Download Rod-L M100AV/BV and M500AV/BV Manual
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Artisan Technology Group is your source for quality new and certified-used/pre-owned equipment • FAST SHIPPING AND DELIVERY • TENS OF THOUSANDS OF IN-STOCK ITEMS • EQUIPMENT DEMOS • HUNDREDS OF MANUFACTURERS SUPPORTED • LEASING/MONTHLY RENTALS • ITAR CERTIFIED SECURE ASSET SOLUTIONS SERVICE CENTER REPAIRS Experienced engineers and technicians on staff at our full-service, in-house repair center WE BUY USED EQUIPMENT Sell your excess, underutilized, and idle used equipment We also offer credit for buy-backs and trade-ins www.artisantg.com/WeBuyEquipment InstraView REMOTE INSPECTION LOOKING FOR MORE INFORMATION? Visit us on the web at www.artisantg.com for more information on price quotations, drivers, technical specifications, manuals, and documentation SM Remotely inspect equipment before purchasing with our interactive website at www.instraview.com Contact us: (888) 88-SOURCE | [email protected] | www.artisantg.com HOD-L c e r t i f i e s t h a t this i n s t r u m e n t \,;as t i ~ o r o u g h l y i r ~ s ~ e c t ezdn d t e s l e d 2nd found t o m e e t i t s published specifications v;ien i t \.:as shi.a,?rd f r o m t h e factory. WARRANTY AND A S S E T A N C E All ROD-L E l e c t r o n i c s ' i n s t r u m e n t s a r e w a r r a n t e d a g a i n s t d e f e c t s in m a t e r i a l s and workmanship. T h i s w a r r a n t y a p p l i e s f o r o n e y e a r f r o m d a t e of delivery t o t h e original purchaser. \Ce will r e p a i r o r r e p l a c e i n s t r u m e n t s which prove l o b e d e f e c t i v e d u r i n g t h e w a r r a n t y period provided t h e y a r e r e t u r n e d t o R O D L Electronics. z For prompt, e f f i c i e n t s e r v i c e of y o u r i n s t r u m e n t , s e n d i t d i r e c t l y t o R O D L Electronics a l o n g w i t h & s t a t e m e n t describing t h e n a t u r e of t h e problem. . A Return A u t h o r i z a t i o n N u m b e r m u s t b e obtained f r o m R O D L Electronics before r e t u r n i n g a n y i n s t r u m e n t s f o r repair. T r a n s p o r t a t i o n must b e prepaid. R O D L E l e c t r o n i c s will a s s u m e c o s t of s u r f a c e t r s n z p o r t a t i o n when returning equipment t o c u s t o m e r . This w a r r a n t y i s void if t h e i n s t r u m e n t h a s been modified o r s u b j e c t t o g r o s s misuse. No o t h e r w a r r a n t y i s expressed o r implied. R O P L E l e c t r o n i c s i s not liable f o r consequential d a m s g e s . Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com PAGE INTRODUCTION 1- 1 1-1 0 1-1 2 1-1 3 1-14 1- 6 I- 1 General Equipment Supplied S t a r ~ d a r dVersions of Models Special I'ersions of nlodels Identification Specifications INSTALLATION A N D OPERATION General Unpacking a n d Inspection Installation Power Requirements Power Cable Initial Installation and Turn On Storage Repacking for shipmentm O p e r a t i n g con;-rols Safety Feature O p e r a t i o n a l C h e c k f o r A C Hipot T e s t e r s Total C u r r e n t Procedure R e a l C u r r e n t (BV only procedure) T e s t T i m e Adjustment Procedure A u t o m a t i c T e s t Procedure T H E O R Y O F OPERATION T h e o r y of D i e l e c t r i c blithst;nd Testing I n s t r u m e n t Functional Diagram I n s t r u m e n t Assernbly Diagram P o w e r Supply C i r c u i t High Voltage Control/Slow Turn On R e a l C u r r e n t D e t e c t Circuit A 2 1 C o n t r o l Board Total Current Detector/Compartors S a f e t y Ground D e t e c t Circuit Logic C o n t r o l Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com TABLE O F CONTENTS .-.~. (Cont'd) PAGE SECTION - IV hIAINTENANCE AND SERVICE Introduction Calibration S e t Up M e t e r hlechanical Zero T o t a l C u r r e n t Roard Calibration T e s t T i m e Calibration A2-1 R e a l C u r r e n t Board Calibration Offset Adjustment T r i g g e r a n d M e t e r Calibration Voltmeter Calibration Fail Pots Calibration S a f e t y Ground Ohms Calibration R a m p R a t e Calibration I n i t i a l C a l i b r a t i o n of A6-S5 R a m p R a t e Adjustment Troubleshooting T r o u b l e s h o o t i n g T r e e Problem List TABLES, SPECIFICATION C H A R T S AND DIAGRAMS . T a b l e 1-1 F i g u r e 2-1 F i g u r e 2-2 T a b l e 2-1 F i g u r e 3-1 F i g u r e 3-2 F i g u r e 3-3 F i g u r e 3-4 F i g u r e 3-5 F i g u r e 3-6 F i g u r e 4-2 Specifications R a c k h'lounting Kit Installation C o n t r o l s and Indicators C o n t r o l s and Indicators F u n c t i o n a l Diagram HV Amplitude C o n t r o l R a m p Up C o n t r o l General Control Assembly Diagram D e t a i l Assembly Diagram Test Cycle Parameters Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com TABLE OF - CONTENTS (Cont'd) - SECTION V PARTS LIST A1 0 Po:ver Supply A21 Control Logic AE-SS A C Control A2-1 Real Current SCHEMATICS Main Chassis Assembly Wiring Diagram A 1 0 Power Supply A 1 0 Power Supply Assembly A21 Control Logic A 2 1 Control Logic Assembly A G S 5 AC Control A6-S5 A C Control Asse_mbly A2-1 Real Current A2-1 R e a l Current Assembly OPTIONS BV Theory of Operation O t h e r Options P a r t s List Schematics Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com INTRODUCTION Section I 1-1 General 1-2 This p u b l i c a t i o n , v!hich p r o v i d e s o p e r a t i n g a n d s e r v i c i n g i n s t r u c t i o n s f o r t h e R O G - L E l e c t r o n i c s irjodels A1100A\', B\' a n d A?500A\', B\' A C Hipot T e s t e r s i s divided i n t o f i v e sections. S e c t i o n I d e s c r i b e s t h e Instruments a n d l i s t s t h e i r s p e c i f i c a t i o n s . Section I1 c o n t a i n s I n s t a l l a t i o n I n s t r u c t i o n s a n d O p e r a t i o n Procedures. S e c t i o n 111 c o n t s i n s P r i n c i p l e s of O p e r a t i o n . S e c t i o n I\' c o n t a i n s Service Instructions. S e c t i o n 1' c o n t a i n s R e p l a c e m e n t P a r t s I n f o r m a t i o n , P a r t s L o c a t i o n D i z g r s r n s i;nd Schr-matics. 1-3 Models M100, 500, A\', B\' A C Hipot T e s t e r s a r e high v o l t a g e l e a k a g e a n d b r e a k d o w n t e s l e r s w i t h s f l f e t y g r o u n d continuity test c a p a b i l i t y i o r p e r f o r m a n c e of " d i e l e c t r i c w i t h s t a n d " t e s t s in a c c o r d a n c e w i t h a p p l i c a b l e UL, CSA, VDE, BSI, IEC a n d s i m i l a r s t a n d a r d s . T h e MIOOAV, 500AV tests a n d displays t o t a l c u r r e n t , w h i l e t h e MIOOBV, M500BV t e s t s a n d d i s p l a y s t o t a l c u r r e n t a n d t h e r e s i s t i v e art of t h e A C c u r r e n t . 1-4 T h e " d i e l e c t r i c w i t h s t a n d " t e s t i s o n e o f m a n y t e s t s r e q u i r e d by m a n y c e r t i f i c a t i o n a g e n c i e s (UL, CSA, VDE, BSI, IEC, e t c ) a s p r o o f o f a n i n s t r u m e n t ' s a b i l i t y t o w i t h s t a n d A C p o w e r l i n e spikes w i t h o u t b e c o m i n g a h a z a r d to i t s e l f o r t h e user. F o r e x a m p l e , lightning, d r a s t i c l o a d c h a n g e s o r power l i n e outages c a n place s h o r t d u r a t i o n s p i k e s o n p o w e r l i n e s o f m a n y t i m e s nominal line voltage. 1-5 S o m e s p e c i f i c e x a m p l e s of s a f e t y s t a n d a r d s requiring dielectric w i t h s t a n d t e s t i n g i n c l u d e UL 45, UL 1 1 4 , U L 478, U L 506-508, UL 5 4 4 , UL 674, U L 1 0 1 2 , UL 1 2 4 4 , I E C 380, IEC 348, MIL,STD 202, BS1 3361 a s w e l l as CSA 22.7, \'DE 0806, e t c . T h e s p e c i f i c s t a n d a r d s h o u l d b e c o n s u l t e d f o r vo1teg.e r e q u i r e m e n t s a n d s p e c i f i c t e s t procedures. 1-6 T h e ROD-L A C H i p o t T e s t e r s a p p l y high v o l t a g e to t h e .device u n d e r test f o r a d u r a t i o n of t i m e p r e s e t f o r o n e s e c o n d t o 90 s e c o n d s . T h e d e v i c e u n d e r t e s t plugs i n t o t h e f r o n t panel t e s t connector. T e s t l i m i t s f o r t o t a l c u r r e n t (and for Resistive part of t h e A C c u r r e n t w i t h B\'s) a r e p r e s e t b y t h e user via a r e a r p a n e l c o n t r o l . If t h e d e v i c e u n d e r t e s t i s d e f e c t i v e , a u t o m a t i c c i r c u i t r y t u r n s o f f t h e high v o l t a g e , l i g h t s t h e F A L l a m p and sets o f f a n a u d i b l e a l a r m . This a u d i b l e a n d visual a l a r m must be manually r e s e t ( m e e t s UL requirements). Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com . ., - - 1-7 .411 models i n c o r p o r a t e a rapid, a u t o m a t i c solid s t a t e e l e c t r o n i c shutdown c i r c u i t t o turn off t l ~ ehigh v o l t a g e within t w o milliseconds a f t e r a breakdown fault. To prevent t u r n on s u r g e s , t h e high v o l t a g e has an e l e c t r o n i c a l l y c o n t r o l l e d rate-ofrise. 1-8 F o r o p e r a t o r use, t h e t e s t c y c l e is fully a u t o m a t i c ; a c c i d e n t a l t e s t initiation is prevented by u s e of r e c e s s e d s t a r t s w i t c h , f o r o p e r a t o r s a f e t y , a s e c u r i t y "CHASSIS G R O U N D SENSE" v o l t a g e must b e c o n n e c t e d t o a s e c u r e Ion r e s i s t a n c e point on t h e d e v i c e under t e s t . Without this c o n n e c t i o n , t h e t e s t b i l l not e n t e r t h e ''READY" s t a t e . T h e "SAFETY GROUND" of t h e device u n d e r t e s t is monitored a n d s t r a s e d e i e c t r o n i c a l l y . If e i t h e r t h e "SAFETY GROUND" o r t h e "CHASSIS G R O U N D SENSE" c o n n e c t i o n fails during t h e t e s t , t h e HIPOT TESTER a u t o m a t i c a l l y s h u t s down t h e high v o l t a g e a n d a c t u a t e s visual e n d audible alarms. 1-9 The ROD-L A C t e s t e r s a r e c o m p l e t e l y s e l f c o n t a i n e d r u g g e d i n s t r u m e n t s designed f o r l a b o r a t o r y a n d p r o d u c t i o n t e s t i n g e n v i r o m e n t s . AU A C units a r e very s i m i l a r in operation a n d c o n s t r u c t i o n . T h e p r i m a r y e x c e p t i o n i s t h a t BV model m e a s u r e s t h e resistive p a r t of A C t o t a l c u r r e n t . Externally, t h e BV model h a s a n e x t r a c o n t r o l on t h e f r o n t a n d r e a r p a n e l s ( s e e f i g u r e 2-2). InternaUy, t h e s t a n d a r d BV has f i v e P C B a s s e m b l i e s (A2-1, A6-S5, A7-AV, A10, A21) a n d t h e s t a n d a r d AV has four P C B a s s e m b l i e s (A6-S5, A7-AV, AID, A21). . . 1-10 EQUIPMENT S U P P L I E S 1-1 1 T h e R O D L H l P O T TESTER i s c o m p r i s e d of t h e following: i a. 1-1 2 H l P O T TESTER, R O D L Model MIOOAV, MIOOBV, M500AV o r hl500BV. b. Six f o o t p o w e r c o r d , t h r e e pronged. c. Thirty-six i n c h (36") ground cable. d. This manual. e. Extra i n p u t l i n e fuses. - STANDARD VERSIONS O F NODELS T h e s t a n d a r d A C HIPOT TESTER i s a v a i l a b l e with a full s c a l e test v o l t a g e of 1500 VAC, 2800 V A C o r 5000 VAC. A m m e t e r s with F.S. up t o 333mA a r e available depending o n t h e Model. S t a n d a r d F.S. v a l u e s f o r t h e a m m e t e r a r e 10, 25,40, 50, 100, 200 a n d 333mA. F o r t h e NlOO models t h e maximum F.S. values a r e 50mA for t h e 1 5 0 0 VAC unit, 40mA f o r t h e 2800 VAC a n d 25mA f o r t h e 5000 VAC. F o r t h e n1500 m o d e l t h e maximum F.S. v e l u e s a r e 333mA f o r t h e 1500 VAC, 200rnA f o r t h e 2800 a n d 1 0 0 m A f o r t h e 5000 VAC. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com I n s t r u m e n t s with non-standard t e s t vollages and a m m e l e r s a r e c o n s i d e r e d special versions of t h e basic models. In these a p p l i c a t i o n s , t h e c u s t o m e r specifies t h e voltege a n d a m m e t e r full s c a l e values. T h e Hipot T e s t e r h i ~ hvoll8ge F.S. rating and from the hiodel number t h e a m m e t e r F.S. r a t i n g a r e readable c o d e on t h e serial number label on t h e r.ea; panel. An e x ~ m p l e of t h e model number f o r m a t is a s follows: :,;lhcre N.X i r p r e s e n t s F.S. kilovolts t n d in m A . %%Z ri.p;.e.ients FS c ~ i r r e n t 1-15 T h e ROD-L AC Hipot T e s t e r s a r e identified by a hiodel Number a s d e s c r i b e d in paragraph 1-13 and a s e r i a l number (see figure 2-2). T h e s e r i a l number is a m a n u f a c t u r e r identification of t h e instrument. 1-16 SPECIFICATIONS T a b l e 1-1 l i s t s t h e most important e l e c t r i c a l , environmental and p h y s i c a l specifications o f t h e Hipot Tcsters. