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WINPASS ind I- English

1. 94 C Special CASE nn ste 98 DIL3 10 Net tests E cette 99 a Proprammine syntax et ge e SEO MER ODE ce Fr ege venei tae RUP eee PEEL egeo 99 b Naming Of polbls eie eterne haee deed rre cates ete ie ee a oo COEUR Lr ends ete nn tan 100 bu ose Minute 100 D IL 3 11 Multiple tests of one point in relation with the others 102 D IL 3 12 Multiple tests for unitary relay testers sese 103 DIL3 13 TARE T uncton uen n ete n ERR E PTR PLE TRUE EE SpR bien eB EP pe EX oa 105 D IL3 14 Event wait contact state ii nennn retener nest 106 a Waiting for contact opening iii 107 b Waiting for contact closing iii 107 D IL3 15 Event wait voltage state sise 108 a Waiting for a voltage diOp unserer rere eere Ie te eDb encre be ene Eod esa pe RES Reda 108 b Waiting for a voltage to appear 109 D 1E3 16 Displacement isnt EE t EI eer eene nase Ee ire sie rid ese Ego Lope RN ENS Qe dS 110 D IL3 17 Batch management e dedecori tete aiaa cote nha e E4 sho ro CE PUR PE Ra PE eiei 111 a Batch function LOT iie et teet nn ede debere i p esebbep Epacut ape dentistes 111 D Batch function LO DA degere aro rrr utn be oorr esa Pee oa em eade en a edu be rk apad ooa b 113 D IL3 18 Test result in the form of an EXCEL file ss 115
2. B L e a test where B points are described as in this case the programmer has control over the points described and can therefore avoid dangerous conflicts In the event that capacitors or values above 100 nF are present a specific measurement Ic is planned enabling discharge before and after the test This avoids weakening the relays of the switching cards which must not switch current Two cards allow use of stimuli Card 40680 for Tester SYNOR 4207 and 4208 unitary relay Card 40575 for Tester SYNOR 1202 4202 4203 multicontact relay D III 3 1 Using card 40680 Card 40680 can be used as a measurement card to steer a SEFELEC MGR10 microohmeter or as a stimuli card It has been designed to connect one or two power supplies on 22 output channels 40680 stimuli cards can be placed anywhere in the tester SYNOR 4207 or 4208 If there are several of them they do not have to be contiguous a Principle diagram p ns Power supply 1 eo 21 22 eo El eo When there is just one power supply power supply 1 and 2 outputs are gathered together With the unitary relay card each contact can be programmed separately 1 Switching of a single power supply It is possible to use a single power supply This is addressable on all output channels without restriction For example command of a relay coil between points 5 and 22 e fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2
3. Label s name Label s result amp LABEL1 amp RESLABEL1 Label s name Label s result Interface connection PASS SUB D9 HAN Test PASS SUB D9 DEUTSCH Test PASS HAN DEUTSCH test FAIL amp LABEL2 amp RESLABEL2 amp LABEL3 amp RESLABEL3 amp LABELA amp RESLABEL4 spa 3 m l x 4 Page Sec amp Li Col ENR REV EXT RFP Frangais Fr OX AA Termin Poste de travail Fa ino 7 orle S s fi SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 116 179 SCLEIEC D II 3 20 Test variables When using the test report function or LOTA BATCH function or from H test display instructions it is possible to call up the list of variables below System variable amp DIALn returns the field of row n of the dialogue box amp DATE returns the date given by the PC System variable only with the test report function CRT amp LABELn returns the name of the LABEL of row n amp FILE returns the name of the test file amp RESULTAT returns the FAIL or PASS result for the final test amp RESLABELn returns the result of LABEL number n Test between two points only with the test report function The variables described below return either the test number carried out or the number of test faults described by the code between the two see list of test commands Example amp RS_R_ returns the number of resistance tests carrie
4. gt From the TESTER SEFELEC WINPASS TESTER Execution of the test program C SEFELEC WINPAS54200 DEMO essai Fpe tse The operator must then Menu Setup Tools Help use the search probe and put it in contact Z with the programmed Breakdown Current 1 m point HY rise time 10 ms HV hold time 30 ms Once this had been Please touch point 1 with the search probe done the operator must validate by clicking Stop interrogation entry or STOP SEFELEC If the point requested has been touched the test is considered PASSED If the point touched is not the right one or if no point is touched the test is considered FAILED SEFELEC WINPASS TESTER Execution of the test program C SEFELEC WINPASS4200 DEMO essai s Menu Setup Tools Help LEAF Please touch point 1 with the search probe Touch Point not tested md 1 F2 Execute F3 Step by step F10 Partiel test SEFELEC s fe l s SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 81 179 SEIEIEC D II 3 4 High low level swing GO NO GO a High low level swing Authorises the test with the high level parameters The high level test is applied by default Authorises the test with the low level parameters Several test zones can follow in the same file NB After a HL or LL the continuity PC or insulation parameters PI must be redefined for the following tests b GO NO GO tes
5. a __ NE M BER NEL p po pesce pe e ee NN NN pe Ls eg pe prex Ls ose SS B pee B VII 3 SWITCHING CARDS 40418 AND 40428 Switching cards 40418 or 40428 2000 Vdc 1500 Vac 2 A 64 points route the measurement of the SYNOR 1202 4202 and 4203 testers 2 for the SYNOR 1202 They are placed in racks receiving a maximum of 16 cards each They are all identical only their position determines their address They are intermixable with cards 40417 and 40427 see the technical datasheet Since the relays used are multi contact these cards may be used for all tests except tests by groups of points sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 41 179 One card uses two vertical connectors standard 41612 red on the diagram on the front of the tester Columns A and C are used The tester addresses are shown on the diagram S o o I oO a z Board 3 Board 4 Board 6 Q3 mi O gt O on RN M C9 1 to Gba per Cii ALLAN C1 2 C22 C32 C42 C52 C62 C7 2 C82 C9 2 C102 C11 2 C122 C13 2 C142 C15 2 C16 2 En TETTE HARTING reference of interface connectors LLL LL Board 5 a Board 7 th 09 73 164 6907 Male connector 09 03 096 0501 Hood 09 02 000 9911 Grommet 09 02 000 9902 Left locking 09 02 000 9903 Right locking Wires recommended for wiring TYCO RAYCHEM 44A0111 24 n n colour code or choose an insulatin
