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ATi USER MANUAL

1. 5 18 VOLTECH ATI USER MANUAL PAGE 5 3 FIXTURES PAGE 5 4 VOLTECH ATI USER MANUAL FIXTURES 5 1 INTRODUCTION AT Series Testers are able to perform an extremely comprehensive series of tests on a wide variety of transformers To utilize this capability fully it is recommended that test fixtures be constructed to suit each particular type of transformer to be tested Test fixtures are based on a fixture board containing connector pins They provide the interface to the tester via the tester node pins allowing transformers to be quickly inserted and removed in a reliable manner taking full advantage of the high speed testing capability of the tester A broad range of basic fixturing parts and fixture kits are available from Voltech In addition complete ready to use fixturing solutions are also available from Voltech s fixturing partners Visit our website www voltech com for the latest information VOLTECH ATI USER MANUAL PAGE 5 5 FIXTURES 5 2 DESCRIPTION The Voltech AT Series fixture system allows you freedom and flexibility when considering your fixturing needs All fixtures are mounted on fixture boards which are available as a blank fixture plate and also as fixture kit which contains parts to help you The following basic building blocks are available A Fixture Plate Designed for mounting existing fixtures
2. 3 41 3 5 1 Front panel 65 3 42 3 5 2 Editor Error Codes si etd ee eee 3 42 3 6 FIXTURE COMPENSATION SEE ALSO SECTION 2 8 sess 3 45 3 7 PROGRAMMING HINTS AND TIPS ceres enne nennen nnn nnn nnn 3 47 PAGE 3 4 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 1 CREATING A PROGRAM Using the Editor enables you to quickly and easily create test programs for your AT Series Tester without any specialized knowledge of computer programming The Editor will guide you through the programming of the tests you wish to carry out helping you ensure that programming errors are eliminated The features of the Editor Software editor include Full MS Windows application compatibility providing many visual aids for tailoring the test parameters to your needs Schematic diagrams of the transformer under test showing pin to node connections which form the basis of your test program Form fill in dialogue boxes to guide you through the programming of each test A test program under development may be executed and the test results viewed on screen Test programs and results may be stored in a PC running the Server software Transfer of test programs to specified paths or floppy disk for backup A full c
3. m Longitudinal Balance Limits Ce C Minimum 0 dB C Maximum 0 dB Measure Maltech The voltage and frequency are usually determined by the final application of the part under test Select the integration period that is normally Medium Enter the required terminal names Terminals X the energized winding Terminals X the measured voltage VOUT1 Terminals Y the energized terminals for creating a common mode voltage VOLTECH ATI USER MANUAL PAGE 7 83 TESTS AND TEST CONDITIONS Terminals Y the measured voltage VOUT2 Note that the PC Editor s Measure button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value PAGE 7 84 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 21 RESP Frequency Response Measurement Test Test Basic Range Voltage Frequency Accuracy 100dB to 100dB 1mV to 5V 20Hz to 3MHz 1 0dB Rs EA E AT Series Tester Where Used The frequency response test RESP may be used to check that the variation in power loss of a telecommunications or audio transformer over a specified frequency range is les
4. 7 96 1 25 X Reactance eee hel 7 99 VOLTECH ATI USER MANUAL PAGE 7 3 TESTS AND TEST CONDITIONS 7 1 26 ANGL Phase Angle of 7 101 7 1 27 PHAS Interwinding Phase Angle sss 7 104 7 1 28 TRIM Pause Testing in Order to Trim a Component Value 7 107 7 1 29 OUT Control External 7 109 7 2 SERIES AND PARALLEL CIRCUITS eere enne nnne n nnn n nnn n nn nnn nn nn nnn 7 112 7 3 CAPACITOR MEASUREMENTS eere nennen nnn n nnn nnn nnn nnn n nn nan an nn nn nn nnn 7 114 PAGE 7 4 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 INTRODUCTION Tests and Test Conditions This chapter provides guidance for the use of each of the tests currently available for the ATi For the latest information please check the Voltech web site at www voltech com 7 1 1 Choosing Tests for a Transformer In order for a completed transformer to function properly in its intended application it should be constructed in accordance with the designer s specification The test specification or ATi test program calls for various electrical parameters to be measured such that the transformer construction is verified For example a measurement of inductance will help to confirm that the correct number of turns
5. a E E E E PAGE 7 70 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency Programming the Test Using the PC Test Editor Low Open Circuit Voltage X Test Parameters Measurement Integration Voltage 2 v AC Voltage C Shot Medium Frequency fo Hz C DC Voltage C Long Energised Terminals r Measured Terminals High Terminal Low Terminal High Terminal Low Terminal zj Voltage Limits r Polarity INE E Minimum o omy Cy C ve INE Maximum 1 my CY C ve 6 No Test Measure Cancel 5 al Choose the integration period normally Medium Energized Terminals The terminals where the test signal will be applied This is normally the winding with the greatest number of turns Primary Terminals High and Low The zero phase reference terminals that are often the same as the energized terminals Secondary Terminals High and Low The turns ratio and polarity measurement will be made between the primary and secondary terminals VOLTECH ATI USER MANUAL PAGE 7 71 TESTS AND TEST CONDITIONS Use the PC Editor s Measure button together with a sample part if you are unsure of ho
6. 9 5 Weight remm 8 32 Winding 1 neto 3 7 ATI USER MANUAL
7. 5 6 17 06 3 6 19 6 3 1 ECR BNC MON abebectctdsiicsseares 6 19 6 3 2 LCR FIX enne ii eead eearri neina 6 20 6 3 3 ECR Mod 6 21 6 4 COMPENSATION Eaa Ea aaaea a akaa Era iaaa EEEa 6 29 6 4 1 Performing Compensation sess sss 6 31 6 4 2 Compensation 6 33 6 5 LCR MODE ERROR MESSAGES eene eene nennen nenne nnns nnn 6 35 6 6 PROGRAM MODE 5 xen roe uoa a orsa Ee Dea iiia 6 39 6 6 1 Creating a New Test Program esse eene 6 40 6 6 2 Setting Up Test Program Options seen 6 45 6 6 3 Running a Test Program sse nnns 6 47 6 6 4 Password Protection essen nnne 6 48 VOLTECH ATI USER MANUAL PAGE 6 3 FRONT PANEL MODES PAGE 6 4 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 1 LCR Mope Basic FUNCTIONS As well as executing complete test sequences at high speed on multiple windings for production testing the ATi can make LCR and turns ratio type measurements on a component or single winding without using the PC based test program editor Measures L C R DC and Z 6 X Q D Turns Ratio Leakage Inductance and Insulation Resistance All parameters required to fully characterize a winding or component BNC to Kelvin
8. Then press Enter V to adjust the IR voltage VOLTECH ATI USER MANUAL PAGE 6 15 FRONT PANEL MODES Enter value Delete 123 Enter Bi mE Cancel at Enter the required test voltage using the 12 key numeric keypad Press softkey 4 ENTER to accept the value that you have typed Press softkey 5 CANCEL to discard changes and return to the previous menu Press softkey 3 DELETE to correct mistakes Insulation resistance set ups cannot be stored in memory but the voltage and used nodes are automatically stored and recalled the next time IR is selected The Integration and Print settings are common to all LCR measurements and are described later in this chapter PAGE 6 16 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 2 TESTS AVAILABLE IN THE LCR MODES The available combinations are More 1 4 Softkey 1 Ls Lp Cs Cp More 2 4 Softkey 1 Z R More 3 4 Softkey 1 Rdc IR More 4 4 LCR FIX only Softkey 1 TR TRL LL C Softkey 3 Q D Rs Q D Rp D Q Rs D Q Rp Softkey 3 06 Q D X Softkey 3 Off On Softkey 3 POL PHAS POL The active display combination is always shown in inverse video The results are always shown to five significant figures using normal engineering notation and normal symbols for the units of measurement VOLTECH ATI USER MANUAL PAGE 6 17 FRONT PANEL MODES The symbols used are Measurement Symbo
9. Control limits Specification limits C None laste 6 Use temporary limits computed from data in the chart 10 0000026 C Apply selected saved control limits below to the chart Target 0 0000025 Lower 0 0000024 r Saved control limits saved while viewing chart Use Extend Ind UCL Ind CL IndLCL Orderby Calcfrom View Data Save as default 4 32 VOLTECH ATI USER MANUAL AT SERIES SERVER Under the Control Chart tab display options including axis scaling can be altered EX CHARTrunner Inductance Chartname type Data source Data definition Limits Control chart Titles Misc Chart options X axis Y axis D grid je Id Data grid ja Date valnes Sum xr 5 grid Ja Burn fp A Iv Data line Iv Data line markers Iv Perform out of control tests Vertical grid lines Iv Out of control test boxes Horizontal grid lines Outof control test lines Iv Draw mean line on chart Iv Outof control test numbers Draw median line on chart Iv Upper spec line M Target spec line Subgroups in moving range po M Lower spec line e F Color 1 2 3 sigma zones Chart width in subgroups blank all Blank chart E Sun atis Show negative limits P ster sit dei Decimal places for statistics e Clear Default View Data Save as default OK Cancel Other options including chart
10. 2 10 Installing the PC 2 12 Insulation Resistance 7 72 Integration esses 6 27 Interface Details 8 23 Inter Winding Phase Angle 7 103 IR LCR Settings 6 13 Iron Core Transformers 7 8 Kelvin Connections 5 18 Keypad eter 2 8 LCD 5 2 7 6 7 LCR FIX an iatis itane 6 11 6 19 LCR Mode Basic Functions 6 5 LCR Mode Error Messages 6 35 Leakage Inductance 7 42 4 50 Longitudinal Balance 7 75 7 80 Measure Button 3 31 NOES EO 9 8 Options eee me 3 14 QUT i irent 7 108 Package Contents 2 6 PASS Indicator 2 7 PC Specification 2 12 Phase Angle 7 100 PIDE nite AEEA FS 6 28 Printer Port rm 8 26 Program Edit 3 19 Program Mode 2 76 Quality Factor 7 26 Quick Start Tutorial 2 19 7 98 Registration 4
11. Signal Specified voltage Specified current Auto Frequency Specified Specified Specified Note that a fixed signal cannot be used with an Auto frequency Programming the Test Using the PC Test Editor D Factor x r Test Parameters r integration Signal m CY CmA C Short 5 Medium Frequency o Hz kHz C MHz C Long Terminals High Terminal Low Terminal D Factor Limits CZ gt lt Minimum Maximum 0 Measure Cancel C Noltech I i PAGE 7 30 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Choose the integration period normally Medium and enter the terminals to be measured Use the Editor s Measure button together with a sample part if you are unsure of the nominal value Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only lt Amaximum value only Use the PC Editors Measure button together with a sample part if you are unsure of the nominal value Typically D is tested against a maximum value A typical film dielectric capacitor may have a D 0 01 Because D is a ratio of two impedances it has no units VOLTECH ATI USER MANUAL PAGE 7 31 TESTS AND TEST CONDITIONS 7 1 8 RLS RLP AC Resistance Series and Parallel Circuit Measurement Test Test Basic Range Voltage Frequency Accuracy 0 to 10
12. 8 3 3 Auxiliary Port RS232 interface for connection to a PC running the Voltech AT Series Editor software 9 pin male D type connector Cms No connection No connection TX i CTS ip RX RTS No connection No connection VOLTECH ATI USER MANUAL PAGE 8 25 SPECIFICATIONS 8 3 4 Printer Port Standard parallel printer interface 25 pin female D type connector me sem vin Site o p ISTROBE i BUSY o p DO i PE o p DI No connection o p D2 o p AUTOFD o p D3 i p IERROR o p D4 o p o p D5 o p ISLCTIN o p D6 o p D7 bet i p ACKNLG 1 2 3 4 5 6 7 8 9 o Signals with a name starting with are active Lo Printing options can be chosen from the Options dialogue of the Editor software If you intend to print all results for each program you will need a high speed thermal printer or similar There are no options for printing from the LCR modes PAGE 8 26 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 3 5 Remote Port TTL compatible interface for operation with various peripherals including foot switch remote controller and monitor output 15 pin female D type connector o p BEEP DO NOT USE OV IPASS Binl 12V i ISTOP o p FAIL BinStrb i IRUN DO NOT USE OV OV 5V o p BUSY BinO NOT USED DO NOT USE 1 2 3 4 5 6 7 8 Signals with a name starting with are active Lo IRUN Input Pin 12 The RUN input is an active Lo in
13. 9 5 9 3 SERVICE AND CALIBRATION ccccceceeeeeseeeceeeeeeeeseeaneeseeeeeeeeseeeseeeeeeeeeeneees 9 6 9 4 OBTAINING SERVICE AND APPLICATIONS 9 6 9 5 FIRMWARE UPGRADES see nnne nnmnnn annen nnn 9 7 9 6 VOLTECH AT CALIBRATION 9 9 VOLTECH ATI USER MANUAL PAGE 9 3 WARRANTY AND SERVICE PAGE 9 4 ATI USER MANUAL WARRANTY AND SERVICE 9 1 WARRANTY The Voltech ATi is warranted against defects in materials and workmanship for a period of twelve 12 months from the date of shipment OR ten million 10 000 000 wound component tests whichever occurs first The electrical switching relays are warranted against defects in materials and workmanship for a period of twenty four 24 months OR ten million 10 000 000 transformer tests whichever occurs first In the event of failure of a customer unit during this period Voltech will e At Voltech s discretion repair or replace the faulty unit free of charge for a unit returned to an authorized service center Shipment from the customer address will be the responsibility of the customer e Voltech reserve the right to waive this benefit in any event where it is clear upon inspection that the cause of the failure is due to customer misuse e Voltech will be the sole arbiter in this ciicumst
14. atr is the reserved file extension used by the Server to indicate a stored test result file What follows is an example of the first part of a batch result file as viewed in a standard text editor Note the DOS file name c6200697 atr and the part name TUTORIAL are both listed within the file VOLTECH ATI USER MANUAL PAGE 4 11 AT SERIES SERVER VOLTECH ATi RESULTS FILE Server Program Version 2 37 Communication Channel 6 ATi ID 0571 ATi Software Version 2 46 File name C6200500 atr Test Date 20 May 2000 Part Tutorial Fixture ID Universal Operator Batch No Fixture Compensation Result x F Serial f Time Pass Fail i m j 001 R y wu wu 002 wu wu nn Minimum Maximum Reading Minimum Maximum R 10 44 20 Pass 59 73 6 776850E 01 Pass 3 223899E 00 P 10 44 23 Pass 59 73 6 776832E 01 Pass 3 110549E 00 P 10 44 24 Pass 59 73 6 776363E 01 Pass 3 125640E 00 P 10 44 26 Pass 59 73 6 777967E 01 Pass 3 3 135034E400 P 10 44 27 Pass 59 73 6 777842E 01 Pass 3 3 185198E400 P 10 44 29 Pass 59 73 6 778374E 01 Pass 3 3 152627E400 P And so forth for each result until a change of batch or part If a result window is closed the connection to the transformer tester will be lost A warning is issued before connections are removed PAGE 4 12
15. e A precision digital multi meter not supplied e Anoptional IEEE488 interface for the PC for fully automatic calibration not supplied Fully automatic Calibration Semi automatic Calibration Less than 60 minutes About 90 minutes No manual readings Many readings read manually from the meter and entered into the PC IEEE488 interface required Normal PC serial COM interface NI PCII IIA loTech GP488 and required CEC suitable HP3458A 875 digit DMM essential HP 3458A DMM or similar required DMM Specification for Semi automatic Use e The Voltech calibration system relies on the accuracy of the DMM used to achieve the published specification of the tester The meter must measure e Volts to 0 04 100Hz 3 1MHz and 5 3MHz e DC Volts to 0 003 2V and 0 005 3 600V e DC resistance using a four terminal connection to 0 05 for 500m and 0 01 for 750 Calibration Environment Calibration should be carried out at 23 C 5 C relative humidity 10 9096 non condensing PAGE 9 10 ATI USER MANUAL 10 INDEX Applications Support 9 6 4 15 Auxiliary Port sssss 8 25 Barcode 2 9 Barcode 8 23 Beepet ripe 2 8 Beeper Volume 2 79 BNC Connectors 6 8 BNC Lead Calibration 2 80 Calibra
16. o Drive Output PAGE 8 30 VOLTECH ATI USER MANUAL SPECIFICATIONS User Inputs pins 4 and 9 The User Inputs have the following equivalent circuit 5V kQ User Input Specification Maximum input voltage 5V Minimum input voltage OV Minimum logic 1 input 4V Maximum logic 0 input 0 25V The zero reference voltage for these inputs is the OV ground 4mm socket situated on the right of the ATi unit The user inputs have no function at present and should be left unconnected 12V pin 5 Total maximum current User port pin 5 Remote port pin 3 100mA VOLTECH ATI USER MANUAL PAGE 8 31 SPECIFICATIONS 8 3 7 Environmental Conditions Line Input IEC 3 pin socket 87 to 265V ac 47 to 440Hz 100VA Fuse 1 6AT Dielectric Strength 2kV ac 50Hz for 1 minute line input to case Storage Temperature 40 to 70 C Operating Temperature 0 to 40 C Humidity 10 to 90 RH non condensing Mechanical Weight approx 5 5kg A 65mm Height of front edge B 434mm Full length C 147mm Rear height Width 387mm PAGE 8 32 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 4 EMC COMPLIANCE 8 4 1 Declaration of Conformity DECLARATION OF CONFORMITY Manufacturer s Name Voltech Instruments Ltd Manufacturer s Address 65 Milton Park Abingdon Oxon United Kingdom Declares that the product Product Name Transformer Tester Model Number ATi conforms to the following produc
17. 1 VOLTECHIATS600 RESULTS FILE j 2 Server Program Version 2 04 3 Communications Channel 6 4 AT3600 ID 0571 8 AT3600 Software Version 2 16 6 File name C6200697 atr 7 Test Date 20 Jun 1997 8 9 Parn 10 Fixture ID TEST 11 Operator 12 Batch 13 No Fixture Compensation 14 15 16 Result Serial Time Pass Fail 001 R 002 LS 17 Minimurn Maximum Reading Minimum Maximum Reading 18 19 1 10 44 20 Pass 59 73 6 78E 01 Pass 3 322840 20 2 10 44 23 Pass 59 73 6 78E401 Pass 3 341E40 21 3 10 44 24 Pass 58 73 6 78E 01 Pass 3 3138401 22 4 10 44 26 Pass 59 73 6 78E401 Pass 3 344830 23 5 10 44 27 Pass 58 73 6 78E401 Pass 3 3 19840 24 6 10 44 29 Pass 59 73 6 78E401 Pass 3 3 15E 0 25 26 2 z I4 4 FTF C6200697 tite E Ready ERI NMI T fF Z You may need to adjust the cell number format of the spreadsheet and the width of the columns in order to display the required number of decimal places Using functions built into the spreadsheet the data obtained may now be used to create graphs and bar charts for a visual representation of your results As an example to produce a graph select a group of results from one column then click the Chart Wizard button and use this to create the graph that you require in the normal way For additional help on what may be possible please refer to your spreadsheet user manuals VOLTECH ATI USER MANUAL PAGE 4 49
18. 1 4 1 Standard Program Tests CTY Continuity R DC resistance RLS AC resistance series circuit RLP AC resistance parallel circuit LS Inductance series circuit LP Inductance parallel circuit LSB Inductance series circuit with bias LPB Inductance parallel circuit with bias Interwinding capacitance QL Quality factor D Dissipation factor tans Magnitude of complex impedance ZB Complex impedance with bias ANGL Angle of complex impedance TR Turns ratio and phase or by voltage IR Insulation resistance 1 4 2 Optional Program Tests LL Leakage inductance LLO Leakage inductance with user offset R2 DC resistance match L2 Inductance match C2 Capacitance match TRL Turns ratio by inductance PHAS Interwinding phase GBAL General longitudinal balance LBAL Longitudinal balance PAGE 1 8 VOLTECH ATI USER MANUAL Optional program tests continued ILOS Insertion loss RLOS Return loss LVOC Low voltage open circuit RESP Frequency response TRIM Trim adjustable part OUT User port relay control 1 4 3 ATi LCR Mode Functions INTRODUCTION Measurement Symbol Units Display Units DC resistance Rdc Ohms DC resistance using high voltage source IR Ohms AC resistance series circuit Ohms AC resistance parallel circuit Ohms Inductance series circuit Henries H Inductance parallel circuit L Henries H Capa
19. Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value PAGE 7 80 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 20 LBAL Longitudinal Balance Measurement Test Test Basic Range Voltage Frequency Accuracy 0 dB to 100 dB 1mV to 5V 20Hz to 3MHz 0 5dB Longitudinal balance is a measure of the common mode rejection ratio CMRR of a transformer That is the ability of the transformer to reject unwanted noise signals that are common to both input terminals with respect to a common point An ideal transformer would have infinite CMRR Vout1 0 In practice differences in symmetry of transformer construction mean that input common mode signals appear as unwanted output voltages See also the GBAL test Where Used The longitudinal balance test is used to confirm the CMRR of audio and telecommunications transformers that are designed to be connected to a balanced line The test ensures that the transformer will reject common mode noise signals as required in use Faults in the placement of windings or core may be detected using this test VOLTECH ATI USER MANUAL PAGE 7 81 TESTS AND TEST CONDITIONS Test Conditions The source and load resistors RS and RL are connected to th
20. ERE e em eds 2 19 p e eed ee oe vio tee Fete p 2 47 2 5 Production Mode ed t PP trees 2 50 2 6 Stop ON Fail cst tete ento Eee EEE re opo PEDE d De 2 67 2 EFI e t aate tn eta og die utt tbetata te dt Seed 2 69 2 8 Fixture 2 71 2 9 Setup Mode etH dene 2 75 3 PROGRAM EDITOR rte indere deese insvseiesisissdiasiadatesisacedeaeistares 3 1 327 Creating uci ie ient 3 5 3 2 Creating the Transformer Schematic sss 3 6 3 3 Creating the 6 8 3 13 3 4 Using the Measure BUON sri giria a aa aei iaa 3 31 3 0 Eror COGS 4 repe o E 3 41 PAGE IV VOLTECH ATI USER MANUAL 3 6 Fixture Compensation see also section 2 8 sese 3 45 3 7 Programming Hints and Tips enne 3 47 4 AT SERIES SERVER E cx esie si EA FRR chen ea tasccdusciacsscacsdasckectasiedicdiscectases 4 1 AA EE 4 5 4 2 Test Program Handling 4 6 4 3 Test Results Handling on aie As 4 11 4 4 LICENSE Registratio
21. PAGE 6 24 VOLTECH ATI USER MANUAL FRONT PANEL MODES Enter value Fix Pri Hz Ab Auto Sec AUTO Y AUTO Hz mAb Delete f 15 5 Enter L 161 63pH Cancel at 4 98 U 1 35mA Z2BBkHz Shift When the Shift key softkey 6 is pressed it is shown in reverse video Press 5 with the Shift key in reverse to enter the multiplier k x1 000 Press 6 with the Shift key in reverse to enter the mulitiplier M x1 000 000 Press softkey 4 Delete to correct mistakes The value is changed when you press the Enter softkey Pressing Cancel will return you to the previous screen VOLTECH ATI USER MANUAL PAGE 6 25 FRONT PANEL MODES Signal settings Enter f Pri EN v FE skh pee Enter u Sec AUTO V AUTO Hz BmBHb Enter I Enter IBias L 4 8866 H Pri cec at Ws As Hz New settings are diplayed as above once they have been stored Since no measurements have been made with these new conditions measured values cannot be displayed on bottom line Having entered fixed values of voltage frequency and IBias as required and pressed softkey 6 OK the screen will show 2 1020mH 232 95 Fixture comp reqs AUTO JU 18 5kHz usw T 2mH 18 The Bias level is only shown when its program value is not zero Press OK again to return to the normal measuring menu PAGE 6 26 VOLTECH ATI USER MANUAL FRONT PANEL MODES Note that comp req is now displayed because a
22. VOLTECH ATI USER MANUAL PAGE 1 11 INTRODUCTION The ATi is very easy to use However it is a complex instrument which can be installed and operated in many ways In order to maximize the benefits that the ATi can bring to your test environment please study the following section carefully 1 6 TYPICAL PRODUCTION INSTALLATION Editor PC used only when creating Server PC for handling detailed or editing test programs results and large numbers of test programs Untested transformers Tested transformers S Fail Manual or robotic operation Barcode input Run pad or footswitch to initiate operation Simple PASS FAIL operation by an unskilled operator Results Direct printing from the ATi printer port Results archiving to disk using the Server application e Results for analysis can be easily exported to other Windows applications PAGE 1 12 VOLTECH ATI USER MANUAL INTRODUCTION Test Program Creation Simple easy to use Windows based Editor for creating test programs See chapter 3 e Requires no software programming skills or expertise e Test conditions may be entered manually or chosen automatically by measuring a sample transformer Program Archive Management e Windows based Server software for easy management of all test programs See chapter 4 e Optionally programs may be resident in the tester for stand alone operation VOLTECH ATI USER MANUAL PAGE 1 1
23. Choosing Test Limits Although the tester is capable of measuring insulation resistance values greater than 1GQ there is no need to specify so high a value to check that windings are isolated In many cases specifying a lower value will speed up the execution of the test A value of 100MQ is generally suitable for most applications Where higher voltage safety testing is required see the Hi Pot tests that are available with the Voltech AT3600 VOLTECH ATI USER MANUAL PAGE 7 75 TESTS AND TEST CONDITIONS 7 1 19 GBAL General Longitudinal Balance Measurement Test Test Basic Range Voltage Frequency Accuracy 0 dB to 100 dB 1mV to 5V 20Hz to 3MHz 0 5dB AT Series Tester IEEE 455 Fixture Transformer FCC 68 310 Longitudinal balance is a measure of the common mode rejection ratio CMRR of a transformer That is the ability of the transformer to reject unwanted noise signals that are common to both input terminals with respect to a common point An ideal transformer would have infinite CMRR Vout1 0 In practice differences in symmetry of transformer construction mean that input common mode signals appear as unwanted output voltages See also the LBAL test Where Used The general longitudinal balance test as opposed to the standard longitudinal balance test LBAL is used to confirm the longitudinal balance or CMRR of PAGE 7 76 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS audio and telecommuni
24. High Terminal Low Terminal m Resistance Limits Cz gt lt Minimum 180 5 Ohm kOhm C MOhm C lt Maximum 200 5 m hm C Ohm kOhm MOhm Measure Cancel e Fill in the fields of the dialogue box e Click on the OK button VOLTECH ATI USER MANUAL PAGE 3 21 PROGRAM EDITOR You will now see this test added to the test program Program List Maximize Winding Resistance Integration Medium High Terminal A Low Terminal B Minimum Value 59 000 Ohms Maximum Value 73 000 Ohms Winding Resistance Integration Medium High Terminal C Low Terminal D Minimum Value 180 00 m hms Maximum Value For Help press F1 3 3 3 Inserting Tests Normally if you are creating a new test program you would add the tests in the correct order of execution as described in the previous section You would also use this procedure for modifying an existing program if you needed to append further tests at the end However if you wish to add an extra test somewhere in the middle of an existing program a different procedure is required 1 Inthe Available Tests window click with the left button of the mouse to highlight the test you wish to insert 2 Inthe Program window click with the left mouse button to highlight one of the existing tests in the list This will become the point of insertion i e the new test will be inserted in front of the one you have selected
25. PAGE 3 22 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 From the top level menu bar select Program gt Insert Test s Voltech Test Program Editor New Part Part Schematic NE EM Tester Server Setup Help Options Edit Maximize Available Tests Minimize c CTY Continuity Edit Test R Winding Resistance Ls Inductance Series Circ LP Inductance Parallel Cit Q Factor RLS Equivalent Series Resi RLP Equivalent Parallel Res Leakage Inductance Leakage Inductance wi Interwinding Capacitant Turns Ratio Delete Test Magnetising Current Open Circuit Voltage Insulation Resistance High Pot dc High Pot ac Program List High Terminal C Low Terminal D Minimum Value 180 00 mOhns Maximum Value 200 00 nOhns Inductance with Bias S Inductance with Bias P Wattage Stress Test Surge Trimming Adjustment Output to User Port x gt Low Terminal B a eee Insert a new test above the currently selected test NUM In this example a turns ratio test will be inserted before the inductance test number 3 in the test program You will now see the dialogue box for the test you wish to insert 4 Enter the appropriate test data in the fields of the dialogue box and click on OK VOLTECH ATI USER MANUAL PAGE 3 23 PROGRAM EDITOR You will now see the new test inserted into the program Winding Resistance Integration Medium High Terminal C Low Terminal D
26. www voltech com AT UsER MANUAL AT Voltech Instruments Inc Voltech Instruments Ltd 2725 East Millbrook Road 148 Sixth Street Suite 121 Harwell International Business Centre Raleigh NC 27604 U S A Harwell Didcot Oxon OX11 ORA U K Tel 1 919 431 0015 Tel 44 0 1235 834555 Fax 1 919 431 0090 Fax 44 0 1235 835016 sales voltech com sales voltech co uk VOLTECH ATI USER MANUAL PAGE Voltech Instruments is committed to a policy of continuous product development Hence product specification and the information given in this manual are subject to change without notice No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without prior written permission of Voltech Instruments Voltech Instruments 2002 All rights reserved The Voltech ATi is protected by the following patents USA US 5500598 UK 2261957B Europe 0621953B Microsoft Windows and the Windows logo are either registered trademarks or trademarks of Microsoft Corporation in the United States and or other countries Voltech Part Number 98 067 Issue 6 May 2002 PAGE Il VOLTECH ATI USER MANUAL gt gt P p DANGER OF ELECTRIC SHOCK Only qualified personnel should install this equipment after reading and understanding this user manual If in doubt consult your supplier RISQUE D
27. 0 20929300 1 Kurtosis 0 17929887 Y Coeff Of Variation 12 27195690 Dpm 1000000 S 1 Subgroup Statistics mR 2 i H Avg Range 0 00256057 m i f Avg Sigma 0 00181059 Estimated Sigma 0 00227001 Capability Indexes Cp 0 00001468 Cpk 3 51684307 Cr 68100 19539731 Chi square e 5 724 2 degreesof freedom Normal distribution Confidence Level 90 Fits the curve Resistance Distribution Analysis CHARTrunner Overall PassFi File Edit View Help Count Percent Overall Pass Fail Analysis PAGE 4 28 VOLTECH ATI USER MANUAL AT SERIES SERVER ChartRunner Example Database Connection The chart will show the trend of inductance measurements over time an Individuals chart type See the ChartRunner help system for how to set up control limits change the display appearance or set up any of the other available chart types In the ChartRunner software create a new chart CHARTrunner Inductance G x Chart name type Data source Data definition Limits Control chart Titles Misc Chart name Chart style Jincuctance Default control chart style v Description Refresh interval blank none 10 seconds m What type of chart do you want C X bar range C Histogram capability C X bar sigma C p chart C Individuals moving range C np chart C
28. 96 The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 0396 3 2 0 000002 Im Az 0 5 0 001 Zm Where Iu is the measured current A Zu is the measured IR value MQ VOLTECH ATI USER MANUAL PAGE 8 15 SPECIFICATIONS 8 2 10 L2 C2 and R2 Tests The accuracy is dependent on the accuracy of the two inductance capacitance or resistance measurements made and is given as Ar Where Ar Ax Av Ax Ay is the total accuracy is the accuracy of the X measurement is the accuracy of the Y measurement Refer to the accuracy specifications for the LS C and R tests to determine the accuracy of the X and Y measurements PAGE 8 16 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 11 GBAL Test The accuracy is based on the test conditions chosen to measure the longitudinal balance of the transformer under test and is given as Ar Ag 0 87 Ac Avx Avy Where Ar is the total accuracy dB An is the basic relative accuracy dB Ac is the correction for calibration Avx is the correction for the X measurement voltage level Avy is the correction for the Y measurement voltage level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 1 0 0000001 x Fy Age 0 001 AV M Ye 0 001 AVcuyy Vuy Where Fu is the meas
29. C gt Maximum 42 mOhm Ohm CkOhm C MOhm Measure Cancel Woltech Maximum limit only Many of the tests available for the AT Series have all four limit types There are obviously some tests where it is not sensible to have four limits types IR Insulation Resistance being a clear example where only a minimum limit is applicable as the perfect insulation between windings has no upper limit to its resistance To choose which type of limit you wish to use simply use the mouse to click on one of the buttons 96 gt lt gt or lt VOLTECH ATI USER MANUAL PAGE 3 29 PROGRAM EDITOR After you have entered the limits in one form you may change to another form of limits by clicking with the mouse on another one of the radio buttons Note If you are using minimum and maximum limits gt lt the values of your minimum and maximum limit cannot be the same or you will be prompted by an error message to change one or both of your limit values PAGE 3 30 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 4 USING THE MEASURE BUTTON While working through the Quick Start Tutorial chapter 2 you may have noticed that the dialogue box for the test R Winding Resistance contained a button labeled Measure In fact most tests have a Measure button within the dialogue box It is included there to allow you to fill in various fields in the dialogue box by using the AT to measure the value from a
30. Measuring the expected Q figure gives further indication that the correct wire turns and cores have been used Q is usually measured once only on the primary TR Turns Ratio and Phasing Turns ratio checks the correct number of turns has been wound in the right direction or phase Turns ratio should be performed on every winding with the PAGE 7 6 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS winding used for inductance and Q as the reference winding The test TRL Turns Ratio by Inductance can provide improved measurement accuracy in cases where the coupling between windings is poor C Interwinding Capacitance A capacitance test between windings can check for insulation thickness between them and for their correct placement along the length of the bobbin This can be important not just for confirming the insulation but to check that unwanted signal noise are not unexpectedly coupled in the final application Check the main primary to secondary capacitance and between secondaries where insulation is important LL Leakage Inductance The leakage inductance is a measure of how good the magnetic coupling between windings is A higher than expected leakage inductance can indicate inaccurately aligned core halves or poor layering of the windings Check between the primary and the secondaries The ATi automatically creates short circuits across the secondary windings that you specify for this test IR Insu
31. Minimum Value 180 00 mO0hms Maximum Value 200 00 m0hms Inductance Series Circuit Test Voltage 1 0000 V Test Frequency 50 000 Hz Integration Medium High Terminal A Low Terminal B Minimum Value 3 0000 H 3 3 4 Modifying Tests As part of creating a new test program you would normally experiment by running it with a sample batch of transformers At this point you may find that some tests need to be modified a typical example being that you need to change the test limits With the Editor software modifying a test is very simple 1 In the Program List window double click with the left mouse button on the test you wish to modify This will re open the dialogue box for that particular test Make any changes you require to the test data in the fields of the dialogue box and click on OK You will now see the test with the modified data in the Program List window PAGE 3 24 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 3 5 Deleting Tests To delete a test from the test program is very simple with the Editor software 1 Inthe Program List window click with the left mouse button to highlight the test you wish to delete NOTE Take care to correctly select the test to be deleted as the Editor software will permanently delete the test 2 From the top level menu bar select Program gt Delete Test zs Voltech Test Program Editor Part 40235 File Q Pat Schematic Mas Tester Serv
32. Note The OK softkey does not allow you to exit the test set up screen until all required test parameters have been entered E Type Energise Measure Set Up Program options PAGE 6 44 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 6 2 Setting Up Test Program Options To set up program options for the test that has been created select Set Up This will take you to the program options screen where you can now change or set the test program name fixture ID and all other program options that are also available in the AT Editor software For example under Name enter TUTORIAL as the program name and under Fix ID enter UNIVERSAL as your fixture ID To enter those names scroll to the appropriate line use the Delete softkey to delete the default description of PART 1 and then use the instrument keypad to enter your own description Program options Mame TUTORIAL Fix ID UNIVERSAL_ Results printing Off Delete Operator numbering OFF Batch numbering OFF Note that on this screen the shift key is not available for character entry On the program options screen the buttons on the instrument keypad will consecutively scroll you through both numbers and letters Once the character that you want to enter appears in inverse on the LCD pause briefly and the chosen letter or number will be entered To choose other program options such as sending test results to the Server highlight the approp
33. Once an AT Server to database connection has been made it is possible to connect third party analysis software to the same database for live online or offline data analysis The example reports presented here were created using PQ Systems ChartRunner but many other charting and analysis programs are available Voltech does not recommend one package more than any other You should choose to use the one that best meets your needs x CHARTrunner Inductance File Edit View Help INDUCTANCE 0 00000270 Temporary UCL 0 00000255 Mean 0 00000253 LCL 0 00000252 mR 2 0 00000265 4 J 0 00000260 REM PC 1 al Juel 0 00000255 0 00000245 0 00000240 0 00000235 1 p onnonzan 2 55 Astort AA tina filled inbmp SBAT Seiver ATonC B CHARTrunner S CHARTrunner I JS 11 07 Inductance Trend Analysis VOLTECH ATI USER MANUAL PAGE 4 27 AT SERIES SERVER CHARTrunne File Edit View nductance Fit Help RESISTANCE ue 7 7 E 3 Basic Statistics al Ei b 50 Data points 5 D Maximum 0 034 Mean 0 02395237 Minimum 0 016 Sigma 0 00293942 i Skewness
34. Secondary Terminals High and Low The turns ratio and polarity measurement will be made between the primary and secondary terminals Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Notes The signal is applied to the primary winding or the winding that has the largest number of turns However if by doing this the expected voltage on the winding with the smallest number of turns falls below 1mV then the test voltage should be increased This may also require an increase in the test frequency so that the current taken by the driven winding does not become too large but in general this frequency increase should be kept as small as possible to avoid problems caused by stray capacitance at high frequencies Where Matching in Groups Is Important In some transformer designs the turns ratio between a primary winding and a secondary winding is not as important as the ratio between different primaries or different secondaries To make the most accurate measurements in such cases apply the test signal to the primary winding and measure the turns ratio from primary to one of the secondaries Then leaving the primary energized as above measure the turns ratio between the secondaries Next energize a secondary winding possibly at a different voltage and or frequency depending on its inductance and measure the turns ratio between the various primari
35. Series Circuit is one of the tests where both the test voltage and frequency and the actual measurement may be obtained by using the Measure button The following example assumes that this is what you wish to do Initially select the LS test in the normal way by double clicking with the mouse in the Available Tests list In the LS test dialogue box Enter the terminal names in the normal way Select the integration you require if different from the default setting of Medium In the Test Parameters section leave both the Signal and the Frequency boxes blank The default units button for the Signal is mV With this setting the Editor will enter the test voltage chosen by the tester changing as appropriate to the V button if the signal is large Alternatively if you wish the test signal to be determined as a current click on the mA units button Finally in the lower section of the dialogue box select the desired limits type PAGE 3 32 VOLTECH ATI USER MANUAL PROGRAM EDITOR At this point the dialogue box should be as follows Winding Inductance Series Circuit x Test Parameters Signal 0 Cm CV C mA C Short Medium Frequency 0 Hz kHz MHz C Long Terminals High Terminal Low Terminal s r Inductance Limits CE C Nominal 0 CnH CuH CmH CH CkH 9 Negative fo x Positive x ok M Cancel RE Now usin
36. Server Results nTest 3 nNumRuns 3 sComPort COM2 Dummy read to clear any previous result vntResult nTest objServerResult GetVariantResult sComPort nTest MsgBox Press the RUN softkey on the AT For nRun 1 To nNumRuns Get the results Do vntResult nTest objServerResult GetVariantResult sComPort nTest Loop Until vntResult nTest lt gt NO RESULT And _ vntResult nTest INVALID RESULT NUMBER Cells 3 5 nRun vntResult nTest Put result in spreadsheet Next nRun MsgBox Done End Sub PAGE 4 42 VOLTECH ATI USER MANUAL AT SERIES SERVER When you have finished typing the code return to Sheet 1 of the spreadsheet To run the code again from the Excel top level menu bar select Tools gt Macro At the dialog box select the name of the macro OLE_Demo and click on the RUN button The code will now start to run and after a few seconds you will see the first message box defined in the code i Microsoft Excel Press the RUN soft key on the AT Click on the OK button When you have pressed the RUN softkey and the first result has been read the message box will disappear and you will then see the first result entered into cell F3 of the spreadsheet Continue pressing the RUN softkey until the second message box is seen Microsoft Excel Done Click on the OK button to finish running the code 4 3 8 Additional No
37. This will be due to the one turn error being on the winding with the largest number of turns In the above example then set absolute limits of 75 turn pri and 0 turn sec Remember to use the n 7 rule The equivalent limits used by the tester will be 20 05 and 19 95 This will certainly detect a one turn error in the primary but because of the physical errors already described these limits may be too severe for a normal good part This is why a combination of inductance and turns ratio tests are normally used to confirm the correct assembly of transformers The polarity test may be selected as ve ve or no test To measure the exact interwinding phase angle use the PHAS test Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value VOLTECH ATI USER MANUAL PAGE 7 63 TESTS AND TEST CONDITIONS 7 1 16 TRL Turns Ratio by Inductance Measurement Test Test Basic Range Voltage Frequency Accuracy 1 100 100 1 1mV to 5V 20Hz to 3MHz 0 1 AT Series AT Secondary Tester measurements The correct ratio of the number of turns on one winding to the number of turns on another winding is important for the proper operation of any transformer The turns ratio is often determined by calculating the ratio of the voltages produced across the windings the TR test but it can also be determined from a measurement of the two winding inductances The inductance of a winding i
38. V lm is the measured current A lg is the bias current A VOLTECH USER MANUAL PAGE 8 21 SPECIFICATIONS 8 2 16 PHAS Test The accuracy is given as Ar AptActAytaAy Where Ar is the total accuracy Ar is the basic relative accuracy Ac is the calibration accuracy is the correction for voltage level An is the correction for turns ratio The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 000005 x Fy 0 002 1 Vp TR Vp Ay 70 05 Vp Vp TR Where Fu is the measurement frequency Hz Vp is the measured voltage across the primary winding V TR is the turns ratio between the primary and secondary windings PAGE 8 22 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 3 INTERFACE DETAILS The following interfaces are available at the rear of the ATi 7 j ATC ce Voltech Instruments Inc N C USA Tet 919461 1701 Emai salesivoltech com Voltech Instruments Ltd Oxon UK L Tek 44 1235 834555 Emad sales vortech co uk 4 CAUTION 16 2000 Votech Copyright and inetectu Property rights ot USER MANUAL TALLAN teret nature ertoded in Da Muren we Use NO USER SERVCEANLE PARTS NSOE DO NOT Sd wai renan Bw property cl Voc hatumerts ere pee ay MOVE COVERS Patents USAUSSE00808 UK 22619578 Europe 06219590 Tra EQUIPMENT MUST DE EARTHED BARCODE From left to right Barcode Serve
39. a a Interwinding PHAS 360 360 ImV 5V Phase Test TRIM L imming n a n Adjustment Port Notes 1 basic relative accuracy full specifications follow Specification at 23 C 5 C after one hour warm up and long integration 2 Absolute maximum ratings for all tests 5Vrms and 0 4Apeak except IR 500VDC 3 Where used the bias current accuracy is 10 of the requested value n a n a a a n PAGE 8 6 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 ACCURACY SPECIFICATIONS AVAILABLE TESTS 8 2 1 R Test The accuracy is based on the test conditions chosen to measure the winding resistance and is given as Ar Where Ar is the total accuracy Ar is the basic relative accuracy 96 Ac is the calibration accuracy 96 is the correction for voltage level 96 A isthe correction for current level 96 The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 296 Av 0 0396 0 01 Vm 0 0396 0 01 Iu Where Vm is the measured voltage V Im is the measured current A VOLTECH ATI USER MANUAL PAGE 8 7 SPECIFICATIONS 8 2 2 LS LP LSB LPB RLS RLP and X Tests The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test and is given as Ar Ac Av Aj Ao Ap Where Ar is the total accuracy 96 Ar is
40. gt lt limits will be used The Ohm units button is selected by clicking with the mouse VOLTECH ATI USER MANUAL GETTING STARTED xi C Short Medium C Long Terminals High Terminal Low Terminal zi m zi Resistance Limits CX Minimum 59 CmOhm Ohm kOhm MOhm C C Maximum 73 C mOhm Ohm CkOhm MOhm Measure Cancel 3 Click on the OK button The test and its parameters will now appear in the Program List window Program List Winding Resistance Integ o High Termin i Low Terminal B Minimum Value 59 000 Ohms Maximum Value 73 000 Ohms 4 Again by double clicking the left mouse button select R Winding Resistance from the Available Tests window At the dialogue box enter the data as before this time for the second winding Integration Leave as the default Medium High terminal C Low terminal D Minimum 590 Maximum 7T30 Click on the OK button Again the test and its parameters will appear in the Program window VOLTECH ATI USER MANUAL PAGE 2 25 GETTING STARTED 5 Now by double clicking the left mouse button select LS Inductance Series Circuit from the Available Tests window At the dialogue box enter the data required for the inductance test Signal 1V again choose the V units button by clicking with the mouse Frequency 50Hz Integration Leave as the default Medi