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com . . T a b l e 1-1 SI'ECIFICA'TIONS T e s t Voltage and C u r r e n t User a d j u s t a b l e up t o 5000 \'AC RMS, 50160 Hz, 0-333rnA. Note: Voltage and c u r r e n t range combinations a r e d e t a i l e d in paragraphs 1-12 a n d 1-1 3. - High \!oltage Shutdown Within 2ms a f t e r a breakdojvn i e u l t is d e t e c t e d ( e l e c t r o n i c shutdown circuit). Automatic Test Cycle O n e second t o Y O seconds. Initial Turn-on P e r i o d Requires 2 ~ e c o n d s f o r s a f e t y ground t e s t b e f o r e H.V. is a2plied. S a f t e y Ground C o n t i n u i t y R e j e c t l e v e l 0.5 ohm 1 0.1 ohm; o p e r a t e s whenever ground i s connected. (Low c u r r e n t , 1.0 a m p applied). Volt M e t e r A c c u r a t e t o 1 3 % F.S. Voltage Monitoring C i r c u i t r y -t1.0% through full range. Ammeter A c c u r a t e t o 1 3 % F.S. C u r r e n t Monitoring C i r c u i t r y + f 0 % through full range. A m m e t e r Resolution B e t t e r t h a n 3% F.S. Current Circuitry Resolution B e t t e r t h a n 1.0% F.S. Voltmeter Resolution B e t t e r t h a n 3% F.S. Voltage C i r c u i t r y R e s o l u t i o n B e t t e r t h a n 0.1% F.S. Input Power 1101240 VAC, f 0 / 6 0 Hz, 5001V m a x (3OW typical); 115/23OV w i t c h . Environmental O p e r a t i n g Conditions Physical Color Mint grey/Olive g r e y I'i'eight 351bs (15.9 kg) N e t 381bs (17.2 kg) Shipped Dimensions 1 6 314 X 5 114 X 1 3 114 inches 4 3 X 1 3 X 34 c e n t i m e t e r s Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - SAFETY FEATURES Sequences design of operation. ' Loss of s a f e t y ground i e r n i n a t e s Hipot Test cycle. external HV leads. recesses START button. ' Visual and audible alarm a t failure. High voltage lockout requiring manual reset. ' No Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com INSTALLATION AND OPERATION S e c t i o n I1 GENERAL T h i s s e c t i o n c o n t a i n s t h e r e c o m m e n d e d p r o c e e u r e f o r unpackinp, inspection, instellation, operation sto;zye and reshipment. U N P.A - CKING AND INSPECTION --- Any sh;??ing c a r t o n t h a t c;,,?ears darr.a,oed should b e ur1;mcked ~ r i t ht h e c a r r i e r ' s a g e n t p i e s e n t . I n s p e c t t h e i n s t r u m e n t f o r d a m a g e If the ( s c r a t c h e s , d e n t s , b r o k e n k n o b s o r m e t e r s , etc.) i n s t r u m e n t is d a m a g e d or f a i l s t o m e e t s p e c i f i c a t i o n s ( p e r f o r m a n c e t e s t s , S e c t i o n IV), n o t i f y t h e c a r r i e r a n d ROD-L E l e c t r o n i c s i m m e d i a t e l y . R e t a i n t h e shipping c a r t o n a n d t h e padding m a t e r i a l f o r t h e carrier's inspection. INSTALLATION T h e ROD-L A C H i p o t T e s t e r s a r e s u i t a b l e f o r e i t h e r b e n c h o r . r a c k m o u n t i n g . To r a c k m o u n t t h e i n s t r u m e n t , use R a c k Mounting K i t ROD-L O p t i o n # 1 5 , Part No. M100-50D1. O r d e r R a c k Mounting Kit from factory. - POWER REQUIREMENTS T h e A C H i p o t T e s t e r r e q u i r e s e p o w e r s o u r c e of 115-23fl volts A C s i n g l e p h a s e , 5 0 t o G O Hz. I n s u r e t h a t t h e p o w e r s o c k e t to w h i c h t h e i n s t r u m e n t c o n n e c t s h a s a f u n c t i o n i n g s a f e t y ground. To protect operating personnel, the National Electrical n l a k u f a c t u r e r ' s A s s o c i a t i o n (NEMA) r e c o m m e n d s t h a t t h e i n s t r u m e n t p a n e l a n d c a b i n e t b e g r o u n d e d . This i n s t r u m e n t is equipped with a t h r e e - c o n d u c t o r p o w e r c a b l e which, when plugged i n t o a n a p p r o p r i a t e r e c e p t a c l e , g r o u n d s t h e i n s t r u m e n t . T h e o f f s e t pin on t h e t h r e e - p r o n g c o n n e c t o r i s t h e g r o u n d pin. WARNING T h i s i n s t r u m e n t t o b e used ONLY in t h r e e w i r e g r o u n d e d o u t l e t s . I t is recommended t h a t periodic checks of t h e o u t l e t a n d t h e ground cable be m a d e t o i n s u r e o p e r a t o r s a f e t y . Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com \ FILLER STRIP BOTTOM COVER Installation 2-1 0 INITLAL INSTALLATION AND TURN-ON 2-1 1 This i n s t r u m e n t i s shipped ready f o r 115 VAC operation unless specifically r e q u e s t e d by customer t o b e s e t a t 230 VAC. Spare f u s e s a r e provided f o r 230 VAC. operation. Prior t o applying power t o t h e instrument, perform t h e follol-ing: CAUTION Disconnect t h e AC llipot T e s t e r from power source and install t h e proper r a t e d fuses, otherwise damage t o t h e i n s t r u m e n t may result. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - a. Set t h e T O T A L C U R R E N T control t o full clockwise position. b. Set t h e R E A L o r RESISTIVE C U R R E N T control t o full clockwise position. (AIIOOBV o r N5OOB\' only) c. Set t h e r e a r panel A C LINE 115/230\' voltage s w i t c h t o i n d i c a t e t h e number t h a t corre5ponds t o t h e l i n e v o l t a g e being used. The n u m b e r visible on t h e slide s w i t c h i n d i c a t e s t h e line v o l t a g e f o r h h i c h t h e primary c i r r u i t is connected. d. With a n A C v o l t m e t e r , c h e c k t h e primary power line for nominal line voltage condition. e. Check t o b e s u r e t h a t t h e p r o p e r fuses a r e installed in a c c o r d a n c e with markings o n r e a r panel. f. C o n n e c t t h e 6-foot power c o r d b e t w e e n i n s t r u m e n t and power source. g. If t h i s i s t h e initial turn-on of t h e instrument, perform Operational Check p r o c e d u r e p e r p a r a g r a p h 2-28. 2-12 STORAGE 2-13 It is strongly r e c o m m e n d e d t h a t t h e equipment b e p a c k e d as if f o r reshipment. Environmental conditions during s t o r a g e and reshipment should b e a s follows: a. Maximum t e m p e r a t u r e 167'F(75OC) b. Minimum t e m p e r a t u r e - 4 0 ° F (-40°C) 2-14 REPACKING F O R SHIPMENT 2-15 If possible, use t h e original shipping c o n t a i n e r and packing materials, or: a. Wrap t h e i n s t r u m e n t in h e a v y p a p e r o r plastic b e f o r e placing i t in t h e shipping container. f b. Use p l e n t y of packing m a t e r i a l zround t h e i n s t r u m e n t end p r o t e c t t h e f r o n t panel w i t h cardboard. P r o t e c t t h e i n s t r u m e n t with 2 inch rubberized/foam padding p l a c e d along a l l s u r f a c e s of instruments, o r with a l a y e r of excelsior about 6-inches t h i c k p a c k e d f i r m l y a g a i n s t a l l s u r f a c e s of t h e instruments. c. Use a s t r o n g , well s e a l e d shipping c o n t a i n e r (350 lb/sq in. bursting test). d. Mark t h e c o n t a i n e r FRAGILE-DELICATE INSTRUMENT. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - 2-16 A t t a c h a t a g t o t h e i n s t r u m e n t , giving t h e follo:.:ing i n f o r m a t i o n : e. T y p e of s e r v i c e r e q u i r e d b. I n s t r u m e n t m o d e l n u m b e r . c. Full s e r i e l nurriber. d. R e t u x a d d r e s s . by n o Z e l n u m b e r 2-17 In a n y c o r r e s p o n d e n c e , r e f e r t o t h e ins:rument a n d full s e r i a l n u m b e r . 2-18 OPERATING -CONTROLS .. . . .. . .. , , .. ~ i ~ 2-2 ~ F i lel u s t r a t e s t h e f r o n t p a n e l arid r e a r panel c o n t r o l s f o r t h e A C H i p o t T e s t e r s . T a b l e 2-1 d e s c r i b e s t h e f u n c ~ i o n sof all t h e controls a n d indicators. 2-19 I4 I 3 12 I 11 10 I I 0 B I I I . . 9 1 2 BY Model 4 3 5 . 6 ;. only F i p r e 2-2 Controls and Indicators Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com Fig. 2-2 INDEX NO. 4 FUNCTIONS CONTROLS LINE POWER ( ~ 1 ) This switch applies or removes power from the instrument. A C ON lamp (11) When lit, it indicates poc-er is applied t o t h e instrument even if fuses are blown or out. ST.4RT Pushbutton (S2) \Then depressed, the t c s t sequence begins if t h e instrument is grounded properly and not ali.eildy indicating grounded test failure. RESET Pushbutton (S3) Resets a depressed; early. TIMING Select Switch A o r B (S4) Selects preset test t i m e s and ramp r a t e s assigned t o position A and B. Standard factory setting a r e a t full scale voltage: failure indication when also terminates a test DWELL- - RAMP -- Position A: 20OV/sec* Position B: 200V/sec* * For 5KVAC F.S. is 500V/sec. 60 sec 1 sec Models t h e ramp R e a l P a r t Pushbutton (S5-BV) (Model BV only) Expands t h e current meter scale by ten t o indicate t h e real part of t h e A C current flow when depressed during a test. CHASSIS GROUND SENSE post (BPI) Connect t h e chassis of t h e device under t e s t t o this terminal. The lead used should be of low resistance and preferably a s short a s possible (36" cable supplied). High Voltage Connector (J1) An instrument t o be t e s t e d for leakage is t o b e plugged into this outlet. Only t h r e e pronged A C line plugs for three-wire cords a r e t o be inserted (unless adaptor is required). OUTPUT VOLTAGE meter (MI) Provides a direct reading of the AC test voltzge applied t o t h e instrument under test. . Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - - Fig. 2-2 INDEX NO. CONTROL FUNCTION.- M I L L I A~ T ~ ~ E T E R m2) Indicates a m o u n t of AC l e a k a g e (in mA) flow during a test. 11 FAIL Indicator l a m p (14) Displays a visual warning t h a t DUT failed test. 12 TESTING Indicator l a m p (13) Indicates a t e s t i n process. R E A D Y Indicator l a m p (12) Indicates proper ground is established bet iveen t h e t e s t e d i n s t r u m e n t and t h e HIPOT 'TESTER. Instrument will n o t o p e r a t e if READY l a m p is not on. ,\is0 indicates a c c e p t a b l e i m p e d a n c e during Ohm Sense test. Audible Warning (AL-1) E m i t s a warning sound when a t e s t resrrlts in failure. AC LINE Voltage Switch (S7) Slide s w i t c h to s e l e c t either 1 1 5 VAC o r 230 VAC. T h e exposed number indicates t h e l i n e v o l t a g e selected. 16 A C LINE p o w e r (J2) Connects t o instruments. 17 Hi h Voltage Line F u s e 14 - - - (~5) power cable current supplied with . - Provides o v e r c u r r e n t protection for t h e ~ r i r n a r y circuit of the high voltage transformer. A t 115 VAC i s 2A f a s t blow a n d a t 230 VAC use 1 A f a s t blow f u s e (unless otherwise noted). Power Line Supply Fuse (F1) Provides overload protection f o r low voltage t r a n s f o r m e r p r i m a r y circuitry. Use 1A f o r 115 VAC a n d f A f o r 230 \'AC operation. REAL C U R R E N T FAILURE SETPOINT p o t e n t i o m e t e r (R3) Establishes a maximum level f o r resistive c u r r e n t blow which cannot b e exceeded during a t e s t . If t h i s velue i s exceeded, a failure indication i s given. - TOTAL C U R R E N T FAILURE SETPOIN' T p o t e n t i o m e t e r (R2) Allows t h e user t o specify a maximum value A C c u r r e n t flow during a test. If t h i s value i s exceeded, a failure indication i s given. \'ARIAC C O N T R O L (7'3) Allows Xlanual C o n t r o l for t h e high voltage output. Indentification Label C o n t a i n s i n s t r u m e n t model a n d serial number information. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - - 2-23 SAFETY F E A T U R E S 2-24 The s a f e t y f e f i t u r e s built t h e ROD-L AC liipot T e s t e r s a r e 2s follow: a. T h e s e c u r i t y CHASSIS GROUND SEXSE wire must be c o n n e c t e d f r o m t h e AC Iiipot T e s t e r t o t h e chassis o r expose m e t a l t o s e c u r e low r e s i s t a n c e point on t h e unit under t e s t . This will allow t h e R E A D Y Iight t o t u r n on find t h e AC Hipot T e s t e r t o o p e r a t e . Tnis w i r e p a r a l l e l s t h e n o r m a l groimd wire in t h e power cord. T o insure t h a t b o t h wires a r e s e c u r e , 1 a m p r m s a t 1.5 volt AC is passed t h ~ o u g hboth wires a t all l i m e s . If t h e t o t a l path r e s i s t a n c e proi'es g r e a t e r t h a n .5 ohm, t h e READY l a m p will not light. (.I0 ohm optional). b. When t h e FAIL l a m p i s a c t i v a t e d a f t e r a breakdown t h e AC high v o l t a g e i s i m m e d i a t e l y r e m o v e d from t h e A C Hipot T e s t e r HV o u t p u t c o n n e c t o r s withing 2 rnsec. T h e FAIL l a m p c a n a c t i v a t e d if a n y of t h e following conditions occur: R e a l o r T o t a l A C c u r r e n t e x c e e d s t h e p r e s e t value; t h e s e c u r i t y CHASSIS GROUND SENSE c o n n e c t i o n b e c o m e s f a u l t y while t h e high voltage i s applied; a n a r c i n g occurs. If a f a i l u r e is indicated, t h e d e v i c e did not pass a n d should b e i n v e s t i g a t e d f o r reason, r e p a i r e d and r e t e s t e d . c. T o p r e v e n t surges, t h e A C t e s t v o l t a g e i s turned on slowly using e l e c t r o n i c circuitry. d. T h e S T A R T p u s h b u t t o n i s r e c e s s e d to p r e v e n t a c c i d e n t a l triggering. e. T h e R E S E T pushbutton c a n b e used to p r e m a t u r e l y s t o p t h e t e s t if d e s i r e d a n d m u s t used w h e n e v e r t h e d e v i c e under t e s t has failed (unless a u t o reset option is used). -- 2-26 USER RESPONSIBILITY 2-27 The u s e r 'is responsible f o r d e t e r m i n i n g C t h e applicable t e s t v o l t a g e and t e s t d u r a t i o n f o r t h e i r p r o d u c t in a c c o r d a n c e w i t h c e r t i f i c a t i o n agency (UL, CSA, VDE, BSI, JEC, e t c ) requirements. User also d e t e r m i n e s t h e n o r m a l t o t a l l e a k a g e c u r r e n t (or t h e maximum allowed agency) from a r e p r e s e n t a t i v e s a m p l e of p r o d u c t s under t e s t conditions. F r o m t h i s t h e user e s t a b l i s h e s t h e m a x i m u m t o t a l l e a k a g e considered a c c e p t a b l e f o r t h e d e v i c e . T h i s t h e n is t h e TOTAL C U R R E N T FAILURE SETPOINT f o r t h e device. In a s i m i l a r m a n n e r , t h e R E A L C U R R E N T F.4ILURE SETPOINT i s e s t a b I i s h e d f o r t h e R O D L Model BV. m Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - 2-28 OPERATIONAL FOR S T 4N D A R D AC HIPOT TESTERS -CHECK -- 2-29 This i s a n o p e r a t o r o r i e n t e d p r o c e d u r e which allows o p e r a t i o n a l c h e c k of t h e ROD-L AC Hipot T e s t e r without t e s t equipment. Operational procedure is a s folloivs: a. S e t LINE POI\-'ER s w i i c h t o OFF. b. C o n n e c t 36" groand s e n s e c a b l e t o t h e CH4SSIS GROUND s e n s e t e r m i n a l . A t t a c h t h e c a b l e clip e n d t o t h e AC hipot t e s t e r on t h e Ensure grounded p o h e r c o r d of DUT m e t a l portion of t h e handle is plugged i n t o f r o n t panel r e c e p t a c l e of Hipot Tester. . c. S e t l i n e PO\VER s w i t c h t o ON a n d A C ~ o w e rk i m ~should plow. A f t e r a p p r o x i m a t e l y t w o seconds, t h e green R E A D ? l a m p s'hould light. d. If t h e R E A D Y l a m p d o e s n o t light, insure t h e ground s e n s e connection is secure. e. With READY l a m p l i t , push t h e s t a r t b u t t o n ( a m b e r TESTING l a m p should light) a n d quickly disconnect t h e ground s e n s e cable. T h e r e d FAIL larnp should light a n d t h e audible a l a r m should b e heard. A l s o t h e R E A D Y l a m p i s extinguished. - -- f. Push t h e RESET b u t t o n t o extinguish t h e FIAL l a m p a n d audible alarm. g- R e c o n n e c t t h e ground s e n s e c a b l e p e r s t e p "b" and t h e r e a d y l a m p should light. -- WARNING High v o l t a g e is p r e s e n t at HV o u t p u t c o n n e c t o r s when TESTING L a m p i s l i t a n d m a y b e e x t r e m e l y h a r m f u l to o p e r a t o r i f c o n t a c t e d . h. Push s t a r t button: A m b e r TESTING l a m p should l i g h t a n d t h e O U T P U T VOLTAGE m e t e r should i n d i c a t e t h e proper v o l t a g e under n o r m a l o p e r a t i o n . (Depends on s e t t i n g of Lvariac). 