6. Contact state 4 t min t maxt Example the diagram above must be programmed as follows PCe VAL 5 500m 20 1 5 NCe A P1 2 B P5 12 The event is correct if the contact closes R 5Q within 1 to 5 seconds The chosen current is 500 mA and the generator is limited to 20 V sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 107 179 D II 3 15 Event wait voltage state The following instructions should be followed to detect the moment when a voltage appears or disappears Parameters ne va mm Eee The measurement is the DC voltage measurement A voltage range for the voltmeter must therefore be entered If the test is PASSED the tester moves automatically to the next measurement If the test is failed for example if there is never any voltage the message no event appears Limit of event wait parameters voltage state Parameter Min value Max value V 0 500 V time 0 1000 s a Waiting for a voltage drop At the start of the test a voltage is present The tester will wait for the measured resistance to be smaller than the min V For the test to PASS this event must occur between min t and max t V Voltage state 12V 4 5 L 8VL 4 Elestoeneneiscedscct t min t maxt Example the diagram above must be programmed as follows
7. e Process each paragraph of the error list thoroughly clearly mentioning the repair to be made not forgetting that the wiring order is rarely the same as the order of tester addresses Check that a chain is not affected by several errors with other chains forming several paragraphs This will require use of the wiring list The entire error list must therefore be processed in a single operation NOTE f there is a faulty interface contact on a continuity test the tester will indicate an insulation fault and a continuity fault on the same points If this contact is lost completely the tester will indicate a continuity fault which will not be found on the equipment If this fault repeats itself check the interface In the case of an insulation fault on a long chain the tester will indicate the chain and the faulty point but will not indicate the exact location at which the surplus wire arrives The wire must therefore be traced back from the faulty point to the chain but the exact point of arrival can only be determined visually If breakdown occurs because of a damaged wire frequently the case if wires are wrapped the tester may for some configurations only indicate a single point on the error list corresponding to the point not found or parameters too high message This is due to the fact that at high voltage levels the faulty point causes a breakdown that the tester detects as a fault but during the search since the co
8. sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 87 179 The different parameters available depending on the tester options Parameter type option Parameter syntax dielectric strength AC AC Generator PJ VAL U insulation breakdown HV rise t 34019 application t Vcc measurement ZLC or 40535 PVC VAL minimum voltage maximum voltage Vca measurement ZLC PVA VAL minimum voltage maximum voltage Inductance ZLC PLR VAL minimum inductance maximum inductance Capacitance in alternating current ZLC PCR VAL minimum capacitance maximum capacitance Inductor coil impedance ZLC PZL VAL minimum impedance maximum impedance Capacitive impedance ZLC PZC VAL minimum impedance maximum impedance GMOV GMOV PGM VAL minimum voltage maximum voltage test voltage series resistance application time Voltage generation on U generation PGU VAL voltage measurement switching Voltage generation current on U generation Pu VAL voltage current measurement switching 40549 External power supply on U generation Pue VAL voltage current measurement switching external ps External power supply 1 or 2 on Stimuli with Pusn VAL current voltage n 1 or 2 Stimuli switching external ps NB The parameters must always be indicated before the zone in which they are to be applied A new parameter cancels out the previous one of the same type sefelec SY
9. H c t text HV c t text HC c t text HCM c t text HCB c t text HM c t text C t H c t text amp DIAL n text Y text DEP nnnnn HN BN GN DELAI nnnn DIAL program name NDIAL program name waiting for a voltage cut waiting for a voltage to be established remark unconditional text screen printer unconditional text screen conditional text linked to a faulty test conditional text linked to a faulty test conditional text linked to a correct test typewriter mode text colour N black B blue R red character size 8 to 48 introduces the text of field n of the dialogue box likewise for HV HC HCM HCB HM Stop test displaces the addresses of a file by nnnnn start of high level test zone start of low level test zone start of GO NO GO test zone programs a delay time in ms calls up a program of dialogue with the operator DIA field of dialogue box is not visible in test report MB question reply YES reply NO calls up a dialogue box reply with YES or NO and sends a text according to the reply CRT file source file destination LOT and FLOT ECRAN file path CONDITIONAL JUMPS SER and FSER TESTB and FTEST TESTM and FTEST LABEL label name FINLABEL WAITING for an event PCe Ce NCe PVCe VCe NVCe sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition Test report in html format use variable system lo