41. secondary In general the voltages obtained during any voltage turns ratio test will not equate exactly to the theoretical calculation of Np Ns because for example of the relative positions of the windings with respect to each other and the core General Rule When setting turns ratio limits in absolute terms use a limit of 1 2 turn less than the number of turns you want to detect In this case set a limit of O pri and 72 sec This will result in equivalent limits of 19 and 21 Ideal for detecting errors of one turn or more What happens if set absolute limits for both primary and secondary windings If you want to detect up to a ten turn error on the primary and one turn on the secondary in the above example set 9 5 pri and 2 sec The tester uses the equivalent ratio limits 21 95 and 18 05 Setting both limits WIDENS the limit to allow for an error of ten turns on the primary SIMULTANEOUSLY with one turn on the secondary l e to allow 190 11 17 27 and 210 9 23 33 Notice that these limits will NOT detect just a one turn error on the secondary because you have now chosen limits to allow for errors on both primary and secondary resulting in a broader tolerance on the absolute ratio VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS How do set limits that will detect a one turn error on either the primary or the secondary To do this you must set limits that will detect the smallest possible error
42. signal cannot be used with an Auto frequency The DC bias current level must always be specified VOLTECH ATI USER MANUAL PAGE 7 37 TESTS AND TEST CONDITIONS Winding Inductance with Bias Series Circuit r Test Parameters Integration Signal mv Cv C Short Frequency fo Hz kHz MHz 6 Medium Bias Current 0 mA f Long Terminals High Terminal Low Terminal E zj Inductance Limits CX C Minimum DL nH CmH CH Maximum po nH CmH CH CkH Measure Cancel Woltech Programming the Test Using the PC Test Editor Choose the integration period normally Medium and enter the terminals to be measured Do use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use Editor s Measure button together with a sample part if you are unsure of the nominal value PAGE 7 38 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Remember to click on the units of limits mH etc when entering absolute values as limits Test limits should be set as close as possible to detect assembly faults A transformer made with a pair of gapped ferrite cores can often be test
43. the B H curve of the core and give a true ratio Choosing Test Conditions The simplest method of setting the test conditions is to use the Measure button of the PC Editor software There are two other methods of inputting the test parameters one is to set the primary voltage and frequency and let the editor set the secondary voltage and the second is to set both voltages manually VOLTECH ATI USER MANUAL PAGE 7 65 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Turns Ratio from Inductance x Test Parameters Integration Voltage P 3 C mv Short Voltage S 0 cmv Auto Medium Frequency 0 Hz C kHz C MHz C Long Primary Terminals Secondary Terminals High Terminal Low Terminal High Terminal Low Terminal zi z z zi Ratio Limits Polarity Primary Secondary 0 Cove Ce Ca Neg 0 Pos 0 No Test OK Measure Cancel Using the Measure Button to Set Test Parameters Select the integration period you require enter the primary and secondary terminals then click on the Measure button as explained in the Editor section of this manual The Editor will then enter the test signal and show the measured turns ratio Set percentage limits on this ratio and click OK you may select a polarity test before clicking OK Using the Auto Button to Set Secondary Voltage To do this you must know the p
44. together with a sample part if you are unsure of the nominal value Remember to click on the units of limits pF nF etc when entering absolute values as limits Test limits should be set as close as possible to the nominal value in order to detect faults A typical tolerance would be 20 VOLTECH ATI USER MANUAL PAGE 7 51 TESTS AND TEST CONDITIONS 7 1 13 CS and CP Capacitance Test Series and Parallel Circuit Measurement Test Test Basic Range Voltage Frequency Accuracy 100fF to 1mF 1mV to 5V 20Hz to 3MHz 0 1 SEE ALSO THE C TEST AND THE CAPACITOR TESTING SECTION OF THIS CHAPTER AT Series Tester The CS and CP tests can be used to measure the capacitance of a wide range of components up to 1 milli farad Test Conditions To measure capacitance the tester applies an AC voltage across the designated terminals It then measures the voltage and the resulting current Dividing the voltage by the current gives the complex impedance from which the capacitance is extracted using harmonic analyses Choosing the Test Signal Recommended test conditions for different values of capacitance are the same as for the C test PAGE 7 52 VOLTECH AT USER MANUAL TESTS AND TEST CONDITIONS Test Conditions for Capacitance Measurement The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a fixed volt
45. 12 key numeric keypad The combination of AUTO f and a fixed value of voltage or a fixed value of current is NOT allowed Hence you must always enter a fixed frequency before entering a fixed voltage or current You may enter a DC bias current when any measurement is displayed but bias is not applied during C Cs or Cp measurements To enter for example a fixed frequency press ENTER f softkey 1 on the previous screen and you will see VOLTECH ATI USER MANUAL PAGE 6 23 FRONT PANEL MODES Enter value Pri Uu Hz Ab Auto Sect AUTO W AUTO Hz mAb Delete f Enter L 1 1 5 Cancel 1 35mA Shift Press Fix to enter the value currently being measured by the ATi This does not apply to IBias the DC bias current Press Enter to accept the value that you have entered Press Auto to have the ATi automatically choose a voltage or frequency Remember that the combination of AUTO f and a fixed voltage or current is not allowed Press Cancel at any time to discard any changes that you have made and to return to the previous screen The Shift key is used to enter the multipliers k x1 000 or M x 1 000 000 IBias is always entered and displayed in mA There are no multipliers for IBias To enter 10 5 kHz for example Either press 1 0 5 ENTER f or press 1 0 5 SHIFT 5 ENTER f
46. 2 6 STOP ONIFAIL e eee ea 2 67 2 1 TRIM intet mte 2 69 2 8 FIXTURE COMPENSATION ccccccececeeeceeeeeeeeeeeeeeneeseeensnseseseeneeenseenenseseseenses 2 71 VOLTECH ATI USER MANUAL PAGE 2 3 GETTING STARTED 2 9 SET UP T 2 75 2 9 1 Setup SOfIKey WP pas tee pe 2 76 2 9 2 Groups Sofltkey e Fee tote ocu 2 82 PAGE 2 4 VOLTECH ATI USER MANUAL GETTING STARTED 2 1 INTRODUCTION This chapter is designed to introduce you to the basic facilities of the ATi and help you to realize the benefits of automated transformer testing in the shortest possible time If you are reasonably familiar with the testing of transformers and how to install and use Windows programs this chapter may be all that you need but you are nevertheless urged to read and understand the complete contents of this manual in order to achieve the maximum benefits that the ATi can bring For production testing the use of good quality test fixtures is very important Please see the fixturing section of this manual for details of parts that are available from Voltech If you have any questions or are unsure of what to do at any point please do not hesitate to contact your Voltech supplier Once installed The ATi will enable you to rapidly accurately and reliably test wound components in your production or goods inwards environment The PC Editor will enable you
47. 3 9 PROGRAM EDITOR 3 2 5 Adding a Terminal to an Existing Winding To add a terminal to a transformer winding 1 Select Add Winding from the Schematic menu on the menu bar to create a second two terminal winding 2 Nowplace the new winding on the same side of the schematic as the winding that requires the additional terminal Upon clicking the left mouse button a form fill in dialogue box will appear on the screen with prompts to insert the terminal names of the new winding Voltech Test Program Editor New Part 181 x Part Schematic Program Tester Server Setup Help Isi Schematic Enter Terminal Names x Cs n Terminal 1 3 Name the terminals of the second winding giving one terminal the same name as a terminal of the previous winding 4 Press ENTER or click on OK The dialogue box will be removed and the schematic will show the two windings joined at the common terminal as Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Help PAGE 3 10 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 2 6 Deleting a Terminal From an Existing Winding To remove a terminal from a transformer winding 1 Select the terminal that you would like to be removed by using the mouse pointer and clicking the left mouse button once 2 Choose Delete Winding from the Schematic menu on the menu bar The bottom terminal of the
48. 38 VOLTECH ATI USER MANUAL AT SERIES SERVER GetTestUnits LPCSTR ComPort short TestNumber Returns the test units as a string i e Ohm GetCompensationStatus LPCSTR ComPort NO COMPENSATION STATUS no status received yet No Fixture Compensation program has not been compensated Fixture Compensation successful compensation all OK Fixture Compensation fail ExtraString compensation has failed GetUnitType LPCSTR ComPort Returns AT3600 AT1600 or ATi depending on the type of instrument connected to the COM port GetResult LPCSTR ComPort short TestNumber The number returned is a float representing the value of the result measured or a zero if no result was available This function is included for compatibility with older versions of the Voltech AT Server It is not recommended for new applications VOLTECH ATI USER MANUAL PAGE 4 39 AT SERIES SERVER This section shows available functions for controlling an attached instrument via the Server This is to allow basic instrument control in applications where the AT is being used entirely remotely The functions available allow a program to be loaded into an AT and give the ability to run and stop it Variant LoadProgramToAT LPCSTR ComPort LPCSTR ProgName PROGRAM DOES NOT EXIST INVALID PROGRAM LOADING LOADED Program is not in the Server s program folder Program fails AT test program validation Returned when
49. 50 Remote 8 27 Renaming a Terminal 3 9 Resistance 7 13 7 32 RESP Frequency Response 7 84 Return 55 7 91 RUN Indicator 2 7 Run Pads 2 9 PAGE 10 1 INDEX Schematic Creating 3 6 Screen Connection 3 12 Self Test miniis 2 10 2 48 Series and Parallel Circuits 7 111 Server Hardware Connections 2 14 Server Installation 2 14 Server Port iens 8 25 DEVICE ee UNE 9 6 idee 6 21 SIMA Tt 6 22 SOftKByS nre es 2 8 Specification Summary 8 5 Statistics Basic Statistics 4 14 Stop on Fail 2 68 Stop on Fail Editor 3 17 Switching on 2 10 PAGE 10 2 ete rius Terminals Test Limits Editor Tests Adding Tests and Test Conditions 7 5 c tiie ees 2 70 7 106 Turns 7 56 Turns Ratio by Inductance 7 63 Upgrade s s eee 9 7 User Port eee 8 29 Voltage Open Circuit 7 68 Warranty
50. 5V 20Hz 3MHz 0 5 Factor tan Equivalent Series 10 10MO ImV 5V 20Hz 3MHz 0 05 Resistance Equivalent Parallel 10 10MO ImV 5V 20Hz 3MHz 0 05 Resistance Leakage InH IkH 20 100mA 20Hz 3MHz 0 196 Inductance Leakage Inductance InH IkH 20 100mA 20Hz 3MHz 0 1 with Offset Interwinding i 100fF ImF ImV 5V 20Hz 3MHz 0 196 Capacitance Capacitance 100fF ImF ImV 5V 20Hz 3MHz 0 196 Parallel C it 100fF ImF ImV 5V 20Hz 3MHz 0 1 Series ImQ IMO 5V 20Hz 3MHz 0 2 Turns Rati TR pP 1 100k 100k 1 1mV 5V 20Hz 3MHz 0 1 and Phasing VOLTECH ATI USER MANUAL PAGE 8 5 EE CP CS SPECIFICATIONS User Entered Test Data Test Ag Measurement Range Test Signal Test Frequenc Turns Ratio by TRL 30 1 1 30 ImV 5V 20Hz 3MHz 0 1 Inductance Low Voltage LVOC er 100 5V ImV 5V 20Hz 3MHz 0 1 pen Circuit Insulation 0 Induct Md 1 10000 10000 1 ImV 5V 20Hz 3MHz Interwinding Capacitance 1 1000 1000 1 ImV 5V General Longitudinal 0 100dB ImV 5V 20Hz 3MHz 0 5dB Balan 20Hz 3MHz 0 5dB Longitudinal OdB 100dB ImV 5V Balance i 20Hz 3MHz 0 5dB 100dB 100dB ImV 5V 20Hz 3MHz 1 0dB Response 20Hz 3MHz 00dB 1004B 5v ImO IMQ ImV 5V 20Hz 3MHz Imped ZB penu ImO IMQ mV 5V with Bias Impedance 360 360 Imv 5V 20Hz 3MHz 005 Phase Angle 20Hz 3MHz
51. 62 VOLTECH ATI USER MANUAL GETTING STARTED Enter the serial number Use either the keypad or a barcode reader to enter the operator batch serial number then press the ENTER key on the keypad or the Enter softkey Cursor softkeys lt appear in context and may be used with the Delete softkey to correct mistakes Serial Number Entry After the First Transformer When the serial number option is enabled after the measurements for each transformer have been completed the following display will be seen with the fourth display line indicating Pass Fail or Stop as appropriate VOLTECH ATI USER MANUAL PAGE 2 63 GETTING STARTED Enter the new serial number Last 1 Last transformer PASS Delete Abort Shift If the next serial number to be used simply follows on in sequence after the previous one then press the Last 1 softkey or the touch pads This will enter the next serial number automatically and return the display to the RUN FINISH selection Note Last 1 will be displayed only if the serial number is of the form xxxAnnnn Where xxx is a field containing any characters A is a non numeric character and nnnn is a field of all numeric characters Both xxx and nnnn can be of any length provided that the total serial number is no more than 20 characters When nnnn is all 9 s for example 99 the next number will show nnnn as all 0 s
52. AC Source None is Cancel VOLTECH ATI USER MANUAL PROGRAM EDITOR You may now set up any of the following options by simply clicking with the left button of the mouse Results Printing Printed reports may be obtained from the printer port of the tester as follows Failures Only Full Reporting Operator Numbering Batch Numbering Serial Numbering Send Results to Server Send Retry Results to Server Stop on Fail VOLTECH ATI USER MANUAL The results of the tests producing a fail result will be printed The results for all the tests in the program will be printed out for each transformer tested During program execution the operator will be prompted to enter his or her identity code All results will then be tagged with this code During program execution the operator will be prompted to enter a batch number which will be attached to the test results During program execution the operator will be prompted to enter a serial number for each transformer The number will then be attached to the results for the next transformer tested Select this option if you wish to have the tester send all the measurement results back to the Server PC for archive or analysis Enable this function if you wish the Server to contain the results from the additional measurements associated with re running a program for example after execution has been halted by the STOP ON FAIL program option S
53. AT SERIES SERVER 4 4 LICENSE REGISTRATION 4 4 1 Enabling the Licensed Features The Server software is supplied to you under the terms of our current license agreement and is for use on a single PC only It is not necessary to register the software to use the program storage CSV results storage or OLE features of the Server software The software must be registered however before you can use the database and basic batch statistics features The software may be registered in either trial i e demo or full mode A FREE trial of the software may be obtained from your Voltech supplier and will enable you to make full use of the database results storage feature for up to 30 days from registration Please see below BEFORE requesting your trial code Software Registration x Software Un Reagistered ID Code BX21HE LXXLBJ BPH703 Key Code To use licensed features of this software please contact your Voltech Supplier with the ID Code shown above to request a Key Code which you should enter above Transfer ID Code Transfer Key Code PAGE 4 50 VOLTECH ATI USER MANUAL AT SERIES SERVER To register the software e Look at the registration details found under Registration from the Help menu This dialogue will display an ID Code that is unique to that PC installation e Contact your Voltech supplier with the exact ID Code and you will be issued with a Key Code provided that the appropri
54. Conditions To measure insulation resistance the tester applies a DC voltage between two groups of windings with the windings in each group being shorted together Each group may contain as many windings as you wish The voltage and current are measured dividing the voltage by the current gives the insulation resistance Choosing Test Conditions The voltage should normally be set to just greater than twice the peak working voltage of the winding Programming the Test Using the PC Test Editor Insulation Resistance Ei Test Parameters Integration Voltage ev cw C Shon Medium Long Note AT1600 maximum voltage is 500V High Terminals Low Terminals Available Used Available Used A A B B c C D D Add gt lt Remove Add gt lt Remove Insulation Resistance Limit Minimum Resistance 0 MOhms CGOhms Note AT1600 maximum resistance limit is 1 GOhm m Caen Choose the integration period normally Medium and enter the terminals to be measured More than one terminal can be High and more than one terminal can be Low This is to allow testing for example of the complete primary to secondary insulation resistance of a transformer by taking all primary terminals High and all secondary terminals Low Note that the Editor s Measure button CANNOT be used to determine the test voltage PAGE 7 74 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS
55. ELECTROCUTION L installation de cet quipement ne doit tre confi e qu un personnel qualifi ayant lu et compris le pr sent manuel d utilisation Dans le doute s adresser au fournisseur GEFAHR VON ELEKTRISCHEM SCHOCK Nur entsprechend ausgebildetes Personal ist berechtigt diese Ausr stung nach dem Lesen und Verst ndnis dieses Anwendungshandbuches zu installieren Falls Sie Zweifel haben sollten wenden Sie sich bitte an Ihren Lieferanten RISCHIO DI SCARICHE ELETTRICHE Solo personale qualificato pu installare questo strumento dopo la lettura e la comprensione di questo manuale Se esistono dubbi consultate il vostro rivenditore VOLTECH ATI USER MANUAL PAGE III Contents T INTRODUCTION ied ants Seen eed 1 1 1 1 How to Use this Manual sse eene nnne nnne 1 5 1 2 General 1 6 ATi and AT3600 t eds 1 7 LATES SUPPE cto text eee rer E e Rc aede o 1 8 1 5 ATi Features Summary sse eene nnne nennen nnne nnns 1 11 1 6 Typical Production Installation sss 1 12 1 7 Using the ATi for Design and Evaluation esee 1 14 1 8 OVGIVIBW vei eret REED NA RENE 1 15 1 9 How Does the ATi Tester Run a Test sees 1 26 2 GETTING STARTED 2 1 2 4 aee pte pes 2 0 2 2 Installation eee to ee e e oes 2 10 2 3 Quick Start Tutorial
56. Frequency Response x Test Parameters Integration Voltage 1 my ey Short Medium Reference Frequency 400 Ce Hz C kHz MHz Long Test Frequencies Input New Frequency Frequency List High Terminal Low Terminal 5 C Hz 200 00Hz Ja 1 0000kHz kHz 2 0000kHz 3 0000kHz m Output C MHz 5 0000kHz Low Terminal b x E High Terminal Add Delete Frequency Response Limits 3 dB Cancel Upper limit 1 dB Moltech Lower limit e Enter the voltage and frequency parameters of the reference test signal e Select the integration time required Normally Medium e Enter the names of the Hi and Lo input terminals e Enter the names of the Hi and Lo output terminals e Add test frequencies as required by entering the frequency and clicking add There are normally at least 2 additional test frequencies one at either end of the frequency band of interest Additional mid band test frequencies can be entered to ensure that the transformer response is flat throughout the band e Setthe frequency response limits e Select OK The test specification will then be displayed in the program window Note that although resistors should be fitted to the fixture there is no need to enter their values here since the RESP test result is the difference between VOLTECH ATI USER MANUAL PAGE 7 87 TESTS AND TEST CONDITIONS two ratios based on the same resistor values The resistor values can
57. Help Network Drives c ms dos amp IMPORTANT Once a part has been deleted it may not be recovered Before deleting a part it is advisable to open and view the part to ensure that you are deleting the correct test program VOLTECH ATI USER MANUAL PAGE 4 9 AT SERIES SERVER 4 2 5 Grouping Test Programs Programs that are used on the transformer tester at similar times may be grouped for convenience For example a number of transformers all based on the same bobbin may be tested at the same time When a program group has been defined it may be downloaded to the tester Each of the parts within the group will then be available for local use The parts will be stored in non volatile RAM No programs are lost after power down The following dialogue is used to configure groups and may be found under the Setup menu in the Server Edit group BATCH1 x Parts in current directory Parts in group Directories OK c at3600SERVER yes E3 at3600 34063E TwINDING Add To Group gt gt lt lt Remove From Group Double clicking on any part in the left hand list will add it to the right hand grouped list When you have completed editing a group you will see it added to the available group list To transfer the group to the tester it must be requested by the tester See chapter 2 for details IMPORTANT The group function does not store a new copy of each part when a group
58. PROGRAM EDITOR After you have pressed the Re Run softkey the tester will then be executing a retry When results are sent to the Server unless you have enabled the program option Send Retry Results to Server then no result will be sent to the Server results file except those for the final execution run i e the one that produces the pass or fail front panel display If you wish to see the measured results from each retry in your Server results file then you should enable the program option Send Retry Results to Server when the program is created in the Editor This option could provide data for example that allows you to improve your production process and yield Notes The third line showing the graphical comparison of the measured value and user programmable limits has a logarithmic scale The measured value may be represented by either a vertical bar as shown when it lies within the range that can be displayed on the LCD or by an arrowhead lt or gt at the end of the horizontal bar when it lies outside the range that can be displayed on the LCD Should the tester be returning results to a PC running the Editor software then the Editor software will freeze when this screen is displayed until the appropriate softkey Re run Continue or Abort is pressed Program Edit After you have created the program schematic and selected the program options you may start creating the actual program of te
59. Tab to move to the Terminal 2 box and type the name of the second terminal e g B in that box Then click OK or press Enter PAGE 2 20 VOLTECH ATI USER MANUAL GETTING STARTED 4 Repeat steps 1 3 to create a second winding This time place the winding on the right hand side of the screen a mirror image of the first winding and use different terminal names e g C and D The screen should then look like this zs Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Help a A c ce Now you must connect the windings to the test nodes of the tester Place the mouse pointer over terminal A press and hold the right mouse button Continue holding this mouse button down and drag the mouse pointer to test node 9 Release the button A wire will now connect terminal A to test node 9 Repeat this procedure to connect the other three terminals B C and D to nodes 7 10 and 8 The screen should now look like this Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Help ipa Sl v se ee ee a RIGHT MOUSE Ed CLICK TO DRAG CONNECTIONS For Help press NUM You have now created a schematic layout of a four terminal transformer VOLTECH ATI USER MANUAL PAGE 2 21 GETTING STARTED 2 3 3 Creating the Test Program After creating the transformer schematic you may now create an example pro
60. VOLTECH ATI USER MANUAL PAGE 5 13 FIXTURES en a Example probe box drilled for multiple RM bobbin types M Series Kelvin Fixture PAGE 5 14 VOLTECH ATI USER MANUAL FIXTURES 5 4 1 Fixture Plate Voltech Part Number 91 184 Designed for mounting existing fixtures to an AT Series tester the fixture plate comprises Item 1 Base plate including contact pins with cover Item 2 Test piece interface plate Fittings and fasteners for above 5 4 2 Custom Fixture Kit Voltech Part Number 91 185 A kit of parts for constructing your own fixtures Interconnecting wire test probes or clips and a drilling template will also be required The custom fixture kit comprises Item 1 Base plate including contact pins with cover Item 2 Test piece interface plate Item 3 Probe housing box Item 4 Bezel Item 5 Guides 12 off Fixings for above VOLTECH ATI USER MANUAL PAGE 5 15 FIXTURES 5 4 3 Socket Fixture Voltech Part Number 91 186 A fixture board fitted with 40 4mm sockets 20 red power and 20 black sense The sockets are wired to the 40 contacts which align with the tester s 40 nodes This fixture may be used for convenient wiring to existing fixtures or as a means of connecting flying leads and clips for use in developing test programs or testing parts in a design laboratory 5 4 4 Connection Lead Set Voltech Part Number 78 030 A selection of Kelvin and non Kelvin crocodile clips and spring l
61. VOLTECH ATI USER MANUAL PAGE 7 21 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Winding Inductance Series Circuit x r Test Parameters Integration Signal o Cm CV C mA C Shot Medium Frequency 0 MHz C Long Terminals High Terminal Low Terminal H z Inductance Limits CE oo Minimum 0 nH Cut CmH CH CkH 9 Maximum 0 CuH mH CH CKkH Measure Cancel Choose the integration period normally Medium and enter the terminals to be measured Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions PAGE 7 22 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Notes When choosing test conditions the following potential problems should be considered a Current Levels The upper voltage limits should be chosen to give a maximum current level of about 50mA rms for the lowest inductance expected In some cases this current may cause core saturation and a lower voltage should be used The minimum voltage level must be chosen so that the test current does not become so low that it cannot be sensibly measured The lower voltage limits in the table above always give test currents higher than 3pA rms b Self resonant Frequency At lower frequencies the capacitance of the windings can normally be ignored because its impedance is much higher than that of t
62. a database For this feature to operate a license for use must first be obtained from your Voltech supplier All results formats can be saved simultaneously Basic statistics displays on line a summary of the results for the current batch of transformers that is being tested on every AT connected to the Server Results for previous batches can also be opened and the statistics displayed and printed PAGE 4 14 VOLTECH ATI USER MANUAL AT SERIES SERVER Part Name Operator 1135 PART NUMBER Transformer Serial No Last Part Pass Tested 37 PASS 36 FAL 1 AQL AQL Disabled RE TRIES 0 FAIL 2 703 Last 10Tx 0 Failed Test Min Max Last Result FAILS Polarity PolFAILS 1CTY 10 000 kohm 62277 mOhm 1 2L8 1 1640 mH 1 2360 mH 1 1847 mH 0 3TR 2 6460 2 7540 2 7084 1 0 The batch statistics window display is automatically shown once this feature is enabled For each AT connected to the Server the following information is displayed The type of AT and its serial number the part name operator and batch PASS or FAIL for the last part tested the total tested so far and the serial number of the last part tested The number that have passed and failed and the AQL lt gt Acceptable Quality Level of the transformer The number of re tries that have been attempted the percentage of failures so far and the number of transformers that failed out of the last 10 tested For each test in the program the t
63. and safely The following symbol conventions are used throughout Important safety information To ensure operator safety all safety information must be read and understood Important information that explains a general principle or refers to other sections of the manual The contents of this manual are believed to be accurate at the time of printing Voltech reserves the right however to change the operation or specification of the ATi without notice No liability is accepted for the inappropriate negligent or incorrect set up of the ATi by the user by either manual or automated means VOLTECH ATI USER MANUAL PAGE 1 5 INTRODUCTION 1 2 GENERAL SAFETY INSTRUCTIONS WARNING The ATi must be connected to a safety ground earth Only insert the power lead into a socket with a protective ground contact Ensure that the power lead is in good condition and free from damage before use Replace the fuse only with the same type and rating as indicated on the rear of the ATi Refer servicing only to qualified personnel who understand the danger of shock hazards WARNING The ATi wound component tester can generate voltages of up to 500V during insulation resistance testing Although the available energy of the source has been limited in accordance with EN61010 1 and can be considered safe care should be taken to avoid accidental or unexpected electrical shocks e Ensure operators are aware of the potential shock haza
64. any time simply click on Schematic then Edit on the top level menu Bottom Left The Program Window This is the list of tests that currently make up the test program Normally for a new program this window would initially be empty The display above shows the program of one resistance test created in the quick start tutorial Right The Available Tests Window This is the list of tests that are available to be used in creating or modifying the test program From this display you may create the test program suitable for your transformer by adding tests to the program from the PAGE 3 20 VOLTECH ATI USER MANUAL PROGRAM EDITOR Available Tests list The following sections describe how to do this 3 3 2 Adding Tests A test program is a list of tests chosen from the Available Tests list To create a new program you simply add tests to the list To add a test use the mouse to select the test you require from the Available Tests list and double click on that test with the left mouse button This will open the dialogue box particular to that test Fill in all the fields of the dialogue box and then click OK The test will be added at the end of the program As an example if you wish to add another R Winding Resistance to the program e Double click on the R Winding Resistance test in the Available Test list Winding Resistance E x C Short Medium C Long M Terminals
65. are a nominal value together with and percentage limits Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Test limits should be set as close as possible to detect assembly faults PAGE 7 42 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 11 LL LLO Leakage Inductance and Leakage Inductance with Offset Measurement Test Current Test Basic Range Frequency Accuracy 1nH to 1kH 20 to 100mA 20Hz to 3MHz 0 1 LLO Offset Range 1H to 1H in 1nH steps Leakage L AT Series AT Secondary Tester measurement Due to imperfections in the coupling between windings a short circuited transformer acts as if there is inductive impedance in series with the winding This impedance is known as the leakage inductance Low leakage inductance implies good coupling high leakage inductance poor coupling Leakage inductance is important in many transformer designs such as switching power supply power transformers and electronic lighting ballasts The test is used to ensure that the windings and core have been positioned correctly VOLTECH ATI USER MANUAL PAGE 7 43 TESTS AND TEST CONDITIONS Test Conditions Leakage inductance is tested by measuring the inductance of a primary winding when one or more secondary windings are shorted out See also the LS test Typically the impedance to be measured is very small so a constant current AC test signal is
66. available on your tester If the tester is connected any tests not available will be greyed out Lower left The program window displaying the tests programmed so far lu Far Help press FT T NUM By double clicking the left mouse button select R Winding Resistance from the Available Tests window VOLTECH ATI USER MANUAL PAGE 2 23 GETTING STARTED The following dialogue box will appear Winding Resistance x Integration Short Medium C Long Terminals High Terminal Low Terminal Resistance Limits C C lt Minimum 0 C mOhm Ohm CkOhm C MOhm C gt LE Maximum f mOhm COhm CkOhm C MOhm OK Measure Cane Valtech Initially enter the terminal names Input A as the high terminal and B as the low terminal moving between the fill in boxes using the TAB key Click anywhere over the High and Low Terminal drop down boxes to see a list of the available terminals Now enter the resistance limits This can be done in four ways Click on this button to enter a nominal value with a percentage tolerance for example 666 with 10 tolerance gt lt Click on this button to enter minimum and maximum values for example 590 and 73 gt Click on this button to enter just a minimum value for example 2590 Click on this button to enter just a maximum value for example lt 73Q In this example
67. available terminals to the used section of the dialogue NOTE Because leakage inductance is measured with a secondary winding shorted out be careful to choose a test signal that will not cause excessive currents to flow This is particularly significant in transformers where the turns ratio is very high and the shorted winding has only a few turns If for example the primary winding has 300 turns and the secondary 3 turns a test current of 10mA flowing through the leakage inductance on the primary side will give rise to a current of 1 Amp flowing in the shorted secondary winding In order to protect transformer windings the test current when measuring leakage inductance is limited in the table to 50mA maximum In addition the problem of self resonant frequency listed under the primary inductance test also applies when measuring leakage inductance so always use the lower of the available band of frequencies Use the Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be Anominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value PAGE 7 46 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Remember to click
68. be connected to each Server PC PAGE 1 20 VOLTECH ATI USER MANUAL INTRODUCTION Limitations e Requires the Server PC to be permanently connected This is to allow the tester uninterrupted access to the Server for the purposes of accessing programs and storing results e Usually requires an additional PC which could be a portable to be attached locally to the auxiliary port of one of the testers when a new program needs to be developed and evaluated VOLTECH ATI USER MANUAL PAGE 1 21 INTRODUCTION Small Production Facility At the other extreme and possibly more suitable for a small production facility with a single AT series tester and limited or temporary access to a PC 1 Connect the AT to the PC running both Editor and Server software as shown above when developing the test programs 2 Download a group of programs from the Server to the AT where they will be held in the internal non volatile memory 3 Remove the PC and run all the production test programs from the AT s internal memory Advantages Requires only occasional use of a PC which could be a portable to develop test programs and load them into the AT Test programs can be executed by the AT without the PC attached which may be of advantage if the working space is limited Limitations Suitable for small numbers of test programs 50 Test results cannot be archived to disk or analyzed by other Windows based applica
69. calibration requires a FORE resistor 7 250R Note that you will need a nominal 750 Ohm resistor later in the process A typical 680 Ohm 1 4 Watt resistor will be sufficient The exact value of the resistor is not important to this process but you must use exactly the same resistor whenever it is required during this process The BNC calibration process consists of six measurements an open circuit short circuit and 750 Ohm measurement across nodes 13 and 15 of the fixture and then the same measurements made using the BNC leads VOLTECH ATI USER MANUAL PAGE 2 79 GETTING STARTED e Press Continue short together nodes 13 and 15 on the fixture and press Continue again to make the first measurement which is a short circuit compensation e Next remove the short but ensure that the power and sense terminals are short circuited together on nodes 13 and 15 Press Continue to run a short circuit compensation e Next connect the nominal 750 Ohm resistor between nodes 13 and 15 and press Continue BHC Lead Calibration Measuring 756R resistor on the fixture EN h h h b Next the process is repeated using the BNC leads e Ashort circuit compensation on the BNC leads e An open circuit compensation on the BNC leads e Ameasurement of the 750 Ohm resistor using the BNC leads At the end of the process press Continue to save the new calibration factors or press Abort to discard them and return to th
70. clip leads provided for accurate 4 terminal measurements Quick and easy connection eliminates contact resistance errors Intuitive softkey control sets up measurements in a few key presses Ready to test in a few seconds Ideal for design and prototyping of wound components Rapid change of test and test conditions without programming Fully automatic or manual test voltage and frequency Automatic test conditions for quick accurate results or fully programmable almost infinite steps of voltage and frequency for complete control Inductance and AC resistance tests with bias Test windings designed to operate with a DC current bias Simultaneous large character display of two parameters and test conditions Easy to read no hidden factors or warnings VOLTECH ATI USER MANUAL PAGE 6 5 FRONT PANEL MODES From the top level display Programs LCR EHC LCE Set Up Self Test Two LCR modes are available LCR BNC mode uses the flexible leads attached to the four connectors on the control panel of the ATi to perform LCR Inductance Capacitance Resistance measurements on a single winding or component LCR FIX mode uses nodes 13 14 15 and 16 of the fixture bay to perform LCR type measurements plus turns ratio leakage inductance and interwinding capacitance on two windings of a transformer The LCR fixture supplied with your ATi provides full Kelvin four wire connections to these nodes for convenie
71. command is first sent to Server and every subsequent time it is sent until loading finishes The program has been successfully loaded this will continue to be returned and the program will not load until either StopAT is called or the Server receives results on that COM port Variant RunProgramInAT LPCSTR ComPort NO PROGRAM SENT DONE Variant StopAT LPCSTR ComPort STOPPED PAGE 4 40 The AT has no program to run Returned when the program has started to run and every subsequent time the function is called until the Server receives results The program has finished running results will be available If the function is called after it has returned this value it will cause the program to be run again The AT must stop whatever test it is running VOLTECH ATI USER MANUAL AT SERIES SERVER Example of On line Analysis This section contains a simple example to illustrate how you may use OLE to transfer the measured results into a spreadsheet as they happen in real time The spreadsheet used in the example is Microsoft Excel 97 and the module of code illustrated is written in the Visual Basic supplied with the spreadsheet Before attempting to create the spreadsheet set up the AT and Server e Use the Editor to create a program containing five tests where test number 3 measures a winding resistance e Ensure that the program option Send Results to Server is set to On e Transfer t
72. considered as an on line storage system The Server will handle two types of data e TEST PROGRAMS e TEST RESULTS Test programs that are created using the Editor application may be uploaded into the Server central file store All testers connected to the Server then have access to the central store Programs are called up from the Server sent to and then executed within the tester The features of the Server include e MS Windows application style dialogues and tools e Storage of all previously created test programs e Transfer of test programs to the tester on request e Viewing of test programs outside the test program Editor environment e Test results may be received and stored in a database ready format for easy off line analysis e OLE2 support allowing real time analysis of your production test system Test programs may be stored on floppy disk for back up or inter site transfer Installation and set up of the Server program is explained in chapter 2 VOLTECH ATI USER MANUAL PAGE 4 5 AT SERIES SERVER 4 2 TEST PROGRAM HANDLING 4 2 1 Storing Test Programs After a test program has been created using the Editor application it will be ready for use with your AT Series Tester The diagram below shows a potential connection scheme for use with a single tester and two PCs Before program requests or uploads may be completed the tester must be configured for Server mode See chapter 2 Network connection
73. frequency has been chosen at which compensation measurements have not been made before For accurate measurements compensation should now be appiled See the compensation section in this chapter for details Press the Integration softkey on the settings menu to reveal the integration options Integration Short Medium Long Cancel The integration level controls details of the measurement method including the number of readings that are averaged together to provide the displayed measurements To achieve the specified accuracy of the ATi the default Medium measurement should be chosen Choosing Short integration will provide faster but less stable and accurate results For maximum stability and accuracy choose Long integration Compensation Compensation is described in detail in the next section VOLTECH ATI USER MANUAL PAGE 6 27 FRONT PANEL MODES Print Press the Print softkey in the settings menu and the measurement information displayed will be output to the printer port of the ATi Measurements can be recorded on any standard printer with a conventional PC type parallel centronics input The output is formatted using standard codes so that a simple 40 column ticket printer may be used DATE 30 JAN 02 14 55 26 LS 27 138uH Q 16 785 BNC comp req Prg AUTO V 123Hz Mes 1000mV 1 33mA 123Hz PAGE 6 28 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 4 COMPENSATION Measurements o
74. from the Editor The following section describes how to run a test program from the Editor To do this you must first create a program which includes only the test options installed in your tester Having created both the transformer schematic and the test program the program is now ready to run on your tester under the control of the Editor PAGE 2 28 VOLTECH ATI USER MANUAL GETTING STARTED Before proceeding further make sure that the interface cable between the tester s auxiliary port and the selected PC COM port is correctly fitted and that the COM Port is correctly configured in the Editor see page 2 14 Ensure that the tester has been switched on To run the program 1 From the top level menu bar select Tester gt Download Program s Part TUTORIAL File TUTORIAL atp Voltech The Editor will now download Part Schematic Program Tester Server Setup Help the test program to the tester olea a vals Donnicad tle el Upload Program After a few seconds you Compensate Fixture should see a message that the Run Program download was successful Download Firmware If you see a message SEDES indicating that the download has failed check your cable COM port connections and try again If the download continues to fail reboot your PC and try again The front panel of the AT will now display SALE PROGRAM Continue Saving this program to the local store will overwrite an existing progr
75. is defined Only reference is made to the part being in a group DO NOT delete a part after including it in a group other wise the part will be lost and the group rendered invalid PAGE 4 10 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 3 TEST RESULTS HANDLING 4 3 1 Receiving Test Results By default the AT Series Tester does not automatically send test results back to the Server Results will only be sent back for test programs that have been set up with the Send Results to Server option enabled The Server receives test results from the tester via the same serial connection used for transferring test programs to the tester Results handling is a separate function of the Server program and is not part of program transfer Where more than one tester is connected to your Server PC the one Server program handles all the transformer tester results as well as acts as the central Server All results sent by one tester s channel during one day are collected together and formed into one large file This file is known as the batch results file One batch results file will be generated per open channel per day Batch files are stored under the specified results directory see chapter 2 section 2 2 6 The DOS filename of the batch results file is generated as follows c lt n gt lt dd gt lt mm gt lt yy gt atr Where n channel number dd day number mm month number yy year number Example c1250297 atr Channel 1 25 02 1997
76. level is reached or exceeded the Server will display a warning Wat on comM2 ATi Part Name Operator 1138 PART NUMBER AT Server x AT on COM2 Transformer Serial No Last Part F al ae AQL Exceeded PASS 5 FAL 1 AQL 1 RE TRIES 0 FAIL 16 667 Last 10 Tx 1 Failed Test Min Max Last Result FAILS Polarity PolFAILS 1 CTY 10 000 kOhm 2 0238 GOhm 1 218 1 1640 mH 1 2360 mH 1 1801 mH 0 3TR 2 6460 2 7540 73 441 1 0 Click on OK to acknowledge the warning You will be given the option to disable the warning for further parts in the batch Normally you would select No to leave the AQL checking active for the rest of the batch When a new batch is started the AQL level is reset according to the level entered for the part using the Voltech AT Editor PAGE 4 16 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 3 5 On line Analysis via a Database The AT Server software can store test results in an electronic database This provides a very powerful and versatile method of recording and analysing test results historically or on line The Server uses standard Windows methods including OLE DB and ODBC to connect to a variety of databases that conform to these specifications Once stored in a database the data may then be analysed using tools available in the database application or tools provided by specialist software packages such as those available for SPC Statistical Process Control One example of this