1. If O U T P U T VOLTAGE m e t e r d o e s n o t i n d i c a t e proper v o l t a g e adjust t h e VARIAC C O N T R O L in t h e proper position. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - 2-30 TOTAL C U R R E N T P R OCEDURE 2-31 To s e t t o t a l l e a k a g e c u r r e n t t r i p point f o r rievice under t e s t (DUT). p r o c e e d a s follows. S e t t e s t t i m e per applicable agency specification if different from s t a n d a r d factor!; s e t t i n g ( R e r e r t o T a b l e 2-7, Index +6) S e t T O T A L C U R R E N T c o n t r o l fully clockwise. C o n n e c t D U T t o A C Hipot T e s t e r a n d s t a r t t e s t . C U R R E N T r e a d i n g f o r unit. R e c o r d TOTAL While t h e high v o l t a g e i s on, slorvly r o t a t e t h e TOTAL C U R R E N T p o t c o u n t e r clockwise u n t i l t h e FAIL l a m p a n d audible a l a r m a r e activated. N o t e t h e position of t h e T O T A L C U R R E N T pot. This position is p r o p o r t i o n a l t o t h e t o t a l c u r r e n t r e a d i n g on t h e f r o n t p a n e l m e t e r . -- C a l c u l a t e t h e position in which you w a n t to l e a v e t h e p o t e n t i o m e t e r using t h e formula: S e t t i n g D e s i r e d = S e t t i n g i n step x max current acceptable s t e p c measured c u r r e n t R e s e t t h e T O T A L C U R R E N T F A I L U R E SETPOINT c o n t r o l t o position c a l c u l a t e d above. T h i s c o n t r o l c a n b e used t o set a c u r r e n t betvteen a m e t e r F.S. r e a d i n g a n d a p p r o x i m a t e l y 0.05 x F.S. - 2-32 REAL C U R R E N T (BV O N L Y P R O C E D U R E ) . * This p r o c e d u r e i s i d e n t i c a l t o t h a t a b o v e , e x c e p t t h e REAJ, C U R R E N T i s a d j u s t e d a n d t h e "PUSH F O R CURRENT-REAL P A R T - 10" pot .. pushbutton i s d e p r e s s e d t o r e a d r e a l c u r r e n t . Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com . .- . 2-34 TEST TIJi'IE ADJUSTMENT PROCEDURE 2-35 The Test Time Adjustment potentiometer is set as outlined in Table 2-1, index $6, a t the factory. The user should set this control in accordance with the regulator^ agency's suggested test time for the device under iest if different from standard factory setting. To reset the test time duration, proceed 2s folloivs: a. b. CA ueno::HV E X P O S U R E -Turn off pobver to the A C h'ipot Tester. .Remove top cover and locate Test Time Adjustment potentiometer R37 on A21 board. Set TIMING Sivitch on Front Pnnel "A". c. Re-apply power to t h e AC Hipot Tester. d. With top cover removed from Hipot Tester, use a stopwatch t o time the duration the TESTING lamp remains ON. e. By adjusting the Test Time Adjustment trimpot and timing the TESTING lamp duration with a stopwatch, you should be able t o s e t any duration desired between one second and 90 seconds. . -. f. Set TIMING switch on-front panel t o "B" and set potentiometer R2 on board A21 per steps (b) thru (el. CAUTION Do not touch any of the 'other potentiometers on the PC Boards, otherwise t h e calibratio'n of t h e instrument will be ruined. 2-36 AUTOMATIC TEST PROCEDURE 2-37 The following procedure assumes the ROD-L Hipot Tester has been calibrated and adjusted for normal operation. Proceed as follows: a. Place device under test (DUT) next to Hipot Tester. b. Plug the power cord of DUT into high voltage connector of Hipot Tester. c: . . - .--- between Connect Ground Sense. .cable .- .. DUT and Chassis Ground Sense READY lamp will light' t e r k 6 a l : i? ground is less than 0.5 ohm, the - - - .. ~. Z 0 ohm optional). ~ Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com d. P r e s s t h e START pushbutton. The 'TESTING l a m p should light. (If ohm sense option is used r e f e r t o t h e correspondent description). WARNING High Voltage applied t o t h e device l~rlder t e s t . Do n o t touch t h e DUT power cord o r chzssis while t h e TESTING Iarnp i s lit, o r e x t r e m e shock may result. . c h e c k t h a t t h e O U T P U T ' VOLTAGE' m e t e r i n d i c a t e s t h e t e s t s e l e c t e d voltage. If v o l t a g e is high or low adjust r e a r panel \'ARIAC CONTROL a p p r o p r i a t e l y t o compensate. . . . e. f. .. R e s t a r t t h e test. O b s e r v e t h e t o t a l c u r r e n t indication. (Model BV h a s a n additional f e a t u r e : press t h e "PUSH F O R REAL CURRENT PART 10" pushbutton t o observe t h e 'real p a r t ' current). The t e s t will a u t o m a t i c a l l y a b o r t , giving a f a i l u r e indication if o n e of t h e p r e s e t c u r r e n t f a i l u r e setpoints i s exceeded, t h e ground sense connection i s i n t e r r u p t e d or a n a r c i n g condition o c c u r s d u e to d i e l e c t r i c insulation breakdown. T h e o p e r a t o r should investigate t o - d e t e r m i n e which f a i l u r e o c c u r r e d in t h e e v e n t a FAIL indication i s given. F o r t h i s reason t h e a m m e t e r should be continuously monitored during t h e test. + g. F o r a n o r m a l test, t h e TESTING l a m p will extinguish a f t e r a c o m p l e t i o n of t h e p r e s e t test t i m e duration. If a test results in a f a i l u r e condition, t h e FAIL l a m p will light a n d t h e audible a l a r m will sound. T h e o p e r a t o r must t h e n manuaIly press t h e RESET pushbutton b e f o r e a t e s t c a n b e r e p e a t e d . NOTE A t I e a t 5 seconds must elapse b e t w e e n TURN-ON a n d t h e f i r s t Hipnt Test a n d 3 second m u s t elapse b e t w e e n successive Hipot tests or random hi pot indications will occur. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com -. --TIIEORY O F OPERATION - SECTION I n 3-1 THEORY OF "DIELECTRIC - -- --WITHSA'IXD -. TESTING 3-2 The dielectric withstand t e s t is t h e t e s t required by many c e r t i f i c a t i o n agencies (UL, CSA, BSI, VDE, JEC, ect.) a s "PROOFn of a n instrument's ability t o withstand excess surges on t h e A C pov:er lines without becoming a hazard t o itself o r t h e user. It is v ~ e l lknown t h a t lightning, d r a s t i c load chhrlges o r power line outwges can place short duration spikes on t h e A C power line of man)- t i m e s t h e nominal line v o l t ~ g e ; and d e v i c e s sllould b e designed with this in mind. Thus, testing 1abo;trtories require t h a t e a c h i n s t r u m e n t c e r t i f i e d by t h e m be t e s t e d f o r dielectric withs!and r e q i ~ i r e n e n t s . A test a t 1 5 0 0 VAC i s required of m o s t i n s t r u m e n t s having a 1 1 5 / 2 3 0 volt switch and f o r sale in both U.S. a n d Europe. However, instruments designed for s o m e different uses may h a v e o t h e r requirements. The R O D L A C s e r i e s t e s t e r applies a s i n e wave a t 6 0 H z o r 50 Hz of t h e required voltage between t h e t w o c u r r e n t c a r r y i n g l e a d s of "device under test" (i.e. t h e "Hot and "Neutral" conductors t i e d t o g e t h e r ) and t h e "Ground" conductor of t h e "device under test". An additional "Safety Ground" connection must b e made t o insure grounding integrity. T h e "Device under t e s t " must "withstand" this application of v o l t a g e without displaying any indication of d e t e r i o r a t i o n archover, sparking, overheating o r o t h e r t y p e of failure. Visual inspection of m o s t o f these-.. characteristics is precluded in a closed i n s t r u m e n t . An a m m e t e r i s provided on t h e A C series i n s t r u m e n t s f o r display&g a c t u a l l e a k a g e current. I t may be thought t h a t if t h e r e i s n o physical connection b e t w e e n t h e A C power line a n d t h e chassis o f t h e i n s t r u m e n t under test t h e r e c a n be n o c u r r e n t flow. This i s not, in g e n e r a l , true. T h e r e a r e a l w a y s parasitic c a p a c i t a n c e s and resistances p r e s e n t which allow s o m e c u r r e n t t o flow. A t 1 5 0 0 VAC, 6 0 Hz, every 1 7 7 0 pf of s t r a y c a p a c i t a n c e allows 1 mA of c u r r e n t flow. If a power transformer is c o n t a i n e d in t h e c i r c u i t interwinding l e a k a g e c a p a c i t a n c e s of from I 0 0 pf to 1 0 0 0 pf a r e common. Furthermore, many i n s t r u m e n t s r e q u i r e capaci;ors to b e c o n n e c t e d between t h e AC po\<er Line a n d chassis t o e l i m i n a t e any R F energy being t r a n s m i t t e d through t h e line cord. The c i r c u i t s c h e m a t i c of t h e "device under test" should be i n s p e c t e d - a n d l e a k a g e c u r r e n t f o r m y c a p a c i t o r s of this t y p e should be computed using t h i s formula: = 1 5 0 0 x 377 x C ( a t 1 5 0 0 VAC) ( a t 60Hz) and these c u r r e n t s considered "normal" f o r t h a t instrument. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com The above forrr,ula essurnes that the cnpacitors being Iestcd are "periect", i.e. linear and have "zero" dissipation. The real world is never so obliging. Cerzmic c ~ ? a c i t o r s (tliese norrnally ~ ~ s efor d this purpose) have lo?erances of 20% or worse, have very nonlinear I-V responses a t high voltages snd have dissi~8tionfactors at high voltages of 3 0 % or more. Thus, the actual current flow may be 150% or more of t h e t t ~ e o r e t i c a l flow for that capacilor. Actual currents can only be con?irn>ed by tesiing of a !arge n u a b e r of instruments and c ~ m p u t i n g tables of ~ > ; p ~ i eend d ~,.o:.sl c ~ s evalrles. Then 6ny current above this "~::orse cnse" value can be considircd a c8use ior rejection. The B\' t e s t e r mc.;?sures the "Xeal Part" of the AC cuiient es ??ell e s t h e l o t e l cui.rent. K ~ r ~ l i n e aor e r i t i o n s (sparks, arcovers, elc.) invariably influence 'he ''Real Part" o i the current much rnore than they influence ;';ie 1o:al crjr;cnl. Thi!s, ;hese e i i e c t s can be rnore eesily deiec.1 ed on t h e a\' ;esiers. Resistive paresitic effects can occur as well. These can be caused by moisture or dust between conductors, losin or acid flux "bridges" between P C board traces, leaky insulating nalerials, etc. Considerable power can be concentraled in lhese leakage paths. Only 1 mA of current a t 1 5 0 0 volts means that some point must dissipate 1.5 watts of power. That much power concentrated in t h e very small area of flux "bridge" can easily cause a fire hazard. Real current also flow due t o non-ideal filler capacitors. The "Real Current" flow in a capacitor can be computed by multiplying the capacitor dissipation factor by the total current flow, and a s has been stated, this can be appreciable and very nonlinear. The published low voltage dissipation factors of capacitors gives only a limited projection of what t o expect a t high voltages and actual results a r e invarjably high. 3-3 INSTRUhlENT FUNCTIONAL DIAGRAM Functionany, t h e A C Hipot Tester is divided i n t o three sections: The HI1 generator, the HV control and t h e General Control. A remote control option can be added t o t h e total system. (As shown in Fig 3-fi. 3-4 The I i V Gcr~eraforconsists of an AC H\' tr2ns;ormer (50/60 Hz) specially designed t o provide the high vollage end current needed in Hipor Testing. 