10. Since the function of the SYNOR 4200 is to test wiring basic self learning is only possible on nets The presence of components resistances diodes condensers etc could lead to false interpretations To warn the user of defective programming due to components or bad contacts during self learning the tester gives the number of points listed more than once or never listed It is easy to compare these data with the wiring documents and carry out a quick check to make sure that no gross errors have crept into the test programme some risk that an error of connection or a bad contact will induce an error of programming will inevitably remain A WARNING However many precautions may be taken when carrying out self learning The resulting file must always be compared with the wiring documents bearing in mind that it is very much quicker and less tedious to compare and modify a test programme than to write a whole program by hand B III 5 SELF TESTS As we mentioned in the chapter on maintenance the tester possesses two types of self test automatic self tests and self tests on demand B III 5 1 Automatic self tests As soon as the tester is switched on or a when a function test self learning or self test is initialized the measurement units used by the function called are automatically tested In addition at each measurement the voltages and currents applied are compared with the value measured In the event of a difference
11. TARE 3 7 EI B 1 B 5 B 10 B 11 B 15 B 20 B 21 B 25 B 30 B 31 B 35 B 40 B 41 B 45 EI B 2 B 7 EI B S EI B 4 EI B 6 EI B 8 B 9 B 28 B 44 EI B 12 EI B 13 EI B 14 B 16 B 18 B 34 B 38 B 50 sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 144 179 EI B 17 B 46 EI B 19 B 24 EI B 22 EI B 23 El B 26 B 29 B 33 EI B 27 EI B 32 EI B 36 EI B 37 EI B 39 EI B 42 B 43 B 47 EI B 48 EI B 49 REM Third parterre TESTM H The preceding tests are bad H repair and start test again FTEST REM Fourth party TESTB H fit components Y HV test of resistances PR VAL 325 340 R A 36 B 37 R A 37 B 39 PR VAL 990 1100 R A 22 B 23 HV test of condenser PF 90n 110n F A 48 B 49 HV test of diode D1 Pd 0 6 0 8 0 1 d A 3 B 4 H test of switches H set K1 K2 K3 to ON Y C A 51 B 52 C A 51 B 53 C A 51 B 54 H set K1 K2 K3 to OFF Y A 51 B 52 A 51 B 53 sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 145 179 A 51 B 54 H if the test is GOOD disconnect tools FTEST D III 4 Comments on test program All the points described are in tester addresses a First part The first code indicates to the tester that it is to operate at high level Next the unconditional texts identify the program and give instructions to the opera
12. To create a table of correspondences select FILE NEW EQUIVALENCE TABLE The window shows one column headed MACHINE which gives the tester points in decimal The second INTERFACE gives the name corresponding to the points of the intermediate interface The third USER will contain the names of the access points of the equipment to be tested The connectors programmed can be called up using the left hand part of the screen To write this table the programming tool INSERT CONNECTOR must be used This tool is used to choose the library and the names of the connectors to be inserted in order to create the table E I 3 1 Description of the interface The interface in our example is made up of three connectors which we shall call P1 P2 and TB1 P1 is a connector of 25 numerical pins described in the CONNECTOR library under the name CONNECTOR Its first pin is connected to point 1 of the tester P2 is a connector of 50 alphanumerical pins described in the CONNECTOR library under the name CONNECTOR2 Its first pin is connected to point 32 of the tester TB1 is a connector of 25 numerical pins described in the CONNECTOR library under the name CONNECTOR Its first pin is connected to point 97 of the tester On the tester the wiring to be tested will therefore occupy connectors C1 to C4 that is to say 128 points at 500V For convenience of wiring each connector begins at the start of a tester output connector which will leave ga
13. i Fall time in seconds Application time in seconds Rise time in seconds Al High threshold leakage current Low threshold leakage current Test voltage Test parameters of the RXS in DC gnd component tip cold point 1 component tip hot point XSRC measurement between two points group of B points cold points group of A points hot points XSRC measurement per group Table of limit parameters for the SXS depending on the hipot DC mode Parameter Minimum value Maximum value Test voltage 100 Vdc 6 KVdc Leakage current 0 110 mA Al 1mA 100 mA Rise fall time 0 999s Application time 0 999 s sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 129 179 D III 1 3 Command codes of the SEFELEC MGR10 microohmeter See the SEFELEC manual for the MGR10 Since this device is intended to measure very low resistances up to 100 uQ it will still be used in 4 wire mode Only the uneven tester addresses are programmed as a result force the following even address is only reserved for the sense Main characteristics of the MGR10 according to the measurement ranges Range Resolution Max Min Resolution Measurement specification current current 30 KO 10 100 pA 10 pA 1 pA 0 03 of the reading 0 02 of the range 3 KO 100 mO 1 mA 100 pA 10 pA 0 03 of the reading 0 01 of the range 300 Q 10 mQ 10 mA 1 mA 100 pA 0 03 of the reading
14. sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 179 179