77. limits mOhm Ohm etc when entering absolute values as limits Test limits should be set as close as possible to detect assembly faults PAGE 7 34 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 9 LSB LPB Inductance with Bias Series and Parallel Circuit DC Bias Measure Test Test Basic Range Voltage Frequency Accuracy 1mA to 1A 1nH 1MH 1mV to 5V 20Hz to 3MHz 0 0596 AT Series Tester Inductance is the electrical parameter that is commonly used to check that a high frequency transformer has been constructed according to its design and that it will operate properly in use As well as operating with AC signals some transformers and chokes are designed to operate with a DC bias current flowing in a winding The inductance of a winding is determined by the number of turns and the construction and dimension of the core materials it may also vary with test conditions such as voltage and frequency Where Used The series and parallel inductance tests are used with DC bias when testing transformers with ferrite type cores that carry a significant DC bias current in normal operation Such transformers and chokes are common in switched mode power conversion circuits VOLTECH ATI USER MANUAL PAGE 7 35 TESTS AND TEST CONDITIONS Faults in numbers of turns core material and core gapping may be determined using this test For line frequency iron cored transformers where the inductance varies rapidly with voltage a
78. on the units of limits mH etc when entering absolute values as limits Note that more than one secondary can be short circuited at the same time by adding more of the available terminals to the used section of the dialogue User Offset LLO Test Only This is used to offset the result returned by the AT by a user defined amount l e Result returned Measured result user offset Normally a user offset would not be required However for small values of leakage inductance 14H when there are a number of additional low terminals it is not always possible during fixture compensation for the tester to remove all of the parasitic errors of the test fixture In this case the user offset may be required to fully remove the errors The LLO test provides this additional feature See also the notes under test conditions above Choose test limits as close as possible to the nominal value in order to detect faults It is common practice to specify a maximum limit only VOLTECH ATI USER MANUAL PAGE 7 47 TESTS AND TEST CONDITIONS 7 1 12 C Interwinding Capacitance Test Parallel Circuit Measurement Test Test Basic Range Voltage Frequency Accuracy 100fF to 1mF 1mV to 5V 20Hz to 3MHz 0 1 SEE ALSO THE CS AND CP TESTS AND THE CAPACITOR TESTING AT Series Tester SECTION OF THIS CHAPTER Capacitance occurs in transformers due to the physical proximity of and electrostatic coupling between different turns of wi
79. opportunity The ATi will continue to function without new boot code PAGE 9 8 ATI USER MANUAL WARRANTY AND SERVICE 9 6 VOLTECH AT CALIBRATION SYSTEM e Calibrates tester to full specification including high voltage tests Precision circuits and built in components for reliable error free calibration Minimizes production downtime return to service center not required e Also calibrates AT3600 e Semior fully automatic calibration process controlled by easy to use PC software Voltech recommends that the ATi is calibrated every 12 months to ensure optimum measurement accuracy The calibration system is designed for use by owners of Voltech AT testers and third party calibration companies who regularly calibrate testers or who wish to avoid the production downtime of returning a tester to a Voltech service center e Complete record of results stored on PC e Prints formal calibration certificate showing verification results e Calibration verified by making precise measurements on built in sample R L and C Verification may be performed at any time e Verification L and C may be calibrated separately for external traceability VOLTECH ATI USER MANUAL PAGE 9 9 WARRANTY AND SERVICE The complete calibration system consists of e The calibration fixture that fits into the normal position at the top of the tester pictured e PC software disk to run on a PC 386 or better with 4MB RAM PC not supplied
80. option display is very similar to the beeper volume display again with and J softkeys which this time adjust the display contrast To change the display background select LIGHT or DARK LIGHT has been chosen as the default setting as this will provide the clearest display across a broad range of contrast settings and ambient temperature Clock There are five fields to set up Initially the cursor will be in the first field yyyy which is the year Type the number you require using the keyboard and press the ENTER key or the softkey to move to the next field For the second field mmm which is the month the softkeys change to give the names of each month Press the appropriate softkey to select the month PAGE 2 78 VOLTECH ATI USER MANUAL GETTING STARTED The remaining fields dd hh and mm day hours and minutes are changed in the same way as the year using the number pad BNC Lead Calibration For optimum measurement accuracy in LCR mode using the BNC leads calibration factors are stored within the ATi This calibration is set at the factory for the BNC leads supplied with the ATi and it is not normally necessary to adjust this calibration If the leads are replaced by others or modified in any way then the leads should be re calibrated To calibrate the leads press the softkey Change when BNC lead calibration is selected BHC Lead Calibration Continue BHC
81. processor 486 or better Memory 4MB minimum Hard disk space 2MB minimum Operating system Windows 95 or later Supported screen resolutions 640 x 480 800 x 600 1024 x 768 1280 x 1024 CD ROM drive x2 minimum speed To install the Editor software place the ATi CD ROM supplied with your tester into the CD ROM drive of the computer and follow the on screen instructions PAGE 2 12 VOLTECH ATI USER MANUAL GETTING STARTED The set up program will suggest a directory in which to place the Editor files C Program Files Voltech Instruments Voltech AT Editor This directory will be created if it does not already exist If you want to place the files elsewhere browse to another directory If you have a previous version of the Editor software already installed on your PC the procedure outlined above may also be used to install a new version None of your program files will be lost The same Editor program is used for all AT Series testers excluding the discontinued AT3500 and AT1000 PC COM Port Configuration When the installation of the Editor has been completed you will see the Editor icon in the program group Voltech Software Double click with the left mouse button on the Editor icon to start the program Initially configure the Editor to use the chosen COM port sa New Part Voltech Test Program Editor Part Schematic Program Tester Server Setup Help Setup menu D bell amp 9 9 Communications Prefe
82. softkey b change the set up of by choosing Set Up or c delete from the program store by choosing Delete Or you may choose to create a new test program directly from the front panel VOLTECH ATI USER MANUAL PAGE 6 39 FRONT PANEL MODES Local programs Heu program 3 PROGRAM 1 Delete 6 6 1 Creating a New Test Program In order to create a new test program select New program using the arrow softkey and choose Set Up softkey 2 Local programs Hew program PROGRAM 1 The next screen shown is the test selection screen initially with the absence of any tests PAGE 6 40 VOLTECH ATI USER MANUAL FRONT PANEL MODES Type Energise Measure Set Up Program options To create a new test select Add which will take you to the test selection screen for the standard measure mode see below Select measurement CTY Continuity Winding Resistance Series Inductance Farallel Inductance Use the arrow key softkey 2 to select a test to be set up For example scroll down one line to R Winding Resistance and press Enter to set up a winding resistance test on your ATi tester The next screen that you will see is the set up screen for the selected test In this example the Set up R screen see below VOLTECH ATI USER MANUAL PAGE 6 41 FRONT PANEL MODES Integration Medium Limit type Percentage Delete Hominal limit Hext Hegative
83. table details further Hex Code 0000 xxx1 2 xxx4 XX2x Xx4x Axx 1 Error Test passed with no errors Voltage over range occurred Current over range occurred Ramp up process has been aborted too much load The test parameters could not be trimmed to required value incorrect test parameters for the load An error occurred after ramp down current did not decay away in time Current limit fail hi pot tests only test current exceeded pre programmed limit AT3600 only Voltage present Vpres did not go away in time something on the fixture is staying charged AT3600 only The test has failed due to an interrupt see table below Where reason for interrupt fail The safety interlock interrupt has terminated the test a break has occurred from the safety interlock port AT3600 only A hi pot trip interrupt has terminated the test a flashover has occurred or the current has exceeded the AT s current capabilities can occur on HPAC HPDC and IR AT3600 only A STOP interrupt has terminated the test from the STOP flag of the remote port An 8kV interrupt has terminated the test voltage gt 8kV AT3600 only An over temperature interrupt has terminated the test unit has become too hot AT3600 only An auxiliary trip interrupt has terminated the test this can be created by an attached device to the peripherals port PAGE 3 44 VOLTECH AT
84. the basic relative accuracy Ac is the calibration accuracy Av is the correction for voltage level is the correction for current level 90 Ao is the correction for Q factor 96 is the correction for Bias 96 The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 08 0 00001 x 0 08 0 001 Vy 0 08 0 0001 Im 0 03 x 8 Im Aq 0 08 2 Qy LS LP LSP LPS and X Aq 0 08 2 x Qy RLS and RLP As 0 03 x lg Iu Where Fu is the measurement frequency Hz Vm is the measured voltage V lm is the measured current A lg is the bias current A Qm is the Q factor of the measured impedance PAGE 8 8 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 3 LL and LLO Tests The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test and is given as Ar tAc Av Aj Ao Asc Where Ar is the total accuracy 96 An is the basic relative accuracy 90 Ac is the calibration accuracy 96 Av is the correction for voltage level 96 Ai is the correction for current level 96 Ao is the correction for Q factor 96 Asc is the correction factor for the short circuit impedance 96 The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 08 0 00001 x 0
85. the normal operating conditions of the transformer which could involve for example hundreds of volts This is because the core material can normally be assumed to behave linearly in the operating region and the inductance measured at a low level represents the inductance that will appear in use Also it can usually be assumed that the inductance value does not vary significantly with frequency Therefore although high frequencies are available with the tester measurement frequencies above a few hundred kilohertz should be used with caution This is because the errors caused by the stray inductance and capacitance of your fixture may become much more significant at these frequencies Compensation can be used to eliminate these errors Choosing the Test Signal Wherever possible the table below should be used for all inductance tests The inductance range should be chosen based on minimum value of inductance expected PAGE 7 20 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Preferred Test Signal Frequency Voltage Inductance Range 300KHz 100KHz 30KHz 10KHz 1KHz 100Hz 100Hz 50Hz 50Hz 50Hz 20Hz Ideal Test Conditions for Inductance Measurement The test conditions can also be determined automatically by the ATi according to this table Signal Specified voltage Specified current Auto Specified Specified Frequency Specified Note that a fixed signal cannot be used with an Auto frequency
86. titles and size can be altered by selecting the Titles and Misc tabs Click on OK when finished Double click on the chart definition to display the chart Please refer to the help system of the analysis software that you are using for further advice and information on chart types connectivity options and statistical analysis in general VOLTECH ATI USER MANUAL PAGE 4 33 AT SERIES SERVER Free trial versions of ChartRunner are available from PQSystems at www pqsystems com or any of their regional offices United States PQ Systems Inc Corporate Headquarters Toll free 1 800 777 3020 Phone 1 937 885 2255 E mail sales pqsystems com Europe PQ Systems Europe Ltd Phone 44 1704 871465 E mail sales pqsys demon co uk Asia Pacific PQ Systems Pty Ltd Tel Australia 03 9770 1960 E mail sales pqsystems com au PAGE 4 34 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 3 7 On line Analysis via OLE The MS Windows environment provides a system of transferring data between active applications in real time known as Object Link Embedding OLE OLE2 is the latest version of the transfer standard and is fully supported by the Voltech Server application Embedded data links allow test results received by the Server to automatically pass into a second application which may be your own custom software or a spreadsheet such as Microsoft Excel Server OLE commands also allow you to load and execute test programs O
87. to an AT Series Tester Comprises Base plate including contacts with cover Test piece interface plate B Custom Fixture Kit A kit of parts for constructing your own fixtures Interconnecting wire test probes or clips and a drilling template will also be required Comprises Base plate including contacts with cover Test piece interface plate Probe housing box Bezel Guides 12 PAGE 5 6 VOLTECH ATI USER MANUAL FIXTURES C 40 Socket Fixture A fixture board fitted with 40 4mm sockets 20 red power and 20 black sense The sockets are wired to the 40 contacts which align with the tester s 40 nodes This complete fixture may be used for convenient wiring to existing fixtures or as a means of connecting flying leads and clips for use in developing test programs or testing small quantities D Fixture Clamp The hand clamp is supplied with 7 height blocks and fixings VOLTECH ATI USER MANUAL PAGE 5 7 FIXTURES 5 2 1 Basic Fixture Plate The fixture plate may be used to mount existing test fixtures onto an AT Series Tester or to create test fixtures for flying lead parts where spring probes are not required Fixture Plate Components 1 Base Plate Already fitted with 20 pairs of contacts the base plate fits into the top of the tester and makes electrical connection to the tester s 20 pairs of test nodes The base plate has moulded indents and guides
88. to ease the fitting and wiring of larger test sockets and posts for flying leads 2 Cover Plate This mounting plate allows convenient attachment of various sockets and connectors Please note that this plate is only 1mm in thickness and is therefore not suited for probe or Kelvin pin mounting Refer to the custom fixture kit for this purpose PAGE 5 8 VOLTECH ATI USER MANUAL FIXTURES 5 2 2 Custom Fixture Kit The custom fixture kit enables many types of transformers and other wound components to be quickly and securely connected to an AT Series tester for fast and accurate testing The system can accommodate transformer sizes of up to 63 5mm 2 5 and with suitable probes parts with surface mounting pin blade or flying lead connections can be connected The fixture system is supplied as detailed in the comprehensive user guide to fixture construction The kit is designed such that fixtures can be quickly assembled using a basic vertical drill and simple hand tools NN v m Fixture Kit Components 1 Base Plate Already fitted with 20 pairs of contacts the base plate fits into the top of the tester and makes electrical connection to the tester s 20 pairs of test nodes VOLTECH ATI USER MANUAL PAGE 5 9 FIXTURES The base plate has moulded indents and guides to ease the fitting and wiring of larger test sockets and posts for flying leads 2 Probe Housing Box This 9mm thick plate is designed e
89. used to provide stable accurate results over a broad range of values The tester applies the short circuit automatically without using any external switches or components By measuring and analysing the small voltage present across the short circuit the tester compensates for the impedance of the wiring and other connections in the shorted path The error due to the small short circuit impedance can often be ignored This is the term Asc quoted in the accuracy specifications When measuring on certain components and particularly where the leakage inductance is below 14H it may not be possible for the AT to properly compensate for all parasitic effects To confirm the accuracy of the LL test during program development manually apply a good short circuit to the transformer and run a normal LS test The best short circuit will be a length of tinned copper wired as short as possible securely soldered directly across the secondary connections If the result of this LS test is significantly different to the LL test without the manual sort circuit but under the same test conditions then use an LLO leakage inductance with offset test with an appropriate offset for production testing For example LL 550 nH LS 500 nH perfect short circuit same conditions Use an LLO test with 50nH offset Choosing the Test Signal Choose a suitable test current and frequency based on the expected value of the leakage inductance using the follo
90. using the Editor PC Part Schematic Program Tester Server Setup Help DSa S 2 r Download Program Upload Program Compensate Fixture Run Program Download Firmware Set Password Once a program has been entered using the Editor and downloaded to the tester the tester will display SAVE PROGRAM Continue Saving this program to the local store will overwrite an existing program group Local Save Press Local Save and the program that has been downloaded from the PC Editor will be saved in the tester s local program store Note that any programs previously stored in the tester will be lost All PC connections to the tester may now be removed PAGE 2 86 VOLTECH ATI USER MANUAL 3 PROGRAM EDITOR VOLTECH ATI USER MANUAL PAGE 3 1 PROGRAM EDITOR PAGE 3 2 VOLTECH ATI USER MANUAL PROGRAM EDITOR Contents Program Editor 3 1 CREATING A PROGRAM eene nn nn nnn nn 3 5 3 2 CREATING THE TRANSFORMER SCHEMATIC eren eene nennen 3 6 3 2 1 Adding a Transformer Winding eene 3 7 3 2 2 Connecting the Winding Terminals to 5 3 8 3 2 3 Deleting a D etre 3 8 3 2 4 Renaming a Terminal sss sienne ehh sinn 3 9 3 2 5 Adding a Terminal to an Existing Winding sss
91. values of capacitance Capacitance Range Preferred Test Signal Frequency Voltage 100KHz 100KHz 10KHz 1KHz 100Hz 100Hz Test Conditions for Capacitance Measurement The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 49 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Capacitance r Test Parameters Set Limits Test Voltage CV Short Medium Test Frequency fo Hz CkHz CMHz C Long r High Terminals Low Terminals Available Used Available Used JA B B Cc C D D Ad gt Ad gt Remove Capacitance Limits C Gx Minimum 0 pF C nF CuF s Maximum 0 pF C nF C uF Measure Cancel Voltech Choose the integration period normally Medium and enter the terminals to be measured More than one terminal can be High and more than one terminal can be Low This is to allow testing of the complete primary to secondary capacitance of a transformer by taking all primary terminals High and all secondary terminals Low When choosing the test conditions the following potential problems should be considered a Current Levels For larger capacitance particularl
92. winding will be removed from the screen together with any connections to that terminal that are present Note that ALL tests containing the deleted terminals will also be DELETED 3 2 7 Adding a Core Connection To add a core connection 1 Choose Add Core Connection from the Schematic menu as Voltech Test Program Editor New Part Part Tu sl ud Tester Server Setup Help A connection from the core will appear on the screen You may now add a core to node connection 3 2 8 Deleting a Core Connection To delete a core connection 1 Select the core connection that you wish to delete by left clicking on it with the mouse 2 Choose Delete Core Connection from the Schematic menu 3 The connection from the core will be removed from the schematic Note that ALL tests containing the deleted core will also be DELETED VOLTECH ATI USER MANUAL PAGE 3 11 PROGRAM EDITOR 3 2 9 Adding a Screen Connection To add a screen connection 1 Choose Add Screen Connection from the Schematic menu Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Help Diem eem C L A connection from the screen will appear on the schematic You may now add a screen to node connection 3 2 10 Deleting a Screen Connection To delete a screen connection 1 Select the connection that you wish to delete by pointing at it with the mouse pointer and pressing the left mouse butto
93. 08 0 001 Vy 0 08 0 0001 Im Aa 0 08 2 Qm As 0 03 x Ig Iu Asc Zscx Turns Ratio x 100 Measured LL Where Fu is the measurement frequency Hz Vm is the measured voltage V lm is the measured current A lg is the bias current A Qm is the Q factor of the measured impedance Zsc is the impedance of the applied short circuit See Chapter 7 Tests and Test Conditions for a guidance on Asc VOLTECH ATI USER MANUAL PAGE 8 9 SPECIFICATIONS 8 2 4 C CS and CP Tests The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test and is given as Ar Where An Ac Ay t Aj Ag Ar is the total accuracy 96 is the basic relative accuracy 96 is the calibration accuracy 96 is the correction for voltage level 96 is the correction for current level 90 is the correction for Q factor 96 is the correction for C 96 The value of Ag is given in the section 1 1 of this chapter The values of the other factors are given below Ac Av Ag Af Where Fm Vm Iu Qu Cm PAGE 8 10 300x10 0 08 0 00001 x 0 08 0 001 Vm 0 08 0 0001 Im 0 08 2 Qu 15 x 100 CM is the measurement frequency Hz is the measured voltage V is the measured current A is the Q factor of the measured impedance is the capacitance of the measured impedance VOLTECH ATI USE
94. 13 7 1 4 R2 DC Resistance Match 7 16 7 1 5 LS LP Inductance Series and Parallel Equivalent Circuit 7 19 7 1 6 QI Quality Factor iua ia ag aie arid eee 7 26 7 1 7 D Dissipation Factor or Tan essssse eene 7 29 7 1 8 RLS RLP AC Resistance Series and Parallel Circuit 7 32 7 1 9 LSB LPB Inductance with Bias Series and Parallel Circuit 7 35 7 1 10 L2 Inductance Match seen 7 40 7 1 11 LL LLO Leakage Inductance and Leakage Inductance with Offset 7 43 7 1 12 C Interwinding Capacitance Test Parallel Circuit 7 48 7 1 13 CS and CP Capacitance Test Series and Parallel Circuit 7 52 7 1 14 C2 Capacitance Match seen 7 54 7 1 15 TR Turns Ratio and Phasing eeen 7 57 7 1 16 TRL Turns Ratio by Inductance eene 7 64 7 1 17 LVOC Low Voltage Open Circuit eene 7 69 7 1 18 IR Insulation Resistance ssse eee 7 73 7 1 19 GBAL General Longitudinal Balance see 7 76 7 1 20 LBAL Longitudinal Balance sees 7 81 7 1 21 RESP Frequency Response ss eee 7 85 7 1 22 ILOS Insertion Loss eiie 7 89 71 28 REOS Ret tm dae iri d e Pit daseeg oc atideda 7 92 7 1 24 Z ZB Impedance Impedance with 5
95. 3 INTRODUCTION 1 7 USING THE ATI FOR DESIGN AND EVALUATION e Tests L C Z D Q Rac X Z 8 Rdc Insulation Resistance Turns Ratio Leakage Inductance Bias current up to 1A e Fully programmable 5V 3MHz or AUTOMATIC test conditions 0 05 basic accuracy e 4 terminal Kelvin connections using high quality leads supplied e Easy to use e Compensation for stray resistance inductance and capacitance 161 86H 1 6646 More 15 PAGE 1 14 CBHC made Settings Pegi AUTO U AUTO Hz Mes 9 91ml 2 33mBH 1kHz ERIT 365 57m a TRL LL C More C445 IL Hp NE CFixture mode Set AUTO Us AUTO Hz uu zb n H a uw m n es aai Mes 2 84 lU 1 a me VOLTECH ATI USER MANUAL INTRODUCTION 1 8 OVERVIEW This section gives a more detailed overview of your ATi and how to use it It is recommended that you read this section before attempting to use your tester Topics covered in this overview e The features and functionality of the ATi in a production environment e What appears in a test program e How programs are created archived and then used in actual test e Test fixtures e Typical manual and robotic test situations Internal functionality How the tester executes each test Note This overview is intended as an introduction to each of the above topics so that you may quic
96. 3 10 3 2 6 Deleting a Terminal From an Existing 3 11 3 2 7 Adding a Core Connection essen 3 11 3 2 8 Deleting a Core Connection seen 3 11 3 2 9 Adding a Screen Connection seen 3 12 3 2 10 Deleting a Screen Connection sss eene 3 12 3 3 CREATING THE TEST PROGRAM eese enne nennen nnn nn nnn nnn nnns 3 13 3 3 1 Setting the Program Options 3 14 95 2 Adding T651S cg mese toit ee Pant so PLI e deoa 3 21 3 3 3 Inserting Tests E EE 3 22 3 3 4 Modifying Tests eic Hee nete e Enea 3 24 3 3 5 Deleting Tests si eoe eee enne 3 25 35 6 Test Parameters eie Ep tr dte tur eater 3 26 3 9 7 Test Limits e net e deer es 3 27 3 4 USING THE 3 31 3 4 1 Hardware Connections for Using the Measure Button 3 31 3 4 2 Example of Using the Measure Button with the LS Test 3 32 3 4 3 Restrictions for Automatically Obtaining Test Parameters 3 37 3 4 4 Verifying Your 8 1 3 38 VOLTECH ATI USER MANUAL PAGE 3 3 PROGRAM EDITOR 3 5 5
97. 7 GETTING STARTED Server programs Fur FROGFEHM 1 Set Up TUTORIAL Delete 11 4 When the download has been successfully completed you will see a message to fit the fixture similar to the following Fit the fixture Compensate FISTURE ID I 5 As the fixture is already fitted and compensation is not required with the sample transformer simply press the No Comp softkey to move on to the Run Finish display PAGE 2 38 VOLTECH ATI USER MANUAL GETTING STARTED Fart number TUTOR TAL Settings 6 Press the Run softkey to start program execution As the program is running the RUN indicator the yellow LED to the left of the display will be illuminated and the display will indicate the test currently being executed Part number TUTORIAL Executing test 1 At the end of program execution the PASS indicator the green LED to the left of the display should be illuminated and the display should show VOLTECH ATI USER MANUAL PAGE 2 39 GETTING STARTED Fart number Fur TUTORIAL Settings Total 1 Failed B Hx Results Last transformer A 5 7 Press the RUN softkey several times to repeat the program execution On each run of the program the test results should be passed back to the Server where they may be viewed in the On line Monitor window ioi l CTY 624 02 mOhm PASS 0000 2 15 1 1846 mH PASS 0000 3 TR 2 7096 PASS 0000 1 POL PASS If batch statistics have b
98. AGE 6 13 FRONT PANEL MODES OFF contols are provided for maximum operator safety To measure insulation resistance select IR from either the LCR BNC or LCR FIX modes Insulation Resistance Ma Mare 5 4 tf Un Fixture made Settings Fregi i88 U CAUTION The insulation resistance test can generate voltages of up to 500V DC Although the available energy of the source has been limited in accordance with EN61010 1 care should be taken to avoid accidental or unexpected electrical shocks For this reason the high voltage insulation resistance source must be turned on by pressing softkey 3 every time this screen is displayed When softkey 3 HV Off On is pressed the high voltage is applied to the chosen nodes On is shown in reverse video and both the program and measured voltages are shown at the bottom of the display Press softkey 3 HV Off On to switch off the high voltage when handling or connecting the part under test Press softkey 6 EXIT to return to the main LCR sreen PAGE 6 14 VOLTECH ATI USER MANUAL FRONT PANEL MODES Settings for the voltage integration can be changed by pressing softkey 4 Settings A Print option is included in the following menu Insulation Resistance IR Woltage Integration CFixture modes Prq 188 m 3 a a 7 ce Press softkey 1 IR Voltage IE voltage settings IR 8 88868 i at
99. ARRANTY AND SERVICE The firmware upgrade will now commence and the Editor screen will show a series of dialogue boxes to identify each stage in the process The download should take approximately 30 minutes In the unlikely event that the Editor display shows an ERROR dialogue box before the download is complete try repeating the entire procedure Should the error persist contact your Voltech distributor At the end of the download the tester will reset itself You may then carry on using your tester as normal with the benefits offered by the new firmware being available immediately If you were supplied with a BOOTATI ABS file the Editor will now check the boot code version already inside the AT If the boot code requires upgrading the Editor will prompt you with a warning that communications must not be disrupted during the 12 minutes that it takes to upgrade the boot code WARNING You must NOT switch off the AT or interrupt the communications during the 12 minutes required for this part of the upgrade If the power is removed from the ATi or the communications disrupted in any way during this process the ATi may be rendered inoperable and require service at a service center For optimum performance and reliability always upgrade the boot code when prompted If there is a risk that power or communications may be disrupted you may choose not to upgrade the boot code at this time but you should do so at the earliest
100. ATI USER MANUAL GETTING STARTED 2 1 3 Other Data Inputs To give you the greatest ergonomic flexibility methods other than the keyboard can be used to initiate testing and enter data Run pads Two stainless steel discs at the front of each side of the ATi Lightly touching the programmable run pads will start the programmed test sequence Footswitch The Run input of the Remote Port on the tester s rear panel can be optionally connected to a footswitch Barcode Input A barcode reader connected to the Barcode Port on the tester s rear panel can optionally be used to input text data such as the name of the test program or the transformer batch or serial number of the transformer VOLTECH ATI USER MANUAL PAGE 2 9 GETTING STARTED 2 2 INSTALLATION 2 2 1 Switching on the ATi Place the tester on a stable level work surface in the position where it is to be used Ensure that the top surface of the tester is not fitted with any test fixture and nothing is touching any of the test nodes Connect the tester s line input to the available supply and switch on using the switch next to the line input at the back of the ATi 0 7 off You must connect the power lead to a socket with a safety ground contact When the ATi tester is switched on it performs a self test which lasts for about 10 seconds During power on self test you will see information concerning your ATi s configuration on the display includi
101. D TEST CONDITIONS 7 1 7 D Dissipation Factor or 8 Measurement Test Test Basic Range Voltage Frequency Accuracy 0 001 to 1000 1mV to 5V 20Hz to 3MHz 0 5 SEE ALSO THE CAPACITOR TESTING SECTION OF THIS CHAPTER AT Series Tester The parameter D is most often used as a measurement of the losses in a capacitor It is analogous to Q for a transformer winding For this equivalent circuit the Dissipation Factor D is defined as D Rs where o 2zf 1 aCs For a given capacitance the lower the equivalent series resistance the lower is the value of the dissipation factor or tan i e the better the capacitor Where Used The dissipation factor test would normally be used for capacitors of all types A D factor test will help to determine that the capacitor has been manufactured correctly VOLTECH ATI USER MANUAL PAGE 7 29 TESTS AND TEST CONDITIONS Test Conditions To measure Dissipation Factor the tester applies an AC voltage across the selected winding and measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain a complex impedance from which the Dissipation Factor is obtained Choosing the Test Signal For optimum accuracy and performance use the test conditions chosen for capacitance in a later section of this chapter The test conditions can also be determined automatically by the ATi according to this table
102. Device Contention 1 0 Address E Always Warn Never Wain IRQ Line Idle in sec Example of set up for DIGIBOARD Server Software Set up When the installation of the Server has been completed you will see the Server icon in the program group Voltech Software Double click with the left mouse button on the Server icon to start the program Before you can use the Server the PC communication channels must be assigned for each tester connected PAGE 2 16 VOLTECH ATI USER MANUAL GETTING STARTED When the Server is executed for the first time the following dialogue will be displayed Configure Server Communications x Voltech Tester Type COM Port __ COM1 AT x Open COM4 Add gt Remove Do not display this dialogue at Startup Close A check box Do not display this dialogue at Startup exists to prevent it from being displayed each time the Server application is launched When this option is activated this dialogue box can be accessed via the Setup Communications menu To assign a particular AT Series Tester to a COM port 1 Select the communication port to which your tester is connected from the COM Port selection box 2 Click on the Add button to append your connection to the current connection list 3 To remove a current connection select it from the list and then click on the Remove button
103. ES V 100mV Rc sme Rc 5mO Rc 5mo Rc 5mo R 1 000 4 wire measurement circuit The current flowing is the same 1 100 0mV 1014mQ 98 62mA But the voltage measured is now 1 0000 x 98 6mA 98 6mV And the dc resistance calculated is VwR 98 6mV 98 6mA 1 0000 4 wire R 1 0000 The correct result In general a true Kelvin connection provides the most accurate means of sensing the voltage across any impedance AC or DC and hence helps to produce an accurate measurement of that impedance without errors due to lead and contact resistance The voltage measured can also be used to trim Vm to the desired voltage PAGE 5 20 VOLTECH USER MANUAL FIXTURES Ideally all impedance measurements would be made using Kelvin connections However many terminals do not permit the use of four wires all the way to the body of the component under test In such cases separate power and sense leads are used up to the base of the terminal and the length of common lead from the junction of the power and sense leads through the terminal and the component lead to the body of the component should be kept to a minimum The common lead length is shown as AA and BB in the diagram below Semi Kelvin Connection VOLTECH ATI USER MANUAL PAGE 5 21 FIXTURES The AT Series testers provide all the connections required to take advantage of Kelvin measurements A test node m
104. H ATI USER MANUAL PAGE 7 113 TESTS AND TEST CONDITIONS 7 3 CAPACITOR MEASUREMENTS The ATi and its front panel LCR mode are ideal for making precise measurements on capacitors Capacitance Farads To measure the capacitance use the C test in the PC editor or simply select C on the top line of the LCR mode The measurement conditions can be fully automatic or user programmed following the guidelines given earlier in this chapter Measurements are usually made using the parallel equivalent circuit see the preceding section D Dissipation Factor or tand D can be selected as a second line parameter of the LCR mode Disa measure of the losses in a capacitor and is defined to be D Energylost Real part of impedance Rs tan 5 Energy stored Imaginary part of impedance X Where is the angle between the total complex impedance Z and the imaginary axis PAGE 7 114 VOLTECH AT USER MANUAL TESTS AND TEST CONDITIONS ESR Equivalent Series Resistance This is also a measure of the losses in the capacitor The ESR is the equivalent AC resistance of the series equivalent circuit To measure ESR choose the test RLS in the PC editor or select Rs SERIES circuit from the front panel LCR mode Use the test conditions determined for the C test ESR is a measure of equivalent AC resistance at a specified frequency and will be different to the expected DC resistance of contacts and leads Compensation For most capac
105. I USER MANUAL PROGRAM EDITOR 3 6 FIXTURE COMPENSATION SEE ALSO SECTION 2 8 Often when measuring small values of resistance inductance or capacitance the effects of the fixture can add significant errors to the results To allow you to make more accurate measurements the AT Series Testers have built in firmware to compensate for fixture parasitics If fixture compensation is required follow steps 1 2 and 4 of the procedure described earlier in this chapter so that the tester is connected and the program is downloaded Then from the top level menu bar select Tester gt Compensate Fixture Most programs will contain at least one test where fixture compensation can be applied In this case you will then see one or two messages Series Editor Software A X e Short Circuit Fixture Compensation will be applied to this program Fit a short circuit link in place of each winding Yes No At this point you should ensure that the appropriate fixture has been placed on the tester and a short circuit bobbin fitted For the following open circuit compensation remember to remove the short circuit bobbin After you have clicked on the OK button at either of the messages the tester will be commanded to make the compensation measurements for your test program VOLTECH ATI USER MANUAL PAGE 3 45 PROGRAM EDITOR If errors are encountered such as a shorting link is not fitted the Editor will display the appro
106. IMPORTANT You must have at least one AT Series Tester connection to use the program transfer or results storage functions of the Server application VOLTECH ATI USER MANUAL PAGE 2 17 GETTING STARTED The final stage of setting up the Server involves specifying the file location paths L AT Server File Setup View Help amp Communications Results Select directories used when looking For and saving programs and results The directory set up dialogue will prompt you with the current directory Change these settings if you wish to nominate your own program and results storage directories Set Default Directories E 2 x Program Directory cr 3600 SERVER Results Directory C PROGRAM FILESSVOLTECH Cancel The setting of program path directories may be altered at any time The directory set up dialogue may be found under the Setup section of the menu bar IMPORTANT If you change the factory default settings remember that the Server will only look in the directories specified for test programs or results PAGE 2 18 VOLTECH ATI USER MANUAL GETTING STARTED 2 3 QUICK START TUTORIAL 2 3 1 Introduction After you have installed your ATi and its associated Editor and Server PC software packages as described in the previous section you may wish to follow through this tutorial before trying to create any programs for actual use The purpose of this tutorial is to familiarize you with the
107. Individual moving sigma C c chart C Moving average moving range C wchart C ber C Pareto chart bar or pie chart C Range C Scatter diagram C Sigma C Trend chart 1 to 4 data lines Individuals C Median C Run chart View Data Save as default OK Cancel VOLTECH ATI USER MANUAL PAGE 4 29 AT SERIES SERVER Enter a chart type the refresh rate for online analysis and the chart type Click on the Data source tab to choose the results database CHARTrunner Inductance Chartname type Data source Data definition Limits Control chart Titles Misc Database or file name C Program Files Voltech Instruments Voltech AT Server Sample Access Datab Iv Keep current column mappings and allow for non existing file Under the Data definition tab CHARTrunner Inductance G x Chart neme type Data source Data definition Limits Control chart Titles Misc Source for data records Table Table Iv Keep columns Plauen arview thlVoltechResults v Column to use for Order By C Stored procedure C Custom query Filtering SQL settings n Advanced The Filter is disabled Result records to include 1 How to treat the columns Column name Data type Treat as Display name TestNo Long OC_Comp Text SC Comp Text Load Comp Text Result Double Measurement TestStatus Tex i Re
108. LE is the analysis and control method preferred by users who wish to operate the AT under software control OLE is already configured ready to go within the Server application Your client application will need to be set up to request data from the Server Refer to your own application handbook for details of OLE set up IMPORTANT Attempting to make more than ten data requests per second may result in data loss or corruption NOTES The automation object is called Server Results The exposed OLE automation methods are GetVariantResult LPCSTR ComPort short TestNumber Where LPCSTR ComPort is a pointer to a string ComPort ComPort COM 2 COM9 The port connected to the AT Series Tester that gives the required result TestNumber Integer number for test within program VOLTECH ATI USER MANUAL PAGE 4 35 AT SERIES SERVER The number returned is a float representing the value of the result measured or a zero if no result was available This call returns a result on success or a failure string INVALID COM PORT no valid COM port found COM PORT IS NOT OPEN COM port requested not connected to an AT Series Tester INVALID RESULT NUMBER the requested result number is out of range NO RESULT no updated result data available Further Voltech Server OLE functions are described below They use the same format and failure strings as GetVariant Result Only function specific responses and return values
109. M SPECIFICATION The Voltech custom fixture is designed to connect to wound components with the following characteristics Size A footprint of up to 63 5mm square A height of up to 63 5mm A connection matrix up to 60mm square Connection types Surface mount Pin connection Blade connection Flying leads Pitches of 1 27mm 2 00mm 2 50mm 2 54mm 0 1 3 81mm 0 15 There are some application limitations to the above For example the minimum pitch of the blade type that can be connected to is determined by the minimum pitch that the necessary connector can be put on Also although a 1 27mm pitch is available it is only anticipated that component connections will be on multiples of this pitch and there will not be two connections only 1 27mm apart PAGE 5 12 VOLTECH ATI USER MANUAL FIXTURES Compatible connection types Kelvin clips Kelvin blades 4mm sockets ATE pin types Rotary point Castellated Point Cup Crown 5 4 FIXTURE PARTS AVAILABLE FROM VOLTECH A number of components parts and kits are available from your Voltech supplier to help you assemble your own fixtures MORE INFORMATION A comprehensive guide to the construction of your own custom fixtures is supplied with each custom fixture plate kit A copy of the guide is also available on the ATi CD ROM in Adobe PDF format Please contact your Voltech supplier for more information or visit our website at www voltech com for details
110. MQ to 5V 20Hz to 3MHz 0 05 AT Series Tester The equivalent AC resistance of a winding may be different to that measured at DC The resistive part of the complex winding impedance will be modified by in phase core losses and skin and proximity effects The transformer PR losses will then be different to those calculated using the DC resistance Where Used The equivalent series or parallel resistance test is used to determine the AC equivalent resistances of a transformer As opposed to the DC resistance test R which uses DC voltages the RLS and RLP tests apply AC voltages at a specified voltage and frequency The measurement of AC resistance at a particular frequency helps to ensure that the winding has been correctly wound with the correct gauge of wire and correctly assembled onto the correct type of core material Normally the equivalent resistance test would follow an inductance test on the same winding Using the same test conditions for both tests will speed the execution of the program PAGE 7 32 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Test Conditions To measure equivalent resistances the AT applies an AC voltage across the selected winding and measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain a complex impedance from which the equivalent series and parallel resistances are obtained Choosing t
111. N As an example the sequence for measuring inductance may be summarized below Select Nodes Select Type Set up Source Relay Switching Of Source Frequency Ramp up Source Voltage Y Change Source Measure V amp I Voltage Harmonic Analysis Signal Level Correct Y Compare With Calculate L Ramp down Test Limits Inductance Source Voltage For other tests the sequence may be more complicated Notes All the relay switching is completed before the test source is energized This will ensure that there can be no arcing and prolong the life of the relays In contrast to some LCR bridges the AT Series testers trim the test source to give the user programmed test conditions This will guarantee that the same test conditions are applied to all transformers that use the same test program At the end of the test the source is safely ramped down so that the relay switching for any subsequent test will always occur with the source removed PAGE 1 28 VOLTECH AT USER MANUAL 2 Getting Started VOLTECH ATI USER MANUAL PAGE 2 1 GETTING STARTED PAGE 2 2 VOLTECH ATI USER MANUAL GETTING STARTED Contents Getting Started 2 1 INTRODUCTION cis ccdacciecicecocescdaceccadaccedicelacedenizasecctadsccctictsacetacdssitanaciateacsiae 2 5 2 1 1 Package Contents cccccccccceesseneeececeseenenaeeesecsssaenaneesecstsaeeaanesteseensens 2 6 2 1 2 The eo eene 2 7 2 1 3 Oth
112. O C Comp to begin open circuit compensation PAGE 2 72 VOLTECH ATI USER MANUAL GETTING STARTED 4 Press softkey 4 No Comp to abort compensation and begin running the program Once you have chosen either S C compensation or O C compensation the ATi will make very accurate measurements of the stray components A typical S C compensation measurement might take 10 seconds or more during which time you will see a progress bar on the display Compensating fixture Following one compensation and assuming that you have performed S C compensation first you will be prompted to perform the other compensation O C compensation in this case Remove the S C bobbin but leave the fixture in place before performing an O C compensation You do not have to perform both types of compensation but it is always recommended VOLTECH ATI USER MANUAL PAGE 2 73 GETTING STARTED 5 compensation FAIL SC Comp For S7C COMP connect all used terminals together Ho SC Comp Should either S C or O C compensation display a FAIL as shown above check e The short circuit connections for S C compensation e That there are no erroneous short circuits on the fixture e That the fixture is properly seated and locked down into the fixture bay e That for each node that is used the fixture short circuits power and sense together when there is no test piece in place Once compensation has been successfully completed the compensatio
