Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
1. Knurr case removal. 2. Rittal case removal. 3. A/D board, I/O board, and controller board access instructions. 4. Voltage Busline and Crystal Checkout. 5. Open Ground fault indicator lamp lit. Open Ground circuit disable instructions for 6kV, 12kV, 24kV, D-Series testers. 6. Hipot Trip fault indicator lamp lit. 7. Hipot Current Bar display not present. 8. CRT blank when PTT button depressed/surge mode. 9. Hipot voltage bar display not present. 10. Seconds/div, volts/div, A/div, or function display incorrect. 11. Printer does not work properly. 12. No Baker logo displayed. 13. No Hipot voltage at test leads. 14. No surge voltage display. 15. Voltage drops when PTT button released. 16. Zero Start Interlock does not engage. 17. PI Value or current measurement inconsistent. 18. Display locked up after self-test. 19. Display unreadable and flashes on/off, does not initiate self-tests.
Handle Assembly for Rittal Case 3 Baker Instrument Company The Measure of Quality
measuring if the supply that is defective is restored. If not, replacement of the Power Supply board would be required. If a board is found to be loading a supply then any component on that board that is tied to the supply can be suspect. To narrow to the component level will require a one component at a time isolation from the supply via desoldering. 1. Loss of or loading of the 12 volt supply will cause no output in the surge mode when the PTT button is depressed. The trace will be visible at its most right upper position on the CRT and will be non-adjustable with the vertical or horizontal position potentiometers. Surge trigger will be present, but no surge waveform will be attainable when the PTT is engaged. In the Hipot mode, a Hipot trip LED will illuminate and the voltage bar will show a six (6) division up and the current bar will be extended off the screen. No Hipot output will be attainable and numeric display for voltage and current will stay at zero (0). 2. Loss of or loading of the +12 volt supply will cause a total non-operation of the tester. There will be no display upon power up or self-tests or no change when any of the output controls are used. 3. Loss of or loading of +5 volt supply will cause a total non-operation of the tester. There will be no display upon power up or self-tests or no change when any of the output controls are used. 4. Loss of crystal frequency X1 on the A/D board will cause the loss of positional trace control with the surge waveform in the upper right quadrant. In the Hipot mode, after PTT is depressed hipot voltage and current bars will be the same as in step #1 but numeric display for voltage will show 11950 volts and the current will show 996.0 A. Replace X1. 5. Loss of crystal frequency on U6 on the A/D board will show an erratic unstable sawtoothed pattern once the PTT button is depressed and also will fail the A/D memory self-test upon power up. Replace U6. 6. Loss of crystal frequency on XTA1 on the Controller board will cause total nonoperation of the tester. There will be no display upon power up or self-test, or no change when any of the tester controls are used. Replace XTA1. 7. Loss of frequency on Y1 on the Controller board will cause a blinking effect on the tester CRT with no recognizable lettering or numeric display. Tester will not initiate it s self-tests nor will any controls have any change on the display. Replace Y1.
Unit D6000 D12000 DS206 DS212 Lower 100 Volts AC 100 Volts AC 220 Volts AC 220 Volts AC
Line Voltage Range Upper 120 Volts AC 120 Volts AC 250 Volts AC 250 Volts AC
7. Check signal at Q1 collector on the Power board for a .4 volt ripple, if not replace Q1. 8. Check U9 pin 3 on the I/O board for a 0 volts and U9 pin 4 for five (5) volts DC, if not replace U9. 9. Check Q6 on the I/O board for a collector to emitter short, if so then replace Q6. 10. Check for a shorted Open Ground LED.
Open Ground Circuit Disable instructions for 6kV, 12kV, and 24kV D Series Testers.
