ROD-L M100DC 5.5-5 Operation & Service
Contents
1. An Under Current FAIL is indicated with a tone that is about one second long then the Hipot Tester resets itself Option 05 Hands Off FAIL signal is about two seconds long and then the Hipot Tester resets itself automatically Option 20 Ohm Sense FAIL emits beeps at about 1 to 2 per second until the reset button is pushed Also there are no TESTING nor FAIL lights This does not denote failure When Option 10 Audible Test Tone is installed in a Hipot Tester the alarm will sound pulses at 3 to 6 beeps per second whenever a TEST is in progress 2 12 Set Current Fail Point When the I SET switch is in the set position adjust the I dial on the rear panel until the desired setting is indicated on the current meter CW clockwise to increase 2 13 Preset Test Voltage With the V SET switch in the set position adjust the V dial to the desired setting CW to increase Be sure to return the SET switches to the RUN position 16 2 14 Preset Test Time Rise Time With the A B switch in the A position the A Test Time Pot can be adjusted CW to increase A TEST must be in progress to adjust for desired Ramp Rate rate of rise to full voltage Remember increasing the time will decrease the Ramp Rate The A test time pot is used to adjust for desired dwell time at full voltage These adjustments may reqire starting the TEST several times The B times are adjusted with the A B switch in the B position f 2 15 Aut2. AC DC switch is switched to AC and the Start button on the DC Hipot Tester is pressed the AC Hipot begins a test and the high voltage is connected to the Front Panel Receptacle of the DC Hipot Tester 18
3. B switch chooses A or B Ramp Rate and Test Time Select switch Optional chooses different parameter sets Chassis Ground for DUT chassis ground connection Sense jack If the instrument is found to be damaged upon receipt notify the carrier and Rod L Electronics immediately 2 3 Installation The Rod L DC Hipot Test Instruments are suitable for either bench or rack mounting To rack mount the instrument use Option 15A The instructions for rack mounting are on page 39 11 Pigura 2 2 M100 0DC Rear Panel controls Vset set 232 i 6 8 a0 aif E run spur test 09 test tige aa ne AC Fuses FL F2 3A 115VAC 1 SA 230VAC Voltage chooses 115VAC or 230VAC input Selector Switch be sure to install correct fuses AC line power in receptacle HV In connector for AC Hipot Interface HV Out connector for Ground Tester Interface AC Hipot Chassis connects Gnd of DC Hipot to Gnd of AC Hipot Gnd Sense jack to enable AC Hipot Test to start Chassis Ground for DUT chassis ground connection Sense jack Remote connector Optional for Remote Interface Hands Off con s Optional for Hands off palm switches V SET pot for voltage programming I SET pot for current trip programming V SET switch in set position allows voltage programming pot to be adjusted and viewed on the voltage meter 31 I SET switch in set position allows current trip fail point programming pot to be adjusted and viewed on the
4. current meter 32 Ground jack for connecting tester s chassis together 33 A Test Time Adjustment potentiometer 34 B Test Time Adjustment potentiometer 35 A Voltage Rise Ramp Rate Adjustment potentiometer 36 B Voltage Rise Ramp Rate Adjustment potentiometer 37 Burn Switch enables DC Hipot to perform destructive test Note that on the M120DC all controls are on the Front Panel 2 4 Power Requirements The Rod L DC Hipot Testers require a power source of either 115 or 230 volts AC 44 to 66 Hz single phase Prior to applying power to the instrument ensure the AC line voltage selector switch on the Rear Panel is in the appropriate position When using the Rod L Hipot with other Rod L Testers the Ground Sense Circuit often works better when the Rod L Testers are connected to a line input with the same ground circuit 12 2 5 Operating Controls The front panel and rear panel controls and indicators for the M100DC are shown and briefly described in Figures 2 1 and 2 2 They would all be on the Front Panel of the Model M120Dc 2 6 Storage It is strongly recommended that the DC Hipot be packed as if for reshipment Environmental conditions during storage and reshipment should be as follows A Maximum temperature 167 F 75 C B Minimum temperature 40 F 40 C 2 7 Repackaging for Shipment If possible use the original shipping container and packing materials Otherwise A Wrap the DC Hipot in