113. OM port from the Editor to the Server e Close down the Editor by clicking on Part gt Exit in the top level menu e Startthe Server by double clicking on its Windows icon e Configure the COM port as shown earlier e Remove the cable between the AT auxiliary port and the PC COM port e Connect the cable between the AT Server port and the PC COM port VOLTECH ATI USER MANUAL PAGE 2 33 GETTING STARTED 2 3 6 Running a Program on the Tester Having stored the program in the Server archive it is now possible to run the program on any AT that is connected to the Server Before proceeding further make sure that the Server is running with the interface cable correctly fitted between the tester s server port and the selected Server PC COM port and the COM port is correctly configured in the Server software At this point the tester should still be powered on and the display should still show a Last transformer message produced when the test program was run from the Editor It will be similar to the following Fart number Fur TUTORIAL Settings Total 1 Failed amp Results Last transformer P 5 Finish Before running any new test program return the tester to the top level menu by pressing the Finish softkey PAGE 2 34 VOLTECH ATI USER MANUAL GETTING STARTED Use the following sequence of key presses to ensure that the AT is configured to use the Server as the source for test programs 1 From t
114. Part sse nnne 4 8 4 2 4 Deleting a Test Program sss sisisssssss sees th nennen nina 4 9 4 2 5 Grouping Test Programs seen 4 10 4 3 5 5 4 11 4 3 1 Receiving Test Results esee 4 11 4 3 2 Result Display and Analysis ssssssssssssss seen 4 13 4 3 3 Simple On line Monitoring sss 4 13 4 3 4 Batch Statistics On line Analysis ssssssssssseen 4 14 4 3 5 On line Analysis via a 5 4 17 43 6 Database Tables e eterna 4 24 4 3 7 On line Analysis via OLE sss 4 35 4 3 8 Additional Notes for the Above 8 4 43 4 3 9 Offline Analysis petit ee dia ee PU das d duet Lado 4 45 4 4 LICENSE 4 50 4 4 1 Enabling the Licensed Features sssssenn 4 50 4 4 2 Transferring the License to Another PC seen 4 52 VOLTECH ATI USER MANUAL PAGE 4 3 AT SERIES SERVER PAGE 4 4 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 1 INTRODUCTION The Server program supplied with your AT Series Tester may be
115. R MANUAL SPECIFICATIONS 8 2 5 QL and D Tests The accuracy of measuring Q factor and D factor is given as Ar Ar A Aap Where Ar is the basic total accuracy Ar is the basic relative accuracy is the correction for current level 96 Aap is the correction for Q or D factor The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below 0 08 0 0001 Im Aap 0 2 x Qu 1 Qu Q factor Aap 0 2 x Du 1 Dm D factor Where is the Q factor of the measured impedance Dm is the D factor of the measurement impedance Iu is the measured current A VOLTECH ATI USER MANUAL PAGE 8 11 SPECIFICATIONS 8 2 6 TRTest The accuracy is based on the test conditions chosen to measure the turns ratio and is given as Ar Where Ar An Ac Asv An Ar Ac Apv Asv An is the total accuracy is the basic relative accuracy is the calibration accuracy is the correction for primary voltage level is the correction for secondary voltage level is the correction for the turns ratio value The value of Ar is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac Apv Asv An Where Fm Vem Nu PAGE 8 12 0 1 0 00003 x 0 1 0 01 Vem 0 1 0 01 Vsu 0 1 0 1 Ny is the measurem
116. S AND TEST CONDITIONS Programming the Test Using the PC Test Editor Return Loss Test Parameters m Integration Voltage 1 C mv oy C Shot Medium Frequency 0 Hz CkHz C MHz C Long Terminals Reference Impedance High Terminal Low Terminal Real fo Ohms D nni nn i Imaginary Ohms Return Loss Limits Caj Minimum jo dB C C Maximum jo dB OK Measure Cancel Voltech X Choose the integration period normally Medium and enter the High and Low Terminal names The reference impedance values are the nominal values of the transmission line to which the transformer will be connected in its final application This is a complex impedance Z R jX where R is the real part of the impedance and X is the imaginary part A typical impedance might be 600 resistive only or 6000 in series with a 2 15uF capacitor Entering the impedance in terms of R and X allows even more complex networks to be used for the RLOS test Remember that X the imaginary impedance is the impedance at the specified test frequency 1 2nfC Note that the PC Editor s Measure button CANNOT be used to determine the test voltage PAGE 7 94 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt Amaximum value only U
117. Shift Use the arrow key to scroll through and set up the test parameters For example to set up limits scroll to the Limit type line and press softkey 3 three times to enter both minimum and maximum limit values Set up R Integration Medium Limit type Min amp Max Percentage Minimum limit Delete Maximum limit Hext Hi nade Shift Use the down arrow key again to scroll to the Minimum limit and Maximum limit lines and enter your limit values from the instrument keypad For example enter 59 and 73 using the numeric keypad PAGE 6 42 VOLTECH ATI USER MANUAL FRONT PANEL MODES Set up R Minimum limit 53 Hi nade Delete La nade Hext Shift Then scroll down again to choose your high and low nodes Set up E Hi node 3 Delete Hext Shift Choose Next At the following display see below you may choose to Measure if the test that is being set up supports this functionality Pressing Measure will update the limits as well as signal and frequency if those parameters are set to Auto similar to the Measure button in the AT Editor program VOLTECH ATI USER MANUAL PAGE 6 43 FRONT PANEL MODES Set up R Hi node 3 Measure Lo node 7 Delete Back Shift Choosing OK will return you to the program test selection screen which should now correctly display the test parameters that have been entered in a table format see below
118. T CONDITIONS Test Conditions To measure capacitance match the tester makes two capacitance measurements see the C test and compares the two results Limits for the match of the two measured capacitances may be set in terms of the ratio between them e g 1 1 5 By adding further capacitance match tests to the program any number of inter winding capacitances can be tested for match The AT Series Testers use a parallel equivalent circuit for capacitance match measurements Programming the Test Using the PC Test Editor Choose the integration period normally Medium To enter the capacitor terminals into the Editor C2 test dialogue box add the terminals for the first capacitor X into the High and Low areas For example if the capacitance is between terminals A and B add A to the High Terminals X Used area and B to the Low Terminals X Used area Interwinding Capacitance Match Test Parameters Integration Voltage o C mv cy C Shot Medium Frequency 0 GHz CkHz CMHz C Long High Terminals X Low Terminals X Available Used Available Used Add Remove Add Remove Matching Limits Terminals Y i i 0 Nominal Ratio X Y Negative Positive zz 5 Error Error VOLTECH ATI USER MANUAL PAGE 7 55 TESTS AND TEST CONDITIONS Then click on the Terminals Y button and add the High and Low term
119. T alter the designation of primary 13 15 and secondary 14 16 Turns ratio is always displayed as the ratio between primary 13 15 and secondary 14 16 windings 365 57M TRL LL C More C445 PHA Np REE Fixture modes Settings Pergi AUTO Y AUTO Hz es fae Sec Mest 2 64 lU 1 m5mH EXIT PAGE 6 12 VOLTECH ATI USER MANUAL FRONT PANEL MODES By default the number of primary turns is assumed to be 1 In this example Np Ns 1 0 365 To display the actual number of turns as measured enter the number of primary turns by pressing the appropriate buttons on the numeric keypad Note Only numbers and a decimal place can be entered for Np E g Np 1000 Np Ns 1000 365 365 47 TRL LL C More C445 FHAS ELEM CFixture mode Settings Prg AUTO Us AUTO Hz Mes 2 84 lU 1 The number of primary turns entered will be retained by the tester until the More softkey is selected i e if you exit LCR FIX and re enter or if you select TRL LL or C the value for Np remains the same 6 1 3 Insulation Resistance Insualtion resistance measurements involve applying a relatively high DC voltage to the part under test in order to measure a high value of resistance Because of the high voltages involved IR meaurements operate in a slightly different way to other tests There is a separate voltage setting menu and ON VOLTECH ATI USER MANUAL P
120. Up To modify an option Press the cursor softkeys T and J which appear in context to scroll up and down the list so that the option you wish to modify is positioned on the third line For most options press the third softkey to cycle through the available settings for that option In the example of Pass Beeper this will be PAGE 2 76 VOLTECH ATI USER MANUAL GETTING STARTED Set Up Fail Beeper SHORT Key Response CLICK Beeper Volume Display Contrast The full list of available options is shown below Fail Beeper SHORT CONTINUOUS OFF Pass Beeper SHORT OFF Key Response CLICK BEEP Beeper Volume CHANGE Display Contrast CHANGE Display Background LIGHT DARK Clock yyyy mmm dd hh mm Touch Pad Options LAND R LORR LONLY RONLY OFF Pad Response CLICK BEEP OFF BNC Lead Calibration CHANGE AT Password CHANGE Program Store SERVER INTERNAL Five of the options require more than just pressing the third softkey VOLTECH ATI USER MANUAL PAGE 2 77 GETTING STARTED Beeper Volume Pressing the softkey Change brings up an additional display Beeper Wolume Press T and to adjust then ERIT Press the f and 4 softkeys until the beeper makes the level of sound that you require then press the EXIT softkey to return to the set up list Display Contrast The additional
121. VOLTECH ATI USER MANUAL AT SERIES SERVER 4 3 2 Result Display and Analysis Four approaches have been provided to allow observation of your test result data e Simple on line monitoring e Batch statistics on line analysis e Ondine analysis e Off line analysis 4 3 3 Simple On line Monitoring Each time a COM to AT Series Tester connection is opened using the Setup Communications menu an accompanying result monitoring window will be created One result monitoring window will be present for each open channel When results are sent from the tester they will be displayed in the monitoring window before passing to the batch result file The most recent result for each channel will be visible in the window An open result window may be minimized at any time and subsequently maximized using the icons indicated Minimize Maximize AT3600 Server AT3600 om Ele Setup View Window Help W AT3600 on COM5 AT3600 on COMG 1 R 67 826 Ohm PASS 0000 3 2 L5 3 3237 H PASS 0000 3 TR 1 0007 PASS 0000 VOLTECH ATI USER MANUAL PAGE 4 13 AT SERIES SERVER 4 3 4 Batch Statistics On line Analysis Setting Up Batch Statistics From the Set up menu select Results to see the following dialogue Results Setup x Standard Results Saving CSV Display Basic Statistics Database Results Saving Advanced Cancel Select Display Basic Statistics to save results to
122. able in the ATi s front panel LCR meter mode Programming the Test Using the PC Test Editor Continuity x Test Parameter ER Max Continuity Resistance fio kOhm C MOhm a value of 10 kOhm is optimum for speed Cancel Choosing the Test Limit When specifying the test limit remember that the same limit is applied to each winding so you must choose a value higher than the resistance of the biggest winding For most transformers where the winding resistances are less than 1kQ a test limit of 10kQ should be used as this will give the quickest test execution PAGE 7 12 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 3 R DC Resistance Measurement Range Basic Accuracy 1000 to 10MQ 0 1 AT Series Tester R1 represents the resistance of the copper wire used to wind the transformer When current flows in the winding the resistance causes losses in the winding PR losses which cause undesirable heating within the transformer In addition the winding resistance causes a voltage drop in the winding when current flows causing the output voltage to fall with increasing load Where Used A DC resistance test should be used to check each winding to ensure that the correct wire gauge has been wound with the correct tension and that the winding is terminated properly Test Conditions The winding resistance is calculated by measuring the DC voltage across a winding and the current flowing
123. able of the length you require To use more than one or two AT Series Testers with the same Server host PC an intelligent COM port expansion card will be required The Server application supports the DIGIBOARD XE eight channel device PAGE 2 14 VOLTECH ATI USER MANUAL GETTING STARTED Programs Programs Programs Results Results Results Before installing an expansion card ensure that the PC is switched off and that you follow all of the manufacturer s instructions All supporting software must also be installed before attempting to configure the Server application The same Server program is used for all AT Series Testers excluding the discontinued AT3500 and AT 1000 VOLTECH ATI USER MANUAL PAGE 2 15 GETTING STARTED PC COM Port Configuration Before proceeding any further check within the Windows Control Panel to ensure that the desired COM Port s are recognized by Windows S Port Setup Ports Board DigiBoard Windows Virtual Base Virtual Char Alt Type Port Port 170 Address IRQ Ready Pin disabled disabled COM4 disabled disabled OFF OFF COM5 disabled disabled OFF OFF COM6 disabled disabled OFF OFF COM disabled disabled OFF OFF COM8 disabled disabled OFF OFF COM9 disabled disabled OFF OFF Settings Windows Port Port Options Windows COM Port COM3 Char Ready Flag Auto Enumerate Alt Pin Virtual Enable Virtual Port for DOS Virtual Port
124. accessed by pressing Details at the above display and contact your Voltech supplier immediately For more detail on AT error codes see chapter 3 VOLTECH ATI USER MANUAL PAGE 2 49 GETTING STARTED 2 5 PRODUCTION MODE This is the normal operating mode of the ATi when used for production testing of transformers Before you try to use the tester in production mode make sure that all of the following have been carried out 1 Test programs have been created for the transformers that you wish to test 2 Either the programs are archived in the Server which is connected to the tester and running and the tester has been set up to use the Server as the program store or the programs have been downloaded into the tester which has been set up to use its internal memory as the program store 3 Fixtures have been created for the transformers you wish to test Note If you have a footswitch fitted to the remote port on the tester pressing it will take the same action in production mode as pressing the upper softkey For text entry such as the name of a program or the serial number of the transformer under test you may optionally use a barcode reader connected to the tester s rear panel barcode port PAGE 2 50 VOLTECH ATI USER MANUAL GETTING STARTED 2 5 1 Production Mode With No Options Enabled For simple test programs where Top level P P gt g Display none of the following options are e
125. age signal cannot be used with an Auto frequency CS and CP are currently only available on the Ati s front panel LCR mode Contact your local supplier or check the Voltech website at www voltech com for up to date information VOLTECH ATI USER MANUAL PAGE 7 53 TESTS AND TEST CONDITIONS 7 1 14 C2 Capacitance Match Measurement Test Test Basic Range Voltage Frequency Accuracy 1 1000 to 1000 1 1mV to 5V 20Hz to 3MHz 0 256 AT Series Tester Capacitance occurs in transformers due to the physical proximity of and electrostatic coupling between different turns of wire In general the capacitance is distributed between different layers within a winding and between the outside layer of one winding and the inside layer of the next Although the capacitance is distributed it is usually represented by a simple equivalent circuit showing a single capacitance from one winding to the next Where Used The capacitance match test as opposed to an ordinary capacitance measurement C is used on power conversion audio and telecommunications transformers where it is important that the capacitance between different pairs of windings is controlled and matched Mismatched capacitances may couple unwanted noise signals from one winding to another or ground The test will determine if one winding has been placed incorrectly or if the wrong thickness of insulation has been used PAGE 7 54 VOLTECH ATI USER MANUAL TESTS AND TES
126. ailure To view the error code at the FAIL display press the Details softkey The following display will show the two status error codes the first four digits being the DSP status error code and the second single or two digit number in parentheses being the reason for DSP status error code Important Note Should self test fail for any reason contact Voltech technical support immediately providing the following information e Serial number of the instrument e Status error codes the four digit number and the one or two digit number in parentheses on the display 3 5 2 Editor Error Codes Status error codes are also shown when using the Editor software in download and run mode They are shown at the end of each test result Only the first four digit error code is displayed when using the Editor PAGE 3 42 VOLTECH ATI USER MANUAL PROGRAM EDITOR lt Part TELECOMT File TELE Voltec 10 x Patt Schematic Program Tester 5 Dice amp N Minimize Interwinding Phase ILOS Insertion Loss RLOS Return Loss OUT 0 0000 B RESP 74 405 ndB PASS 0000 OUT 0 0000 PASS 0000 R 103 62 Ohm PASS 0000 R 131 46 Ohm PASS 0000 tema Source 11 IP 21 998 H PASS 0000 Memal Sourc 12 TR 1 0044 PASS 0000 13 HPAC 22 349 u PASS 0000 7 28 sec off oft oft it Winding Impedance Test Voltage 1 0000 Test Frequency 1 0000 kHz Integration Medium High Term
127. am group Local Saue 2 This allows the program to be stored on the AT by pressing the softkey next to Local Save See section 2 3 4 for a description of running the program on the transformer tester VOLTECH ATI USER MANUAL PAGE 2 29 GETTING STARTED 3 For now run the program from the Editor software and ignore the AT display Again from the top level menu bar select Tester Run Program The test program will now begin execution When it is finished you will see a dialogue box containing the results of the test If the transformer had been connected up as in the schematic to nodes 7 8 9 and 10 then the results might be 1 R 65 571 Ohm PASS 0000 bd R 65 358 Ohm PASS 0000 3 LS 3 7752 H PASS 0000 4 TR 1 0151 PASS 0000 RUN TIME 977 msec Re Run Test If no transformer is fitted the results will have no meaning but you have now successfully installed the ATi and the Voltech AT Editor software The results window will give you the options to 1 Printthe test results 2 Re runthe test program 3 Close the window Closing the window will return you to the top level menu PAGE 2 30 VOLTECH ATI USER MANUAL GETTING STARTED 2 3 5 Server Quick Start Transferring the Program to the Server The Voltech Server software is supplied with every AT Series Tester The use of the Server software is required for handling and storage of test results and is recommended for handling large numbers
128. an be compensated for Let s assume it is 2mO for good quality leads Rc the connection or contact resistance is a variable and cannot be compensated for Rc will vary with the cleanliness of the leads and connector the pressure applied and the contact surface area all of which can be difficult to control Let s assume Rc varies from a few mQ to tens of mQ but is typically 5 mQ PAGE 5 18 VOLTECH USER MANUAL FIXTURES R 1 0000 2 wire measurement circuit The measurement system applies 100 0mV dc to the leads measures the current flowing and divides V by to obtain R the dc resistance R V I In this case the total resistance of the circuit is 2 5 1000 5 2 1014 mO 100 1014 98 62mA 2 wire R V 100 98 62 1 014 Q 2 wire R 1 0140 This shows that the resistor is 1 4 and out of tolerance when it is really exactly 1 000 Q Notice also that the voltage applied to the resistor is NOT exactly 100mV because of the voltage drops across and Rc In a Kelvin or 4 terminal connection the voltage is applied in exactly the same way through a pair of Power leads but the voltage is MEASURED using an extra pair of Sense leads The voltage measuring circuit is designed to have a very high input impedance 1 on the ATi and so negligible current flows in the Sense leads there being a negligible error in the voltage measurement VOLTECH USER MANUAL PAGE 5 19 FIXTUR
129. ance e Voltech will pay all return shipment charges from the Voltech service center to the customer e Voltech will recalibrate the customer unit before dispatch A certificate of calibration will be issued as a matter of course 9 2 LIMITATION OF WARRANTY The foregoing warranty shall not apply to defects resulting from unauthorized modification or misuse or operation outside specification of instrument No other warranty is expressed or implied While every care has been taken in compiling the information in this publication Voltech Instruments cannot accept legal liability for any inaccuracies contained herein Voltech Instruments has an intensive program of design and development which may well alter product specification and reserve the right to alter specification without notice and whenever necessary VOLTECH ATI USER MANUAL PAGE 9 5 WARRANTY AND SERVICE to ensure optimum performance from its product range Because software is inherently complex and may not be completely free of errors you are advised to verify your work In no event will Voltech be liable for direct indirect special incidental or consequential damages arising out of the use Of or inability to use software or documentation even if advised of the possibility of such damage In particular Voltech is not responsible for any lost profits or revenue loss of use of software loss of data cost of substitute software claims by third parties or for other s
130. and Z Most types of power and many signal transformers will be tested using the tester s internal relay matrix to perform switching and an OUT test is not required for these Test Options The OUT test is programmed into a test sequence like any other test The OUT test programmes any of the six available relay drives in any pattern desired The drives stay in the programmed state until another OUT test is performed or a new part is tested The relay drives controlled by the OUT test are designed for switching external user supplied relays only and should NOT be connected directly to the tester s test nodes Choosing Test Options Each of the relay driver outputs can be set to on or off closed or open respectively as shown Relay Settings Relay 0 On C Off Relay 1 On C Off Relay 2 C On Off Relay 3 C On Off Relay 4 C Off Relay 5 C On Off Cancel 7 Maltech Once the settings are correct click on OK to accept them PAGE 7 110 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Note The relay drivers are only set as and when the tester encounters an OUT test The settings given will remain in place until another OUT test is encountered Therefore if the settings are required for one part of the test program only two OUT tests will be required the first to turn the appropriate relay drivers on and the second to turn them back off See the Specification for details of the
131. are shown NewDataAvailable LPCSTR ComPort Returns TRUE or FALSE Boolean 1 or 0 as variant depending on whether new data is available If this function returns true it means that new data can be read back via the OLE If false then no new data has come in since the last read GetPartID LPCSTR ComPort Returns the part name on success or a failure string NO PART ID no valid part name found GetFixturelD LPCSTR ComPort This call returns the fixture name on success or a failure string NO FIXTURE ID no valid fixture name found GetOperatorlD LPCSTR ComPort This call returns the operator name on success or a failure string NO OPERATOR ID no valid operator name found GetBatchlD LPCSTR ComPort PAGE 4 36 VOLTECH ATI USER MANUAL AT SERIES SERVER This call returns the batch number on success or a failure string NO BATCH ID no valid batch number found GetFirmwarelD LPCSTR ComPort This call returns the firmware version number on success or a failure string NO FIRMWARE ID no valid firmware version found GetUnitID LPCSTR ComPort This call returns the tester serial number on success or a failure string NO UNIT ID no valid AT serial number found GetTransformerSerialNo LPCSTR ComPort This call returns the transformer serial number on success or a failure string NO SERIAL no valid transformer serial number found GetResultsFilename LPCSTR ComPort This call returns the results f
132. ata Link Properties x Provider Connection Advanced All These are the initialization properties for this type of data To edita value select a property then choose Edit Value below Name Value Data Source C Program Files Voltech Ins Extended Properties SCOUNTRY 0 CP 1252 LAN Jet OLEDB Database Password Jet OLEDB Global Partial Bulk Ops 2 Jet OLEDB Registry Path Jet OLEDB System database Locale Identifier 1033 Mode Share Deny None Password Persist Security Info False UserID Admin OK Cancel Help Click on OK to complete the setting of the data link properties A typical AT Server advanced database results dialogue would be Database Results Advanced x Connection String Provider Microsoft Jet OLEDB 3 51 Persist Security Info False User ID Admin Data Source C Program Files Yoltech Instruments Voltech AT Server Sample Access Database mdb Mode Share Deny None Extended Properties COUNTRY 0 CP 1 252 LANGID 0x0409 Jet OLEDB System databases Jet OLEDB Registry Path Jet OLEDB Database Password Jet OLEDB Global Partial Bulk Ops 2 Clear Connection OK Cancel Click on OK to return to the results dialogue At this point the AT Server will automatically create the required database tables if they do not already exist VOLTECH ATI USER MANUAL PAGE 4 23 AT SERIES SERVER Ensure that Database Results Saving is checked and click on OK Whenever a results window is open
133. ate payment has been received A 30 day trial key code may be supplied FREE OF CHARGE e Open the Registration dialog as above and enter the Key Code The software is now fully operational e The Key Code is not time related and may be entered at any time after you have sent the ID Code to Voltech VOLTECH ATI USER MANUAL PAGE 4 51 AT SERIES SERVER 4 4 2 Transferring the License to Another PC If you wish to use the software on another PC you must transfer the license as described below BEFORE losing access to the existing installation To transfer the license Software Registration E x Software Registered ID Code MCBSUP DXB4UJ AMPWUX Key Code Your software is registered If you wish to transfer the software license 1 Install the software on another computer 2 Enter the new ID Code from the new software installation in the Transfer ID Code box below 3 Enter the Transfer Key Code generated into the Key Code box of the new software installation This operation will disable this copy of the software Transfer ID Code Transfer Key Code e Install the software on the new destination PC e Take the ID code displayed in the new installation and enter it into the Transfer ID Code section of the dialogue of the licensed software as above on the old installation e Take the Transfer Key Code that will be displayed in the dialogue above of the old installation and ente
134. ave Press Local Save and the program that has been downloaded from the PC Editor will be saved in the tester s local program store Note that any programs previously stored in the tester will be lost All PC connections to the tester may now be removed To run the program at any time return the tester to the top level display press Programs at the top level display choose the program from the list of programs and press the Run key and continue as before Storing Groups of Programs Inside the ATi Using the PC Server Rather than dealing simply with individual programs the AT Server allows you to create groups of programs which may be downloaded to the AT tester and then used individually from within the local tester facilities Having executed programs from the Server as it is connected to the tester you may want to download a group of programs to the tester so the tester can be used in a stand alone situation To do this use the Server software to create a named group of programs Ensure that the Server is still running and connected to the tester as described above PAGE 2 44 VOLTECH ATI USER MANUAL GETTING STARTED On the tester at the top level display choose Set Up Then at the Set up display press the Groups softkey followed by the List softkey to obtain a list of program groups available for download Enter the group name Select the group to be downloaded to th
135. ay be considered to be a pair of connections consisting of one power and one sense terminal The following diagram indicates how to identify the node terminal function Power Sense POWER terminals are all on the outside of the fixture area SENSE terminals are all on the inside of the fixture area The BNC to clip leads supplied with your ATi provide true 4 terminal Kelvin connections IMPORTANT Kelvin four terminal connections are generally advised to be used in all test fixtures they are essential for transformers whose winding resistance s are less then 10 PAGE 5 22 VOLTECH ATI USER MANUAL FIXTURES When Kelvin connections are not possible because of space limitations use a semi Kelvin connection Below are two examples of Kelvin connections Clips supplied with BNC leads Kelvin pins VOLTECH ATI USER MANUAL PAGE 5 23 FIXTURES PAGE 5 24 VOLTECH ATI USER MANUAL 6 FRONT PANEL MODES VOLTECH ATI USER MANUAL PAGE 6 1 FRONT PANEL MODES PAGE 6 2 VOLTECH ATI USER MANUAL FRONT PANEL MODES Contents Front panel Modes 6 1 LCR MODE BASIC 5 6 5 6 121 ECR BNC Mode S228 nln dtes 6 7 E CR FIX MOJE sia tater ind ain dabei 6 11 6 1 3 Insulation Resistance 6 13 6 2 TESTS
136. been carried out thus speeding up the test process When a fail is encountered the tester will display a warning screen and stop the program The display will inform the user of a test failure and indicate which limits have been exceeded VOLTECH ATI USER MANUAL PAGE 3 17 PROGRAM EDITOR An example of this display for an inductance test is shown below TUTORIAL FAIL at test 4 15 Continue H 1 1847mH Vertical bar Represents Box Represents the user the value measured programmable limits for the test From this display after you have pressed the Continue softkey the tester will execute the remaining tests in the program and the transformer will be recorded as a fail If any further tests fail then there will be another display similar to the one above for each failing test If you simply wish to throw away the failing transformer at the earliest opportunity then press the Abort softkey to terminate this program run and return to the RUN FINISH display from where you can start the program again for the next transformer in the batch Alternatively you may use the Re Run softkey if for example the failure is due to the fact that the transformer is not correctly inserted in the test fixture In this case program execution starts again and the transformer will receive a pass if the only fault was that it had been wrongly inserted at the first attempt PAGE 3 18 VOLTECH ATI USER MANUAL
137. cally a limit of 5 or 20mO whichever is greater is set The minimum value is not usually so critical It can be set to any value that ensures that there is no solder splash causing a short circuit between pins Typically 20 VOLTECH ATI USER MANUAL PAGE 7 15 TESTS AND TEST CONDITIONS 7 1 4 R2 DC Resistance Match Measurement Test Test Basic Range Voltage Frequency Accuracy 1 1000 to 1000 1 N a N a 0 296 R1 z AT Series AT Secondary Tester measurements R2 b v Where Used The DC resistance match test as opposed to an ordinary DC resistance measurement R is used on audio and telecommunications transformers where it is important that the resistance of different pairs of windings is controlled and matched to a specified ratio The absolute value of the resistances may be of less importance to the performance of the transformer than the match between two resistances Test Conditions To measure DC resistance match the tester makes two DC resistance measurements see the R test and compares the two results Limits for the match of the two measured resistances may be set in terms of the ratio between them e g 1 1 5 By adding further DC resistance match tests to the test program any number of DC resistances can be tested for match PAGE 7 16 VOLTECH AT USER MANUAL TESTS AND TEST CONDITIONS Choosing Test Conditions For optimum accuracy and performance use the test conditions shown
138. cations transformers to the standards IEEE455 and FCC 68 310 and wherever similar connection methods are specified Test Conditions The source and load resistors RS and RL and the measuring transformer are connected to the transformer under test as shown This may be done automatically using the tester s OUT test The voltages Vout1 and Vout2 are measured whilst Vin is held constant The ratio of these two voltages reflects the transformer under test s ability to reject common mode voltages General Longitudinal balance is calculated as the ratio GBAL 20 log Vout2 Vout1 IEEE 455 Method Used in Canada Europe and ROW Energized Vin Hi Lo Terminals X Terminals Y VOLTECH ATI USER MANUAL PAGE 7 77 TESTS AND TEST CONDITIONS FCC 68 310 Method Used in USA Ri Fixture Transformer Energized Vin Measured Vout Hi Lo Hi Lo Terminals X Terminals Y Choosing Test Conditions The source and load resistors and the fixture transformer for the IEEE and FCC methods are assumed to be on the fixture but are not shown on the Editor schematic They are switched in circuit using an OUT test that must be inserted in the program before the GBAL test The relay patterns associated with inserting and removing fixture resistors have deliberately not been included in the GBAL test dialogue for two reasons a it would make the dialogue too complicated and b it is not always necessa
139. ceeds directly to the next test after the TRIM test If the test before the TRIM test produces a Fail result then the front panel display will be similar to the following TUTOR TAL TRIM at test 5 LS Continue a 1 1842mH The main difference between this and the Stop on fail display is that the reading on the fourth line will be continuously updated allowing adjustments to be made to bring the test result within limits Pressing the Abort softkey again stops the program and allows the operator to throw away a transformer that cannot be adjusted to give a Pass result After pressing the Continue softkey the remaining tests in the program will be executed and at the end of the measurement the component will be classed as a Fail Pressing the Re Run softkey will re start the test sequence from the beginning VOLTECH ATI USER MANUAL PAGE 2 69 GETTING STARTED Note After making the necessary adjustments you must press Re Run to enable the component to be recorded as a Pass If further adjustment is necessary you may re run from the start as many times as you like Unless the option Send Retry Results to Server is enabled there will be no data sent back to the Server until the measurements for all tests in the program have been completed PAGE 2 70 All transformers are capable of generating voltages much higher than the test voltage When making adjus
140. cel out in the calculation PAGE 7 88 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 22 ILOS Insertion Loss Measurement Test Test Basic Range Voltage Frequency Accuracy 100dB to 100dB 1mV to 5V 20Hz to 3MHz 0 5dB Rs L AT Series Tester The insertion loss is a measure of the power lost by a transformer relative to the maximum theoretical power that the transformer could transmit to a given load Core and winding resistance losses mean that some power is always consumed by a transformer reducing the power available to the load from the theoretical maximum Where Used The insertion loss test is used to check the power loss of audio and telecommunications transformers The test helps to ensure that the transformer has been assembled properly using the correct core and winding materials Test Conditions The source and load resistors RS and RL are connected to the transformer under test as shown This may be done automatically using the testers OUT test VOLTECH ATI USER MANUAL PAGE 7 89 TESTS AND TEST CONDITIONS The tester applies the specified voltage Vin and the voltage Vout is measured The ratio of actual to theoretical power loss is calculated using the formula ILOS 10log o Vin2 RL 4 Vout2 RS Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test Programming the Test Using the PC Test Editor Insertion Los
141. citance series circuit CS Farads F Capacitance parallel circuit CP Farads F Quality Factor Q Dissipation Factor or tand D AC impedance magnitude of complex impedance Z Ohms Q Phase angle of impedance 0 Degrees AC reactance imaginary part of impedance X Ohms Turns ratio by voltage TR Turns ratio by inductance TRL Leakage inductance LL Henries H Interwinding capacitance C Farads VOLTECH ATI USER MANUAL PAGE 1 9 INTRODUCTION To determine which options were installed on your tester during manufacture check the list attached to the calibration certificate shipped with your ATi PAGE 1 10 VOLTECH ATI USER MANUAL 1 5 ATI FEATURES SUMMARY INTRODUCTION The ATi tester is a fast accurate and versatile automatic LCR meter FAST Typically more than 10 DIFFERENT tests per second e 20 way switching matrix e Automatically switches from making measurements on one winding of a transformer to another winding e Measures across different windings e No need to manually change connections e Fast execution of a sequence of different tests on multiple windings of a transformer ACCURATE 0 05 basic Inductance from Any frequency from Any voltage from AC constant current source DC bias up to VERSATILE e Easy to use e High speed production tester e Laboratory grade LCR meter 1nH to 1MH 20Hz to 3MHz 1mV to 5V 204A to 100mA 1A Upgrades and new tests installed from disk
142. cluding Microsoft Access using the Microsoft OLE DB Provider for ODBC Drivers Click on Next when you have chosen the correct provider Provider Connection Advanced All Specify the following to connectto Access data 1 Select or enter a database name 5 2 Enter information to log on to the database User name Admin Password Iv Blank password F Allow saving password Test Connection Select the database name that you will be using by clicking on Select If you wish to create a new database for AT Server results do so now using your database program The default user name Admin with no password may be adequate Consult your database administrator if you need a specific user name and password PAGE 4 20 VOLTECH ATI USER MANUAL AT SERIES SERVER When you click on Test Connection you should see something similar to C Program Files Voltech Instruments Yoltech AT Servery 9 L Next click on OK of the Test connection succeeded dialogue and select the Advanced tab VOLTECH ATI USER MANUAL PAGE 4 21 AT SERIES SERVER E5 Data Link Properties a Share Exclusive Check that the Access permissions for the database are as required Share Deny None is the default and is usually the most suitable setting PAGE 4 22 VOLTECH ATI USER MANUAL AT SERIES SERVER Under the All tab all of the individual settings can be reviewed and adjusted if necessary Ls D
143. connection string click on Clear Connection PAGE 4 18 VOLTECH ATI USER MANUAL AT SERIES SERVER To establish a new connection click on Connection Type Provider Connection Advanced All Select the data you want to connect to M O Microsoft Jet 4 0 OLE DB Provider Microsoft OLE DB Provider for Internet Publishing Microsoft OLE DB Provider for ODBC Drivers Microsoft OLE DB Provider for OLAP Services Microsoft OLE DB Provider for Oracle Microsoft OLE DB Provider for SQL Server Microsoft OLE DB Simple Provider MS Remote MSDataShape The Data Link Properties dialogue is a standard one that is supplied by Windows You should choose the provider that will provide the connection to the type of database that you are using Several different types of provider are installed along with the Server software others may be available if you have a database application installed on the same PC as the Server If the provider you need is not available and the database is installed on another PC ask the database administrator for the database client tools for the Server PC VOLTECH ATI USER MANUAL PAGE 4 19 AT SERIES SERVER Typical provider types are Database Provider Microsoft Access 97 Microsoft Jet 3 51 Microsoft Access 2000 Microsoft Jet 4 0 Oracle Microsoft OLE DB Provider for Oracle SQL Server Microsoft OLE DB Provider for SQL Server In addition it is possible to connect to ODBC compliant databases in
144. current By measuring both the applied AC voltage and the resulting AC current the total impedance is calculated Z is the magnitude of the complex impedance Z Y R X Inductive Capacitive Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test Programming the Test Using the PC Test Editor Winding Impedance Test Parameters Integration Signal G C Short Medium Frequency 0 Hz C Long Terminals High Terminal Low Terminal Impedance Limits C C Minimum 0 mOhm COhm kOhm C Maximum fO mOhm Ohm CkOhm Measure Cancel VOLTECH ATI USER MANUAL PAGE 7 97 TESTS AND TEST CONDITIONS Choose the integration period normally Medium and enter the High and Low Terminal names For the impedance with bias test you may also select a DC bias current Note that the Editor s Measure button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits mOhm Ohm etc when entering absolute values as limits Test li
145. d DANGER Pin 8 may have voltages of up to 500V present during normal operation of the ATi PAGE 8 28 VOLTECH USER MANUAL SPECIFICATIONS 12V pin 3 Total maximum current Remote port pin 3 User port pin 5 100mA 5V pin 14 Maximum current 800mA 8 3 6 User Port The port contains six open collector relay drive outputs and two HC MOS compatible inputs The relay drives are switched on and off by certain optional tests e g the OUT test inserted into your test program This will enable you for example to switch a dummy load on to the secondary winding of the transformer under test so that subsequent tests are performed on the loaded transformer The user port connections must always be fully isolated from the test nodes A coil to contact isolation of 1000V is recommended for the relay Load Test Nodes Resistor Test Nodes VOLTECH ATI USER MANUAL PAGE 8 29 SPECIFICATIONS Connector Details 9 pin female D type connector 5432 1 User Port Cm smaa se User Relay Drive 0 User Relay Drive 1 User Relay Drive 2 User Relay Drive 3 User Relay Drive 4 User Relay Drive 5 User Input 0 i User Input 1 12V User Relay Drive Outputs pins 1 2 3 6 7 and 8 All the user Relay Drive Outputs have the following equivalent circuit 12V L O Pin 5 Specification Relay coil resistance gt 1500 A Maximum sink current 80mA per output Relay
146. d at the sense terminals of the ATi If you are using Kelvin 4 wire connections then these are the conditions measured on the connectors of the part under test Usually the voltage and frequency will be identical to the programmed voltage and frequency because the ATi always attempts to trim its output voltage across the part to be equal to the desired or program voltage see below If the impedance of the part is very low the ATi might not be able to supply sufficient current to maintain the programmed voltage In this case the voltage measured will be less than the program voltage The current passing through the part is also displayed on this line A constant current can be programmed for some tests The ATi is applying the test signal to BNC terminals on the control panel in the following way Program v Measured v Winding under test Note The BNC connectors are also connected internally to nodes 20 P and S and 18 P and S of the fixture bay Remove any fixture from the fixture bay and ensure these nodes 18 and 20 are clear before using the BNC terminals PAGE 6 8 VOLTECH ATI USER MANUAL FRONT PANEL MODES The top softkey number 1 allows you to move through the visible options Press softkey 1 and you will see 5 1202mH 1 4401 Lgs CBHC modes Peg AUTO V AUTO Hz Mes 16ml 3 78mH 188 Hz EMIT Lp and Q The options for the second display line have changed as appropriat
147. d in detail in chapter 4 However before you transfer your program to the Server archive you should always verify it by running it on an actual transformer The Editor software will enable you to download a program directly to the tester and to execute it from the PC keyboard Before you attempt to run the program 1 Make sure you have connected your tester s auxiliary port on the rear panel to a suitable COM port on your PC This may be COM2 if your mouse is already using COM1 2 Setupthe COM port on the PC From the top level Setup Communications Ea menu select a ae ort pue e Communications In the dialogue box select the PC COM port that is connected to the tester WARNING If the chosen COM port is reserved by another Windows application an error message will appear You should select another port 3 Fit the appropriate fixture to the tester and plug in the specimen transformer You are now ready to download and run your test program 4 From the top level menu bar select Tester gt Download Program PAGE 3 38 VOLTECH ATI USER MANUAL PROGRAM EDITOR amp s Voltech Test Program Editor Part TUTORIAL File Part Schematic s 3 Server Setup Help vnload Program Upload Program A Compensate ENS Bun Program Download The Editor will now download the test program to the tester After a few seconds you should see a message to say that the download was
148. directly on the front panel via the Results softkey see below VOLTECH ATI USER MANUAL PAGE 2 57 GETTING STARTED FAIL aaa FAIL FAIL amp amad Results listing screen Note that the total and failed number of transformers tested displayed are reset when the test batch number is changed or a new test program is run If the Stop softkey is pressed or the STOP input of the remote port is held low the ATi will immediately stop testing STOP will be shown on the display all LEDs will be off and no results will be reported back to the Server 2 5 4 Re measuring Fixture Compensation Fart number Eun TUTORIAL Settings Total 1 Failed 1 166 Results Last transformer Finish PAGE 2 58 VOLTECH ATI USER MANUAL GETTING STARTED If you think that fixture compensation needs to be re measured at any time at the above display press the Settings softkey to reveal Fart number Compensate TUTORIAL Total 1 Failed 1 1 Last transformer F L Press Compensate to repeat the fixture compensation measurements or Back to return to the RUN FINISH display without re compensating 2 5 5 Execute Mode With Options Enabled As stated in the following chapter of this manual test programs may be created with any of the following three options enabled or disabled e Operator name e Batch number 9 Serial number In each case if an option is enabled the data entered by