In a testing environment where no ground can be supplied to the surge tester, the following steps can be done so that the tester will operate. Read and follow these instructions prior to proceeding. 1. Locate and remove the two (2) M4 x 7mm black hex head screws on the front panel. The first is located above the function switch knob, and the second is below the seconds/division knob. 2. Grasp the function switch knob in one hand and the seconds/division knob with the other hand and pull away from the tester. By doing this the I/O board will no unplug from the Motherboard. 3. Locate and remove the two (2) M4 x 7mm black hex head screws on the front panel. The first is above the open ground lamp socket and the second is below the horizontal potentiometer knob. 4. With your fingertips, grasp behind the front panel A/D board assembly and pull away from the tester. By doing this the Power board will now unplug from the Motherboard. Caution: DO NOT damage the potentiometers or cause fractured solder joints at the legs of the potentiometers. 5. Remove the remaining printed circuit board, the Controller board. Grasp at the edges of this assembly and pull away from the testers front panel. 6. For the 15kV and 24kV only locate and remove four (4) Phillips screws that secure the blue top cover to the case assembly. Two (2) will be located on the left side and two (2) will be located on the right side. This step applies to 15kV, and 24kV models only. Remove the top cover. Skip to step 10. 7. For 6kV or 12kV models manufactured before August 1998 which are enclosed in a blue shock mounted Knurr design case, removal of the inner chassis from the case will be necessary. If enclosed in a Tan Rittal design case proceed to step 9. 8. Unlock the rear cover latches and unhinge the rear cover. Locate and remove four (4) Phillips M4 x 10mm screws. Two are located on the left side and two are located on the right side. Reinstall the rear cover. Locate and remove the front panel four (4) M5 x 16mm black hex head screws. Two are on the extreme left edge and two are located on the extreme right side of the front panel. Grasp the CRT bezel in one hand and the test leads with the other hand and pull straight out of the Knurr case. Skip to step 10.
9. If a 6kV or 12kV model was manufactured after August 1998 and is enclosed in a tan Rittal design case locate six (6) gray hinge covers on the top cover. With a small slotted screw3driver pry the covers so that six (6) Phillips screws that secure the top cover are visible. Remove all six (6) screws to remove the top cover. 10. Locate the card cage that houses the Power and Signal Boards. 11. Remove the top cover of the card cage. It is secured by eight (8) M4 x 7mm black hex head screws and two (2) M4 kep nuts. Remove this hardware. Position one hand inside the card cage and lift up at the back end to remove the top cover. 12. Locate on the Motherboard an insulated jumper wire J7 that is positioned between connectors J2 and J3. If you intention is to run the tester without a supplied ground permanently, set step 14. 13. If your intentions is to move the tester between environments that do and do not have a supplied ground, see step 15. 14. Remove jumper at J7. 15. Remove jumper at J7. Install two 22 gauge wires one at each connector hole at J7 and exit these wires from the right side of the card cage. The length of these wires should be long enough to reach the front panel. Tie wrap and secure these wires along the right side of the card cage. Obtain a two-position toggle switch that has a common/ NO and NC contacts. Drill a hole between the leads energized light and the right side of the card cage and mount this toggle switch to the front panel 16. Solder the wires from the J7 connector to the toggle switch. This will now enable you to more easily disable the open ground fault detection circuit. Note: The Open Ground LED will still be lit when the tester does not sense a ground connection, but now the tester will operate.
measuring across resistors R1 through R10. Good measurements will be 70K ohms or higher. Replace any SCR s found to be shorted. 4. Check U2 pin 7 on the I/O board, this should be a zero (0) volts DC, if at five (5) volts DC then replace U2 and U7. 5. Check Q3 on the I/O board for a collector to emitter short, if so replace Q3. 6. Check for shorted Hipot trip lamp on the A/D board, if so replace D3.
5. Check U25 pin 4 on the A/D board for the same increase in voltage, if not present, check connection between U3 pin 6 on the I/O board and RPK1 pin 16. Then check RPK1 pin 16 to RPK1 pin 1 for 47K ohms resistance. If open replace RPK1. 6. Check U25 pin 8 for a 2.5-volt positively pulsed waveform with a frequency of 200ms with the tester set at 6kV output with no current deflection on the CRT. If not present check U25 pins 1, 15, 16. Only pin 1 should have a signal which should be a 5-volt waveform pulsing negatively to zero (0) volts every 200ms. If these signals are present at pins 1, 15, and 15 with a measured input at U25 pin 4 then replace U25. 7. Check U22 pin 9 for a 5-volt positively pulsed waveform with a frequency of 200ms. Set the tester to 6 kV output with no current deflection on the CRT. If not present replace U22. 8. Check U23 pin 7 for the same signal. If not present, replace U23.