15. It is entered once and for all unless new multiplex cards or options are added Click on to configure the machine Set up Matrix BTE E S E Two solutions are available 1 Manual method Here we shall declare the position and number of modules of access to the points of the tester Two types of modules are available 500 V and 2000 V To mark a module give the number of the cabinet and the number of the back panel Click on the box corresponding to the voltage M Then click on the box corresponding to the physical position of the module in the tester s f l SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 166 179 Se Le v CC The 500 V modules will be indicated in green and the 2000 V modules in red The read out button will automatically determine the configuration of the selected back panel this function is only available when the tester is switched on The automatic search takes several seconds Once complete the screen displays the number of racks in each cabinet and the position of the cards in each rack The total number of test points is displayed at the bottom left On modernized testers former tester SYNOR 3400 Switching cards fitted with FRB 102 pin connectors are not designed to be recognised by the tester and mixing is not possible In this configuration the screen does not therefore ask for the total number of points 2 Automatic method With the tester switched on just c
16. LED is RED LED is not RED d mM F2 Execute F3 Step by step F2 Execute F3 Step by step SEFELEC 2 sefelec SEFELEC Z SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 79 179 D II 3 2 Delay time out STOP a Delay time out DELAI EE Time in milliseconds When this instruction is being carried out a pause will occur The pause time will be the same as the time given by the instruction in ms Example Fromthe EDITOR C A 1 B 2 DELAI 100 A 4 B 6 This instruction does not display text during the test on the Winpass Tester or on the test report Between the 2 instructions C A 1 B 2 and I Af4 B 6 a pause of 100ms will be taken into account b STOP In a conditional TESTB and FTEST zone for example the STOP function stops the test It can be used to stop the test series if a condition is not met Example Fromthe EDITOR TESTM H R 12 Following a connection error the test will be stopped STOP FTEST sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 80 179 D II 3 3 Search probe The search probe can be called up in a program and used as test point xxxx La If the point touched does not have the programmed address between brackets a failed test is declared and an error message is displayed Example Fromthe EDITOR H V 14 Please touch point 1 with the search probe RPT Ali
17. PVCe VAL 128 1 5 VCe A P1 2 B P5 12 The event is correct if the voltage drops below 8 V within 1 to 5 seconds om fe l 3 SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 108 179 SEIEIEC b Waiting for a voltage to appear At the start of the test there is no voltage between A and B The tester will wait until it reaches a value above the minimum threshold min V For a PASSED result this event must occur between min t and max t Voltage state V Example the diagram above must be programmed as follows PVCe VAL 128 1 5 NVCe A P1 2 B P5 12 The event is correct if the voltage rises to between 8 and 12 V within 1 to 5 seconds The programming of 0 V for min V must be based on a threshold max V Attention residual voltage is always present in an unloaded electromagnetic circuit O V must be programmed after running tests manual mode sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 109 179 D II 3 16 Displacement DEP EE Displacement value The displacement numerical value is added to all the points that follow in the equivalence table It is used to test the same equipment in another zone of the switching matrix A new displacement value cancels out the previous one It is possible to open a dialogue box asking the operator the desired shift In this case the following instruction must be used BEZX ESL NN NN The dialogue box asks for the shift
18. sefelec Test amp Measurement Automatic wiring tester Parc d Activit s du Mandinet 19 rue des Campanules F 77185 LOGNES FRANCE 33 0 1 64 11 83 42 Fax 33 0 1 60 17 35 01 www sefelec com WARRANTY SEFELEC warrants that units are free from defects in material and workmanship SEFELEC warrants also that when properly used that units will perform in accordance with specifications of this manual If within one year after original delivery it is found not to meet this standard it will be repaired at no charge in SEFELEC service facility in Lognes Changes in the unit not approved by SEFELEC will cancel this warranty SEFELEC will not be liable for any indirect damages resulting of the use of the unit This warranty is in lieu of all other warranties INTRODUCTION SET UP Warning This unit must be used by qualified people Every precautions for the use of units connected to the main must be taken during its use In particular this unit must be connected to earth The specifications of this manual the correct operation of the unit as well as the operator s security ate guaranteed only when the supplied are used The measurement probes can include limitation or protective elements therefore it is forbidden to modify without written agreement from SEFELEC company In case of use under other conditions than the one specified in this manual the security of the user will be in danger These u
19. 0 01 of the range 300 1 mQ 100 mA 10 mA 1 mA 0 03 of the reading 0 01 of the range 30 100 pO 1A 100 mA 10 mA 0 03 of the reading 0 01 of the range 200 mO 10 pO 10A 1A 100 mA 0 03 of the reading 0 01 of the range 30 mQ 1 yO 10A 1A 100 mA 0 03 of the reading 0 01 of the range 3 mA 0 1 yO 10A 1A 100 mA 0 03 of the reading 0 02 of the range PMGR VAL 10m 20m 1 100m T Test current see measurement ranges 0 rapid measurement 1 slow measurement Maximum R Minimum R MGR10 parameters MGR A P1 1 B J4 58 m 2 component tip uneven address 1 component tip uneven address MGR10 measurement Table of limit parameters for the MGR10 microohmmeter in the WINPASS software Parameter Minimum value Maximum value Resistance 0 30 KO Test current Depending on the Depending on the resistance resistance measurement measurement range see table above range see table above 2A with standard switching board 10 pA 10 A with 40680 switching board um fe l 3 SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 130 179 seciciec D III 1 4 Command codes of the BURSTER D4462 voltage standard See the BURSTER D4462 manual PD4462u VAL 200m DC voltage generation Parameter of the D4462 in DC D4462u ON OFF activation deactivation of the D4462 D III 1 5 CHROMA 6404 power supply command See CHROMA power supply manual PCHROMA VAL 110 500m 60 L Frequency i