149. e and can be changed by pressing the softkey 3 VOLTECH ATI USER MANUAL PAGE 6 9 FRONT PANEL MODES 5 1216mH 694 77m ae modes Settings Prq AUTO U AUTO Hz 8 Mes 9 99m 5 7 188 Hz ERIT Lp and D More tests are available by pressing More 1 3 softkey 2 2 6453 0 F 55 212 d CBHC mode Settings Peg AUTO AUTO Hz Mes 18ml 3 78mH 188 Hz ERIT Z and 0 Please see the sections following LCR FIX for details on how to use the front panel LCR modes of the ATi PAGE 6 10 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 1 2 LCR FIX Mode Press the LCR FIX softkey and the ATi immediately begins to make measurements 1 881mH 11 791 grs CFixture made Settings Prq AUTO U AUTO Hz B Sec Mes 10m 1 46mR 1kHz EXIT The ATi is making measurements on nodes 13 and 15 the primary and nodes 14 and 16 the secondary The LCR fixture supplied with your ATi has four Kelvin leads already connected to these nodes VOLTECH ATI USER MANUAL PAGE 6 11 FRONT PANEL MODES To change from measurements on the primary nodes 13 15 to measurements on the secondary nodes 14 16 press softkey 5 Pri Sec 161 63 pH 1 7888 IE CFixture made Settings Peg AUTO V AUTO Hz Mes lem kHz For measurements of TR turns ratio and TRL turns ratio by inductance softkey 5 toggles the display of measured test conditions It does NO
150. e previously stored calibration You may press the Abort softkey at any time to stop the process and discard changes PAGE 2 80 VOLTECH ATI USER MANUAL GETTING STARTED BHC Lead Calibration Continue BHC calibration successful Press to save neu calibration factors E 2 9 2 AT Password Pressing the Change softkey brings up the following display Confirmation Enter the neu AT Password Delete Abort Shift Enter the new AT password via the instrument keypad using the Shift softkey to activate letter entry if necessary Press Enter to confirm the new password 2 9 3 Resetting Tester Set Up Options Please note that pressing the decimal point on the instrument keypad VOLTECH ATI USER MANUAL PAGE 2 81 GETTING STARTED during boot up at the general information screen will reset all tester options to the factory defaults including screen contrast screen background and beep volume excluding the real time clock The tester s factory default settings are Option Default Setting FAIL Beeper OFF PASS Beeper OFF Key Response CLICK Beeper Volume 6 Display Contrast 8 Display Background LIGHT Touch Pad Option L ANDR Pad Response CLICK Program Store INTERNAL 2 9 4 Groups Softkey When the tester is set up to use the INTERNAL program store and after you have entered the part name it w
151. e test signal the frequency and the nominal inductance Winding Inductance Series Circuit Test Parameters p Integration Signal 300 CV C mA C Short Medium Frequen 1 CHz kHz CMHz Cu quency ong Terminals High Terminal Low Terminal A z e F Inductance Limits CX C Nominal 4 53091 CoH CuH mH CH Negative md 74 Positive I x OK Cancel From this point it is very easy for you to complete the dialogue box by simply entering the values you require for the negative and positive percentage limits VOLTECH ATI USER MANUAL PAGE 3 35 PROGRAM EDITOR If you have chosen fixed voltage current or frequency conditions it may not be possible for the tester to make a measurement For example if the AC impedance of the winding under test is only 0 19 at the specified frequency and you have specified a 5V test signal then the AT would have to supply 5V 0 10 50 Amps You will then see a warning similar to this Editor Windows Application i A The signal level requested is not ideal Changing V or F will prevent this warning Would you like the tester to choose a signal level Check first that the winding is properly connected to the right nodes Choose Yes and the AT will choose suitable voltage conditions for you and enter them into the test dialogue Choose No and no conditions will be chosen See chapter 7 Te
152. e tester and press Enter If the group download is completed successfully you will see the following display Group successfully downloaded Continue VOLTECH ATI USER MANUAL PAGE 2 45 GETTING STARTED At this point unless you wish to archive measured results on the Server the Server connection may be removed Return to the tester s top level display by pressing the Continue softkey change the set up of the tester to use the internal program store instead of the Server press the Programs softkey and you will find the downloaded group programs available to you locally on the tester Local programs Hew program PROGRAM 1 TUTOR TAL Results Analysis You may wish to use another application for further analysis of test results sent back to the Server Close down the Server so that you may have full access to the results file The results will be stored in the directory chosen for results when the Server was installed in a file with a name similar to C2311096 ATR Where C2311096 is a coded version of the date and ATR is the file extension used by the AT Server for results files As an example use the procedure outlined in chapter 4 of this manual to import the results into an Excel spreadsheet PAGE 2 46 VOLTECH ATI USER MANUAL GETTING STARTED 2 4 SELF TEST Self test is a sequence of checks made by the tester to ensure the unit is functioning correctly Self test checks
153. e transformer this may be done automatically using the tester s OUT test Then two measurements are performed using the circuits above which the tester automatically configures First the test voltage Vin is applied as a common mode signal and the output voltage Vout1 is recorded and then the same Vin is applied as a normal input voltage and the output Vout2 is recorded Longitudinal balance is calculated as the ratio LBAL 20 logio Vout2 Vout1 Energized Vin Measured Vout Hi Lo Hi Lo Terminais o9 A B pap c 5 Terminals Y PAGE 7 82 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Choosing Test Conditions The source and load resistors are not shown on the Editor schematic They are switched in circuit using an OUT test that must be inserted in the program before the GBAL test The relay patterns associated with inserting and removing fixture resistors have deliberately not been included in the GBAL test dialogue for two reasons a it would make the dialogue too complicated and b it is not always necessary e g in the case of a fixture where the resistors are permanently fitted in circuit Programming the Test Using the PC Test Editor Longitudinal Balance Test Parameters Integration 4 Voltage o cy CShor Medium Frequency 0 9 CkHz C Long Input Output High Terminal Low Terminal High Terminal Low Terminal Common Terminal zi
154. ed to a tolerance of 2 For un gapped cores the tolerance may have to be as much as 20 because of the core manufacturer s tolerance VOLTECH ATI USER MANUAL PAGE 7 39 TESTS AND TEST CONDITIONS 7 1 10 L2 Inductance Match Measurement Test Test Basic Range Voltage Frequency Accuracy 1 10000 to 10000 1 1mV to 5V 20Hz to 3MHz 0 1 AT Series j AT Secondary Tester measurements The inductance of a winding is determined by the number of turns and the construction and dimension of the core materials it may also vary with test conditions such as voltage and frequency See the LS and LP tests Windings consisting of the same number of turns and wound on the same core should have the same inductance value Where Used The inductance match test as opposed to an ordinary inductance measurement LS or LP is used on power conversion audio and telecommunications transformers where it is important that the inductance of different pairs of windings is controlled and matched to a specified ratio The absolute value of the inductances may be of less importance to the performance of the transformer than the match between two inductances Test Conditions To measure inductance match the tester makes two series inductance PAGE 7 40 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS measurements see the LS test and compares the two results Limits for the match of the two measured inductances may be set in terms of the
155. een enabled within the Server you will see the summary batch results window PAGE 2 40 VOLTECH ATI USER MANUAL GETTING STARTED at on com2 15 x ATi Part Name Operator 1135 PART NUMBER Transformer Serial No Last Part Pas S Tested 18 PASS 18 FAIL AQL 1 RE TRIES FAIL 0 000 Last 10 Tx 0 Failed Test Min Max Last Result FAILS Polarity 5 1 CTY 10 000 kOhm 624 24 mOhm 2LS 1 1640 mH 1 2360 mH 1 1847 mH 3 2 6460 2 7540 2 7094 0 0 Test results may also be reviewed at any time via the tester s front panel results listing screen which is accessible from the Run Finish display by pressing the Results softkey see below mH r2 361 85 The results listing screen displays all completed tests giving test number type result in both value and pass or fail and status error for a description of status error codes see chapter 3 The listing may be printed by pressing the Print softkey in the same style as the standard results VOLTECH ATI USER MANUAL PAGE 2 41 GETTING STARTED After several program runs press the Finish softkey to return the tester to the top level display This is the end of the step by step tutorial which forms only a very brief introduction to the features available on your ATi Please study and browse through the rest of this manual or the on line help for the Windows software to get the best fro
156. elect this option to give the fastest test throughput During program execution only transformers that produce a pass result will be fully tested failures will be rejected at the earliest opportunity PAGE 3 15 PROGRAM EDITOR Date and Time on Select this option to have the reports date and Reports time tagged Note There will be no results printed out during the test execution AQL Acceptable Quality Level Settings for production test are defined here AQL is the level of test failures in a batch that are acceptable Exceeding the AQL is an indication that there is a problem with the quality of the production process or the quality of materials that are being used AQL monitoring is an optional feature of the Voltech PC Server that displays live summary results from multiple AT testers When the AQL set here is reached or exceeded the Server will display a warning Both types of AQL limits may be used at the same time Reaching any one limit will cause a warning to be displayed on the Server For further details see the AT Server section of this manual AQL No of Parts This is the number of failures in the batch at which a warning will be displayed on the Server This is most often used when the batch size is always the same or zero i e very small numbers of defects are expected AQL of Parts This is the percentage level of failures at which a warning will be displayed on the Server Note that this AQL is only appl
157. ene 1 6 13 ATANDA T S600 Em 1 7 1 4 TESTS SUPPLIED osia ec se 1 8 1 4 1 Standard Program 1 1 4 2 Optional Program Tests sss esent nnns 1 8 1 4 3 ATi LCR Mode Functions ssssessseseses eee nnne 1 9 1 5 ATI FEATURES 1 11 1 6 TYPICAL PRODUCTION INSTALLATION eene nnn nennen nnn nnn nnn nennt 1 12 1 7 USING THE ATI FOR DESIGN AND 1 14 EE 1 15 1 8 1 Creating Programs The Editor sss 1 16 1 8 2 Storing Programs and Results The Server sss 1 17 1 8 3 Transferring Programs between Editor and Server 1 18 1 8 4 Executing Programs sssssssssssssss seien nennen niente 1 20 1 8 5 Test FIXtUFes uite et het tee 1 23 1 8 6 Operating the AT Series Testers in Production Test 1 24 1 9 How DOES THE ATI TESTER RUN A TEST eere 1 26 VOLTECH ATI USER MANUAL PAGE 1 3 INTRODUCTION PAGE 1 4 VOLTECH ATI USER MANUAL INTRODUCTION 1 1 How USE THIS MANUAL Welcome to the Voltech ATi Please study this introductory chapter of the manual carefully It will help you to set up your tester quickly
158. ent frequency Hz is the measured primary voltage V is the measured secondary voltage V is the measured turns ratio primary secondary VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 7 LVOC Test The accuracy for measuring open circuit voltage is given as Ar Where Ar Ac Av is the total accuracy is the basic relative accuracy is the calibration accuracy is the correction for voltage level The value of Ar is given in the section 8 1 of this chapter The values of the other factors are given below Ac Apv Where Fm Vm 0 03 0 001 x Fm 0 03 0 0196 Vm is the measurement frequency Hz is the measured voltage V VOLTECH ATI USER MANUAL PAGE 8 13 SPECIFICATIONS 8 2 8 TRL Test The accuracy for the test is given as Ar Ap As Where Ar is the total accuracy Ap is the accuracy of the primary winding measurement As is the accuracy of the secondary winding measurement To determine the values of Ap and As use the accuracy specification for series inductance PAGE 8 14 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 9 IR Test The accuracy is based on the test conditions chosen to measure the insulation resistance and is given as Ar Ar Ac A Az Where Ar is the total accuracy AR is the basic relative accuracy Ac is the calibration accuracy is the correction for current level 96 Az is the correction for impedance level
159. er Data Inputs eet tak ede eee 2 9 2 2 INSTAEEATION 2 10 2 2 1 Switching on the ATi esee 2 10 2 2 2 Installing the PC Editor eene 2 12 2 2 3 Installing the PC Server seen 2 14 2 3 QUICK START TUTORIAL eese nennen enne nennen nennen nennen 2 19 2 3 1 Introd ction a e EUR t Het eene net Ree 2 19 2 3 2 Drawing the Transformer Schematic eee 2 20 2 3 3 Creating the Test Program seen 2 22 2 3 4 Running the Program from the Editor sse 2 28 23 9 Semer Quick Slants eie RR RR eret 2 31 2 3 6 Running a Program on the 2 34 2 3 7 Storing Programs sss sesenta 2 43 2 4 SELF TEST 2 47 2 5 PRODUCTION MODE cccccccecececececeeeeececeseeeneneeeeeeeeeeseeeeeeesesenesessnsnsnanas 2 50 2 5 1 Production Mode With No Options 2 51 2 5 2 Error Messages eee ee Eee beer ne det 2 54 2 5 3 Indications Displayed While Tests Are 2 56 2 5 4 Re measuring Fixture Compensation seen 2 58 2 5 5 Execute Mode With Options 2 59
160. er Setup He HAEL 4 Options Edit Edit Test C Insert Test fm 3 You will now see that the test has been removed from the list in the Program List window VOLTECH ATI USER MANUAL PAGE 3 25 PROGRAM EDITOR 3 3 6 Test Parameters Some tests such as the R Winding Resistance test as used in the quick start tutorial in chapter 2 of this manual are relatively simple to program because you do not have to set up any test conditions This is not normally the case The LS Winding Inductance Series Circuit test is more typical requiring the test parameters Signal and Frequency to be specified Winding Inductance Series Circuit m Test Parameters Integration Signal C mv CV C Shot 5 Medium Frequency fo Hz C kHz C MHz C Long r Terminals High Terminal Low Terminal 8M r Inductance Limits o Minimum 7 nH un mH CH LIE E Maximum 0 nH uk mH CH Measure Cancel For many tests including the LS test you may enter the test parameters in two ways either by simply keying in the numbers you require or by using the Measure button Clearly you would type in the test parameters if for example they have been specified by the designer of the transformer If you are not sure what values to use some guidance is given in chapter 7 later in this manual If you are using the Measure butt
161. es In this way windings that should be matched are treated equally during the test PAGE 7 60 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Choosing Test Limits The limits may be entered as 1 A nominal value together with a percentage tolerance Enter the nominal Primary to Secondary ratio together with the limits as positive and negative percentage values 2 An absolute number of turns 8 When limits are set as an absolute number of turns the tester converts these limits to the 96 type in the following way PriLimit Sec Limit x 100 Pri Turns Sec Turns You can see the exact result of this conversion by clicking on limits in the Editor dialogue once the absolute limits have bee entered For example take a typical Switched Mode Power Supply transformer with windings in the ratio of 200 10 Typically a prior measurement of inductance will have confirmed the correct number of primary turns have been fitted with the correct cores Setting absolute limits of 0 on the primary and 1 on the secondary will result in limits of Nominal Ratio 200 10 20 Ratio 1 sec turn 18 18 Ratio 1 sec turn 22 22 Limits calculated by tester 0 200 1 10 x 100 10 The equivalent ratio limits used by tester are Upper limit 22 Lower Limit 18 VOLTECH ATI USER MANUAL PAGE 7 61 TESTS AND TEST CONDITIONS PAGE 7 62 Which equates to the actual ratios with a one turn error on the
162. est limits the last result and the accumulated number of fails for each test Results may also be exported or printed using the normal options found under the file menu AQL AQL Acceptable Quality Level settings for production test are defined for each program using the Editor AQL is the level of test failures in a batch that is acceptable Exceeding the AQL is an indication that there is problem with VOLTECH ATI USER MANUAL PAGE 4 15 AT SERIES SERVER the quality of the production process or the quality of materials used AQL monitoring is an optional feature of the Voltech PC Server which displays live summary results from multiple AT testers When the AQL level set here is reached or exceeded the Server will display a warning AQL No of Parts is the number of failures in the batch at which a warning will be displayed on the Server This is most often used when the batch size is always similar or zero very small numbers of defects are expected AQL 96 of Parts is the percentage level of failures at which a warning will be displayed on the Server Note that this AQL is only applied after sufficient parts have been tested to make the percentage meaningful When setting AQL of Parts to be 196 for example a warning will only be displayed after 100 1 100 parts have been tested Both types of limit may be used at the same time Reaching any one limit will cause a warning to be displayed on the Server When an AQL
163. f the screen the winding is mirrored to face the nearest test nodes Click the left mouse button to place the winding 2 Name the winding terminals When the winding is placed a dialogue box appears prompting you to name both of the winding s two terminals Enter Terminal Names x Terminal 1 Terminal 2 Cancer 3 You may move the cursor focus between the fill in boxes by using the TAB key or by pointing and clicking with the mouse 4 When both terminals have been named press ENTER on the keyboard or click on OK with the mouse in the dialogue box 5 To make a winding with more than two terminals see Adding a Terminal to an Existing Winding later in this chapter NOTE Terminal names may be between 1 and 6 characters in length and may contain any upper case letter or AT Series keyboard character excluding SPACE VOLTECH ATI USER MANUAL PAGE 3 7 PROGRAM EDITOR 3 2 2 Connecting the Winding Terminals to Nodes To connect the winding terminals to test nodes 1 Select a terminal to connect with the RIGHT mouse button 2 Keeping the right button pressed drag the wire to the selected test node 3 When the mouse pointer is over the test node release the mouse button Note The connection may also be made in reverse by first selecting the test node and then connecting it to the winding terminal To change a connection simply use the right mouse button to pick it up and move it to another test node or another t
164. for example 00 the characters xxxA will not be changed Alternatively if the next serial number does not follow from the previous one in sequence you may use the keypad or the barcode reader to type in a new number After typing the new number press the ENTER key the ENTER softkey or the footswitch to return to the RUN FINISH display PAGE 2 64 VOLTECH ATI USER MANUAL GETTING STARTED Again cursor softkeys lt appear in context and may be used with the Delete softkey to correct mistakes Note Pressing the Abort softkey will also take you back to the RUN FINISH display but with no serial number entered This would be the correct action if the next softkey you wish to press is FINISH Subsequently pressing RUN would merely return you to the Enter the serial number display Re inputting the Options When options are enabled the RUN FINISH display allows access to additional softkeys that enable you to change the batch number or operator name without having to re enter the test program name You may access those additional softkeys via the Settings softkey from the RUN FINISH display Part number Eun FROGRAM 1 Settings Total 1 Failed Results Last transformer P 5 Finish To change the batch number press Settings and the following display will be revealed Choose the New Batch softkey to enter a new batch number at this time or to change the operato
165. fresh Columns Validate Chart Data Clear all View Data Save as default OK Cancel Select the table of the database that holds the data that you want to chart You may also select a query that has been written in the database or write a Custom query PAGE 4 30 VOLTECH ATI USER MANUAL AT SERIES SERVER In this case the database table tblVoltechresults has been chosen and the column Result flagged as a measurement To do this click on the Treat as column of the Result row and select Measurement from the drop down list Next click on Filtering and filter the data for TestNo 2 Filter for selecting rows from data table x Select data where the date time in THIS column Is Between and Iv Inclusive AND pn n s UL v Additional Conditions See WHERE clause Additional Conditions j Help Clear all OK Cancel This selects only the results for test number 2 of the AT test program which is an inductance test VOLTECH ATI USER MANUAL PAGE 4 31 AT SERIES SERVER Next click on the Limits tab and enter appropriate specification limits that will appear on the chart The ChartRunner software can automatically select appropriate control limits from the data This is the default and recommended setting 4 CHART runner Inductance Chart name type Data source Data definition Limits Control chart Titles Misc
166. g s in place This is called open circuit compensation The DC resistance test Rdc uses short circuit compensation only the other LCZ measurement require both Once L C or Z is compensated this compensation is stored and applied to any L C or Z measurement as long as the measurement conditions and nodes are not changed Compensation values are unique to the voltage and frequency test conditions and thus you must re compensate if any of these values are changed The display will always show comp req when valid compensation measurements are not available PAGE 6 30 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 4 1 Performing Compensation To perform compensation press softkey 3 Compensate in either the LCR BNC or LCR FIX settings menus You will see Compensation Short One All Open One All Full compensation required for 123 Hz If you have chosen a frequency that has not already been compensated that frequency will be displayed as above The One short or open frequency compensation options will be available if you have chosen any fixed frequency Choosing One sets up the ATi to perform compensation measurements at the chosen frequency only and is the preferred choice Choosing All will set up the tester to re compensate at all frequencies and this can take up to two minutes or more and is not normally necessary All is the only available choice if the ATi is set up with an Auto frequency To perf
167. g the mouse click on the Measure button Because the LS test is one where compensation can be applied you will then see the following message LO Measure without Fixture Compensation C Compensate Fixture Disable Compensation If compensation is disabled it can be enabled again by selecting preferences from the setup menu Disable Compensation will stop this dialogue being displayed for subsequent presses of the Measure button for this program only Disable Compensation does not stop you being offered the opportunity to compensate the fixture for all tests when the complete program is downloaded to the ATi later Click on OK with Measure without Fixture Compensation selected if you do not wish to perform compensation This is normal if the value of inductance is high VOLTECH ATI USER MANUAL PAGE 3 33 PROGRAM EDITOR If you click on OK with Compensate Fixture selected then there will be additional messages depending on whether the test requires short or open circuit compensation or both see section 2 8 Compensation In this case the LS test requires both short circuit and open circuit compensation The following dialogue box will be shown first Series Editor Software i Short Circuit Fixture Compensation will be applied ko this program Fit a short circuit link in place of each winding Yes No Fit the required short circuit header and click on Ye
168. gle Audio amp telecom Checks phase angle of complex impedance Interwinding Phase Angle Measuring amp signal Checks phase of voltage between windings Reactance Audio amp telecom Checks imaginary part of the complex impedance at a given frequency Trimming Adjustment Transformers with variable trimmable components Adjusts transformer parameter to desired value during test Output to User Port Performs external switching as part of the test program Check www voltech com for the latest list of available tests Each test is described in detail in the following pages together with programming guidance for use with the Voltech PC Editor VOLTECH ATI USER MANUAL PAGE 7 11 TESTS AND TEST CONDITIONS 7 1 2 CTY Continuity Measurement Range 10kQ to 10MQ Where Used The continuity test should be placed as the first test in the program to check that a transformer has been inserted correctly into the test fixture The test checks that every winding has a resistance less than a user specified limit with the same limit being applied to all windings The continuity test will be quicker to execute than a series of resistance tests applied to each winding Used together with the Stop on Fail option CTY will allow you to re insert a transformer into the fixture without recording a FAIL or wasting further test time CTY is a production oriented test and is not avail
169. gram containing the following four tests Resistance of winding AB 59 to 73Q Resistance of winding CD 59 to 73Q Inductance of winding AB gt 3H Turns ratio AB to CD 1 1 2 It is probable that the actual program used to test such a transformer in production would be the same four tests plus an additional insulation resistance test to check for winding to winding isolation First set up the program options From the top level menu bar select Program gt Options The following dialogue box will appear Configure Transformer Tester Results Printing Operator Numbering Off Batch Numbering Serial Numbering C Failures Only Send Results to Server Send Retry Results to Server C Full Reporting Stop on Fail Date and Time on Reports AGL No of Parts AGL of Parts Fixture ID External AC Source None v Cancel PAGE 2 22 VOLTECH ATI USER MANUAL GETTING STARTED By clicking with the mouse enable the following option Send Results to Server In the Fixture ID box enter the name UNIVERSAL Click on or press Return to accept and close the dialogue box You can now move on to create the program 1 From the top level Program menu select Edit The screen will now be made up of three Windows Top left The schematic window showing the two windings Right The available tests window listing all the tests
170. gs EXIT EXIT Signal M Enter f Fix Integration Enter V Auto Compensate Enter I Delete Print Enter IBias Enter Cancel Shift Short Long Cancel OK Short One All Open One All OK VOLTECH ATI USER MANUAL PAGE 6 19 FRONT PANEL MODES 6 3 2 LCR FIX Menu Programs LCR BNC PAGE 6 20 LCR FIX Lp Cs Cp Set Up More 1 4 p H D Rs More 2 4 99 IR Self Test Settings el QD More 3 4 E e Pri Sec Settings More 4 4 EXIT Sec Settings PHAS EXIT Ea Sec Settings EXIT em s Sec EXIT Signal M Enter f 3 Fix Integration Enter V Auto Compensate Enter I Delete Print Enter IBias Enter Sec Cancel OK OK Shift Short Long Cancel OK Short One All Open One All OK VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 3 3 LCR Mode Settings For maximum convenience and ease of use the ATi automatically chooses the voltage and frequency at which the LCR mode tests are carried out The test conditions can also be programmed to fixed values to match the specification of a part or to ensure that a batch of parts are tested at exactly the same conditions The LCR mode settings screen allows you
171. has been used with the correct grade of core material and that the cores have been assembled correctly with the right air gap To fully verify the transformer construction however a complete series of tests should be carried out VOLTECH ATI USER MANUAL PAGE 7 5 TESTS AND TEST CONDITIONS Recommended Tests EXAMPLE Switched mode DC DC converter ferrite power transformer CTY Continuity A continuity check is a very quick test to determine if the transformer has been inserted correctly into the fixture Used with the Stop on Fail feature of the ATi the transformer can be re seated without wasting test time or recording a FAIL R Resistance Check the DC resistance of every winding to ensure that the correct diameter wire has been used and that it is finished or terminated properly A poor solder joint may not show as an out of tolerance inductance but could lead to a reduced service life for the transformer LS Inductance Series Circuit As described above an inductance measurement will confirm that the correct number of turns has been wound and that the correct cores have been properly assembled The test is usually performed on one winding only If there is no obvious primary winding use the winding with the greatest number of turns for the best accuracy and stability Q Quality Factor Q is the ratio between the imaginary inductive and real AC resistive parts of the winding s complex impedance
172. he Test Signal For optimum accuracy and performance use the test conditions chosen for inductance in the previous section of this chapter The test conditions can also be determined automatically by the ATi according to this table Signal Specified voltage Specified current Auto Auto Frequency Specified Specified Specified Auto Note that a fixed signal cannot be used with an Auto frequency Programming the Test Using the PC Test Editor Equivalent Series Resistance x Test Parameters Integration Signal 1 CmA C Short Medium Frequency 0 Hz kHz MHz C Long Terminals High Terminal Low Terminal H zl Resistance Limits CE C Minimum 0 mOhm Ohm kOhm C MOhm C C Maximum 0 mOhm Ohm CkOhm MOhm Measure Cancel UMaltech Choose the integration period normally Medium and enter the terminals to be measured VOLTECH ATI USER MANUAL PAGE 7 33 TESTS AND TEST CONDITIONS Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of
173. he actual tests used in the program are of course dependent upon the type of transformer to be tested and the number of parameters you have chosen to test However it is recommended that you generally do the tests in the following order a Continuity To detect a transformer not correctly plugged into the test fixture and any open circuit windings b Primary inductance To detect faulty core material and the wrong number of primary turns c Turns ratios To detect any windings with the wrong number of turns VOLTECH ATI USER MANUAL PAGE 3 47 PROGRAM EDITOR d Insulation resistance To detect poor interwinding isolation where safety is not an issue for example between two secondary windings e Safety tests such as hi pot Available only on the Voltech AT3600 hi pot must be used to detect poor interwinding isolation where safety is an issue For example from a primary winding to a secondary winding on a mains isolation transformer For iron cored transformers operating at the 50 or 60Hz line frequency where normal operation extends to the point of core saturation magnetizing current and open circuit voltage measurement are normally the preferred tests These tests are available only on the Voltech AT3600 3 Use test limits that are as wide as possible PAGE 3 48 For example if you are testing the turns ratio between windings where the actual number of turns on one of the windings is only 10 specify limi
174. he inductance However at very high frequencies this is not so the capacitance dominates and inductance cannot be measured The self resonant frequency of the transformer is the changeover point between these two regions Normally to get a good measurement of inductance the test frequency should be less than 20 of the resonant frequency of the transformer In general high values of inductance will have a high inter turn capacitance and hence a low resonant frequency Where there is a choice of test frequencies always use the lower value to minimise any problems due to self resonance c Non linear Inductance Normally inductance measurements should be used for transformers where the B H characteristics are linear However if inductance measurements are attempted for instance with line frequency transformers where the core material is non linear even at low signal levels the measured results can be highly dependant on the applied test signal VOLTECH ATI USER MANUAL PAGE 7 23 TESTS AND TEST CONDITIONS This can be a problem when trying to compare measurements made on commercially available impedance bridges or component testers with measurements made using the ATi The test signal in such bridges is usually determined within the instrument and is often at a fixed frequency and ata voltage level that is not guaranteed to be constant for all value of inductance Usually if the actual test conditions of the bridge can be determi
175. he program to the directory being used by the Server for storing programs e Ensure that the Server program is running and that the COM port to be used has been enabled e Connect the AT to the Server PC and use the Set Up menu to set the program store to SERVER e Atthe AT top level menu press the Programs softkey and type in the name of the program e Runthe program and check that the correct results are displayed in the on line monitoring window Leave the Server program running and on the same PC start Microsoft Excel 97 A new empty spreadsheet will be created From the Excel top level menu bar select Tools Macro Macros Enter the name OLE Demo and then create Excel will then bring up a module sheet labelled Module 1 Type the following code into this module sheet VOLTECH ATI USER MANUAL PAGE 4 41 AT SERIES SERVER Vk ck Ck Ck ck Ck Ck Ck Ck KK KK KK KK KK kk Ck Sk KK KK KK KK KK KK Sk kk Sk kk kk ck Mk Sk ke Sk ko KK KK ko ko ko ko ko OLE Demo Sub Procedure to demonstrate linking AT results into an Excel Spreadsheet in real time using OLE Y The procedure will read the third test in the program and put the result into a cell on the third row of the spreadsheet Y The procedure will do this for a total of 3 program runs and then exit Sub OLE Demo Dim objServerResult As Object Dim vntResult 1 To 99 As Variant Set objServerResult CreateObject
176. he top level menu choose Set Up to change to the following display 2 Press the softkey Set Up and at the following display SHORT Continuous Pass Beeper OFF Key Responses CLICK Beeper Volume 3 Press the 4 softkey until the third line shows the words Program Store VOLTECH ATI USER MANUAL PAGE 2 35 GETTING STARTED Set Up AT Password Program Store IHTERHRL 4 If as shown above the origin is INTERNAL then press the softkey Server so that the third line reads as follows Set Up AT Password Program Store SERVER 5 Press the softkey EXIT to return to the Set Up display and then press the EXIT softkey again to return to the top level display PAGE 2 36 VOLTECH ATI USER MANUAL GETTING STARTED Then use the following sequence of key presses to run the test program for the part TUTORIAL 1 Press the softkey Programs to display Server programs Hew program EXAMPLE 1 Delete FAHA 1 4 PART HUMBER PROGRAM 1 2 The program name can now be chosen from the list of programs available on the PC Server If the list of programs fails to appear after a few seconds check that the AT Server is running the COM port and file folder are configured correctly and that the cable from the AT Server port is correctly fitted to the PC 3 Use the T and 4 keys to select the program and press the Run softkey VOLTECH ATI USER MANUAL PAGE 2 3
177. head lt or gt at the end of the horizontal bar when it lies outside the range that can be displayed on the LCD Pressing the Abort softkey stops the program and allows the operator to discard the failing component at the earliest opportunity to minimize test times The abort is also reported to the Server when the program option Send retry results to server is enabled and printed out when a results printing option is set After pressing the Continue softkey the remaining tests in the program will be executed Stop on Fail will remain active and any subsequent test that also fails will produce a similar display At the end of the measurement the component will be classed as a Fail Pressing the Re Run softkey will re start the test sequence from the beginning You would normally press Re Run if the failure were caused by the component being incorrectly inserted into the fixture Unless the option Send retry results to server is enabled at this point there will be no data sent back to the Server Therefore after you have corrected the mistake following the re run good transformers will be reported as Pass PAGE 2 68 VOLTECH ATI USER MANUAL GETTING STARTED 2 7 TRIM If the TRIM test is included in a program the behavior in production mode is similar to the Stop on Fail option described above If the test before the TRIM test produces a Pass result then the program pro
178. heir return values knowing that all the data will be valid Using the NewDataAvailable function also means that checking for INVALID RESULT NUMBER and NO RESULT return values is no longer necessary 4 3 9 Off line Analysis If you have no requirement for real time analysis but are interested in post test analysis of test results off line data analysis should be adopted An example of this would be to view the results file created the previous day As described in section one of this chapter the batch result file is stored in a text based comma separated variable format CSV A spreadsheet is an ideal environment to analyze and manage your test data Almost all spreadsheet applications are able to import a CSV file Once imported test results may be graphed calculated edited and printed like any other data Using a package such as Microsoft Excel macros may be set up to sort and extract the appropriate result sections calculate and compile reports and finally produce a printout for records Refer to your own application handbook for details of importing and manipulating data VOLTECH ATI USER MANUAL PAGE 4 45 AT SERIES SERVER Example of Off line Analysis The spreadsheet used in the example is Microsoft Excel 97 From the Excel top level menu bar select File gt Open XX Microsoft Excel Book1 ae Edit View Insert Format Tools Data z Close m Save Ctrl S Excel will then bring up the Open File d
179. her processes Parts to be tested before finishing Touch pads or foot Switch to start the test Failed parts for rejection or re work Low cost fixture plates e Quick connections to the transformer under test e Rapid change of fixture for different transformer types PAGE 1 24 VOLTECH ATI USER MANUAL INTRODUCTION Robotic Automatic Handling Use In robotic situations the tester s remote port provides the digital inputs and outputs for connecting it to your system Remote PC records all test data Run Stop Fail Busy for statistical analysis using signals for process Voltech Server software control Good parts for further processes Parts to be tested before finishing Failed parts for rejection or re work Again the tester may be connected to a Server PC or used stand alone as described above VOLTECH ATI USER MANUAL PAGE 1 25 INTRODUCTION 1 9 How DOES THE ATI TESTER RUN A TEST It is not necessary to understand how the tester works in order to install program or operate it successfully This section is provided for your information only The ATi consists of the following seven basic functional blocks Source 1 Up to 5V rms DC Relay MADE and 20Hz to 3MHz Source 2 Up to 1A constant current Source 3 Up to 500V DC for IR Processors Keyboard Display and Interfaces Measurement Circuits Relay Switching Matrix The relay switching matrix
180. ialogue box Select the results file you wish to view and click on Open Open ae Lookin C Server El Lene r 20 06 37 10 51 N 2KB n 20 06 97 10 44 Cancel Advanced Bead Only Find files that match these criteria Filename T Text or property E Eind Now Files of type Microsoft Excel Files Last modified ary time 7 New Search 2 file s found After clicking Open the Text Import Wizard dialog box will appear PAGE 4 46 VOLTECH ATI USER MANUAL AT SERIES SERVER Text Import Wizard Step 1 of 3 BE The Text Wizard has determined that your data is Delimited If this is correct choose Next or choose the Data Type that best describes your data Original Data Type Choose the fil type that best describes your data Characters such as commas or tabs separate each field Excel 4 0 standard dth Fields are aligned in columns with spaces between each field Start Import at Row fi File Origin Windows ANSI Preview of file C X amp T210NSERVERNCB200637 ATR HL YOLTECH AT3600 RESULTS FILE Server Program Version 2 04 Communication Channel Shatseoo 4 AT3600 Software Version 2 16 File name atr Cancel Finish Ensure that the Delimited option is checked and click on Next gt to move to step two Text Import Wizard Step 2 of 3 BE Th
181. ied after sufficient parts have been tested to make the percentage meaningful When setting AQL of Parts to be 1 for example a warning will only be displayed after 100 1 100 parts have been tested Fixture ID Finally you should enter a fixture name The Fixture ID can be up to 20 characters long You may use any of the characters that appear on the tester s keyboard A Z upper case only 0123456789 and space PAGE 3 16 VOLTECH ATI USER MANUAL PROGRAM EDITOR When the test program is run on the AT Series Tester the operator will be prompted to fit the fixture with this name This will help to ensure that the correct fixture is used Note that the fixture name does not have to be the same as the program part name This makes it possible to have one fixture common to a number of transformers which may for example have the same arrangement of pins but have different windings requiring different test programs External AC Source This option is applicable to the AT3600 only When you have selected all the required options click on the OK button to return to the top level menu Stop on Fail With this function enabled the tester will stop program execution whenever a fail is detected rather than carrying out all the tests in the test program and reporting the passes and fails at the end This enables the user to quickly identify a faulty transformer and replace it with another one before all the tests have
182. ile filename on success or a failure string NO RESULTS FILE no valid filename found no results yet GetResultPolarity LPCSTR ComPort short TestNumber NO POLARITY test has no polarity result ET polarity is positive amp polarity is negative GetPolarityPass LPCSTR ComPort short TestNumber NO POLARITY test number has no polarity result PASS polarity result has passed FAIL polarity result has failed VOLTECH ATI USER MANUAL PAGE 4 37 AT SERIES SERVER GetTestPass LPCSTR ComPort short TestNumber PASS test result has passed FAIL test result has failed GetOverallPass LPCSTR ComPort PASS all tests have passed FAIL one or more tests have failed GetNumberOfTests LPCSTR ComPort Returns a short integer variant type giving the number of tests in the program Use for possible determination of the maximum value for TestNumber in other functions GetMinLimit LPCSTR ComPort short TestNumber Float value giving the minimum limit for the test TestNumber NO LIMIT test has no minimum limit GetMaxLimit LPCSTR ComPort short TestNumber Float value giving the maximum limit for the test TestNumber NO LIMIT test has no maximum limit GetTestStatus LPCSTR ComPort short TestNumber Returns four digit hex string 445 giving the test status as seen on Editor results screen GetTestMnemonic LPCSTR ComPort short TestNumber Returns the test mnemonic as a string i e LBAL PAGE 4
183. ill search for that name in the programs that are stored in its own non volatile RAM To store these programs you must use either the Group Download or Tester Download features described here Group Download Using the Server Before attempting to download a group of programs ensure that the Server software is running on its PC the lead is connected from the tester s Server port to the Server PC and the COM port is correctly set up in the Server Also ensure that the group you wish to use has been created within the Server From the Server top level menu select Setup Groups etc as explained in chapter 4 PAGE 2 82 VOLTECH ATI USER MANUAL GETTING STARTED To download a group of programs at the tester s top level display press the Set Up softkey Then at the Set Up mode display press the Groups softkey The next display will prompt you for the name of the program group that you wish to use Enter the group name As with other names the group name can now be typed in from the keypad entered using a bar code reader connected to the bar code port of the ATi or selected from a list using the List option Again the cursor softkeys and the Delete softkey may be used to correct errors After pressing the Enter softkey or the download will commence and after a few seconds you will see the following display VOLTECH ATI USER MANUAL PAGE 2 83 GETTING STARTED Grou
184. imilar costs In no case shall Voltech s liability exceed the amount of the license fee 9 3 SERVICE AND CALIBRATION To confirm the accuracy of your AT series tester a calibration check should be carried out every 12 months Calibration is carried out using a special fixture as described in the next section The calibration can be performed by an authorized Voltech service center or at your own facility if you have the required equipment For details of calibration facilities and any other service request please contact your Voltech supplier Voltech strongly recommends that you discuss your service requirements with your supplier before service is needed Extended warranty and full service agreements are available 9 4 OBTAINING SERVICE AND APPLICATIONS SUPPORT Voltech personnel will be happy to help you with any query that you may have Please telephone fax or e mail your local supplier or your regional Voltech service center as listed at the front of this manual To ensure we provide the fastest possible support we may ask you for e The serial number of the ATi Shown on the back of the instrument PAGE 9 6 ATI USER MANUAL WARRANTY AND SERVICE e The firmware revision level of the ATi Shown on the ATi s front panel during power on e The software revision levels of the PC Editor and Server software that you are using 9 5 FIRMWARE UPGRADES The firmware of the ATi controls how tests are carried out which tes