division settings such as 100A, 10A, or 1A. Possible failures can include a logic gate stuck high or low such as U6 or mux U17. Check the pull up resistors listed above. Check that switch S3:A grounds sequentially as it is rotated. 4. The function display is controlled by switch S3:A on the I/O board and pull up resistors R42, R12, and R14. This is in turn connected to a series of Inverters at U6. A typical fault will be seen as the CRT display not matching the function control knob. Possible failures can include a logic gate stuck high or low such as U6, U5, mux IC s U17 or U15. Check pull up resistors listed above and also pull up resistors at RPK3 pins 8 and 9. Check that switch S3:A grounds sequentially as it is rotated.
2. See Voltage Busline and Crystal Checkout procedures and correct any voltage Busline or crystal output and frequency problems. 3. To determine if the CRT tube is defective a check is needed to ensure that +12VDC is present on P1 CRT pin 7 and then pins 1 and 10 are grounded. 4. Check P1 CRT pin 2 with a digital multimeter, this measurement will be adjustable with the intensity potentiometer, it should range from 14VDC to +5.6VDC, if not check R9 on the A/D board and its connections. 5. Check P1 CRT pin 3, this measurement should be approximately 110VDC. 6. Check P1 CRT pin 4, this measurement will be adjustable with the intensity potentiometer and will range from 110VDC to +5.6 VDC, if not check R9 on the A/D board. 7. Check P1 CRT pin 6 for a 4-volt square waveform pulsing negatively to zero (0) volts. Repetition rate will be every 30S and the negative duration will be 4S. If signal is not present trace back to U24 pin 4 and then to U1 on the Controller board. Replace if necessary. 8. Check P1 CRT pin 9 for a 5-volt positively pulsed waveform. Repetition rate will be every 17mS and the positive duration should be 500S. If not present, trace signal back to U1 on the Controller board. Replace if necessary. 9. Check P1 CRT pin 8 for 2.4 volt data entering from the Controller board U27 pin 13, replace if necessary. 10. If above signals and voltages are correct, replace CRT tube.
4. Check at the terminal block adjacent to the high voltage transformer T1 at the orange wire for the same AC voltage starting with the output control to full counterclockwise position and than at output. If not present, see the section on the Zero Start Interlock does not engage. 5. Locate the secondary T1 high voltage transformer wire connected to D3 anode on the Stack board and disconnect. Connect a P6015A high voltage scope probe or equivalent to the T1 secondary wire with the probe negative lead connected to chassis ground. Set the volts/div on the oscilloscope to 2 volts and the timebase to 5ms. Turn the output control approximately to output. This measurement should be 14kV AC peak to peak. 6. Verify that all other primary and secondary wires of T1 are connected to their respective destinations with a digital multimeter. Ensue that power is off and disconnect when making these measurements. If measurement in step 5 is not present and all connections are verified, then replace the high voltage transformer T1. 7. Reconnect T1 secondary wire and lift D3 cathode on the Stack board. Connect the P6015A probe to this point with the negative lead to chassis ground and turn output control to output. Set scope settings to the same as in step 5. This measurement should be approximately 7kV AC with the negative portion clipped by the diode. If not present replace D3 on the Stack board. 8. Check the SCR cathode to anode resistance for Q1-Q10. Ensue that the power is off and disconnected. These measurements can be obtained by measuring across R1 through R10. Replace any SCR s that are shorted. Good measurements will be 700K ohms or higher while defective SCR s will have much lower readings. 9. Check the resistance of the 25K-ohm 25-watt resistor that connects to the J5 wire from the Stack board. Replace if open. 10. Check continuity from lead 1 alligator clip to the 25K 25 watt resistor. If open, replace test lead 1. Check continuity from the ground lead alligator clip to the Discharge board ground stud. If open, replace the ground lead.