20. 1 The result files are always recorded automatically in Pie d Re IEEE ES a directory bearing the three letters RES plus the name of the test program whose execution they represent The directory is created automatically if it does not EE already exist Program Name By default the directory designed to contain the result EE files is situated in the same place as the test program which gave rise to it Tester name 2 An option enables the operator to define a directory TRACE field selection which will contain all the directories of result files E defined above this option enables the result files to be separated from the test programs FILE NAME CUSTOMIZATION The name of the Delete file by default is the name of the test It is possible add in the name of the result file characters by which it can easily be identified in a list tester name if a name had canceL be given to the tester TRACE field if the option TRACE is used in test file dialogue box field complete during the test if a dialogue box had been created in test file move up or down to select the number of the dialogue box field you choose Gu LOGHESIMES documents othe EG SYNORIWINRASS To delete the structure of the name click on the button Delete click on Name of program to add the name click on Parameter Dialogue to add text from the user dialogue box the number corresponds to the number of the designation to
21. Rev I july 2009 Edition sefelec amp OM Test B VII 2 SWITCHING CARDS 40417 AND 40427 Switching cards 40417 500 Vdc 380 Vac 2 A 128 points or 40427 1000 Vdc 750 Vac 2 A 128 points route the measurement of SYNOR 1202 4202 and 4203 testers They are placed in racks receiving a maximum of 16 cards each 2 for the SYNOR 1202 They are all identical only their position determines their address They are intermixable with cards 40418 and 40428 see the technical datasheet Since the relays used are multi contact these cards may be used for all tests except tests by groups of points One card uses two vertical connectors standard 41612 green on the diagram on the front of the tester Columns A and C are used The tester addresses are shown on the diagram sefelec ci a Board 3 Board 4 Board 6 LL I Board 5 1 Il C o EN A pm O Q o ar T 210 1 C11 1 C121 C13 1 C141 C15 1 C16 1 ERR C1 2 C22 C32 C42 C5 2 C62 CT7 2 C82 C92 C10 2 C11 2 C12 2 C13 2 C142 C15 2 C162 65 97 Remote control 96 28 HARTING reference of interface connectors 09 73 164 6907 Male connector 09 03 096 0501 Hood 09 02 000 9911 Grommet 09 02 000 9902 Left locking 09 02 000 9903 Right locking Board 7 L EIL l Wires recommended for wiring TYCO RAYCHEM 44A0111 24 n n colour code or choose an insulating material as flexible as possible correspondin
22. a H O H E O H sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 52 179 B VII 7 LIMITS OF INSULATION TEST UNDER NORMAL MEASUREMENT CONDITIONS 300 MO 1500 MQ 2000 MO 3000 MQ B VII 8 LIMITS OF CONTINUITY TEST UNDER NORMAL MEASUREMENT CONDITIONS 4 wires Kelvin methode test 596 2 wires test 596 L NEN 4 wires Kelvin methode resistance measurement is possible for resistors greater than 100 mQ sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 53 179 B VII 9 INTERFACE DURING 4 WIRES KELVIN METHODE MEASUREMENT OF RESISTANCE The syntax used for measurement of continuity in 4 wires Kelvin methode mode takes the form 4 A xx B yy The numbers xx and yy are the absolute tester points and must both be odd Example 4 A 17 B 81 The interface between the tester and the resistance to be measured must then be arranged as follows 1 2 3 4 5 6 7 8 9 Points 17 and 31 must be connected to the resistor power points current injection they are named by the syntax see programming Points 18 and 32 are connected to the sense points voltmeter of the resistor to be measured but are not named by the syntax sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 54 179 B VII 10 LAYOUT OF FRONT SOCKET 5 2 1 NC Q 1 Q 2 Measure A Q External output 3 Sen
23. at the end program must be as mentioned below SEFELEC WINPASS EDITOR Test program Eile Preparation Tools Window Help 81 x To check this program a gt lel d PeR PC VAL 0 500 m 20 5m select VAL 100 M 500 1m 10 m 30 m z B P1 A B P1 D PR PARATION B P1 B B Pi C B J4 1 B J4 4 E B J4 6 Relay commands Test one point others Commodity SYNTAX CHECKING B P1 E B J4 2 B J4 3 Tests between two points Nettests Parameters VAL 10 K 12 K 10 m 0 p The message CHECKING A Pi F B J4 9 FINISHED means the aic NS program is validated We can save it and use TESTER mode to check the cabling of this program Opening an equipotential file Sort the connectors Cable tester point Opening an equivalence table Multiple test Add the line s fe l SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 164 179 SELEIEC E I 6 A FEW LITTLE EXTRAS E I 6 1 Graphic display of a test file This function is used to display and print out test programs with each test represented by a graphic simulating either a net or a component The type of test and point addresses are given E I 6 2 Another solution for the parameters applicable to older versions using DOS It is possible to record the test parameters in a table This table will contain 100 lists of values for each type of measurement Once these lists have been completed they can be called up from the