185. impedance will help to determine that the part has been properly assembled using the correct cores and the right gauge of wire Measurement Conditions The AT Series Tester applies the specified AC voltage to the winding under test Using harmonic analysis the phase angle of the impedance is determined from the measured voltage and the current flowing through the winding Inductive Capacitive ANGL is the angle of the complex impedance tan X R Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test PAGE 7 102 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Impedance Phase Angle x Test Parameters Integration Signal o Cmv CV C Short Medium Frequency 0 Hz kHz MHz C Long gt Terminals High Terminal Low Terminal E Phase Limits Cap Minimum 0 Degs gt lt Maximum 0 Degs Mesue Coc FERRET Choose the integration period normally Medium and enter the High and Low Terminal names Note that the PC Editor s Measure button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and limits of up to 90 and 90 deg gt lt Minimum and maximum values Use the PC editor s Measure button together with a sample part if you are unsure of the n
186. in the DC resistance section of this chapter for each of the two windings Programming the Test Using the PC Test Editor Resistance Match x r Integration C Shot Ch r Terminals X Terminals Y High Terminal Low Terminal High T erminal Low Terminal m Matching Limits X Resistance o 6 m hm C Ohm C kOhm MOhm Y Resistance o 6 m hm C Ohm C kOhm MOhm Negative Error o Positive Error o x Gk Measure Cancel e Select the integration time required e Enter the terminal names between which the X resistance is to be measured e Enter the terminal names between which the Y resistance is to be measured e Set the specific resistance for both X and Y terminals and then set the negative and positive percentage 96 limits e Select OK The test specification will now be displayed in the program window Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions VOLTECH ATI USER MANUAL PAGE 7 17 TESTS AND TEST CONDITIONS Choosing Test Limits The test limits are the specific resistances for both X and Y terminals together with and percentage limits Use the PC Editor s Measure button together with a sample part if you are unsure of the resistance values PAGE 7 18 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 5 LS LP Inductance Series and Parallel Equivalent Circuit Ra
187. inal Low Terminal B For Help press F1 NUM 7A start A E A Klinbos Mis Gy Exploring C BY Microsoft W 3 Part BRESA 1214 If you look at the test results screen shown above you will see that test 4 LBAL contains a status error code of 0010 This error code indicates that The measurement had not settled in time Although this test passed it indicates that a problem existed during the test sequence In this particular example the fault was due to a poor connection to the core of the transformer The following table gives the error codes that can appear when using the run facility in the Editor or when viewing on line results with the Server These error codes can give specific help in modifying the test program depending on the tests used The error code is a 16 bit binary code which is shown in hexadecimal notation in the table below The error codes indicate one single bit of the 16 bit code and therefore one or more errors could occur at the same time which will be shown as a full 4 digit hexadecimal code For example if a voltage over range xxx1 and a current over range xxx2 have occurred at the same time during VOLTECH ATI USER MANUAL PAGE 3 43 PROGRAM EDITOR test then the error code is 0003 i e both bits 0 and 1 set in the 16 bit binary error code If a test has failed due to an interrupt then an additional code is attached to bits 12 15 of the error code as the
188. inal value Test limits should be set as close as possible to detect assembly faults PAGE 7 106 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 28 TRIM Pause Testing in Order to Trim a Component Value Trimmable Inductance AT Series Capacitance Resistance Tester Impedance Longitudinal Balance The TRIM test is used on signal audio and telecommunications transformers and other components where a means of physically adjusting a parameter is provided For example the Q factor of a coil may be tuned to within specified limits by adjusting a trimmable core Test Conditions A TRIM test may be used after any low voltage test on the tester If the desired parameter is outside the limits specified by that previous test the tester halts and provides a live display indicating which way ve or ve the operator should adjust the part Once trimming is complete the tester will continue with the rest of the tests in the sequence once the run pad is touched the Run softkey is pressed or the foot switch if fitted is closed VOLTECH ATI USER MANUAL PAGE 7 107 TESTS AND TEST CONDITIONS Tests that may be TRIMmed include R RLS RLP LS LP LSP LSB Q C TR LL LLO TR L2 C2 GBAL LBAL ILOS RLOS and Z Choosing Test Conditions On selecting TRIM Trimming Adjustment from the Available Tests Window the following dialogue box will be displayed Trimming Adjustment Ed Adjust the previou
189. inals for the second capacitance Choosing Test Conditions For optimum accuracy and performance choose test conditions based on the nominal value of capacitance as listed in the previous capacitance section The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency Use the Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions See also the notes relating to choosing tests conditions for capacitance in the previous section Choosing Test Limits The test limits are entered as a and percentage around a nominal ratio Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value PAGE 7 56 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 15 Turns Ratio and Phasing Measurement Test Test Basic Range Voltage Frequency Accuracy 1 100 000 100 000 1 1mV to 5V 20Hz to 3MHz 0 1 AT Series AT Secondary Tester measurements In phase Anti phase Applying an AC voltage to the primary of the transformer will produce an AC voltage in the secondary Turns ratio describes the voltage ratio of the measured voltages from one winding and another The secondary voltage may be in phase with the primary voltage or it may be an
190. ip obe Po etu en s ee dais 8 20 8 2 15 ANGL Impedance Phase 6 8 21 8 2 16 PHAS Interwinding Phase eene 8 22 8 3 INTERFACE 5 8 23 8 3 Barcode Port xo ee br e deerit 8 23 8 3 2 Server Port iae Dei t e 8 25 6 3 3 Auxiliary Port tg t ER es 8 25 8 3 4 Printer POIt ou ii etit b pod d et dai ode 8 26 8 3 5 Remote POI o rt e 8 27 6 3 6 User Port i dt e Rr EHE de aie 8 29 8 3 7 Environmental Conditions essen 8 32 VOLTECH ATI USER MANUAL PAGE 8 3 SPECIFICATIONS 8 4 EMC 8 33 8 4 1 Declaration of Conformity 8 4 2 EMC Precautions PAGE 8 4 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 1 SPECIFICATIONS SUMMARY AVAILABLE TESTS User Entered Test Data o Test Measurement Range Test Signal Test Frequency n a Ik 10MO n a 0 196 DC Resistance DC Resistance 1 1000 1000 1 n a n a 0 296 Match Inductance Series InH IMH ImV 5V 20Hz 3MHz 0 05 Bias Inductance Parallel InH IMH 5V 20Hz 3MHz 0 05 LPB Bias 000 000 m Fig lit QL 0 001 ImV 5V 20Hz 3MHz 0 5 Factor Dissipation 0 001 1mV
191. is screen lets you set the delimiters your data contains You can see how your text is affected in the preview below Delimiters Tab Semicolon M Comma Space Other Text Qualifier I Treat consecutive delimiters as one Data Preview OLTECH AT3600 RESULTS FILE Server Program Version 2 04Communication Channel AT3600 ID 0571 AT3600 Software Version 2 16 File name C6200697 atr 20 Jun 199 In the Delimiters section of this screen ensure that only the Comma option is checked Click on Next gt and proceed to step three VOLTECH ATI USER MANUAL PAGE 4 47 AT SERIES SERVER Text Import Wizard Step 3 of 3 24 x This screen lets you select each column and set Column Data Format the Data Format General General converts numeric values to numbers date C Test values to dates and all remaining values to text les pw C Do Not Import Column Skip Check that the Column Data Format option is checked as General and click on Finish PAGE 4 48 VOLTECH ATI USER MANUAL The results will now be displayed as shown below AT SERIES SERVER S Eie Edt view Insert Format Tools Data Window Help 2181 x OSE SRY o gt Bez mA E 1G aia v0 B 7z u same 8 85 oA AL E VOLTECH AT3600 RESULTS FILE A B Cina ae Da oe En ee Om TASR
192. is to monitor in real time the trend in a winding resistance to identify a defective drum of copper You would then be able to rectify the fault during production rather than producing a large stock of QA failed transformers all wound with the defective wire Setting Up Database Results Storage From the Set up menu select Results to see the following dialogue Results Setup 3 xj Standard Results Saving CSV Display Basic Statistics Database Results Saving Advanced Cancel Select Database Results Saving to save results to a database For this feature to operate properly a connection to the database must be set up first and a license for use must be obtained from your Voltech supplier All results formats can be saved simultaneously VOLTECH ATI USER MANUAL PAGE 4 17 AT SERIES SERVER Click on Advanced to set up your database connection Database Results Advanced x Connection String Connection Type OK Cancel To connect to your database the Server software uses a connection string that contains amongst other things the name of a provider the name and location of the database and a valid database user name and password if required You may need to consult with the database or network administrator to obtain this information If a connection has already been established you will see the connection string in the window inside this dialogue If you wish to remove an existing
193. is used to connect the selected test source and measurement circuits to the particular nodes required in the test PAGE 1 26 VOLTECH ATI USER MANUAL INTRODUCTION Test Sources The three sources are fully programmable in thousands of steps of voltage current and frequency Measurement Circuits Fully auto ranging the measurement circuits are capable of measuring from uV and nA to 500V and 4Apk with great precision Keyboard Display and Interfaces A broad range of programming results display and storage methods Processors The AT series testers are based on a two processor design 1 Astandard microprocessor that acts as controller and also drives the relay matrix the keyboard and display and the various interfaces 2 A fast digital signal processor that controls the test sources and performs the measurements The test sources relay matrix and measurement circuits are all under direct control of the processors to ensure optimum speed accuracy and reliability Running a Test When the test program is loaded into the tester each individual test is assembled into a sequence of operations involving the components in the functional block diagram shown before The sequence is different for each test and in some cases it depends on what the preceding and following tests in the program are but in all cases it is optimized to give the best measurement speed and accuracy VOLTECH ATI USER MANUAL PAGE 1 27 INTRODUCTIO
194. itors and especially film and ceramic types the dissipation factor will be very low typically lt 0 01 The errors due to connections and lead impedances can thus be very significant For the best accuracy always use four terminal connections and perform compensation before recording measurements VOLTECH ATI USER MANUAL PAGE 7 115 TESTS AND TEST CONDITIONS PAGE 7 116 VOLTECH ATI USER MANUAL 8 SPECIFICATIONS VOLTECH ATI USER MANUAL PAGE 8 1 SPECIFICATIONS PAGE 8 2 VOLTECH ATI USER MANUAL SPECIFICATIONS Contents Specifications 8 1 SPECIFICATIONS SUMMARY 5 8 5 8 2 ACCURACY SPECIFICATIONS AVAILABLE TESTS eene 8 7 8 2 1 R Winding Resistance Test 8 7 8 2 2 LS LP LSB LPB RLS RLP and X 8 8 82 30 LL and ELO 8 9 8 2 4 0 CS and CP Tests c ste Mae aiuta 8 10 8 2 5 Quality Factor and D Dissipation 8 11 8 2 6 TR Tums Ratio eere ep ED eee ed 8 12 8 2 7 LVOC Open Circuit Voltage Test 8 13 8 2 8 TRL Turns Ratio by Inductance seen 8 14 8 2 9 IR Insulation Resistance eene 8 15 a 8 16 8 211 GBAL T6SU 8 17 8 2 12 LBAL ILOS and RESP Tests 8 18 8 218 REOS Test x cci ela 8 19 8 214 ZG ZB TSU i
195. kly understand what may be possible If further details are required on any topic they can be found in later chapters of this manual VOLTECH ATI USER MANUAL PAGE 1 15 INTRODUCTION 1 8 1 Creating Programs The Editor The test program is simply the list of tests that you wish to apply to your transformer Individual transformers will each have their own program but as an example a typical program for a three winding switch mode power supply transformer could be as follows Program W2 Resistance Resistance w1 Resistance Inductance Turns Ratio W3 Turns Ratio W1 to W2 W3 Insulation Resistance Part Number SMPSE42 A The Test Program Editor supplied with your tester allows you to create such a program without software programming skills Each test required for the program is selected from a list of available tests by clicking with the mouse The test details such as the transformer terminals test conditions and pass fail limits are then entered into a form fill dialogue box Winding Resistance x Integration C Short Medium C Long Terminals High Terminal Low Terminal Resistance Limits CZ gt lt Minimum jo mOhm Ohm C kOhm C MOhm C C Maximum jo 6 mOhm Ohm kOhm C MOhm Measure Cancel PAGE 1 16 VOLTECH ATI USER MANUAL INTRODUCTION Normally the Editor is used with the auxiliary port of the tester connected to a spare COM p
196. l Lm Frequency Voltage Vm 300KHz 100KHz 30KHz 10KHz 1KHz 100Hz 100Hz 50Hz 50Hz 50Hz 20Hz x is ay E 5 ak 2 The ATi can automatically determine the test conditions according to the following table Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency Choosing Test Limits When specifying turns ratio tests it is preferable to avoid limits which are unnecessarily tight and which may therefore lead to measurement difficulties For example if two equal secondary windings should have 10 turns each the ratio should be 1 1 One turn in error would produce a ratio error of 1096 or 10 i e 11 10 or 10 11 and therefore limits of 5 and 5 would be suitable to detect the error PAGE 7 68 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 17 LVOC Low Voltage Open Circuit Measurement Test Test Basic Range Voltage Frequency Accuracy 100 to 5V 1mV to 5V 20Hz to 3MHz 0 196 AT Series AT Secondary Tester measurements In phase Anti phase Applying an AC voltage to the primary of the transformer will produce an AC voltage in the secondary Low Voltage Open Circuit measures the open circuit voltage produced when the specified test signal is applied The secondary voltage may be in phase with the primary voltage or it may be anti phase depending on the winding and the termination of
197. l Units Display Units DC Resistance Rdc Ohms DC Resistance Using High IR Ohms voltage Source AC Resistance Series Circuit Rs Ohms Q AC Resistance Parallel Circuit Rp Ohms Q Inductance Series Circuit Ls Henries H Inductance Parallel Circuit Lp Henries H Capacitance Series Circuit Cs Farads F Capacitance Parallel Circuit Cp Farads F Interwinding Capacitance C Farads F Quality Factor Q Dissipation Factor or tan D AC Impedance Magnitude of Ohms Complex Impedance Phase Angle of Impedance 0 Degrees AC Reactance Imaginary Part X Ohms of Impedance Turns Ratio TR Turns Ratio by Inductance TRL Polarity POL Interwinding Phase PHAS Degrees 5 Leakage Inductance LL Henries H Please see the chapter Tests and Test Conditions for a detailed description of each of these measurements and their application PAGE 6 18 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 3 LCR MENUS See the previous section for details of the tests that are available The following flow diagrams describe the menu structure for LCR BNC and LCR FIX modes 6 3 1 LCR BNC Menu Programs LCR BNC Lp Cs Cp LCR FIX More 1 3 p Set Up el D Rs More 2 3 ES Settings el QD More 3 3 Self Test Fix Settings EXIT Ed Fix Settin
198. lating Checks winding positioning and insulation thickness between windings Capacitance Series Circuit Testing capacitors Capacitance Parallel Circuit Testing capacitors Capacitance Match SMPS audio amp telecom Checks correct winding position on bobbin Turns Ratio and Phasing Turns Ratio by Inductance Most but usually not line frequency Checks windings have correct turns and polarity Checks windings have correct turns Low Voltage Open Circuit Most but usually not line frequency Checks windings have correct turns Insulation Resistance All Checks winding isolation checks where safety is not involved General Longitudinal Balance Audio amp telecom Checks common mode rejection ratio Longitudinal Balance PAGE 7 10 Audio amp telecom Checks common mode rejection ratio VOLTECH ATI USER MANUAL Description TESTS AND TEST CONDITIONS Transformer Application Reason for Test Insertion Loss Audio amp telecom Checks power lost within the transformer Frequency Response Audio amp telecom Checks losses over a range of frequencies Return Loss Audio amp telecom Checks power returned by a transformer Impedance Audio amp telecom Checks impedance at a given frequency Impedance with Bias Audio amp telecom Checks impedance at a given frequency Impedance Phase An
199. lation Resistance An insulation resistance test applies a high voltage up to 500V DC between windings to check that they are no defects in the insulation Check wherever windings are supposed to be insulated from one another VOLTECH ATI USER MANUAL PAGE 7 7 TESTS AND TEST CONDITIONS More Tests A comprehensive suite of more than 20 different tests is available for the ATi and new tests are constantly being developed Additional tests can be purchased at any time and are available on disk or by e mail so that your ATi can be upgraded in a few minutes with the aid of the Voltech Editor software running on a PC The tests available at the time of printing are listed in the next section of this chapter Check with your Voltech supplier or on the Voltech website at www voltech com for the up to date list Iron Core Transformers For iron core transformers operating at 50 60 400 Hz Voltech recommends the use of a magnetizing current test rather than inductance This test is available only on the Voltech AT3600 Hi Pot or Flash Testing Transformers are often used to provide safety isolation between the AC line and the user Where this is the case very high voltages 2000 to 5000VAC must be used to test this isolation The Voltech AT3600 incorporates this test as well as all of those available for the ATi and more Self Resonant Frequency Practical inductive components are not perfect inductors they have stray resistances a
200. ll automatically compensate for lead resistance and if 4 wire Kelvin connections are used the contact resistance between connector and the part under test Program V Trim V Measured V xX Winding under test ATi basic measurement circuit Measured V Program V This is very different to commonly used LCR bridges which have a nominal impedance in their output to provide short circuit protection for the test signal generator VOLTECH ATI USER MANUAL PAGE 6 35 FRONT PANEL MODES Program V Winding under test Other measurement circuit Measured V Program V There are circumstances when the ATi cannot maintain the measured voltage to be equal to the program voltage For example if the AC impedance of the winding under test is only 0 1Q at the specified frequency and you have specified a 5V test signal then the AT would have to supply 5V 0 10 50 Amps and this is not possible Under these circumstances the ATi display of both program and measured voltages will clearly show the difference PAGE 6 36 VOLTECH ATI USER MANUAL FRONT PANEL MODES 3 4556nH 1 3230 CFixture modes 3 Ws 18 5kHz q Srm 324m 16 5kHz There may also be circumstances where the ATi cannot stabilize sufficiently to make a repeatable measurement in which case the measurement will be 0 and the bottom line of the display will show Overload adjust V or f If you see either of the above error mes
201. m your transformer tester The next section lists more features of the tester that you may wish to investigate yourself at this point before you try to create real programs for production use PAGE 2 42 VOLTECH ATI USER MANUAL GETTING STARTED 2 3 7 Storing Programs For everyday production use programs should be stored either e OnaPCrunning the Server software that will be permanently connected to the AT e Orin the testers own memory Method 1 using a permanently connected PC Server has been described in the previous Getting Started section Method 2 using the ATi s own internal memory is described here The programs can be stored within the tester even when it is switched off Once a program is stored the tester may be used without PC Editor or Server software To operate the tester in this way the origin of the tester s programs must be set to the local program store On the tester at the Set Up display set the Program Store option to INTERNAL This is described in the Getting Started section Working Without a Server Storing a SINGLE Program A single program may be stored in the AT using the PC Editor Once a program has been created using the Editor and downloaded to the tester the tester will display VOLTECH ATI USER MANUAL PAGE 2 43 GETTING STARTED SAVE PROGRAM Continue Saving this program to the local store will overwrite an existing program group Local S
202. magnetizing current test MAGI is recommended This test is only available on the AT3600 See also the LS and LP tests for testing transformers where a DC bias current is not required Test Conditions To measure inductance with DC bias the tester first applies and stabilises the DC bias current and then applies an AC voltage across the selected winding The tester measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain the complex impedance from which the inductance is extracted Generally it is not necessary to measure the inductance at the normal operating conditions of the transformer which could involve for example hundreds of volts or several amps of bias This is because the core material can normally be assumed to behave linearly in the operating region and the inductance measured at a low level represents the inductance that will appear in use Choosing Test Conditions For optimum accuracy and performance use the test conditions chosen for inductance without bias in the previous section of this chapter The test conditions can also be determined automatically by the ATi according to this table Signal Specified voltage Specified current Auto Auto Frequency Specified Specified Specified Auto Bias Specified Specified Specified Specified PAGE 7 36 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Note that a fixed
203. ment and you will be returned to the previous screen Once both short and open circuit compensation have been performed succesfully the words comp req will be removed from the compensation screen and from the main LCR or Rdc IR measurement screen 6 4 2 Compensation Fail Should any compensation measurement fail this is most likely because either the short circuit S C COMP or the open circuit O C COMP were not connected properly VOLTECH ATI USER MANUAL PAGE 6 33 FRONT PANEL MODES Compensation Short One All pen Ore A11 Short circuit comp FAIL OC compensation is required for 123 Hz Check the connection either short or open circuit and repeat the compensation measurement In the unlikely event that compensation continues to fail you can use the ATi without compensation comp req will be shown on the display while contacting your Voltech supplier for applications assistance PAGE 6 34 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 5 LCR MODE ERROR MESSAGES The ATi is a precision measuring instrument with fully programmable test sources The ATi will whenever possible ensure that the programmed voltage frequency and DC bias current are present AT THE TERMINALS OF THE PART UNDER TEST This is done by measuring the voltage and current at the terminals of the part and if necessary trimming the test source to establish exactly the required conditions at the part This means that the ATi wi
204. meters Integration Voltage Cmv C Short G Medium Frequency 50 GHz CkHz MHz C Long Energised Terminals High Terminal Low Terminal A M B Primary Terminals Secondary Terminals High Terminal Low Terminal High Terminal Low Terminal A B M D Ratio Limits Polarity E Primary Secondary Cave Ce Ca Neg 2 Pos 2 No Test Measure Cancel Y Click on the OK button Again the test and its parameters will appear in the Program window VOLTECH ATI USER MANUAL PAGE 2 27 GETTING STARTED The lower left window should now contain the complete program The scroll bars in this window enable you to view each test in the program in turn to check that it is correct The Editor will not allow a program to be run in the AT unless it has previously been saved s Voltech Test Program Editor New Pd From the top level menu bar select MEE Schematic Program Tester Sev New Part gt Save As Open Ctrl O z om schematic Save Ctrl S Print Ctrl P Print Preview Print Header Print Setup Exit Save Part be Part Number Directories Ij At the dialogue box TUTORIAL c at3600 editor t in gae Cancel 3600 yp pi Help TUTORIAL Network as the part name Drives Sc ms dos 6 Click on the OK button to close the dialogue box and save the test program in the Editor default directory 2 9 4 Running the Program
205. mits should be set as close as possible to detect assembly faults PAGE 7 98 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 25 X Reactance Measurement Test Test Basic Range Voltage Frequency Accuracy 1mQ to 1MQ 1mV to 5V 20Hz to 3MHz 0 2 AT Series Impedance Z Tester The impedance of a transformer is usually complex that is it consists of real resistive and inductive or capacitive imaginary parts The total impedance at a specified frequency is the vector sum of these parts Z R jX Where R and X are the real and imaginary parts of the total impedance Where Used The X test checks the reactance or imaginary part of the complex impedance of audio and telecommunications transformers that are to be used with transmission lines of specified impedance The test helps to ensure that the transformer has been assembled properly using the correct core and winding materials Test Conditions The test may be made on the part alone or with a load resistor RL attached to the secondary to simulate the load impedance of the transformer when it is used in its final application The optional load resistor RL is connected to the VOLTECH ATI USER MANUAL PAGE 7 99 TESTS AND TEST CONDITIONS transformer under test as shown This may be done automatically using the tester s OUT test To measure X the tester applies the specified voltage and by measures both the applied voltage and the resulting current Using ha
206. n 2 Choose Delete Screen Connection from the Schematic menu The screen connection will be removed from the schematic Note that ALL tests containing the deleted screen will also be DELETED PAGE 3 12 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 3 CREATING THE TEST PROGRAM This section describes the procedures used when creating the test program with the AT Series Editor By the end of this section you will be able to Set up the program options Add a test to the program Insert a test in the program Modify an existing test in the program Delete a test Use the Measure button to create test parameters Verify the program including fixture compensation VOLTECH ATI USER MANUAL PAGE 3 13 PROGRAM EDITOR 3 3 1 Setting the Program Options Overview After you ha any tests in ve created the program schematic and before starting to insert the program you should set up the program options that you would like to use From the top level menu bar select Program gt Options PAGE 3 14 Voltech Test Program Editor New Part Tester Serer 5 p Results Printing Operator Numbering Off Batch Numbering Serial Numbering C Failures Only Send Results to Server Send Retry Results to Server Full Reporting Stop on Fail Date and Time on Reports AOL No of Parts AQL Z of Parts Fixture ID wv FIXTURE External
207. n x ine e aite 4 50 duraiil eeeE aea a E a a aaa 5 1 5 1 uie ede 5 5 5 2 DOSCHIDUORN ui 5 6 5 8 Fixture System Specification seen 5 12 5 4 Fixture Parts Available from Voltech sse een 5 13 5 5 Kelvin Connections dec be 5 18 6 FRONT PANEL 5 1 6 1 6 1 LCR Mode Basic Functions esee 6 5 6 2 Tests Available in the LCR Modes eene 6 17 G53 ECRMen s 6 19 6 4 sides vases arr 6 29 6 5 LCR Mode Error 6654965 6 35 6 6 Program ie t A 6 39 7 TESTS AND 5 7 1 TEA hi eee ee tr poses 7 5 7 2 Series and Parallel Circuits essen 7 112 7 3 Capacitor Measurements sss siens eene nnne 7 114 8 SPECIFICATIONS te piena EE hs divin EA EEXER vince YR ie i neue E Ra Rag ERY e de 8 1 8 1 Specifications Summary Available 8 5 8 2 Accuracy Specifications A
208. n values are stored within the AT until a new program is loaded the tester is Switched off or compensation is re run Test programs can be run without fixture compensation being performed but this may affect the accuracy of the results depending upon the type of transformer being tested and the fixture design PAGE 2 74 VOLTECH ATI USER MANUAL GETTING STARTED 2 9 SET UP MODE Set up mode has two main functions To change the tester s set up options including setting up for Server operation and to download a group of programs from the Server PC to the tester s internal memory LCR BHC LCR FIK Self Test To access set up mode from the top level menu see above press the Set Up softkey to change to the following display VOLTECH ATI USER MANUAL PAGE 2 75 GETTING STARTED The two main functions of set up mode each have their own softkeys at this display Press the Groups softkey to download a group of test programs from the Server to the tester s internal memory or press the Set Up softkey to change any of the tester s set up options Pressing EXIT at this point will return the tester to the top level display 2 9 1 Set up Softkey Pressing the softkey Set Up at the Set Up mode display shown above will reveal Fail Beeper SHORT Continuous Pass Beeper OFF Key Response CLICK Beeper Wolume This display is the start of a list of options under the title Set
209. n the ATi can be compensated for the effects of stray connection capacitance and inductance that are always present The effect of the strays upon the measurement will vary significantly with the part being tested but for optimum accuracy Voltech recommends that all reference measurements should be made after compensation Program V gt Measured V Winding under test The ATi is fully compensated at the factory for a broad range of frequencies and compensation is often not required when using the LCR modes If compensation is required one of the following measurements will be displayed BNC comp req Fixture comp req Once compensation measurements have been carried out at a particular frequency those measurements will be stored and need not be repeated again VOLTECH ATI USER MANUAL PAGE 6 29 FRONT PANEL MODES To compensate for the effect of stray inductance the ATi must make a measurement with a short circuit in place of the winding s under test This is called short circuit compensation The short circuit should be made of a piece of copper wire that is as short as possible If you are making measurements using a fixture plate it is usually convenient to make a part up with short circuits in place of the windings on a sample bobbin without cores AL T Transformer Shorting bobbin for compensation To compensate for the effect of stray capacitance the ATi must make a measurement with no windin
210. n the group of programs that has been downloaded into the AT At all the above displays pressing the Continue softkey will take you back to the top level display 2 5 3 Indications Displayed While Tests Are Running Part number TUTORIAL Executing test 1 Where 1 represents the position of the test within the test program The operator may terminate the measurements at any time by pressing the Stop softkey Alternatively you may use the STOP input signal on the tester s remote port which may be connected for example to an emergency stop switch As the measurements proceed the test number will increment PAGE 2 56 VOLTECH ATI USER MANUAL GETTING STARTED Fart number zu z 3 TUTORIAL Settings Total 1 Failed 8B t x Results Last transformer P 5 Finish jc Fart number zu C 2 TUTORIAL Settings Total 1 Failed 1 1004 Results Last tranzformer Finish 1 The Run Finish display is seen after a component has been tested The front panel LED green Pass red Fail the output lines of the remote port and the LCD indicate the pass or fail result of the tested transformer so that the operator may place it in the appropriate Pass or Fail bin Results are also sent to the Server at this time if so enabled in the Editor program options and all previous test results may be reviewed on the results listing screen which is accessible
211. nabled batch number operator number or serial number the flow Select diagram shown on the left Programs Soft key summarizes production mode operation Select Test Program to Run Fit Fixture Compensate Fixture Fixture Compensation RUN FINISH Menu RUN Measurements VOLTECH USER MANUAL PAGE 2 51 GETTING STARTED At the top level display press softkey 1 Programs Programs LCF EHC LCF Set Up Self Test The program to be run may now be chosen from a list of programs available on the PC Server or in the ATi s own memory i e local programs entered by swiping a barcode or created directly from the front panel by selecting New program and pressing the Set Up softkey see chapter 6 Local programs Heu program 3 PROGRAM 1 TUTORIAL Once the test program to be executed has been selected pressing softkey 1 Run produces the following display PAGE 2 52 VOLTECH AT USER MANUAL GETTING STARTED Fit the fixture Compenzate For connect all used terminals together FIXTURE 1 is the name given as the Fixture ID in the Editor software Program options dialogue see chapter 3 or under program options in front panel program mode see chapter 6 Press Compensate or No Comp as required Note For fixture compensation see later in this chapter Fart
212. ncy Accuracy 0 001 to 1000 1mV 5V 20Hz To 3MHz 0 5 AT Series Tester When a transformer is energized the changing magnetic field in the core causes two types of losses hysteresis losses and eddy current losses The total of these losses can be represented on the equivalent circuit of a transformer by a resistance associated with the inductance of the winding For this equivalent circuit the Quality Factor Q is defined as Q oLs where 2 8 Rs For a given inductance the lower the equivalent series resistance the higher is the value of Q i e the better the coil Where Used The Q factor test would normally be used for signal pulse and switched mode power transformers where the normal operating conditions require only small excursions of the B H curve never extending beyond the linear region PAGE 7 26 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS A Q Factor test will help to determine that the correct wires and cores have been correctly assembled for the part under test Test Conditions To measure Quality Factor the tester applies an AC voltage across the selected winding and measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain a complex impedance from which the Quality Factor is obtained Choosing the Test Signal For optimum accuracy and performance use the test conditions chosen for inductance in
213. nd capacitances associated with them For certain components especially those with a low inductance value the impedance of the stray capacitance can become significant when compared to that of the inductance 1 X 2 AUTO At a sufficiently high frequency the capacitive impedance can dominate making a measurement of the inductance impossible Under these PAGE 7 8 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS circumstances any measurement instrument may report negative inductance values and measurement errors Should these symptoms be observed reduce the test frequency to avoid problems The frequency at which the inductive impedance equals the capacitive impedance is known as the self resonant frequency SRF of the component At this point the phase angle of the impedance which can be measured using the ANGL test is zero At test conditions where the frequency is low enough for problems with capacitive impedance to be negligible the phase angle will be positive and close to 90 degrees Therefore an ANGL test can be used during program development to confirm if measurement problems are due to the chosen test frequency approaching the SRF of the part under test If the angle is significantly less than 90 degrees consider reducing the test frequency Note that stray fixture capacitance will add to the capacitance of the component and reduce the SRF Performing compensation will remove the effect of stray fixt
214. ned and the tester is then programmed to deliver the same test conditions across the inductance the results will then agree See also the comments below on differences caused by the choice of equivalent circuit d Equivalent Circuit Inductance is always measured as part of a complex impedance the result being expressed in terms of either a series or parallel equivalent circuit Note that for any given winding the inductance values for the two circuits are not necessarily the same This should be born in mind when specifying the test limits Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits mH etc when entering absolute values as limits PAGE 7 24 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Test limits should be set as close as possible to detect assembly faults A transformer made with a pair of gapped ferrite cores can often be tested to a tolerance of 2 For un gapped cores the tolerance may have to be as much as 20 because of the core s manufacturing tolerance VOLTECH ATI USER MANUAL PAGE 7 25 TESTS AND TEST CONDITIONS 7 1 6 QL Quality Factor Measurement Test Test Basic Range Voltage Freque
215. ned to the transmission line instead of being coupled through the transformer Where Used The return loss test is used to check the impedance of audio and telecommunications transformers that are to be used with transmission lines of specified impedance The test helps to ensure that the transformer has been assembled properly using the correct core and winding materials Test Conditions The load resistor RL is connected to the transformer under test as shown This may be done automatically using the tester s OUT test The tester applies the specified voltage and using harmonic analysis measures the combined impedance of the transformer and load resistor PAGE 7 92 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS The return loss is calculated using the formula RLOS 20 logio Zo Zul Zo Zul Where Z is a complex impedance in the form Z R jx Or 2 2117 Ro Rm Xo Xm r 20 logio a Ro x Rm z Xn Where Ro is the resistive portion of the reference impedance Rm is the resistive portion of the measured device s impedance Xo s the reactive portion of the reference impedance Xm is the reactive portion of the measured device s impedance Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test 1000Hz is typical for the mid band of audio telecommunications circuits VOLTECH ATI USER MANUAL PAGE 7 93 TEST
216. ng the firmware version When the power on self test has finished you should see the following display Fower On Test Fraqeamz PASS LCR amp BHC LCR Set Up Self Test The tester is now at the top level menu and the softkeys allow you to select whichever one of the five main functions you require PAGE 2 10 VOLTECH ATI USER MANUAL GETTING STARTED Programs is used when running test programs in production test mode LCR BNC FIX enable the tester to behave like a component analyzer continuously updating front panel readings See chapter 6 for more information on the tester s LCR front panel mode Set Up is used to group download programs from a Server PC to the permanent store of the tester and to set up the options within the tester Self Test is used to perform a thorough self test A detailed explanation of the operation of the ATi that follows pressing the Programs Set Up and Self Test keys is given later in this chapter VOLTECH ATI USER MANUAL PAGE 2 11 GETTING STARTED 2 2 2 Installing the PC Editor Connect the tester s auxiliary port to a spare COM port on the PC as shown The type of connector on the PC will determine the cable that you use For most PCs this will be a 9 pin female PC to 9 pin female ATi cable Auxiliary port Switch on the power supply to the PC Before attempting to install the Editor check that your PC satisfies the following hardware requirements PC
217. nge Test Voltage Test Frequency Basic Accuracy 1nH to 1MH 1mV to 5V 20Hz to 3MHz 0 05 AT Series Tester Inductance is the electrical parameter that is commonly used to check that a high frequency transformer has been constructed according to its design and that it will operate properly in use The inductance of a winding is determined by the number of turns and the construction and dimensions of the core materials it may also vary with test conditions such as voltage and frequency The series and parallel inductance tests are used when testing signal pulse switched mode and similar transformers with ferrite type cores where the inductance remains the same from small signals up to the operating conditions Faults in numbers of turns core material and core gapping may be determined using this test For line frequency iron cored transformers where the inductance varies rapidly with voltage a magnetizing current test MAGI is recommended The MAGI test is only available on the Voltech AT3600 VOLTECH ATI USER MANUAL PAGE 7 19 TESTS AND TEST CONDITIONS Test Conditions To measure inductance the tester applies an AC voltage across the selected windings and measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain the complex impedance from which the inductance is extracted Generally it is not necessary to measure the inductance at
218. nt testing In LCR FIX mode nodes 13 and 15 are assumed to connect to the primary or energized winding of the transformer nodes 14 and 16 to the secondary PAGE 6 6 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 1 1 LCR BNC Mode Press the LCR BNC softkey and the ATi immediately begins to make measurements 3 4556mH 1 4427 Foe CBHC mode AUTO U AUTO Hz 18m 3 78mH 186 Hz EXITI The upper measurement is that of the parameter selected by the 1st upper softkey In this case Ls the series equivalent inductance is 3 4556mH The second measurement is that of the parameter selected by the 3rd softkey In this case Q the quality factor is 1 4427 The next line shows the LCR mode that you are using This may be either BNC mode or Fixture mode If compensation is required see later this line will also say comp req Prg AUTO V AUTO Hz These are the programmed measurement conditions By default the ATi automatically chooses measurement conditions that optimize the measurement accuracy Sometimes these conditions may not be appropriate for the final application of the part under test or may be different to those chosen on other equipment See later sections of this chapter for how to program the measurement conditions of your choice Mes 10mV 3 78mA 100 VOLTECH ATI USER MANUAL PAGE 6 7 FRONT PANEL MODES These are the measured test conditions The voltage and frequency are measure
219. nternal local AT password may be set up directly from the main set up menu of the ATi From the top level instrument menu choose Set Up At the set up screen choose softkey 2 Set Up Use the down arrow key to scroll to the AT Password option and press Change Set Up BHC Lead Calibration AT Password Program Store IHTERHRL If no password has been set the ATi will immediately prompt for a new password to be entered via the instrument keypad Confirmation Enter the new AT Password Delete Abort Shift VOLTECH ATI USER MANUAL PAGE 6 49 FRONT PANEL MODES If a password has already been set the existing password must be entered at the screen below before a new internal password can be set Confirmation Enter the old AT Password Delete Abort Shift The internal AT password protection may be removed by setting the password to a blank password i e not enter any characters Note The AT s local password is set as blank by default PAGE 6 50 VOLTECH ATI USER MANUAL 7 TESTS AND TEST CONDITIONS VOLTECH ATI USER MANUAL PAGE 7 1 TESTS AND TEST CONDITIONS PAGE 7 2 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Contents Tests and Test Conditions TEAS INTRODUCTION eaaa a 5 7 1 1 Choosing Tests for a Transformer sse 7 5 7 1 2 CTY Gontihulty 7 12 7 1 3 R8 DG Resistance reor 7
220. number PROGRAM 1 Settings Finish Place the component to be tested in the fixture and press the Run softkey touch one of the run pads or press the footswitch VOLTECH ATI USER MANUAL PAGE 2 53 GETTING STARTED After the measurement remove the component and place it in the Pass or Fail bin as appropriate Continue in this way until each component in the batch has been tested then press Finish 2 5 2 Error Messages Server Program Store Error Server not responding Continue Possible Causes Faulty cable The cable from the AT Server port to the Server PC has a broken wire or is not plugged in correctly COM port The COM port has not been set up in the Server application Server not running Either the Server PC is not powered on or the Server application is not running PAGE 2 54 VOLTECH ATI USER MANUAL GETTING STARTED If the Server software and connection to the Server PC are working correctly the following error screen may appear Error TEST1 not found in Server program directory Continue Cause The directory set up in the Server application as the location of test programs does not contain a test program file with the requested name Local Program Store Error Error FART not found in program group in AT internal memory Continue VOLTECH ATI USER MANUAL PAGE 2 55 GETTING STARTED Cause The requested part number is not resident i
221. oaded posts are available from Voltech called the Connection Lead Set Each of the clips is finished with 200mm red and black leads terminated in 4mm plugs The connection lead set consists of 10 Spring loaded connection posts 10 Kelvin crocodile clips 10 Non Kelvin crocodile clips 10 Fine non Kelvin clips PAGE 5 16 VOLTECH ATI USER MANUAL FIXTURES 5 4 5 Clamp Voltech Part Number 91 187 The hand clamp is supplied with 7 height blocks and fixings 5 4 6 Tooling Drilling templates are available in a variety of sizes 1 27mm 2 00mm 2 50mm 2 54mm 3 81mm and are sold as a pack Pack of 5 1 of each pitch drilling templates Voltech Part No 50 307 VOLTECH ATI USER MANUAL PAGE 5 17 FIXTURES 5 5 KELVIN CONNECTIONS Kelvin or 4 terminal connections are commonly used in precision measurement systems to obtain accurate measurements of impedance Each of the ATi s 20 measurement nodes including the BNC connectors consists of two terminals Power and Sense to allow complete 4 terminal testing Why use Kelvin connections Consider measuring a perfect 1 000 Ohm resistor to check that it is within its 196 tolerance at dc In a standard 2 terminal measurement there are TWO sources of error The resistance of the connecting leads The resistance of the contact between the connection and the lead of the resistor the resistance of the leads is fixed and c