5. DC OPERATION AND SERVICE MANUAL 60003 07 Revised 3 April 1998 ROD L ee HAMILTON COURT MENLOPARK CALIFORNIA 94025 ELECTRONICS INC 650 322 0711 e 800 548 6305 OUTSIDE CALIFORNIA FAX 650 326 1993 CERTIFICATION Rod L Electronics Inc certifies that this instrument was thoroughly inspected and tested and found to meet its published specifications when it was shipped from the factory WARRANTY AND ASSISTANCE This Rod L Electronics Inc instrument is warranted against defects in materials and workmanship for 5 years following date of delivery Rod L Electronics Inc will repair or replace this instrument at our discretion if proven to be defective during the warranty period provided it is returned to Rod L Electronics Inc Rod L Electronics Inc recommends that this instrument be calibrated on a 6 month cycle Under no circumstance should a 12 month cycle be exceeded This warranty remains valid providing calibration is performed at least once every 12 months by Rod L Electronics Inc This warranty is nontransferable and is offered solely to the purchaser This warranty is void if the instrument has been changed modified or otherwise altered without the expressed permission of Rod L Electronics Inc Rod L Electronics Inc is not liable for consequential damages No other warranty is expressed or implied Returned Material Authorization must be obtained from Rod L Electronics Inc before re
6. N The power ON lamp should illuminate J The green READY lamp should illuminate NOTE If the lamp in the power switch remains off check for proper AC line voltage If the lamp in the power switch is ON and the green READY lamp remains off check the CHASSIS GROUND SENSE connections K With the READY lamp lit push the START switch The HV ON lamp will begin flashing While the HV ON lamp is flashing quickly disconnect the CHASSIS GROUND SENSE cable The FAIL lamp should light and the alarm sound indicating a Safety Ground failure 15 WARNING DC high voltage is present at the front panel HV receptacle block and the rear panel cylindrical connector when the HV ON lamp flashes L Push the RESET switch to extinguish the FAIL lamp and the alarm M Reconnect the CHASSIS GROUND SENSE cable per step H The READY lamp should re illuminate N Push START The HV ON lamp will begin flashing and the OUTPUT VOLTAGE meter will indicate the controlled rise to the preset voltage The HV ON light will remain flashing until the test time has expired or a test failure is detected 2 11 Fail Indications Over Current failures are represented with the FAIL lamp and audible alarm coming on continuously until the RESET button is pressed Ground Continuity faults are also depicted with the FAIL lamp and audible alarm coming on continuously and additionally the READY lamp turns off The Hipot Tester must be manually RESET
7. ard RESET after failure required to perform next test Visually displayed Programming of DC Current Trip Point and High Voltage Adjustable linear Ramp Up of High Voltage Complete discharge of Device Under Test DUT High Voltage Output closed to Ground when not in test Supplied Equipment A B C DC Hipot Test Instrument Power Cord three pronged 6 ft Chassis Ground Sense cable 3 ft Kit for HV connector mate Operation Service Manual Extra fuse set for the alternate Ac supply voltage Section 2 INSTALLATION AND OPERATION The exclamation point within a triangle is intended to tell the user that important operating and servicing instructions are in the papers that are provided with the equipment WARNING Verify that the voltage selector switch is positioned and the correct power supply cord is selected to match the voltage source WARNING panel HV OUT INTERFACE connector To reduce the risk of shock this plug and cover must be used whenever the high voltage interface cable is not installed In addition the high voltage interface cable must only be used when both ends are terminated at their respective equipment connectors To reduce the risk of electric shock the equipment must not be operated with one end not terminated 2 1 General Information This section contains the recommended procedures for unpacking inspection installation and operation 2 2 Unpacking and Inspection Reta
8. bilities and specifications Section 2 Installation and Operation Section 3 Theory of Operation Section 4 Maintenance and Service Section 5 Options Section 6 Parts Lists Schematics and Diagrams 1 2 DC Hipot Tester General Description and Test Features The Rod L DC Hipot Test Instruments are essentially the same The M100DC is the base model and all the controls for the M120DC are on the front panel All are rugged self contained testers designed for production and or laboratory use The DC Hipot Tester s purpose is to provide a means for evaluating the dielectric withstand capabilities of electric and or electronic devices when subjected to abnormally high input voltages This is accomplished by monitoring for breakdown in the form of arcing corona or exceeding of the maximum allowable current determined by the positioning of Current Trip Potentiometers The DC Hipot Testers perform a DC High Voltage leakage and breakdown dielectric withstand test They test and display DC current and voltage Specifications are given in Table 1 1 These models also conduct a low current Ground Continuity Test concurrent with the Hipot Test to ensure that the Device Under Test DUT is capable of effectively shunting the leakage current produced by the high voltage to earth ground For operator safety this CHASSIS GROUND SENSE connection must be made with a low resistance return on the DUT Without this connection the t