24. constraints due to the laws of physics Measurements of continuity can only be significant if no obstacle is presented by interfaces bad contacts high resistances defective insulation etc Measurements of high insulation require an environment of controlled humidity 5596 at 20 C both for the tester and the material to be tested Dust filters enable it to be used in an ordinary wiring workshop For work in places such as sheds which are frequently open to the outside or in difficult environments the interior of the tester can be air conditioned on demand Finally if the electronic systems are to work properly an ambient temperature within the range 15 to 30 is required The air intakes of the instrum ent must be kept clear B IT 2 CONNECTION TO THE MAINS SUPPLY The tester must be connected to a 230V 50Hz single phase supply A switch controls supply of power to the whole instrument The PC may have a separate power supply in the case of the SYNOR 4202 Where a tester comprises more than one cabinet each one has its own mains supply cable T fe l a SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 16 179 sciciec The plugs are 16A single phase earth and must be protected by a 16A magneto thermal circuit breaker and a differential of 30mA minimum The use of a specific measurement earth is recommended impedance lt 30 In regions where the power supply is subject to disturbances microbreaks noise
25. july 2009 Edition 123 179 SEIEIEC D FEE Options external devices and logic control card D III 1 PERIPHERAL DEVICE COMMAND CHARACTERISTICS AND SYNTAX D III 1 1 Command codes of the SEFELEC M1500P picoammeter The parameters of the M1500P can be set at the factory in picoammeter or megohmmeter mode Range in picoammeter mode Range in megohmmeter mode Ranges Resolution Ranges Resolution 00 50 to 20 00 pA 0 01 pA 00 50 to 20 00 pA 0 01 pA 020 0 to 200 0 pA 0 1 pA 020 0 to 200 0 pA 0 1 pA 0 200 to 2 000 nA 1pA 0 200 to 2 000 nA 1 pA 02 00 to 20 00 nA 10 pA 02 00 to 20 00 nA 10 pA 020 0 to 200 0 nA 100 pA 020 0 to 200 0 nA 100 pA 0 200 to 2 000 HA 1nA 0 200 to 2 000 pA 1nA 02 00 to 20 00 pA 10 nA 02 00 to 20 00 HA 10 nA 020 0 to 200 0 HA 100 nA 020 0 to 200 0 HA 100 nA 0 200 to 2 000 mA 1 pA 0 200 to 2 000 mA 1 pA 02 00 to 20 00 mA 10 pA 02 00 to 20 00 mA 10 pA PM1500P VAL 100M 500 1 Application time in seconds Test voltage in Volts Threshold resistance in insulation Code of M1500P parameters M1500P A B M1500PM A Test with the M1500P between two points Test with the M1500P between point A and all the other points at O Volt Test with the M1500P between the group of A points and the group of B points at 0 Volt M1500PM A B Table of limit parameters for the M1500P picoammeter in the WIN
26. july 2009 Edition 32 179 SEIEIEC B IV 4 THE TWO MODES The WINDOWS desktop contains the following icon EI WINPASS exe Open it then you have access to the two mode SEFELEC WINPASS File Language Help SEFELEC EDITOR TESTER The TESTER requires connection of the PC to the tester It gives access to all the test functions test self learning and self test The EDITOR is completely independent of the tester and can be used when the tester is disconnected or not switched on It is used for all operations on the test programmes from creation to modification Note Both these functions can have password control B V Parameters affecting the accuracy of measurements of insulation B V 1 GENERAL Measurements of insulation carried out on the tester are affected by the noise structure of the switching matrix the interface and the wiring to be tested which explains the compromise that has to be reached between speed and accuracy The wiring to be tested brought into communication by the switching matrix with terminals of the measurement apparatus possesses the following structure Rayonnement 50 Hz R2 Rx C1 R1 i C2 where Rx is the resistance to be measured s fe l 5 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 33 179 Se Le u e C C1 R1 and C2 R2 are made up of the noise elements inherent in the wiring and the switching matrix B V 2 INFLUENCES AND SOLUTIONS ADOPTED TO IN
27. measurement This is because the lower the test voltage the lower the signal to noise ratio and the more the influence of this radiation will perturb measurement These effects are warded off by synchronization and integration of the signal for one or more cycles of the supply B V 3 CONCLUSION These phenomena taken together and the solutions adopted to remedy their effects lead to the following conclusions The accuracy of the measurements obtained is a function of the time and voltage of measurement e the longer the time the greater the accuracy of measurement e the higher the voltage the greater the accuracy of measurement After insulation and continuity test the tester SYNOR 4200 complete a 20 ms discharge of the measuring points For tests with high capacitive components this time of discharge might be adjusted Please contact our technical department to fit this time T in s 2 RC for a total discharge time of discharge gt 5T R discharge 1 kO ei fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 34 179 SCIEIEC B VE IMPORTANCE of the measurement of line RESISTANCE B VI 1 FUNCTIONAL TOLERANCE Wiring charts do not generally include any tolerances regarding the line resistance of electrical links At the moment the values given on this subject by most test instructions do not seem to constitute a functional value beyond which a malfunction is present by definition B VI 2 TYPICAL VALUES If