222. of different test programs Having created saved and tested the program TUTORIAL using the Editor you are now in a position to run it again on your AT Series Tester but this time using the Server The procedure for transferring the program to the Server archive will depend on where you have installed the Editor and Server programs Editor and Server on Separate PCs In many situations the Editor and Server can be installed on separate PCs as shown in the illustration earlier In this situation the AT is used to perform the transfer Before proceeding further make sure that all of the following have been set up e The interface cable between the tester s auxiliary port and the selected COM port on the Editor PC is correctly fitted and the COM port is correctly configured in the Editor software see the Editor quick start earlier e The interface cable between the tester s Server port and the selected COM port on the Server PC is correctly fitted and the COM port is correctly configured in the Server software see earlier e Both the Editor and the Server software packages are running e The tester is still powered on as described above VOLTECH ATI USER MANUAL PAGE 2 31 GETTING STARTED To transfer the program from lt sVoltech Test Program Editor Part TUTORIAL File QK13 Pat Schematic Program Tester Setup Help bee ad Program the top level menu bar select Server gt Download Program The Edit
223. ominal value Test limits should be set as close as possible to detect assembly faults VOLTECH ATI USER MANUAL PAGE 7 103 TESTS AND TEST CONDITIONS 7 1 27 PHAS Interwinding Phase Angle Measurement Test Test Basic Range Voltage Frequency Accuracy 360 to 360 1mV to 5V 20Hz to 3MHz 0 05 AT Series Tester When the AC voltage across one winding is compared to the voltage across another they may be different in amplitude and phase Where the turns ratio or open circuit voltage tests measure the amplitude of the voltages the PHAS test measures the phase difference between the two voltage waveforms Where Used The interwinding phase angle test is most often used on measuring and other signal transformers where the phase displacement of signals is important to the operation of the complete circuit or product The test determines the angle measured in degrees between the voltage signals across two different windings This is different to the polarity test PAGE 7 104 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS incorporated into the TR Turns Ratio test that can only determine ve or ve polarity Test Conditions The AT Series Tester applies the specified AC voltage to one winding and measures the voltage produced across two windings one of which may be the energized winding The phase angle between the voltages is determined using harmonic analysis Choosing Test Conditions The voltage and freq
224. on to enter limit values as described in the section later in this chapter you may also at the same time have the AT Series Tester enter the recommended test parameter values To do this in the case of the LS test you simply leave the Signal and Frequency boxes empty at the time that you click on the Measure button If PAGE 3 26 VOLTECH ATI USER MANUAL PROGRAM EDITOR you choose either the mV or V unit button before clicking Measure the test signal determined by the tester will be entered as a voltage Alternatively if you choose the mA units button before clicking the Measure button the test signal determined by the tester will be entered as a current Note that not all tests allow the test parameters to be chosen by the tester The programming details for each test in section 7 of this chapter specify which tests allow the Measure button to enter the test parameter values 3 3 7 Test Limits In the Quick Start Tutorial chapter 2 it was stated that for the R Winding Resistance test the limits could be entered in four different ways The R test is not unique in this respect In fact most tests have several ways in which the limits may be entered allowing you greater flexibility in configuring each test to match your production testing requirements The four types of limits for the R Winding Resistance test are The limits are entered as positive and negative percen
225. ontext sensitive and menu driven help system An additional function available through the Editor is upgrading the firmware of your AT Series Tester See the Firmware Upgrades section in chapter 9 of this manual for details VOLTECH ATI USER MANUAL PAGE 3 5 PROGRAM EDITOR 3 2 CREATING THE TRANSFORMER SCHEMATIC The Voltech AT Series Editor software allows you to recreate the configuration of the transformer on the fixture as a schematic diagram on the screen Once the way in which the AT s nodes are connected to the transformer pins has been entered into this schematic you can create test programs without having to refer to the tester s node numbers This section describes how to create a transformer schematic using the AT Series Editor including how to e Create or add a transformer winding e Connect the winding terminals to test nodes e Delete a winding e Rename a terminal e Adda terminal e Delete a terminal e Add a core connection e Delete a core connection e Adda screen connection e Delete a screen connection PAGE 3 6 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 2 1 Adding a Transformer Winding To add a transformer winding on the screen 1 Select Add Winding from the Schematic menu on the menu bar A selected winding will now be displayed attached to the mouse pointer on the screen You must decide which half of the screen to place the winding on On crossing the mid point o
226. or both installed on the same local PC Editor You may copy program files directly into the program directory used by the server application IMPORTANT When a program file is copied to the Server and a file with the same name is already resident within the Server the incoming file will replace the previous file PAGE 4 6 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 2 2 Viewing a Test Program Each test program has a part name To view a particular test program you will need to know its part name Select FILE PART and then OPEN from the menu bar You may select the part to open from the list displayed or change the path and drive to search for other parts Open Part Part Number Directories OK l TRI c at3600 server Cancel TR2 Delete TR3 TR4 TR5 Herp Network Drives c ms dos_6 m When you have selected the correct part to open click on the OK button You will now be able to view the text listing of the test program chosen Part TUTORIAL File QL081545 ATP lolx Definition E 01 Part TUTORIAL Fixture TUTORIAL Schematic 1 1 1 1 VOLTECH ATI USER MANUAL PAGE 4 7 AT SERIES SERVER 4 2 3 Saving a New Copy of a Part Using the SAVE AS function under the PART menu you are able to save a new copy of the same test program under a new part name e Open the part required and select FILE PART and SAVE AS e Enter the new part name and select the approp
227. or will now download the test program to the Server using the AT After a few seconds you should see a message to say that the download was successful If you see a message indicating that the download has failed check your cable COM port connections and try again If the download continues to fail reboot both PCs and try again Editor and Server on a Single PC If the Server and Editor are installed on the same PC the easiest way to transfer the test program to the Server is to use the Save As menu in the Editor From the top level menu bar select Part gt Save As Voltech Test Program Editor Part TUTORIAL File QF201003 atp Schematic Program Tester Server Setup Help New CtrleN pen Ctrl Save Ctri S Print P Print Preview Print Header Print Setup Exit PAGE 2 32 VOLTECH ATI USER MANUAL GETTING STARTED At the dialogue box type in the part name TUTORIAL Save Part 6 D daa __Gancet_ one selected for pipes Help program storage e g Network C AT3600 SERVER Drives when the Server was wo installed Click on the OK button to close the dialogue box and save the test program in the Server program directory The next section of the tutorial demonstrates running the program on the AT from the archive on the Server Before proceeding to that section if the Server and Editor are using the same COM port on the single PC re allocate the C
228. orm short circuit compensation for stray inductance and resistance first short circuit together all the nodes in this case clip the alligator clips of the BNC leads together and press softkey 1 Short and select One or AII VOLTECH ATI USER MANUAL PAGE 6 31 FRONT PANEL MODES To perform open circuit compensation for stray capacitance remove all parts under test but leave the BNC leads or test fixture in place and press softkey 2 Open and select One or All For optimum accuracy place any leads or other connectors that can move in a position as close as possible to that which will be used when making measurements Compensation To perform short circuit compensation at 123 Hz short the leads together and press the start button Press softkey 5 Start to begin the compensation process Press softkey 6 OK to use any compensation measurements that have just been made and return to the previous LCR screen During short or open circuit compensation the ATi is making very accurate measurements of the small stray or parasitic components Remember that the power and sense terminal of each node must be connected together The PAGE 6 32 VOLTECH ATI USER MANUAL FRONT PANEL MODES measurement may take up to 2 minutes during which you will see the following display Compensation Compensating short circuit E Press softkey 5 Stop at any time to cancel or stop the compensation measure
229. ort on the PC PC running the Auxiliary port Editor software Pull down menus in the Editor allow you to download the program to the tester so that it may be run for the purposes of evaluation and modification 1 8 2 Storing Programs and Results The Server The Editor software previously described allows you to create and evaluate each individual test program It is not intended to manage the large numbers of test programs that may be required on a daily basis once they are in production use This is the function of a second PC program supplied with your ATi called the Server Usually the Server would be installed on a PC with access to a large disk that could be attached to the PC itself or connected via a network The Server and disk would then be used for any of the following purposes e To provide the master archive for test programs To archive test results To interface to an SPC package e To remotely control the tester The tester has a separate server port on its rear panel for connecting to the PC VOLTECH ATI USER MANUAL PAGE 1 17 INTRODUCTION 1 8 3 Transferring Programs between Editor and Server Within your test environment there are several possible ways in which the Server and Editor may be installed and used depending on how many separate PCs are available Programs The standard installation uses separate PCs for the Editor and Server Transferring a new test prog
230. p successfully downloaded Continue Press Continue to return to the top level display Your program group has now been loaded into the tester s internal store and the Server PC may be disconnected These programs will be saved during power off and will only be overwritten by another group download Group Download Error Messages The following is a list of possible error messages that may occur if there is a fault in the group download process together with suggestions for the possible cause a Error Server not responding Continue PAGE 2 84 VOLTECH ATI USER MANUAL GETTING STARTED Possible Causes Faulty cable The cable from the tester s Server port to the Server PC has a broken wire or is not plugged in correctly COM port The COM port has not been set up correctly in the Server application Server not running Either the Server PC is not powered on or the Server application is not running Error GROUP HANE not found in Server program directory Continue Possible Cause The directory set up in the Server application as the location of test programs does not contain a group with the requested name At all the above displays pressing the Continue softkey will take you back to the top level display VOLTECH ATI USER MANUAL PAGE 2 85 GETTING STARTED Tester Download Using The Editor A single program may be stored FSEFTBEITITITETEBEZPEREITITIETTTRE TREES in the AT
231. priate warning message and allow you to try again or cancel the compensation When the compensation measurements have been successfully completed the compensation values for each test in the program will be stored inside the tester Any subsequent measurements started as described above by clicking on Tester Run Program will return compensated results to the Editor If you are not sure whether to compensate or not simply try it If any of the results change significantly then it should be done REMEMBER Whenever you make changes to the program the compensation results in the tester will no longer be valid Make sure to compensate again each time you download a test program to an AT Series Tester whether the program has changed or not PAGE 3 46 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 7 PROGRAMMING HINTS AND TIPS The following is a list of points that should be remembered when you are creating your test programs 1 When you are creating your test programs you should work in the following order a Initially create the schematic b Then set up the program options c Finally create the list of tests that make up the program Note If you make any changes to the schematic after you have created the list of tests then some tests may be inadvertently deleted Examples where this may happen are deleting a winding or a terminal and renaming a terminal 2 Usethe recommended order for the tests in the program T
232. process of creating a schematic and a test program using the Editor Creating a Schematic of a 2 Winding 4 Terminal Sample Transformer This tutorial describes a method of setting up the tester to test a two winding transformer with the following specification aE Resistance of winding AB 59 to 73Q Resistance of winding CD 59 to 73Q Inductance of winding AB gt 3H Before proceeding ensure that the tester is connected to the Editor PC as described earlier in this chapter VOLTECH ATI USER MANUAL PAGE 2 19 GETTING STARTED 2 3 2 Drawing the Transformer Schematic On the PC double click on the Editor icon to start the PC Editor The first thing to do is to draw a schematic of the transformer to be tested 1 Using the left mouse button click on Schematic on the top level menu bar and select Add Winding from the menu Yoltech Test Program Editor New Part Part METEO Program Tester Server Setup Help Delete Winding Rename Terminals Add Core Connection Delete Core Connection Add Screen Connection Delete Screen Connection You will now see a winding with two terminals floating below the mouse pointer 2 Place the winding on the left hand side of the screen and press the left mouse button 3 A dialogue box will ask you to name the terminals of the winding The cursor will be in the box for Terminal 1 Type the name of Terminal 1 e g A Press
233. put with an internal pull up resistor In the execution of programs it is equivalent to pressing the RUN key on the front panel To use this with a footswitch wire the switch between this input and OV VOLTECH ATI USER MANUAL PAGE 8 27 SPECIFICATIONS ISTOP Input Pin 11 The STOP input is an active Lo input with an internal pull up resistor The active going edge of this input halts all Tester activity turning off all signal sources To use this with an emergency stop switch wire the switch between this input and OV Fail Busy and Pass Outputs Pins 4 7 and 10 The status outputs are standard 5 Volt logic signals In the standard set up the three status outputs are active Lo signals which duplicate the three LED s on the front panel Busy Pass and Fail They could for example be connected as status inputs to a robot controller or a bin selector Beep Output Pin 1 This is an active Hi output that copies the internal beeper It is configured in the test program header 1kQ see the Test Editor section of this manual All the outputs pins 1 4 7 and 10 are fitted with 1kQ protection resistors and therefore they cannot directly drive external high current loads such as indicators or bin select relays Minimum input resistance of devices connected to these outputs to be 10kQ DO NOT USE Pins 5 8 and 9 These pins are intended for use with Voltech approved accessories and must be left unconnecte
234. r Printer Auxiliary Editor Remote User Ground these ports may be susceptible to damage from static discharge Switch off and observe anti static precautions when making connections 8 3 1 Barcode Port RS232 interface for barcode entry 9 pin female D type connector Baud rate 9600 Parity None Stop bits 1 VOLTECH ATI USER MANUAL PAGE 8 23 SPECIFICATIONS No connection No connection i p RX op TX No connection No connection 5V No connection The recommended barcode reader for the AT Series Testers is the Smart Wand Barcode Reader from Hewlett Packard available from Farnell Electronic Components Hewlett Packard List No HBSW 8300 The HP Smart Wand reader connects directly to the barcode port no extra interfacing is required to configure the HBSW 8300 Plug the barcode reader into the port and switch the AT on The barcode reader is configured correctly as supplied by If the settings have been changed reset the wand by plugging it in into the tester switching the tester on and swiping the codes below 9600 Baud 0 s Parity none TEM 1 Stop bit PAGE 8 24 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 3 2 Server Port RS232 interface for connection to a PC Server running the Voltech AT Series Server software 25 pin male D type connector Ground Earth No connection RX No connection No connection
235. r name press the Operator softkey VOLTECH ATI USER MANUAL PAGE 2 65 GETTING STARTED PAGE 2 66 Fart number FROGRAM 1 Total 1 Failed Last tranzformer Compensate Operator Hew Batch VOLTECH ATI USER MANUAL GETTING STARTED 2 6 STOP ON FAIL Stop on Fail is another program option that is either enabled or disabled when the program is created see chapter 3 When enabled it will cause the measurements to be terminated after each test that has produced a Fail result A display similar to the following will be seen TUTOR TAL FAIL at test 4 LS Continue H _ 1 184rmH This display shows Part name number Failing test number and test mnemonic Graphical qualification of the failure showing the value measured with respect to the range of legal values where Box Represents the legal limits for the test Vertical bar Represents the value measured Replaced by an arrowhead to represent higher or lower when the measured value is significantly outside of the legal range See notes below Value measured with appropriate units VOLTECH ATI USER MANUAL PAGE 2 67 GETTING STARTED Note The third line showing the graphical comparison of the measured value and test limits has a logarithmic scale The measured value may be represented by either a vertical bar as shown when it lies within the range that can be displayed on the LCD or by an arrow
236. r this as the Key Code on the new PC e The software will now be licensed on the new PC and disabled on the old Please do not hesitate to contact your Voltech supplier if you have any problems with this procedure PAGE 4 52 VOLTECH ATI USER MANUAL 5 FIXTURES VOLTECH ATI USER MANUAL PAGE 5 1 FIXTURES PAGE 5 2 VOLTECH ATI USER MANUAL FIXTURES Contents Fixtures 5 1 INTRODUCTION 7 1 5 5 5 2 DESCRIPTION 1 ied bedded ioe nea desea en Ste de eene ea Dena e eee uk aa engan 5 6 9 221 Basic Fixture Plate seda 5 8 5 2 2 CustonmFixture auis diete te ate d 5 9 5 2 3 40 SOCKOLFIXIUF ce a e na e es 5 11 5 3 FIXTURE SYSTEM 8 5 12 5 4 FIXTURE PARTS 5 13 5 4 1 Fixture Plate Voltech Part Number 91 184 5 15 5 4 2 Custom Fixture Kit Voltech Part Number 91 188 5 15 5 4 3 Socket Fixture Voltech Part Number 91 186 5 16 5 4 4 Connection Lead Set Voltech Part Number 78 090 5 16 5 4 5 Clamp Voltech Part Number 91 187 seen 5 17 5 4 6 Tooling ERU HER 5 17 5 5 KELVIN
237. ram from the Editor to the Server archive can be done in any of three ways e Via the tester e Directly from PC to PC via a floppy disk e Via a network connection between the PCs using Save As in the Editor to transfer the program to the directory used by the Server for programs PAGE 1 18 VOLTECH ATI USER MANUAL INTRODUCTION With both Server and Editor installed on the same PC transferring a new test program from the Editor to the Server archive can be done in either of two ways e Via the tester if the auxiliary port connection is made Directly from the Editor using Save As to the directory used by the Server for programs Auxiliary port connected using the Editor Server port VOLTECH ATI USER MANUAL PAGE 1 19 INTRODUCTION 1 8 4 Executing Programs Large Production Facility The standard installation in a large production facility could use several testers together with a Server PC for test program and results archiving Programs Programs Programs Results Results Results Advantages Convenient storage and management of large numbers of test programs gt 1000 e Easy storage and management of test results e Importing results into other Windows applications for analysis e The Server PC can be located away from the test area for example in a supervisor s office allowing results analysis to be performed where it is required Up to eight AT series testers may
238. ransformer terminal To delete a connection again use the right mouse button to pick up the connection but this time release it when it is not over either a node or a terminal 3 2 3 Deleting a Winding To delete a winding 1 Selecta winding by pointing at it with the mouse pointer and clicking the left mouse button once A selected winding will be indicated by a box surrounding the winding 2 Choose Delete Winding from the Schematic menu The selection will be removed from the screen Note that ALL tests containing the deleted terminals will also be DELETED PAGE 3 8 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 2 4 Renaming a Terminal To rename a terminal either 1 Select the winding containing the terminal to rename by using the mouse pointer and clicking the left mouse button 2 Choose Rename Terminals from the Schematic menu 3 Oruse the mouse pointer and double click on the chosen winding A fill in dialogue box will appear Each fill in box will contain the current names of the winding terminals You may change a name by 1 Selecting the appropriate terminal box with the mouse or by moving between the boxes with the TAB key and typing the new name 2 Pressing ENTER or clicking the mouse pointer on OK The dialogue box will be removed and the corrections will be displayed on the Screen Note that ALL tests containing the renamed terminals will be DELETED VOLTECH ATI USER MANUAL PAGE
239. ratio between them e g 1 1 5 By adding further inductance match tests to the program any number of inductances can be tested for match Choosing Test Conditions For optimum accuracy and performance use the test conditions shown in the inductance section of this chapter for each of the two windings The frequency will be common to both windings being tested for match The test conditions can also be determined automatically by the ATi according to this table Note that a fixed signal cannot be used with an Auto frequency Programming the Test Using the PC Test Editor Inductance Match Test Parameters rntegration siga 3 mV mA C Short Signal v 0 C mV C mA Auto Medium Frequency 0 Hz C MHz C Long r Terminals X Terminals Y High Terminal Low Terminal High Terminal Low Terminal E z El F r Matching Limits Nominal Ratio X Y 0 Negative Error 0 Positive Error 0 OK Measure Cancel Voltei USER MANUAL PAGE 7 41 TESTS AND TEST CONDITIONS Choose the integration period normally Medium and enter the terminals to be measured Terminals X High and Low Winding 1 Terminals Y High and Low Winding 2 Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing the Test Limits The test limits
240. rd e Ensure operators are trained to avoid making contact with the part being tested or any exposed parts of the fixture during an IR test e Construct safe fixtures using the guidelines given in the fixturing section of this manual e Beware of testing parts with high turns ratios such that a small applied test signal can generate an unsafe high voltage e Beware of energy stored with the capacitance or inductance of the part being tested when handling the part after test PAGE 1 6 VOLTECH ATI USER MANUAL INTRODUCTION 1 3 ATI AND AT3600 The ATi is one of a family of automatic testers from Voltech that share the same fixture construction and PC Editor and Server software ATis and AT3600s can share the same Server application simultaneously recalling test programs and recording test results AT3600 AT Features ATi AT360 20 way switching matrix 4 PC test editor and results server Y Y Test fixture system Y Small signal tests e g inductance capacitance turns ratio Y Y Telecom tests e g return loss longitudinal balance v Y Insulation resistance 500V 7000V Hi pot AC 5500V Hi pot DC 7000V Surge testing 5000V Magnetizing current and open circuit voltage 270V Watts Stress Watts Y Leakage current VOLTECH ATI USER MANUAL PAGE 1 7 INTRODUCTION 1 4 TESTS SUPPLIED At the time of printing the following tests are available for the ATi
241. re In general the capacitance is distributed between different layers within a winding and between the outside layer of one winding and the inside layer of the next Although the capacitance is distributed across windings it is usually represented by a simple equivalent circuit showing a single capacitance from one winding to the next Where Used An interwinding capacitance test can be used to check for correct winding position and to check for the correct insulation thickness between windings where isolation between primary and secondary windings is important The test can be used to check for capacitance between windings where for example too large a capacitance may couple unwanted noise signals between power and control circuits PAGE 7 48 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Test Conditions To measure capacitance the tester applies an AC voltage between the windings to be tested usually with all taps on each winding shorted together It then measures the voltage between the windings and the resulting current Dividing the voltage by the current gives the interwinding impedance from which the capacitance is extracted using harmonic analyses Capacitance is measured as part of a complex impedance The AT Series C test uses a parallel equivalent circuit for capacitance measurements CS series circuit capacitance is also available Choosing the Test Signal Recommended test conditions for different
242. relay driver configuration VOLTECH ATI USER MANUAL PAGE 7 111 TESTS AND TEST CONDITIONS 7 2 SERIES AND PARALLEL CIRCUITS The ATi can make measurements of many parameters such as Inductance L Capacitance C and AC resistance R using both the parallel and equivalent circuits The measurements for the series or parallel equivalent circuits will not necessarily be the same and care should be taken when choosing which equivalent circuit to use when testing Any practical inductor or capacitor will not be perfect and will have associated stray parallel and series resistance in its equivalent circuit x Rs Rp Where X is the purely imaginary inductive or capacitive impedance Rp is the stray parallel resistance Rs is the stray series resistance PAGE 7 112 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS For an INDUCTIVE IMPEDANCE Rs represents the copper losses in the wire and Rp represents the in phase core losses X oL is usually much lower than Rp so Rp is insignificant Choose the SERIES equivalent circuit If the inductance is large gt 1 Henry and or the series resistance Rs is very small the parallel equivalent circuit is sometimes used For a CAPACITIVE IMPEDANCE X is usually much higher than Rp making Rp very significant Choose the PARALLEL equivalent circuit If the capacitance is large small impedance then Rp will be insignificant and the series equivalent circuit can be chosen VOLTEC
243. rences select External Sources Communications Setup Communications 1 From the top level 2 In the dialogue box shown here COM Pott select the PC um Cancel communications port that is connected to the tester WARNING If the chosen COM port is reserved by another Windows application an error message will appear You should select another port VOLTECH ATI USER MANUAL PAGE 2 13 GETTING STARTED 2 2 3 Installing the PC Server Check that your PC satisfies the following hardware requirements PC processor 486 or better Memory 4MB minimum Hard disk space 3MB minimum Note 3MB does not include disk space required for storing programs or test results Operating system Windows 95 or later CD ROM drive x2 minimum speed To install the Server software follow the same basic instructions as for the Editor The Server is often installed on a different PC to that which will be used for the Editor depending on your production needs A Server PC needs to be permanently connected to the ATi only if you wish to store test results or use a central program store rather than the ATi s own memory Server Hardware Connections In some applications you may wish to position the Server PC some distance away from the tester which will require a cable longer than the one supplied The AT Series Server port connector details are shown in chapter 8 to enable you to make up a c
244. rent A Zreal is the real part of the reference impedance Q Zimag is the imaginary part of the reference impedance VOLTECH USER MANUAL PAGE 8 19 SPECIFICATIONS 8 2 14 Zand ZB Test The accuracy is given as A A A tA A Where Ar is the total accuracy Ar is the basic relative accuracy Ac is the calibration accuracy Ay is the correction for voltage level A is the correction for current level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 70 0896 0 000000196 x F A 0 08 0 000003 V A 0 08 0 0000003 1 0 03 x Ip Iy Where Fu is the measurement frequency Hz Vu is the measured voltage V Iu is the measured current A lg is the bias current A PAGE 8 20 VOLTECH USER MANUAL SPECIFICATIONS 8 2 15 ANGL Test The accuracy is given as A Where Ar is the total accuracy Ar is the basic relative accuracy Ac is the calibration accuracy is the correction for voltage level is the correction for current level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 03 0 0000005 x Fy A 0 03 0 000003 V A 0 03 0 0000003 I 0 03 x I5 Im Where Fu is the measurement frequency Hz Vm is the measured voltage
245. riate file path e Click on the OK button A new copy of the test program will now be saved with the new part name as specified Save Part Part Number Directories rna c at3600 server Y Cancel acy CX at3600 Ey server Help Network Drives amp c ms dos z IMPORTANT When using the SAVE AS function you must be aware that it is not a RENAME function The previous copy of the test program with the original part name will remain in your program directory Note that if you are attempting to save a new part under the same name as an already existing part a message box will appear asking you if you want to replace the existing part If a Server password has been set you will have to enter the correct authorization password in the Save As authorization dialog box see below PAGE 4 8 VOLTECH ATI USER MANUAL AT SERIES SERVER Enter authorisation password Cancel 4 2 4 Deleting a Test Program If you need to remove a part from the Server program directory a button has been provided within the PART OPEN dialogue Select the part to be deleted and press the DELETE button If a password has been set you will be prompted to enter the password as defined when installing the Server software to allow the part to be deleted The program will then be removed from the Server directory Open Part Part Number Directories TRS c at3600 server Cancel TRI TR2 Delete TR3 TR4
246. riate line on the program option display and choose On or Off For example to automatically send test program results to the AT Server scroll to Send results to Server Off and choose softkey 3 On VOLTECH ATI USER MANUAL PAGE 6 45 FRONT PANEL MODES Program options Serial numbering OFF Send retry ta Serveri Stop on fail off DateTime on Reports Once you have completed the program options set up press OK to return to the program test selection screen and OK again to confirm your set up Note that if a password has been set the AT requests the password to be entered before the program can be saved Enter the password on the instrument keypad using the Shift key to enter letters if necessary and press Enter Confirmation Enter the AT Password YTEDD Delete Abort Shift PAGE 6 46 VOLTECH ATI USER MANUAL FRONT PANEL MODES A Password Valid screen will confirm the correct password entry and return you to the program screen which now lists the new test program that has been created Local programs FROGRAM 1 TUTORIAL Delete 6 6 3 Running a Test Program To run the program use the arrow keys to select it and choose the Run softkey This will run the test program that has been created from the front panel of the instrument in exactly the same way that a program created by and downloaded from the AT Editor would be run i e you will be prompted to fi
247. rimary inductance Select the test voltage and frequency for the primary from the table below and enter them in the TRL dialogue box Enter the turns ratio then press the Auto button next to the secondary voltage parameter the tester will automatically select the appropriate test voltage for the secondary winding when the program is running PAGE 7 66 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Setting the Primary and Secondary Parameters Manually To do this you will need to know the inductance of the primary and secondary windings The optimum test conditions are chosen for an inductance value that is between the primary and secondary Lm Lm A Lp x Ls Look up the recommended test signal for this inductance Enter the recommended frequency for this inductance as the test frequency The primary and secondary voltages can be calculated from the following N N Np Ns Vs Vn Where Lm Intermediate inductance Lp Primary inductance Ls Secondary inductance Vp Primary voltage Vs Secondary voltage Vm Intermediate voltage Np Primary turns Ns Secondary turns If you calculate Vs or Vp to be greater than 5V you should set 5V as your test signal If you calculate Vs or Vp to be less than 1mV you should set 1mV as your test signal VOLTECH ATI USER MANUAL PAGE 7 67 TESTS AND TEST CONDITIONS Choosing the Test Conditions Based on Vm Intermediate Inductance Preferred Test Signa
248. rmonic analysis the measured voltage is divided by the current to obtain a complex impedance from which X the imaginary part of the impedance is obtained Inductive Capacitive X is the imaginary part of the complex impedance Z R jx Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test The X test is only available on the ATi s front panel LCR mode PAGE 7 100 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 26 ANGL Phase Angle of Impedance Measurement Test Test Basic Range Voltage Frequency Accuracy 360 to 360 1mV to 5V 20Hz to 3MHz 0 055 inductive 90 AT Series Tester resistive 90 capacitive The impedance of a winding is usually complex as it consists of real resistive and inductive or capacitive imaginary parts The phase angle 4 of the complex impedance at a specified frequency is 2 tan X R Where R and X are the real and imaginary parts of the complex impedance See also the impedance test Z which measures the magnitude of the impedance Z v R x Where Used An impedance phase angle test may be performed on any ferrite or iron cored winding but it is an especially important test of audio telecommunication and other signal components where the angle of the impedance is important VOLTECH ATI USER MANUAL PAGE 7 101 TESTS AND TEST CONDITIONS Measuring the phase angle of the
249. rs can be used in the password max 25 characters Note that this Editor dialogue also allows the password to be ABCDEFGHIJKLMNOPORSTUMwWAXYZ reset The old 1234567890 SPACE password is not required to do this All New Password that is required is for E 7 the new password to be entered and verified Cancel PAGE 3 40 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 5 ERROR CODES Voltech AT Series testers provide the operator with two types of error detection e An electrically sound hardware integrity test called self test with the provision of error codes should an electrical fault be detected e Return of an error code during transformer testing to assist in diagnosing whether incorrect test parameters have been used or poor connections have caused the fault During normal component or transformer testing and or while running self test voltage and current signals are constantly being generated stabilized measured and dissipated Should a problem occur during one of these four stages a unique error code is produced and displayed by the AT Series tester The error code consists of a DSP digital signal processor status error code and a reason for DSP status error code The DSP status error code is a four digit number that indicates that something has gone wrong Each error code translates into an effect a short description of the fault such as a current or voltage overload tha
250. ry e g in the case of a fixture where the resistors are permanently fitted in circuit PAGE 7 78 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor General Longitudinal Balance Test Parameters Voltage Terminals X Energised Frequency 0 GHz Measured Terminals Y Energised Integration Shortt Medium C Long Measured Hi Hi Lo Lo Optional 2nd Energised Hi Caj OK Longitudinal Balance X Y Limits Maximum Compensation for Test Fixture Scaling 0 dB Measure Optional 2nd Energised Hi 1 fw ae Cancel The voltage and frequency are usually determined by the final application of the part under test Select the integration period which is normally Medium Enter the required terminal names Terminals X the energized winding Terminals X the measured voltage VOUT1 Terminals Y the energized winding normally the same as the Terminals X energized winding Terminals Y the measured voltage VOUT2 The measurement can be compensated for any scaling on the fixture For example where the fixture transformer is not 1 1 Note that the Editor s Measure button CANNOT be used to determine the test voltage VOLTECH ATI USER MANUAL PAGE 7 79 TESTS AND TEST CONDITIONS
251. s The Editor will now command the tester to perform the fixture compensation for the required test in this case LS The tester will then store the zero value and subtract it from the next result returned for the test If the short circuit links are not correctly fitted you may see an error message which allows you to try again or cancel the compensation You will then be prompted to perform open circuit compensation AT Series Editor Software RN x Gi Open Circuit Fixture Compensation will be applied to this program Remove any transformer on the fixture and ensure the Fixture is empty Yes No Remember to remove the short circuit header before performing short circuit compensation You may still select No on either of the above dialogues to perform just one type of fixture compensation or none at all PAGE 3 34 VOLTECH ATI USER MANUAL PROGRAM EDITOR Assuming no errors when the tester has finished the compensation measurement you will be prompted to remove the shorting links and fit the sample transformer After you have clicked on the Ok button the tester will be commanded to make its measurements and you will see the following message Editor Windows Application 1 Fisture Compensation Successful Re connect the component to measure the test parameters When the measurements have finished the display will return to the dialogue box for the LS test with values entered for th
252. s Test Parameters Integration Voltage o C mY cv C Shot Medium Frequency 0 C Hz CkHz CMHz Input Output High Terminal Low Terminal High Terminal Low Terminal Source resistance 0 Ohms Load resistance Insertion Loss Limits C C Minimum 0 dB Maximum dB OK Measure Cancel Vsled Note that the PC Editor s Measure button CANNOT be used to determine the test voltage Select the integration period that is normally Medium Enter the Input and Output terminal names Remember to enter the values of Rs Source Resistance and RI Load resistance as used on the fixture PAGE 7 90 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value VOLTECH ATI USER MANUAL PAGE 7 91 TESTS AND TEST CONDITIONS 7 1 23 RLOS Return Loss Measurement Test Test Basic Voltage Frequency Accuracy Range 100dB to 100dB 1mV to 5V 20Hz to 3MHz 0 256 AT Series Tester The return loss is a measure of the impedance mismatch between the transformer and a transmission line If the impedances are not the same some signal power is reflected or retur
253. s proportional to the number of turns Squared L oN and the turns ratio can thus be calculated as the square root of the inductance ratio PAGE 7 64 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Where Used The turns ratio by inductance test is used on transformers that have poor coupling btween windings and where a turns ratio by voltage TR test may not produce the expected result For example transformers for electronic lighting ballasts are often deliberately wound to have relatively large values of leakage inductance During voltage TR testing some of the voltage will appear across the leakage inductance and alter the result The TRL test is not affected by leakage inductance and other parasitic components in this way Test Conditions To measure turns ratio by inductance two inductance measurements are made one on each winding The same voltage at the specified amplitude and frequency is applied to each winding in turn and the inductance of each is determined from the measured voltage and current using harmonic analysis The turns ratio is then calculated as the square root of the ratio of the inductances The inductance of a winding can often depend upon the flux density in the core windings Since the flux density will depend upon the signal energising the winding it is important that both windings are energized at the same level This will ensure that both inductances are measured along the same region of
254. s test on failure Cancel To program the test Select OK The test will then be displayed in the program window PAGE 7 108 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 29 OUT Control External Devices The AT Series testers normally make all the necessary connections for testing automatically using a matrix of internal relays When for example an external component such as a resistor is required for testing then during the test sequence the resistor may be switched into or out of the test circuit using an OUT test A 12V DC power supply ensures that everything necessary to drive an external 12V DC relay is available SV o Pin5 A Relay O Drive Output ius 5 4 3 2 1 N User Port MI 9 8 7 6 o p User Relay Drive 0 o p User Relay Drive 1 2 o p User Relay Drive 2 7 User Relay Drive 3 3 o p User Relay Drive 4 8 olp User Relay Drive 5 5 4 amp 9 i p Do Not Use The OUT test is used to switch external relays at any point in a test sequence The user relays may in turn be used to switch in external components such as impedance matching resistors important for audio and telecommunications transformers or to connect windings in series for subsequent testing The user port is situated at the rear of the ATi VOLTECH ATI USER MANUAL PAGE 7 109 TESTS AND TEST CONDITIONS See also the tests for audio and telecommunications transformers LBAL GBAL ILOS RLOS
255. s than specified limits Measurement Conditions The RESP test consists of a number of Insertion Loss ILOS tests repeated at different frequencies The resistors shown are fitted to the test fixture and should be switched out of circuit when making other measurements such as resistance and inductance This can be done by fitting relays to the fixture and switching them at appropriate points in the test program using OUT tests The first ILOS test is made at a reference frequency that is usually near the middle of the band of frequencies of interest The result of this test is the OdB reference level Further ILOS tests are then carried out at user selected frequencies and the results referred to the reference dB level VOLTECH ATI USER MANUAL PAGE 7 85 TESTS AND TEST CONDITIONS 0dB REM 5dB 10dB Insertion Loss Frequency The result of a RESP test is a single value chosen as follows If all the referred ILOS results are at or inside the specified limits the result of a RESP test is the referred ILOS result that is closest to the limit If any of the referred ILOS results are outside the specified limits the RESP result is the referred ILOS result that is furthest away from the limit Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test PAGE 7 86 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor
256. sages either decrease the test voltage or increase the test frequency until an acceptable condition is reached You could of course choose AUTO values of voltage and current In either case the ATi will not sustain any damage even if it is left permanently in the overload condition If you are using a value of DC bias current other than 0 you may also see the message Overload reduce bias In which case you should reduce the bias level until a result is displayed VOLTECH ATI USER MANUAL PAGE 6 37 FRONT PANEL MODES If you make a mistake choosing test parameters the ATi will sound a short beep and return to the previous screen condition Examples are attempting to enter AUTO frequency when a fixed voltage has already been entered or entering a value outside the specification of the ATi such as 10MHz for test frequency PAGE 6 38 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 6 PROGRAM MODE As well as using the AT Editor software to create test programs for the ATi programs for your ATi tester may be created directly from the instrument s front panel From the top level menu choose softkey 1 Programs Programs LCR BHC LCR FIKI Set Up Self Test The resulting programs screen displays a list of programs available in the local or Server program store depending upon the general program store set up of the tester which you may choose to a run at this time by pressing the Run
257. sample transformer All tests with a Measure button will allow you to enter a value into the test limits section of the dialogue box In addition some tests can also make use of the Measure button to select the test conditions The programming details for each test in chapter 7 Tests and Test Conditions specify which tests allow the Measure button to enter the test parameter values 3 4 1 Hardware Connections for Using the Measure Button Before attempting to use the Measure button 1 Make sure you have connected your tester s auxiliary port on the rear panel to a suitable COM port on your PC This may be COM port 2 if your mouse is already using COM port 1 2 Setup the COM port on the PC From the top level menu Setup Communications Lx select iM Setup Communications p c Cancel In the dialogue box select COM the PC communications port that is connected to the transformer tester WARNING If the chosen COM port is reserved by another Windows application an error message will appear You should select another port VOLTECH ATI USER MANUAL PAGE 3 31 PROGRAM EDITOR Fit the appropriate fixture to the tester 4 Have available both a sample transformer and possibly a shorting header if you wish to add tests to the program for which you will be applying short circuit compensation 3 4 2 Example of Using the Measure Button with the LS Test LS Winding Inductance