3. Measure at T2 pin 3, this point will be variable depending on the position of the output control knob. At the full counter-clockwise position this voltage will be less than 3 volts AC. At approximately output turning clockwise this voltage will be line voltage. If not present, check the neutral connection to the variac, if this connection is present replace T2. 4. Check at the terminal block adjacent to the high voltage transformer T1 at the orange wire for the same AC voltage starting with the output control to full counterclockwise position then at output. If not present, see the section on the Zero Start Interlock does not engage. 5. Locate the secondary T1 high voltage transformer wire connected to D3 anode on the Stack board and disconnect. Connect a P6015A high voltage scope probe or equivalent to the T1 secondary wire with the probe negative lead connected to chassis ground. See the volts/div on the oscilloscope to 2 volts and the timebase to 5ms. Turn the output control approximately to output. This measurement should be 14kV AC peak to peak. 6. Verify that all other primary and secondary wires of T1 are connected to their respective destinations with a digital multimeter. Ensure that power is off and disconnected when making these measurements. If measurement in step 5 is not present and all connections are verified, then replace the high voltage transformer T1. 7. Reconnect T1 secondary wire and lift D3 cathode on the Stack board. Connect the P6015A probe to this point with the negative lead to chassis ground and turn output control to output. Set scope settings to the same as in step 5. This measurement should be approximately 7kV AC with the negative portion clipped by the diode. If not present replace D3 on the Stack board. 8. Check the SCR cathode to anode resistance for Q1-Q10. Ensure that the power is off and disconnected. These measurements can be obtained by measuring across R1 through R10. Replace any SCR s that are shorted. Good measurements will be 70K ohms or higher while defective SR s will have much lower readings. 9. Check continuity of test leads 1, 2, and 3 back to the selector switch, replace any found to be open. 10. Check continuity from the ground lead alligator clip to the Discharge board ground stud. If open, replace the ground lead. 11. With a 10X scope probe measure at pin 32B on the I/O board with the negative probe lead connected to chassis ground. After engaging the zero interlock turn the output control to approximately output. Set the oscilloscope to 1 volt/div and 10S sweep rate. The signal at this point should be about a 1.8-volt surge waveform. If not check continuity with the tester AC input disconnected from P1 pin 32B & 32C on the I/O board to J1 pins 3 and 4 on the Discharge board. 16 Baker Instrument Company The Measure of Quality
12. Access the Discharge board by removing the Stack board and check resistance measurements of the following components and replace if necessary. Ensure that power is disconnected when making these measurements and disassembling the unit. Check R1 through R14. 13. If the signal in step 11 was noted proceed to check that relay K1 on the I/O board has no contact resistance between pins 2 and 3. If pin 7 of the relay is at a low state and contact resistance is detected, replace relay K1. If pin 7 is at approximately +12 volts DC, then check U6 pin for +5 volts DC, then replace Q1 on the I/O board. If U6 pin 6 is at a low state, replace U6. 14. Replace U19, U20 and U14 on the A/D board.
variac and selector switch for easier access. Remove the A/D, I/O and the Controller boards from the card cage. 1. Remove the AC Hot (black) wires from the PTT button and the footswitch. Connect the black wire to K1:B common, K2:B common, and K2C common. 2. Connect a 20 gauge red wire to TB2 pin 1 on the Power Supply board and terminate the other end to the footswitch pin 1,one end of the PTT button and one end of K1:A coil. 3. Remove wiring from footswitch pin 2 (red) to the PT button to J1 pin 1 on the Zero Start Interlock board to T2 pin 2. 4. Replace the wiring on the other end of the PTT button with a wht/grn wire and connect to the footswitch pin 2 and also K2:A coil and an added 1N4936 cathode. 5. Connect the other end of K2:A coil to the 1N4936 anode and also to the ground terminal block. 6. Connect a red 20 gauge wire from J1 pin 1 on the Zero Start Interlock board to K2:C NO contact. 7. Connect a red 20-gauge wire from T2 pin 2 to K1:B NO and K1:A NO. 8. Connect a 26-gauge jumper on the rear of the I/O board from U6 to P1 pin 1A. 9. Remove top cover of card cage held by eight (8) M4 x 7mm black hex head screws and two (2) M4 kep nuts. 10. Remove four (4) kep nuts securing the Motherboard to the back of the card cage and solder a 26 gauge wire to the rear of the Motherboard J3 connector pin 1A. Run this wire out of the card to a small breadboard containing a 4.7K ohm watt resistor and a 2N2222 transistor. See schematic for electrical connection of this circuit. This breadboard needs to be mounted on the side of the card cage by drilling one hole and mounting with a nylon spacer and M4 hardware adjacent to the K2 relay. 11. Run a 20 gauge green wire from the 2N2222-transistor emitter and connect to the ground terminal block. 12. Reassemble unit.