28. sise 75 ME ru jvoc X x a 76 Sereen imase TURICOTL s cete ei e Ee tained EL PETERE Fel EE E E d ae ie unie N e dns 78 f Message box question for the operator nennen nenne 79 D II 3 2 Delay time out S TOP os ices oerte ede te tesoro esee er E tendent 80 a Delay tme Outs ii eee esegue ertet y ec tene tenant lan tiennent eot eee ei test e 80 De STOP e access 80 D II 3 3 Search M 81 D II 3 4 High low level swing GO NO GO iii 82 a HMighlow JEVEL S WAM AME 82 lC enm exe eur I 82 D 1I 3 5 Chapter Label HE 83 D II 3 6 Conditional Zones iei eie dete coe Lo rgo erede bo yeu be ete ed pU CH o e Pepe ig eed ee a 84 a X Zone executed if all tests have PASSED ii 84 b Zone executed if one of the tests has FAILED nennen nenne 84 c Zone executed only in the first test ss 85 D II 3 7 I Eric E A 86 D II 3 8 Test between TWO POIDS ED 91 Programming Syntaxe sisi nshenntihuntelnalihens Pe eR ELE La Ee HA RUP R D Le popa Ee Lee cL eden 91 b Naming of points Hot points cold points ss 91 D 1I 3 9 Type Of test tess E IP 92 SVNTAX EEE E Sand ers eter Ue voces dede tu dies Sondes Pul nance HE eden eg hera ER REID pst Pepe E PUR der 92 D OPHONS
29. the type of measurement the names of the points concerned and the value measured are all given On the other hand in multiple tests 2 possibilities are available e either a high impedance high voltage insulation test using the insulation unit e ora low impedance low voltage non continuity test using the continuity unit The second case provides for a search for short circuits on assemblies incapable of supporting high voltages When a net is tested in isolation if a break occurs the test is no longer valid for the second part isolated by the break Automatically the tester repeats an insulation test on the second part This means that it is not necessary to repair the breaks to discover all the insulation defects The tester will locate all the faults in a single operation In case of defects the type of measurement the names of the different defective points and the value measured are all given B III 4 SELF LEARNING This enables the tester itself to create the test programme for a wiring system connected to it It uses the switching matrix and the continuity unit to explore the wiring and identify all the nets en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 25 179 SEIEIEC This exploration takes place within a zone of points determined in advance by the user Provided the points within this zone are connected to points located outside it the nets will still be identified in their entirety
30. 10 Connect connectors HAN mi CONTINUE Menu Setup Tools Help HAS Continuity measurement 4A SUBD9 2428 6 B HAN CC95 9 R 5 Ohm Instruction typewriter mode HM cn text The operator can enter free text using the keyboard You must click on CONTINUE to resume the test End of cabling test between SUB D9 and HAN B HAN CC95 8 B HAN CC95 9 HN 10 End of cabling test between SUB D9 and HAN HM COMMENTS FLABEL LABEL SUB D9 DEUTSCH Test zz SEFELEC Z sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 74 179 C Stopping Pausing the program This keyword Y stops the test while it is running A dialogue box indicates that the test has been stopped and tells the user to click when he wants the test to continue A text can be attached to this code in order to provide a user instruction making it easier to identify the stop This text will appear in the dialogue box It is limited to 60 characters Example Fromthe EDITOR Y Connect connectors SUB D9 HAN DEUTSCH Fromthe TESTER Stop the test Connect connectors SUB D9 HAN DEUTSCH STOP While the program is running a dialogue box appears interrupting the test under way and until the operator clicks on CONTINUE or STOP the test stays on pause fe l d SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Ed
31. B 23 B 24 Test result Insulation measurement error A 10 B 2 B 3 B 6 B 7 B 9 As the jumper puts both chains at the same potential it is impossible for the tester to indicate the exact position of the jumper s C II 10 TWO CHAINS CONNECTED TOGETHER BY A FORGOTTEN WIRE ON ONE OF THEM Correct wiring 2 3679 O 0 0 0 O 10 11 13 14 20 21 23 24 O O 0 O 0O O O O Wiring produced 2 3 6 7 9 O 10 11 13 14 20 21 23 24 Test requested EI B 2 B 3 B 6 B 7 B 9 El B 10 B 11 B 13 B 14 B 20 B 21 B 23 B 24 Test result Continuity measurement error A 2 B 3 Insulation measurement error A 10 B 3 B 6 B 7 B 9 Correct wiring 2 3 6 7 9 10 11 13 14 20 21 23 24 O O 0 O O 0O O O Wiring produced 2 4 05 7 D O O O O 10 11 13 14 20 21 23 24 Test requested El B 2 B 3 B 6 B 7 B 9 El B 10 B 11 B 12 B 14 B 20 B 21 B 23 B 24 Test result Continuity measurement error A 2 B 9 en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 63 179 SCICICC Insulation measurement error A 10 B 9 Same remark The tester will only detect one error between the start of the second chain and point 9 C II 11 ISOLATED POINT WIRED IN A CHAIN POINT POSITION Correct wiring 23 67 9 O 0 0 0 O 8 O Wiring produced 2 3679 O 8 Test requested EI B 2 B 3 B 6 B 7 B 9 El
32. DES3 19 Test report Unctionis spiano irre pee ere UE e ceo ere RE DITE en USER late ORE 116 D 113 20 T st variables nd dernieres dent en nice DR Pre er teintes 117 D IL3 21 Test variables specific to the BATCH 118 DUA SYNTAX of specific tests eese eene ene ettet RESONEER EEEE EEEE EEEE 119 T fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 6 179 SEIEIEC D IL4 1 COMPARE f nction eiecit nn e oc eie ER nee e Pl ca e e oe LER nie iii 119 D IL4 2 Clharge Discharge naissante E ees eo a UPC EPI Eo ee it 119 D II 4 3 Variable snam me Eea 120 D IL4 4 Measuring th rmocoupl s sssssiss siens inner e beo s eec La eben de 120 D II 4 5 TRACE FINTRACE xerit leti tre He iE Pre nent EE eed RP pe eer diols 121 D M OPTIONS EXTERNAL DEVICES AND LOGIC CONTROL CARD ertet eene tenes rro 124 D III 1 Peripheral device command characteristics and syntax ss 124 D IHL1 1 Command codes of the SEFELEC M1500P picoammeter eene 124 D IL1 2 Command codes of the dielectrometer SEFELEC XS series 125 D IL1 3 Command codes of the SEFELEC MGR10 microohmeter eeeeeeeeee 130 D IL 1 4 Command codes of the BURSTER D4462 voltage standard 131 D U1 1 5 CHROMA 6404 power supply command ss 131 D IIL1 6 Commands of the AGILENT 34401A multimeter 132 D III 2 Inputs outputs of the PCI 7250 and PCI 7251 logic cont