258. se the PC Editor s Measure button together with a sample part if you are unsure of the nominal value VOLTECH ATI USER MANUAL PAGE 7 95 TESTS AND TEST CONDITIONS 7 1 24 Z ZB Impedance Impedance with Bias Measurement Test Test Basic Range Voltage Frequency Accuracy 1mO to 1mV to 5V 20Hz to 3MHz 0 2 AT Series Impedance Z Tester The impedance of a transformer is usually complex that is it consists of real resistive and inductive or capacitive imaginary parts The total impedance at a specified frequency is the vector sum of these parts z Aq x Where R and X are the real and imaginary parts of the total impedance The impedance test checks the impedance of audio and telecommunications transformers that are to be used with transmission lines of specified impedance The test helps to ensure that the transformer has been assembled properly using the correct core and winding materials Test Conditions The test may be made on the part alone or with a load resistor RL attached to the secondary to simulate the load impedance of the transformer when it is used in its final application The optional load resistor RL is connected to the transformer under test as shown This may be done automatically using the tester s OUT test PAGE 7 96 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS To measure Z the tester applies the specified voltage and for impedance with bias the specified DC bias
259. specially to hold a wide range of ATE probes and Kelvin pins 3 Clamp An optional hand clamp holds the test piece against the test probes The clamp is adjustable in height and spring pressure Voltech Part No 91 187 4 Guides 12 adjustable guides are supplied to locate the test piece in the fixture quickly and accurately 5 Drilling Tools 5 different pitches of template are available for marking and drilling the holes for test probes or Kelvin pins To enable the probe housing box and the test piece interface plate to be drilled to the accuracy required drilling templates are available in the following grid pitches 1 27mm 2 00mm 2 50mm 2 54mm and 3 81mm Pack of 5 1 of each pitch drilling templates Voltech Part No 50 307 PAGE 5 10 VOLTECH ATI USER MANUAL FIXTURES 5 2 3 40 Socket Fixture Red Terminal Power Black Terminal Sense Where Used Ideal for developing test programs or testing small batches of different wound components The 40 socket fixture consists of 20 pairs of red and black 4mm shrouded safety sockets mounted and wired into a blank fixture A variety of clips and posts can be used to enable connection to the component under test When testing larger quantities of the same component 50 or more a custom fixture solution is strongly recommended Ask your Voltech supplier for details on the custom fixture kit VOLTECH ATI USER MANUAL PAGE 5 11 FIXTURES 5 3 FIXTURE SYSTE
260. sts To edit the test program you must first switch to the Program Editor From the top level menu bar select Voltech Test Program Editor New Part Part Schematic Maii Tester Server Se Program 2 Edit Options Fita IHBEr West pelete test VOLTECH ATI USER MANUAL PAGE 3 19 PROGRAM EDITOR You will now see a display with three separate windows 2s Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Help Oleju 8 Schematic a s Maximize Available Tests Minimize CTY Continuity Winding Resistance LS Inductance Series Circ LP Inductance Parallel Cir QL Q Factor RLS Equivalent Series Resi RLP Equivalent Parallel Res LL Leakage Inductance LLO Leakage Inductance wi Interwinding Capacitant TR Turns Ratio MAGI Magnetising Current voc Open Circuit Voltage IR Insulation Resistance HPDC High Pot dc HPAC High Pot ac Maximize Program List Low Terminal B Maximum Vali 73 000 Ohms LSB Inductance with Bias S LPB Inductance with Bias P WATT Wattage SURG Stress Test Surge TRIM Trimming Adjustment su OUT Output to User Port For Help press F1 Top Left A simplified view of the transformer schematic omitting the wiring to the nodes This is a passive window intended to be used as a memory aid It cannot be used to change the schematic If you need to alter the schematic at
261. sts and Test Conditions for suitable values PAGE 3 36 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 4 3 Restrictions for Automatically Obtaining Test Parameters As shown above the LS Winding Inductance Series Circuit test is one where both the test voltage or current and frequency may be obtained automatically by using the Measure button Alternatively you may wish to specify yourself either one or both of the parameters before using the Measure button In this case the tester will attempt to make use of the parameter s that you have specified and enter a value only for parameters that you have not specified In general all tests have restrictions on which test parameters may be or have to be specified and which may be chosen automatically In the case of the LS Winding Inductance Series Circuit test the valid combinations are summarized in the following table The combination that is not allowed is to specify the voltage or current and ask the AT to find the frequency If you have entered a non permitted combination the Editor will display a warning message when you click on the Measure button and there will be no measurement until you correct the error VOLTECH ATI USER MANUAL PAGE 3 37 PROGRAM EDITOR 3 4 4 Verifying Your Program Typically in production use your program would be downloaded to an AT Series Tester from the Server which is a PC resident software package describe
262. successful 5 Again from the top level menu bar select Tester gt Run Program The test program will now begin execution When it is finished you will see a dialogue box containing the results of the test Test Results x 1 R 777 17 Ohm PASS 0000 2 IS 1 9372 H PASS 0000 RUN TIME 399 msec Refun Test VOLTECH ATI USER MANUAL PAGE 3 39 PROGRAM EDITOR From the results you should be able to see any tests where there may be problems Return to the Program Editor to make the necessary changes then download the program again and run the corrected version Continue in this way until you are satisfied that the program is correct before archiving it for use in production The code at the end of each result line should normally be zero any other code signifies that an error occurred in the measurement At this point you may want to protect your test program by setting an AT password To do this select Part TUTORIAL File TUTORIAL atp Voltech Tester gt Set Password Part Schematic Program Tester Server Setup Help The resulting dialogue see Download Program below allows the AT password LIE HIN Upload Frogiem to be set If a password is set this password will need to be entered into the AT whenever a Cs ith ale Set Password test program is changed or Lec deleted mm eT Set AT Password Only the following characte
263. t the fixture choose compensation or no compensation and then run the chosen program by selecting Run VOLTECH ATI USER MANUAL PAGE 6 47 FRONT PANEL MODES Fart number TUTORIAL Settings Finish Running the program will take you to the PASS FAIL display where pressing Finish will return you to the program selection screen where you may choose to re run the test program run a different test program change the set up of am existing test program delete a program or create another new program from the front panel 6 6 4 Password Protection The ATi s front panel program mode allows the operator to edit test programs that are stored in the AT Server or the AT s local program store save new or modified programs or delete test programs directly from the front panel To help protect existing test programs and their set up two AT passwords may be created a Server password and a local password The Server password helps protect programs stored on the AT Server whereas the local AT password protects the local program store When a password has been set up the instrument will force the operator to enter the correct password before a program can be saved or deleted The AT Server password must be set up from within the Server software go to Setup Password PAGE 6 48 VOLTECH ATI USER MANUAL FRONT PANEL MODES Setting the Internal AT Password As well as from within the Editor software see chapter 3 the i
264. t can help the operator diagnose the cause of the problem The DSP status error code is seen on self test failures and on the Editor s results screen The reason for DSP status error code is a one or two digit number displayed in parentheses that explains the reason for the four digit DSP status error code This reason for DSP status error code translates into why a status error was displayed This again can help the operator diagnose the cause of the problem The reason for DSP status error code is only seen on self test failures For the operator the DSP status error codes can assist in determining if the fault is due to a poor fixture or an incorrectly seated part or it could prompt an investigation into the appropriate test parameters being used For the more serious faults the user can contact their local Voltech technical support group and by explaining the application along with the DSP status error code can speed up and help the technical support engineer investigate the cause of the fault VOLTECH ATI USER MANUAL PAGE 3 41 PROGRAM EDITOR 3 5 1 Front panel Error Codes When a fault is detected the first DSP error code seen is a four digit hexadecimal number called the DSP status error code the second is a one or two digit hexadecimal number in parentheses called the reason for DSP status error code This one or two digit code is only displayed with self test failures Status error codes can be seen after a self test f
265. t specifications Safety BS EN 61010 1993 amendment A2 1995 EMC BS EN 55022 1995 Class A BS EN 50082 2 1995 Supplementary Information The product herewith complies with the requirements of the EMC Directives 89 336 EEC and 92 31 EEC and the Low Voltage Directive 73 23 EEC Signed on behalf of Voltech Instruments Ltd M Martin Whitley Quality Manager Abingdon United Kingdom April 25 2000 VOLTECH ATI USER MANUAL PAGE 8 33 SPECIFICATIONS 8 4 2 EMC Precautions Conducted and Radiated Emissions The ATi complies with the limits of BS EN 55022 Class A Immunity The ATi may be susceptible to Fast Electrical Transients on the power line and Electrostatic Discharges which can disrupt the operation of the unit In the event of these circumstances return the ATi to normal operation by 1 Switching off the power 2 Waiting for 5 seconds 3 Switching on again Observe anti static precautions when making connections to the interfaces on the rear panel of the instrument PAGE 8 34 VOLTECH ATI USER MANUAL 9 WARRANTY AND SERVICE VOLTECH ATI USER MANUAL PAGE 9 1 WARRANTY AND SERVICE PAGE 9 2 ATI USER MANUAL WARRANTY AND SERVICE Contents Warranty and Service 9 1 WARRANTY eite ve cack a e e a ede aaaea decdetnceetecssedecderatedeevestecactedvedeseds 9 5 9 2 LIMITATION OF
266. table below assuming that the energized winding is the one with the highest number of turns Inductance of the Preferred Test Signal Energized Winding Frequency Voltage 300kHz 100kHz 30kHz 10kHz 1kHz 100Hz 100Hz 50Hz 50Hz 50Hz 20Hz E ET zh e m E m gt E X PAGE 7 58 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency Programming the Test Using the PC Test Editor Turns Ratio x Test Parameters Integration Voltage 13 Cmv CV C Short Medium Frequency o Hz CkHz C MHz C Long p Energised Terminals High Terminal Low Terminal r Primary Terminals Secondary Terminals High Terminal Low Terminal High Terminal Low Terminal r Ratio Limits r Polarity cx Primary Secondary o B jo C ve C ve CH Neg fo Pos o x 5 No Test ema Choose the integration period normally Medium Energized Terminals The terminals where the test signal will be applied This is normally the winding with the greatest number of turns Primary Terminals High and Low The zero phase reference terminals which are often the same as the energized terminals VOLTECH ATI USER MANUAL PAGE 7 59 TESTS AND TEST CONDITIONS
267. tages about 8 nominal value gt lt The limits are entered as minimum and maximum values gt There is only a minimum limit There is only a maximum limit VOLTECH ATI USER MANUAL PAGE 3 27 PROGRAM EDITOR The corresponding dialogue boxes are as follows Winding Resistance Integration C Short C Long Terminals High Terminal Low Terminal A e Resistance Limits C Co Nominal 40 CmOhm COhm CkOhm CMOhm C C Negative 5 Positive 5 Measure Cancel Veltech limits Winding Resistance Integration C Short Medium C Long Terminals High Terminal Low Terminal Y B m Resistance Limits Minimum 38 mOhm Ohm CkOhm CMOhm Maximum 42 mOhm Ohm CkOhm C MOhm Measure Cancel Woltech Minimum and maximum limits gt lt PAGE 3 28 VOLTECH ATI USER MANUAL PROGRAM EDITOR Winding Resistance m Integration C Short Medium C Long r Terminals High Terminal Low Terminal A X B X Resistance Limits C Co Minimum 38 mOhm COhm CkOhm CMOhm 8 Measure Cancel Minimum limit only gt Winding Resistance r Integration C Short Medium C Long Terminals High Terminal Low Terminal A M B M m Resistance Limits C vo
268. tbIlVoltechRunID Field Format Notes RunID Text 25 Index ID Date Date Time Short Date Date of test run Time Date Time Long Time Time of test run ATUnitID Text 25 As tblVoltechATUnitID PartID Text 25 Part name FixtureID Text 25 Fixture name OperatorID Text 25 Operator name BatchID Text 25 Batch name TransformerSerialNo Text 25 Transformer serial number OverallResult Text 10 PASS FAIL RE RUN ABORT Overall test pass fail and re run result VOLTECH ATI USER MANUAL PAGE 4 25 AT SERIES SERVER Table tbIVoltechTestID Field Format Notes TestID Text 25 Index ID TestMnemonic Text 10 Individual test mnemonic TestUnits Text 10 Individual test units CheckT ype Text 5 NONE MIN MAX DIFF POL Type of test limits see MinLimit Number Single Minimum limit for test see MaxLimit Number Single Maximum limit for test see Notes CheckType NONE CheckType MIN CheckType MAX CheckType DIFF CheckType POL If there are no Min or Max limits MinLimit 0 and MaxLimit 0 If there is a Min limit only MaxLimit 0 If there is a Max limit only MinLimit 0 If there is a Min and Max limit Polarity test If Positive Polarity test MinLimit 0 and MaxLimit 1 If Negative Polarity test MinLimit 1 and MaxLimit 0 PAGE 4 26 VOLTECH ATI USER MANUAL AT SERIES SERVER Charting and Analysis Using SPC SQC Software
269. tes for the Above Example If there appear to be any problems while the code is running press the escape key This will halt the execution and bring up a dialog box to allow you to either exit from the code execution or to debug your code for example by stepping through it VOLTECH ATI USER MANUAL PAGE 4 43 AT SERIES SERVER Do Once the results have been placed into cells in the spreadsheet standard Excel functions may be used to perform further analysis on the data or to present the data in different ways As an example you may wish to use the Excel Chart Wizard to produce a graph of the results Alternatively you may wish to add further code to the example shown above as another way of extending the functionality For guidance of what may be possible please refer to the Microsoft Excel user manuals In the code example shown above it is worth noting the following points vntResult 1 To 99 is declared as a variant type because the GetVariantResult method can return either a numerical value corresponding to a valid result or a string corresponding to an error message The line Set objServerResult CreateObject Server Results creates the Server Results automation object within Visual Basic When trying to read the result with vntResult nTest obj ServerResult GetVariantResult sComPort nTest Loop Until vntResult nTest lt gt NO RESULT And vntResult nTest lt gt INVALID RESULT NUMBER two tes
270. that all of the relays in the 20 way matrix are opening and closing properly and that all the test signal sources and measuring circuits are working properly and within their calibration limits Once the tester has warmed up for one hour you may run self test at any time by pressing the Self Test softkey at the top level menu Remove any test fixture Continue and BHC connections then press the soft key COHTIHUE Before commencing self test please ensure that there is nothing touching any of the test nodes on the top surface of the tester In particular remove all test fixtures and transformers and anything connected to the four BNC terminals VOLTECH ATI USER MANUAL PAGE 2 47 GETTING STARTED As the self test is running the front panel display will indicate progress using a horizontal bar Self Test At the end of the self test you should see the following screen Self Test Pragrans LCR CBHC LOR Set Up qus Self Test PAGE 2 48 VOLTECH ATI USER MANUAL GETTING STARTED If there is a failure at any point in the self test you will see a display similar to the one below Self Test Repeat FAIL Continue Measure bus relay fail Lo Details Made 16 The message shown on the lower two display lines will depend on what caused the failure In the unlikely event that your tester continues to fail please make a careful note of the failure message and error codes which may be
271. the windings Where Used The low voltage open circuit test is used to confirm that windings have the correct ratio of turns between them and that the phasing of the windings is correct This test is used for signal pulse and switched mode power transformers where the normal operating conditions require only small excursions of the B H curve never extending beyond the linear region On the AT3600 only a high voltage open circuit test is available for testing line VOLTECH ATI USER MANUAL PAGE 7 69 TESTS AND TEST CONDITIONS frequency transformers at their operating point up to 270V 1kHz and 2A See also the test TR turns ratio Test Conditions To measure low voltage open circuit the test signal is applied to one winding called the energized winding The voltages across another winding or the same energized winding are measured The low voltage open circuit measurement is the rms value of the voltage measured and can be an AC or a DC voltage It is recommended that you choose the winding with the highest number of turns as the one to be energized Choosing Test Conditions The recommended test conditions depend on the inductance of the energized winding they are given in the table below assuming that the energized winding is the one with the highest number of turns Inductance of the Preferred Test Signal Energized Winding Frequency Voltage 300kHz 100kHz 30kHz 10kHz 1kHz 100Hz 100Hz 50Hz 50Hz 50Hz 20Hz E
272. the operator for that option is included with the results that are sent back to the Server This additional data is then available to be used as you wish for example it may be included in your production reports Note that these options are part of the program not global settings of the ATi allowing you to enable different options for each transformer as required VOLTECH ATI USER MANUAL PAGE 2 59 GETTING STARTED When running programs with any of the above options enabled there will be additional displays depending on which options are enabled after the Fit the Fixture display and before the RUN FINISH display PAGE 2 60 VOLTECH ATI USER MANUAL GETTING STARTED The following flow diagram summarizes the possibilities v Top level Display v Select Programs Soft key v Select Test Program to Run v Fit and Compensate Fixture Enter Operator Name 4 gt Enter Batch Number gt Enter Serial Number gt v RUN FINISH Sad eR New Operator Menu Ll me xti e compensate RUN FINISH v Measurements v Enter New Serial Number 4 VOLTECH USER MANUAL PAGE 2 61 GETTING STARTED Additional Displays After Entering the Part Number Enter the operator name 71 Enter the batch number KANI PAGE 2
273. the previous section of this chapter The test conditions can also be determined automatically by the ATi according to this table Signal Specified voltage Specified current Auto Frequency Specified Specified Specified Note that a fixed signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 27 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Test Parameters Integration Signal m Cmv CY C Short Medium Frequency o Hz kHz C MHz C Long Terminals High Terminal Low Terminal Q Factor Limits CZ gt lt Minimum o EE Maximum fo Measure Cancel Choose the integration period normally medium and enter the terminal to be measured Use the Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt Aminimum value only lt Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Typically Q is tested against a minimum value A typical ferrite cored transformer may have a Q gt 20 A specially designed low loss transformer may have a Q 2100 Because Q is a ratio of two impedances it has no units PAGE 7 28 VOLTECH ATI USER MANUAL TESTS AN
274. the rear of the fixture bay to allow easy access for loading transformers and to avoid accidental damage to the display and keys The main features are as follows LCD Display The brightly lit graphics display is used to display test results and to provide prompts for data entry within the menu structure RUN Indicator The RUN indicator is a yellow LED This is illuminated when the tester is busy for example when running a test program PASS Indicator The PASS indicator is a green LED This is illuminated after running a test program when the result is Pass FAIL Indicator The FAIL indicator is a red LED This is illuminated after running a test program when the result is Fail VOLTECH ATI USER MANUAL PAGE 2 7 GETTING STARTED Beeper A programmable beeper is built into the ATi to give an audible indication of PASS or FAIL as desired Logic level signals representing the RUN PASS FAIL and BEEP actions are available on the REMOTE port at the back of the ATi for use with automatic handling equipment and external indicators Keypad The keypad allows you to enter text data such as the part number i e the test program name of the transformer to be tested Softkeys The six softkeys adjacent to the LCD are provided for functions that vary with different aspects of the tester s operation The function for each softkey at any given time is shown in the text boxes at the right hand side of the LCD PAGE 2 8 VOLTECH
275. the results will now be stored in the selected database 4 3 6 Database Tables The Server software automatically creates the following tables in the selected database if they do not already exist and stores data within the tables using the structure defined here The tables store all the information that is available concerning the results including time date limits operator etc in a very compact and efficient structure Note that new data is not necessarily appended to the end of a table it may appear anywhere within Table tbIVoltechATUnitID Field Format Notes ATUnitID Text 25 Index ID UnitType Text 10 AT3600 AT1600 ATi UnitID Text 10 Unit serial number FirmwareID Text 10 Unit firmware version PAGE 4 24 VOLTECH ATI USER MANUAL AT SERIES SERVER Table tbIVoltechResults Field Format Notes ResultID Text 25 Index ID RunID Text 25 As tbl VoltechRunID RunID TestID Text 25 As tblVoltechTestID TestID TestNo Number Long Integer Test number as in test program OC_Comp Text 5 YES NO N A O C compensation status SC_Comp Text 5 YES NO N A S C compensation status Load_Comp Text 5 YES NO N A Load compensation future development Result Number Single Actual test result TestStatus Text 5 DSP status for test PassFail Text 5 PASS FAIL Individual test pass fail result Table
276. through it The test signal is chosen automatically by the AT and may be a constant current or voltage VOLTECH ATI USER MANUAL PAGE 7 13 TESTS AND TEST CONDITIONS Choosing the Test Signal The DC test signal is set automatically according to the value specified as maximum in the test limits Maximum Resistance 10 100 1000 lt 1kQ lt 10kQ gt 10kQ 400mA 200mA 100mA 30mA 3mA 300 8 0V Programming the Test Using the PC Test Editor Winding Resistance x r Integration C Short Lol C Long Terminals High Terminal Low Terminal Resistance Limits Cz Minimum jo mOhm Ohm lt kOhm MOhm C Maximum jo mOhm Ohm kOhm C MOhm Measure Cancel Choose the integration period normally Medium and enter the terminals for the resistance measurement PAGE 7 14 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only lt Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits mOhm Ohm etc when entering absolute values as limits Normally it is important to set a maximum limit as closely to the nominal value as possible to ensure that the correct wire has been used Typi
277. ti phase depending on the winding and the termination of the windings Where Used The turns ratio test is used to confirm that windings have the correct ratio of turns between them and that the phasing of the windings is correct This test is the preferred test for signal pulse and switched mode power transformers where the normal operating conditions require only small excursions of the B H curve never extending beyond the linear region See also the test TRL turns ratio by inductance VOLTECH ATI USER MANUAL PAGE 7 57 TESTS AND TEST CONDITIONS Test Conditions To measure turns ratio the test signal is applied to one winding called the energized winding The voltages across two other windings one of which may be the energized winding are measured The turns ratio is then measured by dividing one measured voltage by the other and making a compensation for the effects of winding resistance It is recommended that you choose the winding with the highest number of turns as the one to be energized A possible exception to this rule is when you wish to measure the ratio between two windings that should be accurately matched at 1 1 In this case it may be better to energize a third winding with a lower number of turns to ensure that any measurement errors apply equally to the two windings under test Choosing Test Conditions The recommended test conditions depend on the inductance of the energized winding they are given in the
278. tion System 9 9 7 47 Capacitance Match 7 53 Capacitor Measurements 7 113 Clock Setting 2 78 COM Port Configuration Editor 2 13 COM Port Configuration Server 2 16 COMP req tret fett 6 7 Compensation 2 72 3 45 Compensation Editor Measure 3 33 Compensation LCR Mode 6 29 Continuity 7 12 Core Connection 3 11 Database Tables 4 24 Display Background 2 78 Display Contrast 2 78 Dissipation Factor 7 29 EMC Compliance 8 34 5 3 41 ESR ewean 7 114 Execute Mode 2 51 FAIL Indicator 2 7 Fixture Compensation 2 72 Fixture Parts from Voltech 5 13 Fixtures Description 5 6 Footswitch 2 itle 2 9 Frequency Response 7 84 8 Hints and 6 8 Inductance Inductance Match Insertion Loss VOLTECH ATI USER MANUAL 8 8 1
279. tions PAGE 1 22 VOLTECH ATI USER MANUAL INTRODUCTION 1 8 5 Test Fixtures When running the test program in production how do you connect your transformer with its own arrangement of terminals to the test nodes of the AT Series Tester The AT Series of transformer testers has been designed with its own test fixture system to answer just this question e Fixtures are constructed on a standard fixture board which fits into the top surface of the tester e The fixture system uses Kelvin connections to give the best possible measurements when testing wound components The fixture system will accommodate different types of connectors suitable for both PCB mounting and flying lead transformers A single test fixture can be used for all transformers wound on the same bobbin Please see the fixtures section chapter 5 of this manual for more information VOLTECH ATI USER MANUAL PAGE 1 23 INTRODUCTION 1 8 6 Operating the AT Series Testers in Production Test The ATi is suitable for use in both manual and robotic production situations Manual Use Testing Smaller Batches of Different Transformers Operator 1 Chooses transformer part number from a list or swipes a barcode 2 Fits the fixture as prompted 3 Touches pad or presses footswitch Remote PC records all test data for statistical analysis using Run Stop Fail Busy Voltech Server software signals for process control Good parts for furt
280. tments take care not to touch any transformer terminals the transformer body or any exposed metal on the test fixture Ideally make sure that you use a trimming tool with a well insulated handle When applying a test signal to a winding always be mindful of the turns ratio of the transformer that you are testing Very high voltages can be generated on the other windings of the transformer If these voltages exceed 250V the tester may be permanently damaged VOLTECH ATI USER MANUAL GETTING STARTED 2 8 FIXTURE COMPENSATION The AT s fixture compensation eliminates errors due to stray parasitic components on the fixture board itself These are usually a combination of parallel capacitance between adjacent wires sockets or pins and series resistance and inductance along the lengths of wires It is best to try fixture compensation when performing trial runs on the program as it is being developed using the Editor As a guide if fixture compensation changes the test results then it should be applied whenever the program is run in a production situation For optimum accuracy in production test fixture compensation measurements should be made 1 Whenever the test fixture is changed 2 Atthe beginning of each day or work period 3 Whenever a new test program is loaded into the AT for execution Performing compensation on a fixture consists of making TWO measurements Short circuit S C compensation will compensate for the effec
281. to e Enter fixed voltage and frequency test conditions e Compensate for the effect of stray inductance and capacitance from the connection to the part under test e Change the level of integration applied to the measurements e Printthe current measurements to a standard printer e Measure on the front panel using any of the tests that have been purchased This section describes the measurement settings that are available in both LCR BNC and LCR FIX modes VOLTECH ATI USER MANUAL PAGE 6 21 FRONT PANEL MODES 1 988 1 P More C145 11 791 CFixture made Prg AUTO U AUTO Hz Mes lem 1 46mA kHz Press the Settings softkey to reveal the settings menu 2 106 2mH 2 7712 CFixture modes Prq AUTO Ws AUTO Hz Mest 9 928mJ 11mBH 188 Hz Press the Signal softkey to show the signal settings PAGE 6 22 VOLTECH ATI USER MANUAL FRONT PANEL MODES Signal settings Enter f Pri U Hz Ab Enter WJ Sec AUTO Y AUTO Hz mAb Enter I Enter IBias 161 62JH Sec at 4 98 U 1 35mH Z2BBkHz Note that in LCR BNC mode there is only one set of conditions to choose and that the Pri Sec softkey is thus not shown On the bottom line of this display the last measurement and its measurement conditions are displayed if they are available Enter f Enter V Enter and Enter IBias These keys allow you to enter fixed values of voltage frequency and DC bias current using the
282. to quickly and easily create test programs for your tester without any specialized knowledge of computer programming The PC Server will provide a storage system for archiving both the test programs and the test results In this chapter you will learn Howto install the tester e How to set up the Editor and Server software How to create and run a simple test program VOLTECH ATI USER MANUAL PAGE 2 5 GETTING STARTED 2 1 1 Package Contents The following items are supplied in the packing case along with this manual e ATi transformer tester e Power cord e ABNC to Kelvin clip lead four color coded BNCs to two clips e An LCR fixture with four Kelvin leads attached e Q9 pin D 9 pin D F F cable e 9 pin D 25 pin D F F cable e 25 pin D 25 pin D F F cable e CD ROM inside the cover of this manual which contains the Editor and Server installation files and other important information Calibration certificate Product registration information Please report any missing items to your Voltech supplier immediately Returning your product registration card will ensure that you continue to receive the latest product and application information PAGE 2 6 VOLTECH ATI USER MANUAL GETTING STARTED 2 1 2 The ATi Front Panel Liquid Crystal Display LCD RUN Indicator Softkeys t transformer Pass PASS Indicator FAIL Indicator PNE Connectors The front panel of the ATi is mounted towards
283. ts are available and how the interfaces including the front panel function New versions of the firmware are made available periodically and electronic copies are available free of charge To maximize the performance and longevity of your ATi you should install these upgrades as they become available Contact your local supplier or see the Voltech website at www voltech com for details Upgrade firmware is distributed in a file with the extension ABS Upgrade firmware is available at the Voltech website or from your supplier and can be downloaded into any ATi If you have purchased new tests you will be supplied with a file called ATIxxxx ABS that contains the tests you have requested as well as the latest version of firmware An ATIxxxx ABS file can only be used with the serial number xxxx of the tester that it is registered to Save the file to a local or network directory normally C Program Files Voltech Instruments Voltech AT Editori You may also be supplied with a file called BOOTATi ABS You must save this file in the same directory To upgrade locate the ABS file and double click on it Then select ss New Part Voltech Test Program Editor Tester gt Download Firmware Part Schematic Program Tester Server Setup Help amp Download Program alx Upload Program Compensate Fixture Run Program Download Firmware Set Password VOLTECH ATI USER MANUAL PAGE 9 7 W
284. ts for No Result and Invalid Result Number are included The GetVariant method will normally read back No Result until a measurement has occurred The next time it is executed after a new result has been sent to the Server GetVariant will read back the actual result value The act of doing this will set a flag in the Server to say that the data has been read so that any further executions of the GetVariant statement before another result has been transferred to the Server will then return the No Result reply Although the test number is fixed 3 in this example the Invalid Result Number test is also included This is because the GetVariant method can be PAGE 4 44 VOLTECH ATI USER MANUAL AT SERIES SERVER activated at exactly the same time as the results are being transferred from the AT to the Server Depending on the speed and other parameters of your PC there may be a small time during the transfer when the result number requested can be read as invalid Including this test in the loop will trap out this error Instead of using the GetVariantResult function itself to determine if new data is available the NewDataAvailable function can be used This function is recommended for use when more than one item of data is to be read after new data is available For example the NewDataAvailable function can be read in the do loop until it returns true after which any other OLE function can be called to gather t
285. ts of 5 which is equivalent to half a turn Make use of the Measure button For many tests the dialogue box for the test contains a button labeled Measure If when you are creating your test program you have a tester connected to your PC fitted with the appropriate test fixture containing a specimen transformer clicking on the Measure button will signal the tester to measure the actual parameter of the test The result will be returned to the PC and the Editor will insert it as the nominal value in the limits section of the test dialogue box This is often the best way to find the value for some of the parameters that you may wish to test but which do not appear on the actual transformer design documents Finally download and run the program from the Editor and make sure that the results are what you expect before you use it in production VOLTECH ATI USER MANUAL 4 AT SERIES SERVER VOLTECH ATI USER MANUAL PAGE 4 1 AT SERIES SERVER PAGE 4 2 VOLTECH ATI USER MANUAL AT SERIES SERVER Contents AT Series Server 4 1 INTRODUCTION sheets 4 5 4 2 4 6 4 2 1 Storing Test Programs 2 2 pdt dua ne EL ed ule d iiia 4 6 4 2 2 Viewing a Test Program sss nne enn nna 4 7 4 2 3 Saving a New Copy of a
286. ts of stray connection lead resistance and inductance Open circuit O C compensation will compensate for the effects of stray lead capacitance See also the description of 4 terminal Kelvin connections in the fixture section of this manual for how to eradicate the effects of CONTACT impedance between the test part and the fixture To Perform Fixture Compensation Once a program is ready to run you will have the option of pressing the COMPENSATE softkey on the panel Press COMPENSATE and you will be given the option to perform S C or O C compensation BOTH types of compensation should be performed one after the other The order in which S C and O C compensation is performed is unimportant VOLTECH ATI USER MANUAL PAGE 2 71 GETTING STARTED S C COMP connect all SC Comp used terminals together 07C Comp For OC COMP use an empti fixtures Ho Comp For S C compensation first make up a transformer bobbin with shorting links in place of the windings To make a shorting bobbin solder short pieces of wire across the relevant pins or all of the pins of a spare blank bobbin or complete transformer O O O Oo 3 Transformer Shorting bobbin for S C compensation Put the short circuit bobbin into the fixture and 1 Press softkey 1 S C Comp to begin short circuit compensation 2 Remove the short circuit bobbin but leave the fixture in place 3 Press softkey 2
287. uency are usually determined by the final application of the part under test Programming the Test Using the PC Test Editor Interwinding Phase x m Test Parameters r Integration Voltage my Cy Short Medium Frequency fo f Hz C kHz C MHz C Long r Energised Terminals High Terminal Low Terminal r Primary Terminals r Secondary Terminals High Terminal Low Terminal High Terminal Low Terminal f d i 3 fa f d r Phase Limits E Minimum Degs gt lt Maximum o Degs UERMEUNEN VOLTECH ATI USER MANUAL PAGE 7 105 TESTS AND TEST CONDITIONS Choose the integration period normally Medium Energized Terminals The terminals where the test signal will be applied This is normally the winding with the greatest number of turns Primary Terminals High and Low The zero phase reference terminals that are often the same as the energized terminals Secondary Terminals High and Low The inter winding phase angle measurement will be the angle between the primary and secondary terminals High and Low Terminal names Note that the PC Editor s Measure button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and limits of up to 90 and 90 deg gt lt Minimum and maximum values Use the PC Editor s Measure button together with a sample part if you are unsure of the nom
288. um High terminal A Low terminal B Click on the gt button to select a minimum limit only and enter Minimum 3H Winding Inductance Series Circuit E xj m Test Parameters 1 Integration Signal fi Cm C mA C Short Medium Frequency 50 Hz CkHz MHz C Long m Terminals High Terminal Low Terminal A Inductance Limits Minimum EB Cnh CmH CH C Measure Cane Click on the OK button Again the test and its parameters will appear in the Program window 6 Finally by double clicking the left mouse button select TR Turns Ratio from the Available Tests window At the dialogue box enter the data required for the turns ratio test Voltage 1V Frequency 50Hz PAGE 2 26 VOLTECH ATI USER MANUAL GETTING STARTED Integration Leave as the default Medium The AT measures the turns ratio between primary and secondary windings and allows the possibility of applying the test voltage to a third energized winding For this example the primary and energized windings are the same Energized high terminal A Energized low terminal B Primary high terminal A Primary low terminal B Secondary high terminal C Secondary low terminal D Using the default type of limits enter Primary Secondary 1 1 Neg 2 Pos 2 Turns Ratio Test Para
289. ure capacitance on the measurement of capacitance but cannot remove its effect on SRF VOLTECH ATI USER MANUAL PAGE 7 9 TESTS AND TEST CONDITIONS Tests Currently Available Description Transformer Application Reason for Test Continuity All Checks properly installed fixture and part DC Resistance All Checks properly installed fixture and part correct wire used and integrity of terminations DC Resistance Match SMPS audio amp telecom Checks matching between windings Inductance Series Circuit Inductance Parallel Circuit Quality Factor Dissipation Factor tans Equivalent Series Resistance Equivalent Parallel Resistance Most but not usually line frequency Checks primary turns right grade of correctly assembled core material Checks right grade of correctly assembled core material and for shorted turns Inductance with Bias Current Series Circuit Inductance with Bias Current Parallel Circuit Transformers that carry a significant DC bias current in normal operation Checks number of turns right grade of correctly assembled core material Inductance Match SMPS audio amp telecom Checks matching between windings Leakage Inductance SMPS electronic ballasts Checks windings have been installed in the correct position relative to the core Interwinding Capacitance Parallel Circuit High frequency iso
290. urement frequency Hz Vmx is the measured voltage for the X measurement V Vmy is the measured voltage for the Y measurement V AVcmnx is the error due to the common mode voltage in the X measurement AVcmny is the error due to the common mode voltage in the Y measurement The error due to the common mode voltage in the measurement AVcmnx and AVemny is given as AVoyn can 0 00000001 x Fup 398 Where Vomn is the common mode voltage measured VOLTECH ATI USER MANUAL PAGE 8 17 SPECIFICATIONS 8 2 12 LBAL ILOS and RESP Tests The accuracy is given as Ar Ar 0 87 Ac Avi Avo Where Ar is the total accuracy dB Ar is the basic relative accuracy dB Ac is the correction for calibration Avi is the correction for the input voltage level Avo is the correction for the output voltage level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 1 0 0000001 X Ay 0 001 215 Ayo 0001 Tze Where Fm is the measurement frequency Hz Vmi is the measured input voltage V Vmo is the measured output voltage V PAGE 8 18 VOLTECH USER MANUAL SPECIFICATIONS 8 2 13 RLOS Test The accuracy is given as Z x Z Ar 0 174x ZRx Z Where is the total accuracy dB Az is the total accuracy for the Z test Z is Vu ly ZR is Zi E Where Vm is the measured voltage V lm is the measured cur
291. vailable Tests eene 8 7 8 3Interface Delalls 3 tte up EE d 8 23 VOLTECH ATI USER MANUAL PAGE V 84 EMG Compliance Sans oa 8 33 9 WARRANTY AND 9 1 9 1 Warranty cee debe i oe RO 9 5 9 2 Limitation of Warranty sessi esee eene nnn enne nennen 9 5 9 3 Service and Calibration sse nnn 9 6 9 4 Obtaining Service and Applications Support esee 9 6 9 5 Firmware Upgrades ate pariter ge tede n 9 7 9 6 Voltech AT Calibration System seen 9 9 TOSINDEX qq 10 1 PAGE VI VOLTECH ATI USER MANUAL 1 INTRODUCTION Thank you for choosing to use this Voltech product If you experience any difficulty during installation or use of the ATi or are unsure of any of its features or abilities please do not hesitate to contact either your local supplier or a Voltech main service center as listed inside the front cover VOLTECH ATI USER MANUAL PAGE 1 1 INTRODUCTION PAGE 1 2 VOLTECH ATI USER MANUAL Contents Introduction INTRODUCTION 1 1 HOW TO USE THIS MANUAL eere nnn nnn nnn 1 5 1 2 GENERAL SAFETY INSTRUCTIONS eere eere e
292. w to choose the test conditions Choosing Test Limits The test limits can be Anominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits mV or V when entering absolute values as limits Test limits should be set as close as possible to the nominal value in order to detect faults A typical tolerance would be 5 PAGE 7 72 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS 7 1 18 IR Insulation Resistance Test Measurement Test Test Basic Range Voltage Frequency Accuracy IR 1MQ to 160 100V to 500V DC 1 096 Insulation Transformer windings are often insulated from each other and from the core by insulating tape enamel on the wire or by plastic moulding on the bobbin The quality of the insulation can be assessed by applying a DC voltage across the insulation and measuring the resistance The voltage applied is usually greater than the voltage that the insulation will see in normal use Where Used An Insulation Resistance check is recommended as good practice for most transformers to check the integrity of the insulation between separate windings or between a windings or between a winding and a screen VOLTECH ATI USER MANUAL PAGE 7 73 TESTS AND TEST CONDITIONS Test
293. wing table PAGE 7 44 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Preferred Test Signal Frequency Leakage Inductance Range Current 300kHz 100kHz 30kHz 10kHz 1kHz 100Hz 100Hz 50Hz The test conditions can also be determined automatically by the ATi according to this table Signal Specified voltage Specified current Auto Auto Frequency Specified Specified Specified Auto Note that a fixed signal cannot be used with an Auto frequency Programming the Test Using the PC Test Editor Leakage Inductance with User Offset Test Parameters Integration Signal o CuA CmV C Short Medium Frequency 0 Hz C kHz C MHz C Long Primary Terminals Additional Low Terminals High Terminal Low Terminal Available Used J 35 B c D Secondary Terminals High Terminal Low Terminal Add gt Remove Leakage Inductance Limits C G Minimum 0 nH CuH C mH CH C Maximum 0 nH C uH C mH CH F User Offset Enabled nH OK Measure Cancel Moltech VOLTECH ATI USER MANUAL PAGE 7 45 TESTS AND TEST CONDITIONS Choose the integration period normally Medium and enter the terminals to be measured The Primary Terminals are where the test signal will be applied the Secondary Terminals will be short circuited together Note that more than one secondary can be short circuited at the same time by adding more of the
294. y at higher frequencies the current flowing during the measurement can be very high and similarly the measured current could also be very small for small capacitance at lower frequencies and voltages PAGE 7 50 VOLTECH ATI USER MANUAL TESTS AND TEST CONDITIONS Where possible you should use the recommended test signal levels in the table above to ensure that the currents which flow can be measured accurately b Non linear Capacitance Normally non linearities in the stray capacitance of transformers are not a problem and therefore capacitance is measured with as large a voltage as possible c Equivalent Circuit As with inductance capacitance is actually measured as a complex impedance and therefore the result can be expressed in terms of either a series or a parallel equivalent circuit See the Series and Parallel Circuits and Capacitor Measurements sections at the end of this chapter The tester always uses a parallel equivalent circuit for inter winding capacitance measurements Series and parallel capacitance tests CS and CP are also available Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be Anominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button

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