9. ester cannot enter the READY state Both the Chassis Ground and the power cord Safety Ground of the DUT are monitored and stressed electronically If either ground fails during the test the Hipot Tester automatically goes into failure mode i e high voltage is shut down and there is a visual and audible alarn NOTE The CHASSIS GROUND SENSE circuit is intended to act as a safety ground and ground continuity test for devices employing a chassis ground plane For testing of two wire devices or three wire devices that are exempted by the pertinent regulatory agency from performing a chassis ground continuity test the CHASSIS GROUND SENSE connection can be made to either Pin 2 of he rear panel high voltage connector or to any appropriate hipot chassis point e g handle screw etc Connection of the DUT to the Hipot Tester is made via the front panel High Voltage Receptacle DUT s that terminate in a three prong cord or the rear panel High Voltage Connector all others All models incorporate a rapid automatic electronic shutdown circuit to turn off the high voltage within 2ms two milliseconds after a fault To prevent turn on surges the high voltage has an electronically controlled rate of rise adjustable from 50V sec to 5000V sec 1 3 Product Specifications Table 1 1 Table 1 1 DC Hipot Tester Specifications Test Current 40 microamperes uA to 10 milliamperes mA full scale F S Test Voltage User spec
10. heavy paper or plastic before placing it in the shipping container B Use plenty of packing material around the instrument and protect the front panel with cardboard or plastic bubble packing Protect the instrument with two inch rubberized foam pads placed along all surfaces of the instrument or with a layer of excelsior about 6 inches thick packed firmly against all surfaces of the instrument C Use a strong well sealed shipping container 350 lb in bursting test D Mark the container FRAGILE DELICATE INSTRUMENT 13 WARNING This instrument to be used ONLY in THREE WIRE GROUNDED OUTLETS It is recommended that periodic checks of the outlet and the ground wire be made to ensure operator safety 2 8 Initial Installation and Power Up The Rod L DC Hipot Tester is shipped configured for 115 VAC Operation Appropriate fuses 1 5 ampere are also provided for 230 VAC operation Before applying 230 VAC power to the instrument ensure that the correct fuses are installed see Fig 2 2 then ensure that the Voltage Selector Switch on the Rear Panel is in the correct position CAUTION Changing Fuses Turn off the Hipot Tester and DISCONNECT THE POWER CORD Then install the proper fuses Otherwise damage to the instrument and or operator could result Factory Settings N ice The Rod L DC Hipot Tester is shipped with the following factory selected settings unless otherwise requested
11. ified up to 5000 VDC Voltage Rate of Rise 50 V second to 5000 V second adjustable High Voltage Test Time 1 second to 90 seconds adjustable High Voltage Shutdown Within 2 milliseconds after a fault or end of test is detected electronic shut down circuits Initial Turn On Period Requires 2 seconds normally for safety ground test before starting Hipot test Safety Ground Continuity Reject level 0 1 to 0 59 adjustable 0 019 Accuracy Current and Voltage Monitoring Better than 1 Resolution Output Voltage Control 2 5V Resolution Output Current 4 Microamperes HA Input Power 115 230 VAC 44 66 Hz 360 watts max Ripple 1 at full load 0 05 at zero current Regulation 0 05 at full load Environmental Operating Temperature 0 to 50 C 32 to 122 F Exterior Color Mint grey and Olive Grey or Black Weight 24 lbs 10 9 kg net 29 lbs 13 15 kg shipping Dimensions 16 75 x 13 25 x 5 5 inches 43 x 34 x 14 cm Safety Features A B C D E F G H I J K L Chassis Ground Sense Safety ground required to begin a test Loss of safety ground terminates test cycle Front panel receptacle accepts 3 pronged power cord from DUT providing maximum safety and significantly reduces time required to perform the test Recessed START button Visual alarm at failure Audible alarm at failure continuous tone Fast electronic shut down of DC High Voltage H