3-5 The HV Control is the most important part of t h e system, it contains: The unique solid s t a t e HV Amplitude Control and the Ramp Up Control Circuitry. The HV Amplitude Control operates under t h e principle of generating s n adjustable emount of blocking voltage t o the input line voltage coming out from t h e Variac a s shown in Fig 3-2 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com .. AC HIPOT TESTER FEEDBACK k HV C O N T R O L I - IiV OUTPUT 1 'i\ FRONT AND REAR PANEL CONTROLS GENERAL CONTROL HV GENERATOR < 1 f F R O N T PANEL INDICATORS \ ++ (Option ) REMOTE CONTROLLER Fig. 3-1 Functionni Diagram Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com I 1 Fiz. 3-2 - T h e HV o u l p u t i s d i r e c t l y p r o p o r t i o n a l t o Irp. I'ihere Ifp is t h e v o l t a g e 1'1 g i v e n by t h e 1 - s r i a c m i n u s t h e b l o c k i n g v o l l a g e V g gene:aled a c r o s s t h e HI' a m p l i t ~ l d e c o n t r o l . lChen t h e b l o c k i n g v o l t a g e \'B e q i ~ a l so r e x c e e d s t h e v o l t a g e a c r o s s VJ, Vp i s z e r o as i s t h e HV o u t p u t . A s \'B d e c r e a s e s \'p b e g i n s t o b e d l i f e r e n t f r o m This u n i q u e s y s l e m h a s z e r o p r o d u c i n g HI7 i n t h e o u t p u t o f t h e HI' t;ansrorrner. p r o v e d t o b e t h e rnost e f f i c i e n t s o l i d s t a t e v : ~ y t o c o r ~ t r o lt h e HI' a m p l i t u d e n o t only i n t e r m s o f d i s s i p a t i n g p o w e r b u t in t e r m s o i i n v a r i a n c e of b l o c k i n g v o l t a g e V g w i t h r e s p e c t t o t h e n a t u r e o i t h e - I c a d c o n n e c l e d a t t h e HIr o u t p u t , which m a k e s HI1 a m p l i l u d e p r a c t i c a l l y i n d e p e n d e n t o f t h e l o s d a n d sinusoidal t h r o u g h a l l l i n e a r Ramp-Up l o f u l l v o l r a g e . " - T h e R a r n p U p C o n t r o l c i r c u i t r y i n t e g r a t e s t h e d i i i e l c - n c e b e t x e e n t h e r a m p up r e f e r e n c e s i g n a l w i t h t h e v o l t a g e f e e d b a c k p r o d u c i n g a c o n t i o l l i n g signal. This s i g r ~ a lc o n t r o l s Ley p z r a n ~ e t e r si n t h e )I\' A m p l i t u d e C o n t r o l c a u s i n g t h e HI' o u l p u t l o follow t h e R e r n p u p s i g n a l a s sho::.n in Fig. 3-3. FEEDBACK - HI' kmp1i;ude C o n i r o l RU4P UP 0 m ? - -- 4 BLOCK1 NG P HV I 1 : P L I T U O E REFERENCE CONTROL F i g u r e 2-3 - +VOLTAGE X z n p Up C o n t r o l Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - 3-6 T h e G c r ~ e r a lC o n t r o l per:oinls t h e c o o r d i n a t i o n o r t h e d i f f e r e n t a c t i ~ ~ i l i e s a n d m o n i t o r i n g . A s sho:vn in Fig. 3-1 : hV t =>nF?U - t TEST r REX CH22SlS GI23 szlrj~ I TRIP I R E R - >.- rev1 12IP [ a - KtxTY FAIL - t t- ~ t-] - - ~~ v. I m -~ F ~ E .3-4 G e n e r a l C o n t r o l .- The G e n e r a l C o n t r o l c a n b e c o m m a n d e d fiorn t h e d i f f e r e n t f r o n t a n d r e a r p a n e l controls s h o w n on t h e l e f t s i d e of t h e diagram. I t t a k e s c a r e o f c o o r d i n a t i n g t h e d i f f e r e n t a c t i v i t i e s o f t h e HV C o n t r o l a n d s e n s i n g t h e s t a t u s o f t h e operation. It provides c o n t i n u o u s m o n i t o r i n g t h r o u z h t h e f r o n t p a n e l lights, b u z z e r a n d m e t e r shown on t h e right. s i d e o f t h e d i a g r a m . - - . T h e r e m o t e o p t i o n is a n i s o l a t e d i n t e r f a c e f o r m o s t o f t h e c o n t r o l a n d m o n i t o r signals. -- 3-7 . I N S T R U M E N T ASSEhlBLY DIAGRAM T h e i n s t r u n l e n t i s d i v i d e d i n t w o m a j o r s u b e s s e m b l i e s as shown in Fig 3-5 F i g . 3-5 A s s e m b l y D i a g r a m !. . T h e ri,oht s i d e s u b e s s e m b l y is p h y s i c a l l y s e p a r a t e d a n d c o n t a i n s t h e A6-S5 board a n d the e l e c t r i c a l t r a n s f o r m e r s n e e d e d f o r t h e o p e r a t i o n . T h e l e f t s i d e subassemblies contains t h e A10, A 2 1 e n d o p t i o n s A2-1 f o r B V m o d e l s a n d A 8 R E M O T E (all low voltage c i r c u i t r y ) . .. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com C --. i A more d e t a i l e d d i a g r a m of t h e board's f u n c t i o n s is shown in Flg. 3-6 Fig. 3-6 Detail Assembly Disgram 7 - fi Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com POIVER SUPPLY C I R C U I T (A1 --0) Power g e n e r a t e d in t h e 4 7 0 zssernbly board, H V COh'TROL and -15 \:DC r e g u l a t e d f o r t h e analog curcuits. The digital e l e c t r o n i c s r c q i ~ i r e s$5 VDC regulated. 0 0 4 7 5 - 0 6 ) of t h e wiring d i a g r a m . HIGH VOLTAGE -COX'iROl,/SI,OIT -- . consists of +15 VDC 4 s s e e n in t h e schematic (D~i'g. 'I'URN ON (AG-S5) p p p This board c o n t a i n s t h e m o s t i m p o r t a n t p a r t s of t h e systems: The HV CONTROL and RAMP U P CONTROL. .Supporting t h e m a r e t h e RAMP UP GENERATOR aha t h e VOLTAGE FEEDBACK. T h e output C U R R E N T a n d VOLTAGE monitoring circuit and t h e PROTECTION a n d A R C DETECTION a r e a l s o included (See Dwg. 00239-01). HV CONTROL (A6S5) T h e amount of b l o c k i n g v o l t a g e depends on t h e r e s i s t a n c e of t h e p h o t o r e s i s t a n c e PC-1. Q1 and Q 2 are used t o d r i v e t h e p r i m a r y of t h e HV t r a n s f o r m e r . When t h e r e a l y K1 closes, t h e gate $3 i s enabled allowing t h e input l i n e v o l t a g e t o g o through and t o set t h e c i r c u i t r y in a n initial condition prior t o t h e driving of t h e HV. transformer. T h e voltage at t h e p r i m a r y of HV t r a n s f o r m e r i s f e d b a c k through t h e o p t i c a l isolators U3 and R4 producing a f u l l w a v e r e c t i f i e d c u r r e n t proportional t o t h a t voltage. The HV output is f e d b a c k t h r o u g h precision r e s i s t o r s R 3 a n d R6 t o produce a n a v e r a g e c u r r e n t through t h e v o l t m e t e r proportional t o t h e RhlS value. T h e r e s i s t o r R12 is also in series t o p r o v i d e a IT\' monitoring. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com RAMP U P G E N E R A T O R When t h e 'TEST signal a t TP2 g e t s low, t h e \;olthge a t the input of C R I becomes neg6til.e a n d no c u r r e n t flows tt,rough i t , s o only t h e c u x r n t fo?ving t:~rough R 2 9 a n d d e t e r m i n e d by one of t h e pots R 3 0 , R4 goes through t h e capacitor C 2 c h a r g i n g it. Since t h e charging c u r r e n t is cons!ant t h e output of U1 (6) is a l i n e a r E A M P UP. RAMP U P -~ CONTROL U 2 cor;:+r.es t h e c u r r e n t pmdrlced tiii.o:!gh R 1 0 and K l 1 with t h e full : ~ a w recitified c u r r e n t U 3 a n d U 4 a n d i n t e g r a t e s t h e aiiference. An a m o u n t of voltage a p p e a r s a t t h e p r i m a r y o f t h e HV t r a n s f o r m e r such t h a t ' a c e r t a i n value of v o l t a g e d i f f e r e n t from t h e initial + 5 V is produced a t pin 6 of U 2 permitting a n i n c r e a s e in t h e a m o u n t of c u r r e n t sunk by LEDI. This value of current d e t e r m i n e s t h e r e s i s t a n c e of PC-1 t o produce t h e a m o u n t of HV a t equilibrium. A R C DETECTION - U 5 senses f o r c u r r e n t s s e v e r a l t i m e s higher t h a n t h e full s c a l e value. This condition c o m e s u p during t h e a r c i n g a n d i t is t r a n s m i t t e d t o t h e A 2 1 board. 3-12 REAL C U R R E N T D E T E C T CIRCUIT (A2-1) 3-13 The A2-1 b o a r d (Dwg. 00442-01) r e c e i v e s a t pin 5 t h e voltage g e n e r a t e d across t h e v o l t a g e s e n s e r e s i s t o r on t h e A6-S5 board. T h e f i r s t half of U 1 o p e r a t e s a s a buffer. T h e f i r s t half of U 2 m a k e s t h e derivative of t h e v o l t a g e signal which is proportional t o t h e HV o u t p u t and t h e second half of U 2 converts t h i s signal t o a s q u a r e w a v e signal which rises and falls a t t h e peaks of t h e v o l t a g e signal. U 8 produces a s m a l l pulse of approximately 1 0 w width coincident w i t h t h e n e g a t i v e peak of t h e v o l t a g e signal. U4 i s a s a m p l e r and holder of t h e c u r r e n t waveform which provides t h e necessary f i l t e r i n g along C13. -- 2' T h e second half of U 1 is a l e a d i n g c i r c u i t which is adjusted t o provide t h e e x a c t triggering a t t h e n e g a t i v e ~ e a kof t h e v o l t a g e signal t o c o m p e n s a t e f o r t h e c i r c u i t delays. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com . .- The output 1 0 of U 3 i s t h e amplified value given by U 4 , calibrated by R 7 for giving RATS c u r r e n t values t o t h e a m m e t e r through R18. The second half of U3 is c o m p a r i n g t h e a c t u a l c u r r e n t with t h e real current trip-point t o identify o v r r c u r r e n t fhilures. Severe nor,-linearities in a DUT c a n produce R false reading on t h e Iiipot a m m e t e r . F o r avoiding this, U 7 t i m e s t h e generation of t h e I 0 1 s pulse only f o r transitions of t h e waveform a t U 2 (12) occuring n e a r t h e p e a k of i h e v o l t a g e waveform. U 6 provides buffering f o r external tripping programming. U5 is a n analog swiich f o r selecting r e m o t e tripping output m e t e r operation. - 3-14 A21 CONTROL BOARD 3-15 TOTAL C U R R E N-T DETECTOR/COhlPARATORS The A21 Board (DWG 462-01) r e c e i v e s t h e voltage a c r o s s t h e c u r r e n t sense resistor, r e c t i f i e s a n d f i l t e r s i t a n d sends i t t o a c o m p a r a t o r t h a t triggers when preset l i m i t s of t o t a l c u r r e n t a r e exceeded. The A21 board h a s a ground loop circuit to d e t e c t s a f e t y ground violation. Active Rectifier-Filter: U 5 (board A21) functions as a precision full wave rectifier of t h e A C v o l t a g e p r e s e n t on c u r r e n t sense resistor during test. U5 overcomes d i o d e non-Iinearjties by placing t h e rectifying e l e m e n t s C R 2 and C R 3 in t h e f e e d b a c k path; Summing t h i s signal with 4 t h e input signal provides a f u l l w a v e r e c t i f i e d output; C 6 o n A21 board filters t h e signal with U4. T h e o u t p u t is passed through t h e "Total C u r r e n t Metal Cal" p o t R19 t o t h e a m m e t e r . - Current Comparators: U1 is used as high gain amplifier with weak negative feedback a n d acts as a c o m p a r a t o r . R 2 2 a n d R21 provide common mode protection. C7 provides extra filtering. 3-16 SAFETY GROUND D E T E C T CIRCUIT On t h e A21 b o a r d t h e c i r c u i t composed of R24, R25, CR4, C R 5 a n d U8 half wave rectifies t h e Coltage b e t w e e n ground an! t h e "chassis ground sense" his v o l t a g e i s 1;5 VAC if t h e "chassis ground sense" post is binding post. OPEN. When t h e "Device Under T e s t " c o m p l e t e s t h e circuit through i t s ground wire t o ground, t h e v o l t a g e a t t h e post i s proportional t o t h e r e s i s t a n c e of t h e ground w i r e in t h e d e v i c e under test. R26, R27 a n d C20 on A21 board determine t h e t r i p p o i n t f o r t h e darlington pair, 6 3 , Q4 o n t h e ' ~ 2 1 . T h e resistors a r e s e l e c t e d s u c h t h a t a 0.5 ohm loop r e s i s t a n c e l e a v e s t h e transistors OFF. Q3 then o p e r a t e s t h e READY l a m p a n d c o n t r o l s t h e START button. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - -,. - 3-1 7 LOGIC CONTROL 3-18 This assembly I-eceives all push button inputs and sense outputs from t h e fail comparators a n d t h e ground s w s e logic. \,;hen t h e proper conditions a r e satisfied, a t e s t sequence i s permitted. The duration is s e t by a timing circuit. In t h e event of a n operator r e s e t o r fail condition, t h e t e s t is aborted. If t h e r e is a failure, a >...dr~ting , i s p r e s e n t e d until manually r e s e t by t h e user. This essembly includes a z e r o crossing d e t e c t o r , a t i m e r and a set-reset l a t c h with associated logic. 3-19 INPUT/OUTPUT LINES: RESET. T h e r e a r e t h r e e digital inputs: OVERLOAD, START, and An OVERLOAD signal is produced whenever a n arcing condition is d e t e c t e d in t h e A 6 4 5 board, (or a failure i s produced by t h e A2-1 R e a l C u r r e n t Board). This signal combines with t h e o v e r c u r r e n t signal g e n e r a t e d by U1 a n d t h e ground failure signal g e n e r a t e d by pin 3 of U4 t o set t h e f a i l l a t c h a t pin 5 of U7. The ground fail is g e n e r a t e d only when a faulty ground is d e t e c t e d during a Test. This g a t i n g is produced by pin 2 of U7. The START s i g n a l is produced by t h e START s w i t c h which i s tied externally t o t h e ground t e s t signal. If t h i s is low, a s t a r t signal i s produced at pin 1 3 of U3. U3 pin 8 gives s t a r t pulses synchronized w i t h t h e A C line's z e r o crossings if no failure has been l a t c h e d a n d w e a r e not in a test. T h e t i m e r U2 controls t h e t o t a l test t i m e with R2, R3, R37 a n d C2. I t c a n b e reset by t h e f a i l latch. The RESET s i g n a l resets t h e t i m e r U 2 a n d t h e f a i l latch. T h e r e a r e 3 outputs: GND TEST, TESTING, a n d ALARM. The GND T E S T s i g n a l goes low whenever t h e CHASSlS GROUND SENSE loop does not e x c e e d t h e r e s i s t a n c e tripping value: The ALARM s i g n a l g o e s low whenever t h e fail l a t c j is set. The TESTING s i g n a l i s delivered in parallel by Q8 s n d Q 1 and a r e low whenever we a r e in a t e s t . All t h e above signal drive also t h e correspondent lamps. - 3-20 T i m e r and Enable Circuits: To t r i g g e r a t i m i n g period a t U2 on t h e A21 a s t a r t pulse must occure a n d n o f a i l u r e c a n b e p r e s e n t ; The A C hipot t e s t e r also requires a z e r o crossing o n t h e 60Hz A C line; U 3 d e t e c t s this a n d passes i t t o U2, R37, R2, R 3 a n d C 2 o n A21 d e t e r m i n e s test time. P a r t s of U6 drive t h e r e s e t input of t h e t i m e r if a t e s t a b o r t i s required. 3-21 FAIL LATCH: U7 on A2 a r e cross coupled t o form t h e FA% latch. The l a t c h shows a ground f a i l condition only during a t e s t c y c l e a t t e m p t g a t e d by U7 pin 2. Also shows a f a i l u r e whenever a n a r c i n g o r overcurrent conditions a r e produced. Pins 9 and 10 of U7 s e n s e f o r t h e above conditions. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com MAINTENANCE AND S E R \ l C E S e c t i o n IV INTRODUCTION This s e c t i o n provides r n s i n t e n e n c e a n d sei-vice fc)r t h e A C stfries Hipot Testers. Included a r e : t a b l e s of r e c o m m e n d e d t e s t e q u i p m e n t , celibration p r o c e d u r e s , t r o u b l e s h o o t i r ~ gp r o c e d u r e s , plus r e p a i r a n d adjuslrnent data. CALIBRA'TJON Kine m a j o r c a l i b r a t i o n p o i n t s tire r q u i r e d f o r t h e A C ~ e r i e sHi?ot Te5tt.r~. They are: 1. 2. 3. 4. M e t e r nlechanical Zero. " T o t a l A m m e t e r " Cal. Test T i m e Cal. "Real Current" A m m e t e r CaL* 5. 6. 7. 8. V o l t m e t e r Cal. Feil P o t s Cal. S a f e t y Ground O h m s Cal. R a m p R a t e Calibration. Table No. 1 USE TYPE AC/DC D i g i t a l A m m e t e r Voltmeter ( f l o a t i n g i n p u t ) . . D a t a T e c h Model 31 or equivalent. General Purpose and C a l i b r a t i o n of v o l t m e t e r and ammeter. General Radio W8MT3VM o r e q u i v a l e n t A C L i n e v o l t ~ g eset-up. 220/240 t e s t s 120-240 V A C L i n e S t e p Up Trensforrner- $ H P 1 7 5 o r equivelent G e n e r a l Purpose High Voltage P r o b e Simpson +0161 cal t e s t Voltage Measurements ( a l t e r n a t e = Ross Engr. ~vMP-I~-c.~) Standard R e s i s t o r B o x 0.6.ohm a n d 0.4 o h m 1 % General Redio 510-A o r equivalent Safety Check High Voltage L o a d s S e e T a b l e No. 2 C a l i b r a t i o n of ammeters. * Gnd BY Model only. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com Ohms 4-5 SET U P 4-6 The e q u i p m e n t should b e s e t up t o ensure testing a t 115 VAC plus o r minus 1% (low l i n e s w i t c h = "h'orrnal") unless otherwise noted. Foreign users may w a n t t o r e c a l i b r a t e on their s t a n d a r d voltages and frequencies. If line f r e q u e n c y i s different from 60Hz, r e m e m b e r t h a t requii.ed capacitor values will change. / 4-7 METER hlECHANICAL ZERO 4-8 Kith t h e Hipot t e s t e r turned OFF, n o t e i h e pcsitions of t h e vol!6ge and a m m e t e r p o i n t e r s on t h e front panel. They should r e e d ze;o glus or minus one minor division. If they d o not, adjust t h e z e r o screw. 4-9 TOTAL C U R R E N T AMMETER CALIBRATION -- 4-1 0 Turn t h e Hipot T e s t e r on and n o t e t h a t t h e t o t a l c u r r e n t a m m e t e r position is a t zero (plus o r minus o n e minor division). C o n n e c t "Safety Ground Sense" w i r e to t h e chassis in all models s o t h a t t h e "READY" l a m p lights. The m e t e r should s t i l l b e zero. If not, troubleshoot t h e "Full K a v e Total C u r r e n t D e t e c t " circuit. Insure t h a t no load i s placed in t h e High Voltage Output Socket. . . Push t h e "START" button: I' WARNING HIGH VOLTAGE NOW A P P E A R S ON OUTPUT SOCKET Note t h e m e t e r reading. It should b e z e r o (plus o r minus one division). Push t h e R E S E T button. Insert t h e Digital A m m e t e r in s e r i e s with a 0.95% of full s c a l e HV l o a d resistor (AV Onlyj o r HV l o a d c a p a c i t o r (AV and BV) p e r t h e s c h e m a t i c shown on t h e next page. Select t h e value of this load f r o m T a b l e No. 2. - Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com R E Q U I R E D LOAD ~ - -. ~ 16OK o h m 3 % , 3kV, 20 i v a t t r e s i s t o r o r 0.01 6pF, 2kVAC capacitor hll DOA\'-I 5-1 .~ 5 2Sk o h m 3%, 3k\', 1 0 0 v:att r e s i s t o r o r O.OSpF, 2kVAC c ~ a c i t o r h'il 0SAVTl 5opt 001 (e2s -~ 0.01 6 u F , 2kVAC. c a p a c i t o . r , a n d 1.5 m e g o h m 3% 3 w a t t r e s i s t o r 3kV o p e r a t i n g v o l t a g e , non-inductive 0.080uF, 2kxrAC c a p a c i t o r a n d 300k o h m , 3 % 3kI1, non inductive 1 0 w a t t resistor - - O t h e r MI OOA a n d MSOOAV 1 . C a l c u l a t e R e s i s t o r Value f r o m t h i s f o r m u l a : - -H- i p o t V o l t a g e R= 0.95 x F u l l S c a l e C u r r e n t 3%Voltace Tolerance C = 0.95 x F u l l S c a l e C u r r e n t ( t o t a l I m e t e r c a l ) x Hipot Voltage . Hipot Irolta<e 0.095 x Full s c a l e C u r r e n t ( r e a l m e t e r ) - 2nf - All BV A'lqdels p - R = - > Operating voltage - - 3% v o l t a g e t o l e r a n c e > Operating voltage Back-to-backeners ( o v e r 1 oad p r o t e c t ) Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com A m m e t e r m u s t be insc-rted on low voltage side of resistor or or the ninrne:e;'s capacitor brezkdown voltage to zround m a y be exci.eried. Resktor or c a p a c i t o r shnuid b e t c s t e d first t o insure t h a t it c a n c i t l s l a n d - r a t e d voltage. S e t a m m e t e r t o lOOmA full scale. Push START button. A m m e t e r ' s c u r r e n t r e a d i n g should a g r e e w i t h t h e reading on t h e Total L e a k a g e C u r r e n t a m m e t e r with 3% plus o r minus of full s c a l e (e-g. f o r 10 mA FS a m m e t e r t h e t w o r e a d i n z s should b e within 0.30 mA of e a c h other). . If t h e y d o n o t , a d j u s t t h e "Total C u r r e n t A m m e t e r Cal" p o t - R19 on t h e A21 b o a r d u n t i l i t a g r e e s with t h e Digital A m m e t e r reading with 1%. See Dwg. 0 0 4 6 2 - o i f o r p o t positions. Push "RESET" to e n d test. - 4-11 TEST TIME CALIBRATION - 4-1 2 S e t a s p e c i f i c test t i m e p e r i n s t r u c t i o n s of p a r a g r a p h 2-35. T o c h e c k test t i m e l i m i t s , t u r n "Test The" p o t t o minimum a n d maximum. Minimu.n should b e 1 s e c o n d end maximum g r e e t e r than 90 s e c o n d s . If n o t , troubleshoot t i m e r o r c a l l R O D L Applications Engineer f o r a s s i s l ~ n c e . Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com ~- - 4-1 3 A2-I CALIBRATION 4-14 - OFFSET ADJUSTMENT 1. Take t h e A21 Board out. 2. Short Pins 5 and 1 3 of t h e A2-1 Real Current board t o Gnd. 3. Turn R1 t o get O\' DC a t TP2. 4. Short Pins 5 and 1 3 of t h e A2-1 Real Current board t o +5V. 5. Turn R 3 7 t o g e t 01' DC a t TP2. 6. . . .. ., . . , Turn R 3 fully counicr~clock::.ise. Remove i 5 V from pin 5 and 13 and connect i t back t o Gnd. .. . . . . 7. Adjust R2 t o r e a d 0 \ ' DC a t TP3. 8. Adjust R 6 t o r e a d OV DC a t TP12 (ZOmV scale). 9. Adjust R4 t o r e a d OV DC a t TP4 (20mV scale). 10. Adjust R5 and notice level change from about OV t o 15V a t TPl1. Leave R5 e x a c t l y where level change occurs. . 11. Turn R7 fully clockwise. 12. Short TP8 t o g o u o d (U4 Pin 3). 13. Adjust R29 t o r e a d OV a t TP9. 14. Adjust R8 t o r e a d OV DC a t TP7 (20rnV scale). 15. Short (tie) TP5 and TP6 together. 16. Adjust R9 t o produce a level change from 15V t o about -15V a t . TP10 (5V scale). Leave R9 e x a ~ t l ywhere t h e level change occurs. NOTE - Be s u r e t o check z e r o everytirne t h e reference scale is changed on t h e oscilloscope and throughout t h e procedure. After a 20rnV scale is used a 5mV s c a l e is advised. 4-15 . TRlGGER AND METER CALJBRATION 1. Turn R7 t h r e e t i m e s counterclockrvise. 2. Connect a resistor with a value equal t o High Voltage x10 Full Scale Current o r 200K + 3 % ohm 5KV when no other is available t o output with a n e x t e r n a l a m m e t e r in series in t h e low side. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com 3. Push the START button t o g e n e r a t e HI'. Push t h e R E A L button R3 slowly c l o c k ~ v i s e until t h e a m m e t e r deflects in t h e positive Continue slorrly t a m i n g R 3 just until t h e ernrneter slows down its fast ascending trip. Slowly turn up t h e variac if necessary t o g e t on the a m m e t e r equal t o full s c a l e when the H E A L button is pushed. and turn direction. relatively a rcadyng 4. - Adjust R7 t o m a d t h e ssrne ciirreni on t h e Front Pariel :%leteron the e x i e r ~ a l k n ~ m e t e r . Tush tihe KESET buiion. 5. Connect a c a p a c i t o r (typically 0.016pF 5KV) in parallel t o t h e resistor, push the START button and check t h a t the reading on t h e a m m e t e r is about the same a s before, if not, adjust R 3 slowly t o g e t a reading about 3% above t h e reading when t h e resistor was alone. - 6. Take t h e resistor out and push t h e START button. Check t h e real current reading a f t e r t h e r a m p up. This value added t o t h e one when t h e resistor is alone gives t h e real c u r r e n t value when both capacitor and resistor a r e in place. If not, r e p e a t s t e p 4 accordingly. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com 4-1 7 Disconnect a l l l o ~ d sfrom t h e HlPOT TESTER. C o n n e c t t h e High Voltage probe ( c o n n e c t e d a s a I 0 0 0 t o one v o l t a g e divider by shunting t h e output with a 50k ohm r e s i s t o r , t r i m value t o c o m p e n s a t e f o r DVAl input i m p e d a n c e , s y s t e m crccur~icyt o be 1% o r b e t t e r ) t o t h e DI'hl used, Connect t h e ground l e a d of t h e p r o v e end t h e SAFETY GROUND wire from t h e HIPOT TESTER t o t h e HIPOT TEST f r a m e . Push "STA RTn b u t t o n . WARNING !;TC;H VO!,T.IGiiS A P P E A R ON OVii'ilT PANEL BLOCK -~ T h e v o l t m e t e r should rise slowly from z e r o a f t e r a n initial delay. r o t e t h e v o l t a g e reading. Insert t h e p r o b e i n t o t h e OUTPUT SOCKET a n d r e a d t h e v o l t a g e f r o m t h e Digital Voltmeter. T h e t w o should a g r e e within plus o r minus 3% of full s c a l e (or 90 volts.). If t h e y d o n o t c h a n g e t h e value of R 6 on t h e A G S 5 b o a r d until they do. 4-1 8 FAIL P O T S CALTBRATION 4-19 Turn a l l F a i l u r e S e t p o i n t P o t s fully clockwise. Insert t h e Calibration Load l i s t e d in t a b l e No. 2 t o pull nearly Full S c a l e C u r r e n t i n t o t h e HIPOT TESTER O u t p u t Socket. NOTE: Digital a m m e t e r shown on P a g e '4-3 i s n o t n e e d e d in t h i s test. However, t h e dual b a n a n a jacks should be s h o r t e d together. Push "START" button. WARNTNG HIGH VOLTAGES A P P E A R ON T H E T E S T LOAD While t h e high v o l t a g e i s ON, slowly t u r n t h e TOTAL C U R R E N T F A I L U R E SETPOINT P O T counter-clockwise until t h e FAIL l a m p c o m e s ON. Push RESET. N o t e t h e position of t h e s l o t on t h e p o t e n t i o m e t e r . It should b e n e a r t e n (10) on t h e scale. If i t i s l e s s t h a t e i g h t (a), t r o u b l e s h o o t t h e A21 board o r call ROD-L Applici..tion E n g i n e e r f o r assistance. To c h e c k t h e R E A L C U R R E N T FAILURE SETPOINT pot, t h e r e s i s t o r l o a d u s e d in p a r a g r a p h 4-15 i s required (BV only). T h e Digital A m m e t e r i s n o t n e c e s s a r y f o r t h i s test. If i t i s d e l e t e d , s h o r t t h e dual banana plug. R e s e t a l l SETPOINT POTS fully clockwise, S e t up t h e l o a d a n d plug i n t o HIPOT TESTER. Push "STARTn b u t t o n . Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - IIIGH VOLTAGES A P P E A R ON T H E TEST LOAD While t h e high v o l t a g e is O N , slowly t u r n t h e HEAL C U R R E N T FAJLURE SETPOINT POT coilnter-clockwise until t h e FATL l a m p c o m e s on. Push RESET. N o t e t h e position o i t h e slot on t h e p o t e n t i o m e t e r . Jf i t is l e s s t h a n six (6): troubiesimot i h e -421 :):lard o r call R O D L Application Engineer. R e p e a t t h e t e s t b u t t u r n t h e TOTAL C U R R E N T FAILURE SETPOINT P O T until t h e FAIL l a m p c o m e s on. I t should b e n e a r o n e (1) on t h e scale. AV u s e r s may also want t o d o t h i s by c o n s t r u c t i n g t h e a p p r o p r i a t e load. - 4-20 4-21 SAFETY G R O U N D OHMS CALIBRATlON . Disconnect a l l l o a d s f r o m t h e HIPOT TESTER. C o n n e c t a 0.5 ohm resistor b e t w e e n t h e CHASSJS G R O U N D SENSE t e r m i n a l on t h e f r o n t panel and t h e h a n d l e o f t h e HIPOT TESTER. Make s u r e t h a t t h e c o n t a c t r e s i s t a n c e - .. of t h e S a f e t y Ground w i r e i s negligible. Turn o n t h e HIPOT TESTER, t h e S T A R T button. T h e R E A D Y l a m p should c o m e ON. Push WARNING HIGH VOLTAGES A P P E A R ON T H E TEST CIRCUIT The High v o l t a g e should c o m e up normally a n d n o FAIL condition should occur. Push t h e RESET button. R e p l a c e t h e 0.5 ohm r e s i s t o r w i t h a 0.5 ohm resistor. I n s e r t t h i s t e s t c i r c u i t i n t o t h e O U T P U T S O C K E T a n d d o n n e c t t h e GROUND SENSE a s above. T h e R E A D Y l a m p should N O T c o m e on. Push RESET i f necesqary. The li-mits on t h e SAFETY G R O U N D TEST c i r c u i t have b e e n verified. If- t h e l i m i t s a r e n o t c o r r e c t , t r o u b l e s h o o t t h e SAFETY GROUND DETECT c i r c u i t o r c a l l ROD-L Application Engineer. Finally, D i s c o n n e c t l o a d t o HIPOT TESTER. C o n n e c t GROUND SENSE wire to t h e f r a m e of t h e H I P O T TESTER. T h e READY l a m p should c o m e ON. P u s h t h e S T A R T button. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com WARNING HIGH VOLTAGES A P P E A R ON T H E TEST C l R C U l T lfhile t h e high v o l t a g e is o n , disconnect t h e G r o u ~ r dSense wire. The FAIL l a m p should i m m e d i a t e l y c o m e ON a n d t h e high v o l t a g e should drop t o zero. Push RESET. T h e READY l a m p should NOT light until t h e Ground Sense wire is a g a i n coniiected t o t h e Hipot T e s t e r . - 4-22 R.A M P - R A T E CALIERA'I'ION 4-23 Proper o p e r a t i o n of t h e R a m p Up C o n t r o l on t h e AG-S5 board sl!ould be verified. .by w a t c h i n g t h e O U T P U T VOLTAGE METER. . C h e c k t h e delay t i m e (i.e. t h e ' t i m e b e t w e e n pushing t h e S T A R T b u t t o n and t h e beginning of t h e rising voltage) and t h e r i s e t i m e (i.e. t h e t i m e b e t w e e n t h e minimum point a n d t h e 100% point o f t h e rising voltage) o f t h e o u t p u t v o l t a g e ivaveform. D e l a y t i m e should be b e t w e e n 0.5 a n d 1.5 seconds. R i s e t i m e should, b e d e p e n d e n t of t h e R a m p R a t e a d j u s t m e n t . N o spurious oscillations should be s e e n . A t t h e end o f t h e turn-on-period, t h e voltage waveform should b e sinusoidal e x c e p t f o r very s m a l l a m o u n t s o f crossover distortion (assuming a low distortion A C p o w e r line). Under f u l l l o a d conditions ( u s e test l o a d f r o m T a b l e No. 2) t h e o u t p u t voltage should v a r y l e s s t h a n 8% f o r c a p a c i t i v e loads. If not, troubleshoot A6-S5 board. T h e w a v e f o r m should s t i l l look e s s e n t i a l l y sinusoidal (with a c t u a l l y l e s s d i s t o r t i o n t h a n t h e o n e r e c e i v e d a t t h e i n p u t line. 4-24 LNITIAL CALlBRATlON OF A6-S5. Without Running 1. 2. a TEST cycle, a d j u s t t h e following: Adjust R9 t o r e a d a p p r o x i m a t e l y n e g a t i v e lOOmV at TP7. C, 3. 4. . R 3 0 fully clockwise. S e l e c t mode A on t h e f r o n t p a n e l and a d j u s t TEST ?ME f o r approx. 30 sec. A d j u s t - R 3 0 d o c k w i s e until t h e r --. a t e of r i s e i s a s quick as d e s i i e d . ~ e p e a tf o r R4 s e l e c t i n g m o d e B on t h e f r o n t panel. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com ., . Fig 4-2 s h o w s t h e r e l a t i o n b e t w e e n t h e different p a r a m e t e r s of control. Fig. 4-2 - T r s t C y c l e 7z;eme;er The d e l a y t i m e is given by ep?ro>irna.:ely D E L A Y = 0.5 + K (P.AI\IP R A T E Full Scale Voltage Sec) The R a m p R a t e is a conirollable p a r s m e i e r adjusted b y R 3nand R 4 for M o d e A a n d B respectively. F o r e a c h instrument t h e R a m p R a t e v a r i e s f r o m a b o u t F U L L SCALE VOLTAGE/Sec t o FULL SCALE 30/sec. F o r example, f o r a 5kV unit t h e R a m p R a t e is VOLTAGE a d j u s t a b l e f r o m 5000 V/sec t o 166/Ir sec. K is a n i n s t r u m e n t constant. and v a r i e s f r o m a b o u t 30 m s e c t o 40 msec. So t h e e x p e c t e d delay. t i m e i s a b o u t f r o m 0.54 s e c t o 1.54 sec. + The R A M P TIME d e p e n d s VOLTAGE s e l e c t e d . & t h e s e l e c t e d RAhlP R A T E a n d t h e FULL R A h l P TIME = FuU V o l t a ~ . e RAhlP RATE If t i e s a m e R A M P TIME i s t o maintained when t h e FULL VOLTAGE is c h a n g e d w i t h t h e VARAIC CONTROL, t h e RAMP R A T E has l o be readjusted. ? Test t i m e i s t h e t o t a l DELAY plus R A A I P plus D12t'ELL time. The r e c o v e r y l i m e is a b o u t 0.5 sec. So, f o r a 5kV unit with 5000 V/sec R a m p R a t e , 5kV full v o l t a g e , 1 s e c dv:ell time, t h e TEST TIlvlE selected has t o b e 0.54 s e c + 1 sec + 1 s e c = 2.54 sec a n d t h e t o t a l t e s t cycle t i m e is 2.54 + 0 . 5 s e c ( r e c o v e r y t i m e ) = 3.04 sec. 4-26 For r e a d j u s t i n g a R A h l P RATE, t h e following procedure i s suggested 1. S e l e c t t h e c o r r e s p o n d e n t mode A o r B. 2. S e l e c t a l a r g e T E S T TIME accordingly t o R A M P TlhiE Zesired a d j u s t i n g p o t s A or B in t h e A21 b o a r d and running t h e test. 3. P u s h t h e R E S E T b u t t o n e n d a d j u s t t h e p o t R 30 o r R 4 f o r RAMP R A T E A o r B. CJockr.~ise decreasesthe RAMP RATE. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com Push S T A R T b u t t o n and c h e c k t h e RAMP TIME. Repeat S t e p # 4 if necessary. R20 is f a c t o r y a d j u s t e d f o r waveform s i m m e t r y . 4. 5. Adjust t h e TEST TIME b a c k position. 4-27 Equipment Required: Table No. 1. - T h e r e q u i i e d equipment is t h e s a m e a s t h a t lisied in 4-29 TROUBLESHOOTING T R E E PROBLEM LIST . .. . . . 4-30 The foIlowing i s a list of p r o b l e m s and potential causes. A. N O A C POWER. 1. 2. 3. B. C h e c k f u s e s Fl a n d F 2 C h e c k f o r bad AC P o w e r L a m p (11) ON-OFF Switch 611, l i n e f i l t e r (1.1-L2). M e a s u r e f o r l i n e v o l t a g e b e t w e e n A6-S5,. T P 6 and T P 7 - .- I n s t r u m e n t blows fuses. # 1. 2. C. Is F l only blowing? C h e c k f o r s h o r t e d AllOVl o r AIOV2. Check f o r s h o r t e d T1. Troubleshoot A10 board. D o e s F 2 or F 3 only blow? If so, c h e c k f o r s h o r t e d o u t p u t power t r a n s i s t o r s . C h e c k f o r i n t e r n a l s h o r t on T2. High v o l t a g e m e t e r d o e s n o t t u r n on slowly. 1. C h e c k f o r s h o r t e d o u t p u t transistors. board. D. R e a d y lamp d o e s n o t work. C h e c k f o r l e a k y Q 2 on A6-S5 9 1. C h e c k f o r burned o u t bulb. 2. - C h e c k f o r bad c o n n e c t i o n a t B P I o r bad 1 ohm 31Y r e s i s t o r on A6-S5. 3. T r o u b l e s h o o t s a f e t y ground o h m s d e t e c t c i r c u i t on A21. E. No High V o l t a g e 1. 2. . 3. 4. C h e c k f o r b a d f u s e s F 2 a n d F3. C h e c k f o r bad S T A R T s w i t c h C h e c k wiring h a r n e s s f o r f r a y e d wiring. Troubleshoot A6-S5 b o a r d digital logic. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com F. Failure indicators do not work o r work erratically. 1. 2. 3. 4. - G. Excessive power disspation on A6-SS. 1. 2. 3. H. Check t o s e e if t h e l r a k a g e current a m m e t e r h'orks. Check signals gi\:en by U5 on A6-S.5. Determine which of four possible failure modes is being d e t e c t e d . That is, safety ground fault, t o t a l curi.ent overload, o r T2 primary current g r e a t e r than 1 . 2 a m p (overload). Troubleshoot app:.op:.iatc- iunclional block. Check initial condition voltage a t t h e base of Q1 (AG-S5). Check f o r shorts, low b e t a , etc. Check f o r internal shorts, corona, etc. Measure volgate between TP6 and TP7 on A6 board with high voltage OFF. This voltage should equal line voltage. With high voltage ON, this voltage should be less than 5 VAC-RMS fully loaded a f t e r t h e R a m p Up. If not, check troubleshoot A6-S5. . ~- Arcing shutdown does not work. 1. 2. 3. 4. Connect oscilloscope t o A-21 pin 7 which is optoisolator output. Short Hipot T e s t e r output. Adjust trigger f o r a single sweep as optoisolator switches f r o m +5V t o OV and back. Push START. The FAIL l a m p should g o on a f t e r a n approximate delay of 1 sec when t h e HV comes up. The oscilloscope should show a 0.2 to o n e millisecond negative pulse from t h e optoisolator thus verifying operation. If no pulse appears o r pulse does not fall below one volt, repair optoisolator o r associated circuitry. If i t appears, check w i t h t h e factory f o r increased sensitivity for low level energy arcing. . Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com P A R T S LIST SECTION V Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - - ROD-L ELECTRONICS, INC. ASSEMBLY DESCRIPTION: A10 POWER SUPPLY ASSEMBLY NUMBER: 00459-02 REV-A RATING AND/OR ITEM KEFERENCE DESCRIPTION MFR. NUMBER ........................................................................ 1 A10 PCB, RAW 00457-02 ROD-L CASACITOR, EL 470uf 3 5 V 2 C4,CS CAPACITOR, EL 3 3 O O u f 16V 3 C1 luf J5V CAFACITOR. EL 4 C2,C3,Cb CSAOS, COLLRER 5 Ul-U3 DIODE BRIDGE 6 VRI 5V REGULATOR 7905, CLM340T5 7 VH2 -i5V REGULATOR 7915, LM320T-15 + I 5V REGILILATOR 7815, LM340T15 8 VR3 9 Cill-CR3 DIODE 1N 4 0 0 2 10 F1 FUSE 275004 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com QTY. 1 2 1 3 3 1 1 1 3 1 - ROD-L ELECTRONICS, INC. - ASSEMBLY DESCRIPTION: A21.CONTROL LOGIC BOARD ASSEMBLY NUMBER: 00462-02 REV. G RATING AND/OR ITEM REFERENCE DESCRIPTION NFR. NUMBER 1 A21 2 TP1-7 3 C1,3,4,7,8, C9,11,12,13.15 4 C14 5 C2 6 C5 7 C6 8 C10 9 R1.4-9,R30,R44 -: 1 0 R3 . 11 R10,11,33,34,40 12 R43 1 3 R18,20 14 R21 15 R22,23,24,28 R29.35 1 6 R25,R36,R41. 17 R26 1 8 R27.39 19 R38 20 R12-17 21 R2,37 22 R19 23 Q1,2,3,7,8,9 24 (14.5 - ' - - .. . ... . .. ' . 25 Qb 26.. C R ~. 27 28 29 30 31 32 33 34 35 36 37 ....; . . : CRZ-5,8,9 U1,4,5,8 U2 U3 U6 U7 X - X CRl,CR7 R42 . . RAW PCB TEST POINT CAPACITOR CERAMIC PARTS Ll ST QTY. ROD-L 00462-02 1 7 .Oluf 25V 10 CA?FIC I TOR .47uf CAPACITOR TgNT/ELYTIC 150UF 16V CAPACITOR TANT/ELYTIC lOUF 16V CkF'.?CiTOF( TANT/ELYTIC 4.7UF 35V C&F'ACITOR TCNT/ELYTIC 22UF 15V 4.7K 1/4W 5% RESISTOR CARBON . 6 . SK 1/4W 5% RESISTOR CkRRON . . 1K 1/4W 5% RESISTOR CARBON RESISTOR CGRBON B.2K 1/4W 5% RESISTOR CARBON 3.3K 1/4W 5 X RESISTOR CARBON lOMEG 1/4W 5% RESISTOR CARBON 10K 1/4W 5 X 1 1 1 1 1 ' . . . .. . 9 '2 5 1 2 1 6 RESISTOR CARBON RESISTOR CARBON RESISTOR CARBON RESISTOR CARBON RESISTOR METAL FILM POTENT1OMETER POTENTIOMETER TRANSISTOR, NPN TRANSISTOR. NPN TRANSISTOR, PNP 6BK 1/4W 5% 1BK 1/4W 5% lOOK 1/4W 5X - ~- . 56K 1/4W 5% 20K 1/4W 1X 500K 20 TURN 3006P-1-504 2K 20 TURN 3006P-1-203 2N2222 2N3904 ZN2907 DIODE., :,ZENER.: :,I.' . . 14.7V : IN7500 . .. .. . .: .: DIODE, SIGNAL 1N414B IC, O P AMP UA741 IC, TIMER. NE555 SPIN DIP IC, 4 INPUT NAND SN7420N IC, HEX INVERTER i SN7405 14 PIN DIP IC, 2 INPUT NAND DM7400 14 PIN DIP IC SOCKET SPIN LOW F'fiOFILE IC SOCKET 14PIN LOW PROFILE NOT USED IN DRAWING NOT USED IN DRAWING " ' Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com 3 1 2 1 6 2 1 6 2 1 , 1. 6 4 1 1 1 1 5 3 - FARTS LIST ROD-L ELECTRONICS, INCASSEMBLY DESCRIPTION: 06-S5 SLOW RISE CONTROL BOARD ASSEMBLY NUMBER: 00235-02 REV. B RATING AND/OR NFR. NUtlBER ITEM REFERENCE DESCRIPTION ............................................................... 00238-02 ROD-L 1 AbS5 EAW PCB 2 TEST FIN 3 C1 CAPACITOR, ALUM l0UF 12V 4 tiS-1 HEAT SINK DANGER Sl GN MOUNT 5 C2 C W A C I T O R TANT 220UF 6V 6 INSULATOR, RUBBER 7 C3 CA'IAC I TOR 22UF 3 5 V 8 L A P E L , DANGER 9 C8 CSPACI TOR -0 1 UF 25V CAF'ACITOR 3JUF 10V 1 0 C6 . CAPACITOR, DISC . .OlUF 1KV. . . ' 11 C7. 1 2 CRl-B,CR11-13 DIODE 1N914B 13 CR9,CRlO DIODE 1N5245B 14 CR14-17 DIODE 1N4005 6OOV 1AMP 15 K1 REED RELAY GORDOS F81-5053A 16 U1,U2 IC UA741TC OP AMP 17 U3-US OPTICAL COUPLER MCT2E 18 PC-1 PHOTOCELL RESISTOR 19 PHOTOCELL HOUSING ASSMBLY 20 01 TRANSISTOR 2N3439 21 02 TRANSISTOR 2N5416 22 Q3 TRIAC T2700D 23 R1 RESISTOR 1.62K 1/4W 1% 24 R2 RESISTOR 15K 1/4W 1% 25 R3 RESISTOR 1.2MEG ZW 1% 26 R4,R30 RESISTOR, VARIABLE 1MEG 27 R5 RESISTOR 1.21K 1/4W 1% 28 R6,RlB,R19 RESISTOR 330K 1/2W 5% 29 R7,RB RESISTOR 4.64K 114W 1% 30 R9 RESISTOR, VARIABLE 20K 31 R10 3.48K 1/8W 1% RESISTOR . 32 R12 RESISTOR 3.3K 1/2W 5% 33 R13 i 1 OHM 3W 1% RESISTOR 3 4 R14,RZl RESISTOR . 68 OHM l/ZW 5% 35 Rlb,R22,R28 RESISTOR 100 OHM 1/2W 5% 36 R15 RESISTOR 3.6K 1/2W 5% 37 R17 RESISTOR 7.5K 1/2W 5% 38 R29 RESISTOR 20K 1/4W 1% 39 R20 RESISTOR, VARIABLE 25K 40 R23 RESISTOR 1K 1/2W 5% 41 R24,R27 RESI STOR -33OHM 2W 1% 42 R25 RESISTOR 82K 1W 1% 43 R26 RESISTOR lOOK 1W 1% 44 C4,CS. NOT USED IN DRAWING - - Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com QTY. ROD-L ELECTRONICS, INC. FARTS LIST RSSEKBLY DESCRIPTION: 02-1 REAL CURRENT BOARD ASSEMBLY NUMBER:00442-02 REV. D RATING AND/OR DESCRIPTION MFR. NUMBER ITEM REFERENCE .................... 1 AZ-1 2 TPI-12 3 C1 ,Z-12,16,17 4 C2 00442-02 ROD-L R4W PCB TEKMINRL TEST FIN KEYSTONE 1405-3 CGPACITOR CERAMIC -01UF 25V CGF'ACITOR MONLYTHIC -47UF 50V 25V 47UF 5 C13,14,15,21,22 CGPbCITOR EL CGFACITOR TANT/EL IUF 20V 6 ClE,l9 -002UF 25V CAPACITOR CERAMIC 7 C20 CAF'ACITOR. MJNOiYTHIC 2.2UF 8 C23 9 CR1-4,7,8 DIODE, S~G'!AL 1 0 CR5,9,10 DIODE, ZENER 1 1 CRh DIODE, ZENER 1 2 Q1,Z TRANSISTOR, RCA 1 3 Q3 TRANSISTOR, RCA 14 U1-3 IC, NAT 1 5 U4 IC, NAT 16 U5 IC, HOT QUAD ANLG SW 17 U6 IC, NAT QUAD OP AMP 1 8 U7 IC, SIG TIMER 19 U8 IC, RCA 2 INPUT N4UD 20 R1.2,;-9 POTENTIOMETER BOU 21 R3 POTENTIOMETER BOU 22 R4 POTENTIOMETER BOU 20K 3006-1-203 23 R10,14 lOOK 1/4W 5% RESISTOR CARBON 24 Rll,l6,17,19,20 RESISTOR CARBON 1K 1/4W 5% 25 R30 RESISTOR CARBON 15K 1/4W 5% 26 R12 RESISTOR CARBON 680K 1/4W 5% 27 R13,18,23,24 RESISTOR CARBON 10K 1/4W 5% 28 R28,32 4.7K 1/4W 5% RESISTOR CARBON 29 R29 RESISTOR VARIABLE 1K 3006P-1-102 30 H21,15 RESISTOR CARBON 1K 1/4W 5% 31 R22,26 RESISTOR CARBON 47K 1/4W 5% 32 R25 RESISTOR CARBON 100 OHM 1/4W 5% 33 R27 RESISTOR CARBON .20K 1/4W 5% 34 R31 RESISTOR CARBON 56K 1/4W 5% 35 R33 KESISTOR CARBON 10M 1/4W 5% 36 R34-36 . RESISTOR, MF 100K 1/4W 1% 37 R37 POTENTIOMETER 2SK 3006-1-253 38 R38 RESISTOR CARBON 87K 1/4W 5% 39 RN1 RESISTOR SIP 4.7K 1% MSPOE-A-03-472G 40 RN2,3 RESISTOR SIP 1K 1% MSPOE-A-03-102G 41 RN4,S RESISTOR SIP lOOK 1% MSPOE-A-03-104G 42 RN6 RESISTOR SIP 1OK 1% MSPOE-A-03-103G 43 RN7 RESISTOR SIP 2.2K 1% MSP08-A-03-222G 44 SOCKET, IC 14PIN DIP LOW PROFILE 45 SOCKET, IC 16PIN DIP LOW PROFILE 46 SOCKET, IC EPIN DIP LOW PROFILE Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com QTY. 1 10 13 1 5 2 1 1 OPTfONS SECTION W Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com BV THEORY O F OPERATION HIGH VOLTAGE CONFlGURATlON The high v o l t a g e configuration will be essentially t h e one used in t h e standard AV models as shown in t h e wiring diagram of t h e high voltage configuration. R 1 is a set of high v o l t a g e resistors f o r limiting t h e c u r r e n t through t h e a m m e t e r t o 1mA. R v is a f a c t o r y s e l e c t e d resistor f o r producing a voltage of about 3 volts RMS f o r monitoring t h e high