2. Ensure that the test lead select switch is not positioned in the leads ground position. 3. Check that the unit is supplied a proper ground. 4. With a digital multimeter set to DC volts, check the voltage at J2 pin 5 on the Zero Start Interlock board with the negative lead connected to chassis ground. This measurement should be approximately +13.5 volts DC and drop to about +12.7 volts when the PTT button is depressed. If this voltage is not present or is low the fault can be in the following circuits. The microswitch S1 which is mounted on the test lead select switch can be open. Check Q5 base on the I/O board for +12.6 volts DC, if present replace Q5. 5. Check at Q4 base on the I/O board, this should be approximately .7 volts DC, if present replace Q4. 6. Check U8 pin 13 for a +5.5 volts DC, if measured low replace U7. 7. Check U8 pin 12 also for a +5.5 volts DC, if at a low state check R13 and U9. 8. Check at U8 pin 11 for low state, if at +5.5 volts DC, replace U8. 9. Measure at J2 pin 2 on the Zero Start Interlock board, this measurement needs to be +5.5 volts DC and change to approximately .4 volts DC when the PTT button is depressed. If this is present check Q1 through Q5 and OC1, OC2, and OC3 for faults. 10. Measure between R9 and KE2 pin 1, this coil voltage should change from 6.4 volts DC to -.7 volts DC when the PTT button is depressed. If this is noted, replace K1 relay on the Zero Start Interlock board. 11. If the measurement at step 9 is not present, check U15, U7, and R18 for defects, replace if necessary.
IS INCONSISTENT
The digital series design tester will produce accurate results to a +/- 5% specifications. The operators of the digital series may notice fluctuations in the current readings, megohms values and PI data due to fluctuations in the input line power. Small variations in the line power specifically at the one-minute and ten-minute intervals may cause inconsistent readings even when the same windings are analyzed. To greatly improve this occurrence, the steps below can be followed. 1. The use of a Patriot line conditioner in series with the power to the tester will reduce line fluctuations. Contact Baker Instrument Company for price and availability. 19 Baker Instrument Company The Measure of Quality
2. Connecting AC power from an isolated outlet does not have other equipment with high current demands. To check the internal current calibration of the tester will require the I/O board to be on an extender card. Follow the steps in the Quality Control and Calibration Procedure. If one or more range readings outside of +/-5% still occur, see the steps below. 1. Further adjustment may be necessary by altering the values of R33, R35, and R37. Slight resistive value changes of no more than 10% of the existing value up or down. 2. Continue monitoring offset value at the I/O board pin 2A to pin 29C for an offset which drifts away from the nominal measurement of 0.000 volts +/-0.010. If drifting is detected, replaced U10 and U11.
