed Wiring
DeathsFiresElectrical
Distribution
250136040,300Total
10
350
160
320
420
Injuries
104,600
Other
309,900
Lamp, light Fix.
104,900
Switch, Outlet
906,300
Cord, Plug
11014,600
Installed Wiring
DeathsFiresElectrical
Distribution
Testing for safe and efficient branch circuits
Written by Chad Reynolds, Product Manager,
IDEAL Test and Measurement Division

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Questions and Answers

Summary

Branch Circuit Testing Practices

Residential Electrical Fires

Discusses residential structural fires and their causes, particularly electrical distribution systems.

Arc Fault Circuit Interrupters

High Resistance Connections in Fires

Describes high resistance points as a major cause of residential fires due to heat buildup.

Voltage Drop Measurement

Troubleshooting Electrical Circuits

Electrical Shock Hazards

Bonding Receptacle Ground to Junction Box

Understanding False Grounds

Defines false grounds (bootleg grounds) and their potential to energize metal parts.

Earth Ground System

Ground Fault Circuit Interrupters (GFCIs)

Isolated Grounds and Dedicated Circuits

Importance of Branch Circuit Testing

Emphasizes the importance of branch circuit testing for safety and preventing hidden defects.

SureTest Voltage Drop Measurements

Troubleshooting Voltage Issues with SureTest

SureTest Impedance Measurements

SureTest GFCI Testing Procedure

Details the process and purpose of testing GFCI devices using the SureTest.

SureTest AFCI Testing

Overview

The IDEAL SureTest® Circuit Analyzer is a sophisticated diagnostic tool designed to identify and troubleshoot wiring problems in electrical branch circuits. Utilizing patented technology, it "looks behind walls" to detect issues that can lead to personal shock hazards, electrical fires, or equipment performance problems.

Function Description:

The primary function of the SureTest® Circuit Analyzer is to ensure the safety and efficiency of electrical systems by performing comprehensive tests on 3-wire receptacles and circuits. It identifies common wiring errors such as incorrect wiring, polarity reversal, and no-ground conditions, as specified by UL-1436. Beyond basic wiring checks, the device measures critical electrical parameters including line voltage (True RMS), voltage drop under various loads (12, 15, and 20 amps), ground-to-neutral voltage, peak voltage, and frequency. It also measures the impedance of hot, neutral, and ground conductors, which is crucial for identifying high resistance connections that can cause heat buildup and potential fires.

A key feature of the SureTest® Circuit Analyzer is its ability to test Ground Fault Circuit Interrupters (GFCIs) and, for model #61-165, Arc Fault Circuit Interrupters (AFCIs). It verifies the proper operation of GFCIs by simulating a ground fault current (6-9mA) and measuring the trip time. For AFCIs, it applies current pulses (106-141 amps) to simulate an arc fault, ensuring the breaker disconnects power as intended. The #61-165 model also checks for shared neutral conditions that can lead to AFCI nuisance tripping. Additionally, the device can identify false (bootleg) grounds and, with the #61-176 adapter, verify dedicated circuits and isolated grounds.

The SureTest® Circuit Analyzer helps users troubleshoot high impedance points within the electrical system. By measuring voltage drop at different receptacles along a branch circuit, it can pinpoint the location of problems such as bad splices, loose wire connections, or undersized wiring. It also assists in identifying potential hot spots in electrical panels using an infrared temperature meter.

Important Technical Specifications:

  • Display: 128 x 64 OLED with backlight, updating less than 2.5 times per second. Over-range indication is "OL".
  • Voltage Measurement:
    • Line Voltage: 85.0 - 250.0 VAC (True RMS), 0.1V resolution, 1.0% ± 0.2V accuracy.
    • Peak Line Voltage: 121.0 - 354.0 VAC, 0.1V resolution, 1.0% ± 0.2V accuracy.
    • Voltage Loaded: 10.0 - 250.0 VAC, 0.1V resolution, 2.5% ± 0.2V accuracy.
    • Neutral-Ground Voltage: 0.0 - 10.0 VAC, 0.1V resolution, 2.5% ± 0.2V accuracy.
  • Frequency: 45.0 - 65.0 Hz, 0.1Hz resolution, 1.0% ± 0.2Hz accuracy.
  • Voltage Drop: 0.1% - 99.9%, 0.1% resolution, 2.5% ± 0.2% accuracy.
  • Impedance (Hot, Neutral, Ground): 0.00 Ω - 3.00 Ω, 0.01Ω resolution, 2.5% ± 0.02Ω accuracy. Values > 3 Ω are unspecified.
  • GFCI Trip Time: 1mS to 6.500S counter, 1mS resolution, 1.0% ± 2mS accuracy.
  • GFCI Trip Current: 6.0 - 9.0 mA, 0.1 mA resolution, 1.0% ± 0.2mA accuracy.
  • EPD Trip Current: 30.0 - 37.0 mA, 0.1 mA resolution, 1.0% ± 0.2mA accuracy.
  • Operating Environment: 32°F to 122°F (0°C to 50°C) at <80% RH.
  • Storage Environment: 32°F to 122°F (0°C to 50°C) at <80% RH.
  • Altitude: 6561.7 ft (2000m).
  • Dimensions: 6.4" (L) x 3" (W) x 1.4" (D) / 162mm (L) x 76mm (W) x 36mm (D).
  • Weight: 9.4 oz (267g).
  • Safety Rating: UL61010B-1, Cat III-300V; UL-1436 for AFCI, GFCI & Outlet.
  • Power Quality: True RMS sensing AC converter.
  • Maximum Voltage Rating: 250VAC (Warning: Do not exceed).
  • AFCI Testing (Model #61-165 only): Applies 8-12 current pulses (106-141 amps, <8.3ms duration) across hot-to-neutral.

Usage Features:

  • Ease of Use: The SureTest® Circuit Analyzer features a simple menu structure and navigation buttons (down arrow for main menus, side arrow for sub-menus).
  • Quick Diagnostics: Upon insertion into a receptacle, it performs a battery of tests and displays the wiring condition immediately.
  • Load Testing: It can apply 12, 15, and 20-amp loads to measure voltage drop, helping identify hidden defects that static circuit tests might miss.
  • Estimated Load on Line (ELL): Provides a rough estimate of the current load on a branch circuit (up to 15A) to indicate remaining capacity or verify dedicated circuits.
  • Available Short-Circuit Current (ASCC) Calculation: Calculates the ASCC the branch circuit can deliver during a bolted fault, dividing line voltage by circuit impedance.
  • Ground Impedance Measurement: Measures ground impedance, with a rule of thumb of less than 1 ohm for personal protection and less than 0.25 ohms for electronic equipment protection (Note: This test will trip a GFCI protected circuit).
  • Troubleshooting Guidance: The manual provides detailed troubleshooting tips for various voltage and impedance issues, suggesting possible causes and solutions.
  • Optional Accessories:
    • #61-183 Alligator Clip Adapter: Allows testing of non-outlet based circuits (e.g., lighting, ceiling fans, smoke detectors) and 2-wire GFCI circuits by connecting to hot, neutral, and ground wires or a ground source.
    • #61-175 Ground Continuity Adapter: Verifies proper bonding of cabinets or equipment chassis to the system ground and can be used to measure ground impedance of these components. It also helps verify isolated receptacles.
  • AFCI Nuisance Tripping Check (Model #61-165 only): Tests for shared neutral conditions by applying a 300mA load between hot and neutral.

Maintenance Features:

  • Cleaning: The device case can be cleaned with a damp cloth and mild detergent. Abrasives or solvents should not be used.
  • Service and Replacement Parts: The unit has no user-serviceable parts. For service information, users are directed to contact Technical Support or visit the IDEAL INDUSTRIES, INC. website.
  • Thermal Protection: The AFCI circuitry includes a thermal sensor. During repeated AFCI testing, if a thermometer icon appears, the sensor delays further testing until the circuitry cools, automatically resuming afterward.
  • Accuracy Maintenance: To maintain stated accuracies during repeated use, it is recommended to allow 20 seconds between insertions to dissipate heat buildup during load testing.

The SureTest® Circuit Analyzer is a robust and essential tool for electricians and technicians, providing comprehensive testing and diagnostic capabilities to ensure the safety, reliability, and efficiency of electrical installations.

IDEAL SureTest 61-165 Specifications

General IconGeneral
AC Voltage Range0-600V
ContinuityYes
Power Source9V battery
DisplayLCD
Frequency Range45 to 65 Hz
Operating Temperature32°F to 104°F (0°C to 40°C)

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