voltage output. RI is t h e current s e n s e resistor and is also f a c t o r y s e l e c t e d f o r producing about 5 volts RMS max f o r monitoring t h e leakage c u r r e n t . Assuming a pure resistive load t h e c u r r e n t monitoring waveform i s 180' o u t of phase with r e s p e c t t o t h e voltage monitoring waveform. REAL C U R R E N T DETECT BOARD The f o r m e r revision l e v e l C of t h e r e a l c u r r e n t d e t e c t board is a n upgraded version of t h e f o r m e r r e a l c u r r e n t d e t e c t board where a n e x t r a immunity t o noise and distortion is included as well as r e a l c u r r e n t r e m o t e monitoring and t r i p point programming. T h e board i s revised t o revision l e v e l D f o r adapting i t t o t h e high voltage configuration described above. DETERMINATION O F THE RESISTIVE LOAD O R R E A L COMPONENT O F THE CURRENT The high v o l t a g e waveform is mainly a sinusoidal o n e with a c e r t a i n percentage of distortion. T h e AC input line voltage is already a 5 t o 6% distorted waveform.' The primary e f f e c t i s t h a t t h e peak of t h e voltage waveform does not necessarily correspond w i t h t h e 90° position a n d d o e s n o t necessarily remain stable. Since t h e r e a l component of i n t e r e s t during t h e hipot t e s t i n g is t h e o n e reflecting dissipation a n d n o t t h o s e o f t h e harmonics with r e s p e c t t o t h e 60 H z p u r e sinusoidal it is of primary i m p o r t a n c e t o d e t e r m i n e where e x a c t l y t h e peak of t h e voltage waveform o c c u r s under any circumstance. T h e integration of t h e waveform is not practically advised because t h e undesirable o f f s e t e f f e c t s a n d t h e low pass filtering version of t h e integration would provide only a predetermined amount of phase s h i f t which does n o t necessarily correspond t o t h e location of t h e peak voltage waveform w h e r e w e know t h a t with a c a p a c i t i v e load t h e c u r r e n t waveform has t o be z e r o a n d a n y value d i f f e r e n t f r o m z e r o is d i r e c t l y reflecting a resistive component t h a t c a n b e modelled a s a resistive e l e m e n t in parallel with t h e ideal capacitance. This a p p r o a c h p e r m i t s us t o d e t e r m i n e a dissipative c u r r e n t component which c a n t o l e r a t e a l a r g e a m o u n t of distortion in t h e voltage waveform. O n e big l i m i t a t i o n of t h e circuitry, however, is t h e sensitivity of t h e d i f f e r e n t i a t o r to uncommon a m o u n t s of noise a n d distortion. T h e revision level C of t h e real c u r r e n t d e t e c t board already upgraded t h e immunity with e x t r a filtering a n d t i m i n g c i r c u i t r y which p e r m i t s t h e sampling of t h e leakage c u r r e n t waveform only when t h e peak of t h e voltage waveform o c c u r s around t h e 90° where ideally i t should be. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com The approach described above p e r m i t s us t o look a t t h e dissipative component of t h e leakage c u r r e n t under conditions very f a r f r o m t h e ideally linear ones, like distored voltage and c u r r e n t waveforms a n d non-linear capacitances. However, if distortion and nonlinearities b e c o m e m o r e s e v e r e , a t o t a l l y d i f f e r e n t approach t o t h e problem has t o be t a k e n d i f f e r e n t t o t h e linearizing one, but in this case t h e resistive component would l o s e i t s meaning giving ground t o a n o t h e r concept like dissipating power instead, which w e a r e prepared t o t a k e i n t o development. REAL CURRENT DETECT CIRCUITRY REVISION LEVEL D The voltage a c r o s s t h e voltage monitoring resistor R v is connected t o a differential amplifier and its o u t p u t a t pin 1 2 of U1 i s f e d t o t h e phase shifter s o t h a t t h e output a t pin 1 0 of U1 is leading a s m a l l a m o u n t f o r compensating f o r t h e different delays in t h e circuitry. T h e output is applied t o t h e d i f f e r e n t i a t o r where w e obtain t h e inverse of t h e d e r i v a t i v e with t h e leading z e r o crossing being coincident with t h e positive peak of t h e voltage waveform, t h e output of t h e differentiator i s applied t o t h e squaring a m p l i f i e r f o r obtaining a square waveform in phase with t h e derivative but with t h e rising e d g e being coincident with t h e negative peak of t h e high voltage monitoring waveform a n d this i s b e c a u s e t h e l e a k a g e c u r r e n t we want t o look a t is out of phase with r e s p e c t t o high v o l t a g e by 180'. On t h e o t h e r hand, t h e voltage monitoring signal is f e d t o U6, a timing circuitry, through pin 1 of R N 3 which squares t h e waveform a n d produces t h e triggering of t h e monoastable U7 t o set a single pulse out of pin 8 of U8 around t h e negative peak' of t h e voltage monitoring signal. This pulse allows t h e z e r o crossing signal represented by t h e rising e d g e of t h e output of 10. of U2 t o g o through U 8 and produces a signal pulse of about 7 microseconds o u t of t h e output 4 of U8 coincident with t h e negative peak of t h e v o l t a g e monitoring signal. This pulse i s used in t h e s a m p l e and holder U4 t o sample t h e l e a k a g e c u r r e n t waveform which g e t s in through U8 coincident with t h e negative p e a k of t h e v o l t a g e monitoring signal. This pulse is used in t h e sample and holder U 4 t o sample t h e l e a k a g e c u r r e n t waveform which g e t s in through pin 3 of U4 a f t e r being buffered by U6. Any positive value which is sampled is reflecting a dissipative c u r r e n t and i s f e d t o t h e non-inverting amplifier f o r driving t h e a m m e t e r . R 7 a d j s u t s t h e gain of this amplifier U3. T h e o t h e r half of U3 i s used t o compare t h e tripping value with t h e a c t u a l c u r r e n t giving a failure signal if this exceeds t h e former. . The dissipative value given by U 3 is a i s o given externally f o r monitoring purposes. U6 also c a n a c c e p t e x t e r n a l t r i p point programming which i s selected through t h e r e m o t e board a c t i v a t i n g t h e REMOTE signal through t h e pin 6 of t h e board. The analog switch U 5 p e r m i t s t h e driving of t h e a m m e t e r while w e a r e in a test situation and while t h e component of c u r r e n t in phase with t h e n e g a t i v e peak of t h e voltage monitoring signal r e f l e c t s a dissipative c u r r e n t , in o t h e r words, is positive. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com A25 HANDS OFF/SWITCH SELECTABLE FAILURE POINTS THEORY O F OPERATION T h e board was designed t o contain t w o options: HANDS O F F a n d SWITCH SELECTABLE FAILURE Points. The HANDS O F F r e q u i r e s t h e o p e r a t o r o r controller t o hold t h e S T A R T line low during a Hipot Test. If a Hipot T e s t is i n i t i a t e d a n d t h e START line is found high o r rclcased, a RESET and F A I L signal of about 1 second is produced. The FAIL signal a c t i v a t e s both fail light a n d buzzer. At t h e e n d of t h e fail indication t h e unit is completely r e s e t if no r e s t a r t is a t t e m p t e d . The SELECTABLE FAILURE POINTS provide 5 e x t r a p o t e n t i o m e t e r s f o r 5 e x t r a t o t a l c u r r e n t f a i l u r e points. Any of t h e 6 pots c a n be s c l c c t e d by a 6 position switch on t h e f r o n t panel. T h e s i x t h p o t is t h e s t a n d a r d e x t e r n a l pot on t h e r e a r panel. CIRCUIT DESCRIPTION This prototype b o a r d c o n t a i n s f i v e lOOK p o t e n t i o m e t e r s f o r giving out corresponding v o l t a g e through pin 6, 8, 10, 1 2 , 1 4 t o t h e 6 s e l e c t a b l e position s w i t c h on t h e f r o n t panel. This s w i t c h c o n n e c t s o n e of t h e a b o v e v o l t a g e s t o pin J of t h e A21 board f o r comparison with t h e a c t u a l t o t a l c u r r e n t value f o r f a i l u r e t r i p p i n g purposes. Every o n e of t h e p o t s c a n b e c a l i b r a t e d f o r tripping a t o p e r a t o r d e f i n e d value. The hands off consists of a c o m p a r a t o r and a s e t of t i m e r which provides failure, r e s e t a n d s t a r t signals t o t h e rest of t h e systems. T h e s t a r t switch i s c o n n e c t e d t o pin 9 o? t h e e d g e connector. T h e c o m p a r a t o r U2 i n v e r t s and c l e a n s t h e start signal giving a high level o u t p u t when t h e s t a r t switch i s held down. T h e test signal is a l s o i n v e r t e d giving a high l e v e l output when t h e test is on. The i n v e r t e d s t a r t a n d test signals a r e given t o t h e inputs of t h e monoastable U3. While t h e t e s t signal in t h e monoastable is low, t h e o u t p u t t h r o u g h pin 1 of U3 is high. If t h e test signal in t h e monoastable goes high d u e t o a test in progress, t h e monoastable is g a t e d t o a c c e p t triggering f r o m t h e s t a r t signal. If t h e s t a r t signal goes low during a test in progress, t h e monoastable w,iU b e t r i g g e r e d a n d a low level pulse of about 100 microseconds is produced through pin 1, d e t e c t i n g t h e condition when t h e s t a r t s w i t c h is r e l e a s e d during a t e s t . This pulse from pin 1 of U3 t r i g g e r s o n e of t h e t w o t i m e r s in U1 through pin 6 of U1. A high l e v e l pulse is produced a t pin 5 of U1 of about 1 s e c o n d which gives a f a i l u r e a n d r e s e t signal t o t h e r e s t of t h e unit through Ql a n d Q2. At t h e e n d of t h e 1 second t h e unit will b e reset a n d a s t a r t c a n b e r e a t t e m p t e d . T h e s t a r t switch is a l s o c o n n e c t e d t o t h e second t i m e r through C 2 , producing a high l e v e l pulse a t pin 9 of U1 on t h e falling e d g e of t h e s t a r t s w i t c h signal, t h a t is when t h e switch is depressed. This pulse drives Q3 giving a s t a r t pulse t o t h e r e s t of t h e s y s t e m and g e t t i n g s t a r t e d . When t h i s board i s c o m b i n e d with t h e Ohms Sense Option, t h e s t a r t pulse is given by A24 board i n s t e a d . I t h a s t o b e n o t i c e d t h a t e v e n when t h i s option is used with A 8 REMOTE C o n t r o l Option, t h e s t a r t signal has t o b e held down during a test. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com A24 OHMS SENSE CIRCUIT FUNCTIONAL DESCRIPTION - The ohms sense option was developed t o d e t e c t if t h e device under t e s t presents a minimum amount of impedance b e t w e e n HOT a n d NEUTRAL leads b e f o r e a HIPOT TEST is actually performed. Before a HlPOT TEST i s s t a r t e d t h e HOT and NEUTRAL leads a r e untied. The HOT lead which is normally connected t o t h e HIGH VOLTAGE is momentarily connected t o GROUND end a s m a l l voltage of 1.5 VAC RMS is applied t o t h e NEUTRAL lead. - - The CHASSIS GND SENSE in t h e A21 board is used t o process t h e voltage across HOT and NEUTRAL l e a d s during this operation, t h e r e f e r e n c e resistance used normally for t h e ground sense t e s t is also momentarily changed t o a n adjusted pot t o provide tripping for impedances in t h e 1500 ohms range. If t h e READY signal given by t h e ground sense circuitry during t h e test goes high we will have a n ohms sense failure a t t h e end of t h e ohms sense t e s t cycle. This failure r e s e t s t h e board and operates t h e BUZZER in a pulsing mode. If t h e test is passed, t h e HOT a n d NEUTRAL a r e tied back together, t h e reference resistance for t h e ground sense test is reconnected and a start pulse is delivered t o t h e A21 board t o s t a r t a Hipot Test. CIRCUIT DESCRIPTION - When Hipot T e s t e r i s initially turned on K4 i s a c t i v a t e d , c o n t a c t s "A" and "D" of Kq a r e closed, K2 i s closed. The "READYn light i s on and normal ground sense i s performed on A21 board. When t h e start switch is depressed, pins 1 a n d 2 of U2 g o low pin 11 goes low. U1 i s triggered-and t h e output at pin 1 goes high f o r 1 second. The pulse d e a c t i v a t e s Kq opening c o n t a c t s "A" and "D", normal ground sense is interrupted. K2 i s open. The 1 sec. pulse p l a c e s a high on pin 1 a n d 2 of Uq which c a u s e a low output a t pin 3, which a c t i v a t e s (closes) K1 and K3. A t this time, t h e 1.5 VAC i s applied across R ohm, c u r r e n t flows t h r u R ohm and K3 t o W3 which i s connected t o t h e Neutral wire of t h e d e v i c e under t e s t (DUT). Current will r e t u r n f o m DUT t h r u t h e HV r e t u r n which i s t i e d t o chassis. The HOT wire is momentarily connected to HV r e t u r n with K1 eontacts. One side of R ohm is connected t o t h e chassis volt sense pin 1 3 of A21. This cicuitry senses t h a t t h e impedance of t h e DUT i s approximately f o f t h e resistance of R ohm. If this i s n o t t r u e , a high level will appear a t A 2 ~ - l O (READY). A t t h e end of t h e 1 second pulse a pulse i s produced a t pin 8 of U1. If "READY" i s high, t h e Fail Latch U3 will b e set. T h e FAIL L a t c h i s set, U s will b e unreset and give out pulses t o sound t h e sonalert. The f a i l o u t p u t a t Q2 i s connected back t o t h e r e s e t cicuitry s o any kind of f a i l u r e c a n r e s e t t h e board. If t h e resistance of t h e DUT is equal t o o r l e s s than 1500 ohms, t h e negative edge of a pulse g e n e r a t e d a t pin 8 of U1 will trigger U1-11. A 1 second pulse a t U1-9 is generated t o allow t h e normal ground sense circuitry t o s e t t l e down. When t h e 1 second pulse a t U1 ended, K q and K2 a r e a c t i v a t e d and K1 a n d K3 opened. The trailing e d g e of t h e 1 second a t U1-9 triggers a 20 m s e c pulse a t U1-16 which will s t a r t t h e n o r m a l c y c l e of t h e Hipot Tester. R15 i s used t o adjust t h e timing of t h e fail pulsing signal. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com A8 REMOTE CONTROL FUNCTIONAL DESCRIPTION The A8 R e m o t e Control contains two options: AUTOMATIC RESET DIGITAL REMOTE CONTROL The AUTOMATIC RESET option is supposed t o g e n e r a t e a short duration FAIL a n d RESET pulse a f t e r a failure is l a t c h e d in t h e A21 Control Logic Board. A t t h e end of t h e FAIL pulse t h e system is completely r e s e t if no r e s t a r t i s a t t e m p t e d . The DIGITAL REMOTE CONTROL option provides optical isolated control and monitoring of t h e main functions of t h e unit. The inputs are: START and RESET, SELECT A and t h e eutputs are: READY, TEST and FAIL (ALARM). There are t w o revision level boards, D a n d F. Revison D provides high a c t i v e c u r r e n t driven inputs (25mA) a n d low a c t i v e TTL outputs. Revision F provides low a c t i v e TTL inputs and l o w a c t i v e TTL outputs. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com CIRCUIT DESCRIPTION AUTOMATIC RESET OPTION While on TEST, a FAIL produces one s h o t negative pulse in U4. The falling edge produces one s h o t pulse U5, t h i s pulse drives t h e a l a r m through pin B with Q2 and r e s e t s t h e s y s t e m through t h e board pin 5 with U1. A t t h e end of t h e pulse U5, t h e system is r e s e t and t h e a l a r m is off. U1 also r e s e t s t h e system when r e m o t e r e s e t is produced. If t h i s option is n o t needed, A, B, and C , D jumpers a r e placed s o t h a t t h e FAIL signal d r i v e s t h e a l a r m as normal and t h e r e s e t from t h e r e m o t e goes directly t o t h e RESET line. OPTICAL ISOLATED C O N T R O L This p a r t provides 3 inputs: RESET, START, and SELECT "A" a n d 3 outputs: READY, TEST, and FAIL. The input c u r r e n t r e q u i r e m e n t s are: REV P HIGH LEVEL: LOW LEVEL: REV -D 40 pA @ +5V HIGH LEVEL: 1.6 mA f o r 0.4V LOWLEVEL: 18mA @ +5V 0mA The output c u r r e n t capabilities are: HIGH LEVEL: LOW LEVEL: 2.27mA @ +5V 2.27mA m a x @+5V When U3 is driven, a r e s e t signal is produced at pin 5 of t h e board e i t h e r d i r e c t l y through C, D jump or through U1 when t h e a u t o m a t i c reset o p t i o n is in. When U2 is driven, a s t a r t signal goes o u t through pin 9 of t h e board. When U9 is driven, t h e v o l t a g e a t pin 5 of U9 is low a n d Q1 does n o t drive t h e reaiy K1 so t h e c o n n e c t i o n is t h e o n e shown "stand by" a n d A rise t i m e and t e s t t i m e sare s e l e c t e d . If U9 i s n o t driven pin 5 of U9 g o e s high and $1 driven a c t i v a t i n g t h e r e l a y , s o B r i s e t i m e and t e s t t i m e a r e s e l e c t e d . . When GROUND TEST s i g n a l through pin 1 0 i s low, U6 is a c t i v a t e d and a low l e v e l is available from pin L of t h e board t o t h e r e m o t e connector. When TEST is low, t h r o u g h p i n l l , in o t h e r words, when a TEST is in progress U7 is a c t i v a t e d and a low l e v e l is available f r o m pin M t o t h e r e m o t e connector. When U8 is a c t i v a t e d w i t h t h e FAIL signal e i t h e r f r o m pin 12 or pin B when t h e a u t o m a t i c reset o p t i o n is used, a low l e v e l i s available f r o m pin N t o t h e r e m o t e connector. The r e m o t e controller's 5 V a n d GND a r e f e d through pins K and 1 5 respectively. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com REMOTE C O N T R O L OPTION 25 PIN C O N N E C T O R ASSIGNMENT G N D (ISOLATED) 13 RESISTANCE G N D (CHASSIS) 15 i?C/rC EXT V REF 17 REM EXT I T R I P 18 RESET EXT V TEST 19 START E X T V RISE 20 V OUT 21 I OUT 22 E X T IR O U T IR O U T - + 5 v (REMOTE) FxmSY TEST 23 FAILURE 25 SELECT A Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com A l l UNDER C U R R E N T AND HANDS O F F OPTION FUNCTIONAL DESCRIPTION The undercurrent option enables t h e detection of a minimum amount of current required during a hipot t e s t . If not, i t is interpreted t h a t t h e device under test is not connected and a failure and reset signal a r e produced. The hands hipot t e s t , this option the remote off option requires t h e s t a r t signal t o be held down during a o t h e r w i s e a failure a n d r e s e t signal a r e produced. Even when is used with t h e A8 R e m o t e option, t h e s t a r t signal given by controller has t o be held down during a test. CIRCUIT DESCRIPTION The A l l board contains t h r e e circuits: t h e power supply, t h e under c u r r e n t detection a n d t h e hands off. POWER SUPPLY Through pins 1 0 a n d 11 w e f e e d 1 8 VAC t o t h e full wave bridge r e c t i f i e r C R l , 2, 3, 4. C1 a n d C 2 are t h e filtering capacitors and t h e regulator 7815 provides t h e +IS\', while U4 on Q1 combination provides t h e -15V. The operation of t h i s combination i s t i e d up with t h e performance of t h e +15V regulator a n d t h e precision of R2 and R 3 because pin 2 of U4 i s obligated to b e practically zero. - UNDER C U R R E N T T h e start s w i t c h is c o n n e c t e d b e t w e e n pin N ENABLE of t h e board and t h e pin 9 READY of t h e board. This READY signal i s low if t h e chassis ground test passes, a n d only t h e n w e c a n produce a low level ENABLE when t h e start s w i t c h i s Gepressed. Depressing t h e switch also produces a high level a t pin 3 of U1 while t h e switch is depressed. This high level temporarily d r i v e s t h e transistor Q7 t o produce a start pulse o u t from pin 8 of t h e board t o s t a r t t h e hipot test. . The TESTING signal is f e d through t h e pin 12 of t h e board and goes low when t h e hipot t e s t i n g begins. While this signal is high, in o t h e r words, not performing a t e s t , t h e transistor 4 3 is driven through CR13 continuously holding down t h e c a p a c i t o r C10. Also through CR14, pin 2 of t h e t i m e r U2 is held high so n o pulse c a n b e produced o u t of it. The C a p a c i t o r C 1 0 i s p a r t of t h e t i m e r U3 and i t s charging up t i m e determines t h e l e n g t h of t h e pulse produced by U3. U3 i s triggered when t h e TEST signal g e t s low, in o t h e r words, when t h e test begins a n d a high level i s produced a t t h e o u t p u t (pin 3) of U3. That output will remain Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com high until t h e c a p a c i t o r C 1 0 c h a r g e s up t o 2/3 t h e +SV supply b u t e v e n though t h e c a p a c i t o r C10 is now f r e e t o c h a r g e up b e c a u s e t h e TEST signal is n o t driving through C R 1 3 during a t e s t , t h e c o m p a r a t o r US has t o drive $3 a f t e r a c e r t a i n t i m e a n d d i s c h a r g e C10 o t h e r w i s e t h e output of U3 will f a l l t r i g g e r i n g U2 t i m e r which gives a pulse driving t h e FAIL a n d RESET of t h e s y s t e m . In o t h e r words t h e c o m p a r a t o r U3 has t o s e n s e t h e p r e s e n c e of c u r r e n t higher t h a n t h e tripping point b e f o r e C10 c h a r g e s up t o 2/3 of t h e +SITsupply. The tripping value i s f e d through pin R of t h e board. T h e return of t h e a m m e t e r is f e d through pin E of t h e board and t h e c u r r e n t produces correspondent p o t e n t i a l a c r o s s R 4 t o b e c o m p a r e d t o t h e tripping value. HANDS OFF If during a test t h e s t a r t s w i t c h i s r e l e a s e d t h e ENABLE line will g o up a n d t h e t r i g g e r input of U1 will n o t hold t h e o u t p u t 3 of U1 high anymore. The falling transition will t r i g g e r U 2 through C16 producing a FAIL and RESET pulse. Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com UNDER C U R R E N T FAILURE S E T The under c u r r e n t d e t e c t f e a t u r e requires a minimum of three (3) seconds t o react. T h a t i s t h e t e s t e r will not sense for under current until t h e high voltage has r e a c h e d a c e r t a i n voltage. To s e l e c t t h e under current fail point: 1. S e t under c u r r e n t p o t t o maximum counter-clockwise position t o s t a r t off. 2. Follow t h e procedure for s e t t i n g t o t a l current fail point. R e m e m b e r , FAIL will be indicated a t all c u r r e n t levels below s e l e c t e d level. 3. T h e s t a r t switches must b e depressed and held d u e t o t h e HANDS O F F OPTION used in conjunction. 4. Under c u r r e n t failure is indicated by: 5. 6. a. Fail light c o m e s on f o r o n e second b. Audible a l a r m is on f o r one second c. High voltage automatically shuts down d. Tester resets itself Ground f a u l t failure i s indicated by: a. Fail light is on f o r o n e second b. Audible a l a r m on f o r one second c. High voltage automatically shuts down d. Ready l a m p goes off e. Requires manual r e s e t High c u r r e n t (over c u r r e n t ) failure is indicated by: a. F a i l l a m p continuously on b. Audible a l a r m continuously on c. H i g h v o l t a g e s h u t s down d. Requires manual r e s e t Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com - ASSEMBLY DESCRIPTION: A25 HANDS-OFF/CURRENT FAIL ASSEMBLY NUMBER: 0043Z-02 REV. C RATING AND/OR ITEM REFERENCE DESCRIPTION MFR. NUMBER ................................................................... 00433-02 ROD-L RAW PCB 1 A25 .10uf CAPACITOR 2 C1 lOOOpf CAPACITOR 3 C2 CAPACITOR .Oluf 4 C3-9 5 C10-11 CAPACITOR lOuf 25V CAPACITOR .47uf 6 C1Z DIODE IN914 7 CR1.2 ZN2222 TRANSISTOR 8 Q1-4 RESISTOR, CARBON 47K 1/4W 5% 9 R1-5 1OOK RESISTOR, VARIABLE 10 R6-10 10M 1/4W 5% RESISTOR, CARBON 11 R11,12 10K 1/4W 5X RESISTOR, CARBON 12 R13,19,23,24 4.7K 1/4W 5% 13 R14-16.20-22,25 RESISTOR, CARBON 1K 1/4W 5% RESISTOR, CARBON 14 R 1 7 RESISTOR, CARBON 3K 1/4W 5% 15 R18 RESISTOR, CARBON 56K 1/4W 5'L 16 R26 17 U1 IC NE556 18 UZ IC LM311 IC 74121 19 U3 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com QTY. - PARTS LIST ROD-L ELECTRONICS, INCASSEMBLY DESCRIPTION: A24 OHM SENSE BOARD ASSEMBLY NUMBER: 00434-02 REV. C ITEM REFERENCE ------------------1 A24 2 Cl 3 C2,C16 4 C3-C6,8,9,11, 5 6 7 8 9 10 11 12 13 14 15 16 17 C12,15,17,18 C7 C10 C14 Rl,R9,RlO,R13, R14 R2 R3-RS R8,R12,R17 R6,Rll R7 R15 Rl6 Ul U2,U3 U4 ie us 19 Ql,Q2 20 CR1-CR4 2 1 Kl-K3 22 K4 23 C13 DESCRIPTION RATING AND/OR HFR. NUMBER 00434-02 ROD-L RAW PCB CAPACITOR CAPACITOR CAPACITOR 1Ouf 25V .33uf .Oluf CAF'ACITOR CAP?X ITOR CAPPICITOR RESISTOR, CARBON .OOluf .47uf .luf 4.7K 1/4W 5% RESISTOR, CARBON RESISTOR, CARBON RESISTOR, CARBON RESISTOR, CARBON RESISTOR, VARIN3LE RESISTOR, VARIABLE IC TIMER IC IC IC TRANSISTOR DIODE RELAY DOUG-RAND RELAY P & B N O T USED - 10M 1/4W 5% 1M 1/4W 5% 1M 3K NE558 7400 SN75452P NE555 ZN2222 IN4005 378992 HPl lD Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com QTY. - ROD-L ELECTRONICS, INC. - ASSEMBLY DESCRIPTION: AB REMOTE CONTROL LOGIC W / AUTO-RESET ASSEMBLY NUMBER: 00445-02 REV. F RATING AND/OR ITEM REFERENCE DESCRIPTION HFR. NUMBER PARTS LIST RAW PCB CAPACITOR CAPAC ITOR CAFAC ITOR CAPACITOR IC IC IC IC, TIMER 8 PINS IC, TTL HEX INVERTER IC IC RESISTOR, CARBON RESISTOR, CARBON RESISTOR, CARBON RESISTOR, CARBON RESISTOR, CARBON RESISTOR, CARBON RESISTOR, CARBON POTENTIOMETER RESISTOR, CARBON POTENT1 OMETER RESISTOR, CARBON POTENTIOMETER TRANSISTOR TRANSISTOR NPN RELAY . . DIODE . . . . QTY. 00445-02 ROD-L lOuf 25V TANT 6 . auf iov TANT .Oluf - 1 uf 10V TANT HllBl OR HllB3 SN74122 NE555 SN7416 747 7403 330 OHM 1/4W 1K 1/4W 5% 1OOK 1/4W 5% 2K 1/4W 5% 4.7K 1/4W 5% 20K 1/4W 5% 330K 1/4W 5% 1M 10K 1/4W 5% 1495 DPDT SVDC IN914 . . . . Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com 1 .. .. - ROD-L ELECTRONICS, INC. PARTS LIST ASSEMBLY DESCRIPTION: A11 UNDERCURRENT BOARD ASSEMBLY NUMBER: 00294-02 RATING AND/OR ITEM REFERENCE DESCRIPTION HFR. NUMBER ........................................................................ 1 2 3 4 ail C1,C2 C3 C4.6,8,9,11,12, C14.16 R A W PCB CAPACITOR CAPACITOR CAPACITOR ROD-L lOOuf 25V TANT 500uf 16V -01uf 1OOV CERAMIC CAPACITOR CAPACITOR DIODE DIODE FUSE TRANSISTOR TRANSISTOR TRANSISTOR RESISTOR RESISTOR RESISTOR RESISTOR luf 12V 4.7uf 12V 1 N4OO2 IN914 4 AMP 125V 2N6109 2N3904 2N2222 22 OHM 1 W 10% 4.64K 1/8W 1% 470 OHM 1/4W 1% 10K 1/4W 5% RESISTOR RESISTOR RESISTOR RESISTOR RESISTOR RESISTOR POTENTIOMETER IC 2.2K 1/4W 5iC 4.7K 1/4W 5% 470K 1/4W 5iC 2OK 1/4W 5% lOOK 1/4W 5% 1K 1/4W 5% 1HEG UA78 15 UA741 UA7805 00294-02 - NESSS Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com QTY. 1 2 1 8 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com Artisan Technology Group is your source for quality new and certified-used/pre-owned equipment • FAST SHIPPING AND DELIVERY • TENS OF THOUSANDS OF IN-STOCK ITEMS • EQUIPMENT DEMOS • HUNDREDS OF MANUFACTURERS SUPPORTED • LEASING/MONTHLY RENTALS • ITAR CERTIFIED SECURE ASSET SOLUTIONS SERVICE CENTER REPAIRS Experienced engineers and technicians on staff at our full-service, in-house repair center WE BUY USED EQUIPMENT Sell your excess, underutilized, and idle used equipment We also offer credit for buy-backs and trade-ins www.artisantg.com/WeBuyEquipment InstraView REMOTE INSPECTION LOOKING FOR MORE INFORMATION? 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