12. in the shipping carton and the padding material Rod L Electronics may assess a charge for a new shipping container if an instrument is not received in the original container A shipping carton that appears damaged should be inspected and unpacked with the carrier s agent present Inspect the instrument for damage scratches dents broken knobs or meters etc 10 BW NE Ont A S Figure 2 1 M100DC Front Panel Controls Mi100BC Alarm emits audible signal on failure V SET lamp on when V SET switch is in set position off when V SET switch is in run position READY lamp on when ready to begin Hipot Test gt I SET lamp on when I SET switch is in set position off when I SET switch is in run position TESTING lamp on during DC Hipot Test AC lamp on when AC DC switch is in AC position FAIL lamp on if DC Hipot Test fails Current meter indicates current in DC mA wA with Option 09 inactive during AC Hipot Test indicates fail point when in Ts SET mode HV ON lamp flashes when 40VDC or more is present inactive during AC Hipot Test Voltage meter indicates volts in DC kV inactive for AC test indicates max DC kilovolts when in V SET mode HV Output Block for input to DUT where DC or AC HV is applied receptacle LinePower switch turns on and indicates line power input START switch initiates DC or AC Hipot Test if READY RESET button resets Hipot DC AC switch chooses DC Hipot or the input from AC Hipot A
13. in writing by the customer Table 2 1 Factory Settings TEST MODE SWITCH NAN HBU Voltage 1500 VDC 1500 VDC Maximum Current 5 mA 5 mA Test Dwell Time 15 sec 2 sec Ramp Rate 200 V sec 1000 V sec Input Line Voltage Select 115 VAC 14 2 10 Operational Check This is an operator oriented procedure which allows operational check of the Rod L DC Hipot Test Instrument without test equipment Refer to Section 4 of this manual for a complete calibration procedure Place the instrument in a sturdy position preferably on an insulated surface with all surrounding metal conductors grounded Position the power cord so as to avoid being walked on or pinched by other equipment A Set LINE POWER switch to OFF B Validate that fuses Fl and F2 are the proper values C Verify Input Line Voltage Select Switch position D Connect AC Power Cord to AC receptacle on the rear panel E Connect the AC Power Cord to a 115 VAC 10 power source F Ensure that the V SET and I SET switches are in the RUN position Place the AC DC switch in the DC position G Verify Remote Local Switch is in Local position H Connect low current Ground Sense Cable to the CHASSIS GROUND SENSE terminal on the front panel Then clip the other end of the cable to the Hipot Tester chassis the handle is a convenient point When Option 09 Low Current is present the alligator clip end has to be connected to HV Return instead I Set LINE POWER switch to O
14. omatic Test Procedure Connect the Device Under Test DUT to the Hipot Tester output voltage receptacle Then connect the Chassis Ground Cable between the DC Hipot Tester and an electrical ground of the DUT If the READY light goes on a solid ground connection is sensed and the testing may proceed if the READY light does not go on the ground needs checking When the READY light comes on the DUT is ready to be hipot tested with the START signal coming from the REMOTE or the START Switch NOTE If the DC Hipot Tester is operated at maximum voltage and maximum current simultaneously then the operation duty cycle must not exceed 25 where duty cycle shall be defined as operation time x 100 operation time rest time 17 2 16 Using the DC Hipot Tester with a Rod L ac Hipot See the drawings at the rear of this manual s 01076 01 01077 01 and 01076 01 One of these drawings should enable setting up of the DC Hipot Tester with a Ground Continuity Tester and or AC Hipot Tester Ensure the Testers are connected to the same AC Line Power source The Ground Tester Hipot Tester Interface Cable is connected from the AC Hipot Tester to the connector on the Rear Panel of the DC Hipot Tester labeled Ac Hipot which is the input HV connector This ties the high voltage Start and Reset signals from the AC Hipot Tester so that the DUT need be connected only into the Front Panel Receptacle of the pc Hipot Tester Then when the
15. turning this instrument for warranty repair Transportation costs for return of defective instrument for warranty repair must be prepaid and borne by the customer Rod L Electronics Inc will assume the cost of transportation when returning Warranty Repaired Equipment to the customer Such method of transportation shall be at the discretion of Rod L Electronics Inc Section 6 Page Bills of Materials Schematics Diagrams BOMS FOC ASS Vik Sy a aes uae Meg 4 8 o kia wn at ed eck Saree Oe ear eaS 44 Wiring Diagrams Assembly Prints and Schematics for all PCBs in same order as BOMS d esse 78 List of Figures and Tables Table 1 1 DC Hipot Tester Specifications 8 Figure 2 1 M100DC Front Panel Controls 11 Figure 2 2 M100DC Rear Panel Controls 606 12 Table 2 1 PeCeOry Settings 24 64 se oe Buti ad Sart 14 Figure 3 1 Instrument Functional Block Diagram 20 Figure 3 2 RV Generator Functions lt u se da biel G4 21 Figure 3 3 HV COREE OL Functions s 6 3 reac a ew 444 ww BY 21 Figure 3 4 DC Hipot Test Times sssoseros 24 Figure 3 5 General Control Functions s ssses 25 Table 4 1 Fault Location Chart a sassssessss et 34 Section 1 INTRODUCTION 1 1 Scope of This Manual This publication provides operating and servicing instructions for the Rod L Electronics Inc Models M100DC M120DC and M130DC Hipot Test Instruments It is divided into six sections Section 1 Introduction capa
Download Pdf Manuals
Related Search