DISPLAY UNREADABLE AND FLASHES ON/OFF, DOES NOT INITIATE SELF TEST
1. A check of the DC supplies and crystal frequency to verify proper conditions, see Voltage Busline and Crystal Checkout procedures. 2. A loss or loading of any one or more of the following lines due to faulty components or connections will cause this occurrence. Since these signal lines are tied to the A/D board, I/O board, and the Controller card it will be necessary to troubleshoot in the manner outlined in step 3. ___ ____ __________ _________ _________ _________ ____ RD, Reset, CRT Enable, 103 Enable, 102 Enable, 101 Enable, SAD, RD/WR, ALE, Reset, DB0 through DB7, AD1 through AD7 and AD8 through AD14. 3. To determine which printed circuit is defective, unplug the A/D board and the I/O board with the power off. Turn on the tester and observe the tester response. If the tester now begins with a Baker logo then the fault is not on the Controller card. The tester will fail the A/D Memory test due to the A/D card not being inserted into the Motherboard. Turn off the testers power. 4. Insert the A/D board into the J1 connector and switch power on. If the display returns to the original fault condition, then a fault will be on the A/D board. Turn off tester power. 5. Insert the I/O card into the J3 connector of the Motherboard and turn on the testers power. If the display returns to the original fault condition, then the fault will be located on the I/O board. 6. After determination as to which card is defective, remove power and the defective card. Install the faulty card on an extender card and apply power. 7. With a 10X-scope probe begin monitoring the data, address and signal lines noted in step 2. It will be helpful to record all lines, which do not have data present. See Motherboard DST Series schematic for pinout contacts of these signal lines to each card. Data is defined as a high frequency 0 to 5-volt amplitude logic level changes determined by the programmed U3 27C256 EEPROM located on the Controller card. 8. After determination as to which signal lines are stuck low or high, it will be necessary to trace the defective signal lines to all components that are tied to the same line and replace one at a time. It may also be necessary to check defective signals lines with a digital multimeter set to ohms for shorts to GND and to +5 volts DC. Also check 21 Baker Instrument Company The Measure of Quality
continuity on defective signal lines from components that are tied to the same signal line. 9. If the fault is located to either A/D board or the Controller card, replacement boards can be sent without affecting the calibration on the unit. An I/O board replacement will require a calibration of the unit.
10. Install all boards back into the card cage and secure with the original hardware. NOTE: These assemblies contain C-MOS logic which are ES D sensitive. Removal of these boards are recommended to be performed at a grounded station by personnel wearing a grounded wrist strip. Failure to do this may result in integrated circuit damage.
ECO RECORD
Engineering changes have taken place since the manufacturer of D12000 S/D 001. D12000 series after serial number 210 should have these changes installed at the factory. These changes are designed to add more capability and improve the tester s performance. Also they will increase the tester s reliability by protecting components and circuits which have shown over the years to be vulnerable to failure in certain testing applications. The following is a list of these changes we recommend to be checked for installed during servicing. 1. A cooling fan for the CRT circuits was added to eliminate scrolling of the CRT display when internal temperatures reach above 105 degrees. 2. Power board components R3 and C1 were changed to increase reliability of Q1 on the Power board. 3. Discharge board changes include changes in the value of resistor R5 to provide for a greater incoming signal to the I/O board. This allows for a better capability to shape the surge signal so that the displayed surge signal on the CRT display more closely resembles what is shown at the test leads on an oscilloscope. 4. Other changes to this assembly isolation of the surge readout cable from Discharge board ground and ground routing changes. This will improve the noise resolution seen of the first displayed positive peak when surge testing at higher voltages. 5. Changes in the values of Stack board components R1 and R34 were performed to add greater reliability in SCR s Q1-Q5. 6. Changes in the revision of the Zero Start Interlock board form a common neutral design to a common ground design. This revision change allows for the elimination of false hipot trips and adds the capability to disable the Zero Start Interlock when testing armatures when a footswitch is used. 7. The addition of relays K1 and K2 and associated wiring harness changes were added to eliminate the condition where the displayed surge voltage on the CRT would drop approximately 10% when the PTT button was released.
8. EEPROM IC U3 is now at revision level 1.37. These firmware revision changes have added the following capability. A Polarization Index clock was added so that the operator can reset the clock after proper test voltage was reached, resulting in a full one or ten minute megohm test. Other changes in the firmware have added the capability to recall in any summary all three-surge test patterns with the test voltages of each lead displayed. This 1.37 revision change is necessary to upgrade to an inkjet Epson 640 printer or compatible printer. It is also necessary to be installed if this tester is used with MTA for Windows operating software system. 9. A/D board grounding changes, clamping diodes and bypass capacitors were added to increase the reliability of IC U14.