33. For the connector TB1 repeat the same operation starting from machine point 97 so that the points from 97 to 121 are defined The transcoding table is now complete All that remains to be done is to save it using SAVE AS the name of our table for this example will be TRANSCO E I 4 USER DIALOGUE BOX When a test is run a user dialogue box can display a window inviting the operator to enter the data concerning the wiring system to be tested To create a box click on FILE NEW DIALOGUE The window displays a page in which to enter the title and designations of the fields to be completed After completing the box save it by giving it a name This name will be repeated in the test file associated with the instruction DIAL s fi SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 159 179 SCICICC fes Dialogue Without name BEGINNING OF TEST NAME SERIAL NUMBER REFERENCE NUMBER Example The file is named DIALOGUE1 DIA In the test program write DIAL DIALOGUE DIA m FEE SERIAL NUMBER FA REFERENCE NUMBER SYNOR 4200 In this example the dialogue box displayed during the test will be The designations can be used to complete the name of the test results file see ll 1 2 Test configuration Should the user fail to fill in a field the dialogue box indicates the fact The test will not be performed until all the fields have been filled in E I 5 COMPLETING THE TEST FILE
34. IV ANALY SIS OF THE RESULTS 4422 eee ento rette tnnt aur nt e en e Raan iee ede EE ER agn 67 CV ADVICEFOR REPAIRS iicet en tee en cde REN 67 D PROGRAMMING INSTRUCTIONS eerie eene eese esses tn seta sons tn seta sesso seta sees sonata se sa sesso seta sens ena 69 Di INSTALLING PROGRAMS sissssssssstessncsedessasscessonevcenssesantinesacecennsssiias EPEE EE EER eo eV peat dei ESSERNE 69 D I 1 PC CONFIGURATION ee ee tere etne theo Ree eee Yn NR et ike Hee E apes pee Woes ca ttes Yee Eran eae E ado 69 D I 2 WINDOWS regional settings for WINPASS ii enhn tenens 69 D 1 3 CARRYING OUT THE INSTALLATION eese eese eren eene entente nennen tenens 70 D I 4 DESCRIPTION OF THE INSTALLATION cccssssscsesscessseceesceceeceeceeeeeaeceeaeeceeneeseeeseaaeceeaeeenaes 70 T fe l S SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 5 179 SCIEIEC DIS Updating WINPASS teretes aiebicote dece tastes ede E ie eda clin aves dee aaa 70 D I DESCRIPTION OF THE SOFTWARE sisi 71 DHT JFILEMANAGEMENT ite iier tette ra Pn re eek ed Yee rated eoe REEE REEE 71 DIJL2 OPERATING FILES cac ieiee eive ee eerie ier be Dec eese e chapa E Lye ope Ese Eraser ANE cdi 71 D3 SENTAX sise dati deniers E AEA EAE E Debe dd lise die 71 D IL3 1 Commodities text image and dialogue box functions 72 a COMMENT EE 72 b Text function Messages for the operator ss 73 c Stopping Pausing the program
35. L1 to change to lower case Then in MIN type A and do the same in MAX Click on the letter A M and mark 23 in NUMBER OF POINTS Click on Ok and the first column will fill up with 23 a s First letter Last letter E M z a VIH L a MK vL Eu MIN Iv Capital Select all Unselect all sefelec Click in the second box next to the first a and in the list of letters in the box DEFINE CNT click on I o q O In Max enter Z and click on Ok SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 157 79 The pins designated by two characters are now defined As the connector has 50 pins the 5 pins ba bb bc bd and be still remain to be described Repeat the same operation as the last time but this time type 5 in NUMBER OF POINTS and b in MIN and MAX for the first column For the second column put e in MAX To re read each list of pins for verification just click on CONNECTOR 1 or CONNECTOR 2 Before quitting save your data with FILE SAVE AS In our example we shall call this file CONNECTOR and we will place it in WINPASS PRG or the work directory selected by the user E I 3 CREATING THE EQUIVALENCE TABLE Having defined the connectors used in the equipment to be tested we now need to describe the correspondences between the tester outputs and the points on the equipment This operation is equivalent to describing the interface between tester and equipment under test
36. RN d trompeur RE a ee E NN Ooo S S 2 DO LE s E ppp ee RS es JE BO oo CE ae a NN NUN afa Ooo S S mm prompte epe zi C E m Loue e EIE 15 HB C pu E Bo ES a ER ee oo a SENE GEM Hg nt S ee cabing side ES NENNEN NN EN GN Wis OU C JL e oo oo p p ao SE a E a E a NUM NENNEN S Bu pe oo E E s Ba Y Bu a a ee MENNM S3 Lo 1 ee as RE SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 49 179 sefelec B VII 6 SWITCHING CARDS 40680 Switching cards 40680 2000 Vdc 1500 Vac 10 A 22 points route the measurement of the SYNOR 4207 and 4208 They are placed in racks receiving a maximum of 8 cards each 2 slots are occupied by these cards They are all identical only their position determines their address They are intermixable with cards 40570 40670 and 40675 Because the relays used are mono contact these cards may be used for all tests including tests by groups of points One card uses two vertical connectors standard 41612 orange on the diagram on the front of the tester Columns A and C are used The tester addresses are shown on the diagram Each card occupies 2 slots so there are only 8 cards per unit sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 50 179 sefelec 22 N e t wo e Me TD TD TD TD TD TD o I I I I I I I oO oO oO oO oO oO oO o o o o o o o e e a a a a a rens Er n O e iw J C9 1 C10 1C1
37. SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 68 179 SEIEIEC b PROGRAMMING INSTRUCTIONS In addition to the switching matrix the tester also has a measuring unit controlled by a PC type microcomputer This PC provides the dialogue allowing the operator to create test files using WINPASS software All programming modifying and editing possibilities are accessed via the WINPASS editor Under this heading an editor provides all the actions possible on the files There is a programming aid allowing transcoding tables to be set up without worrying about the syntax DTI INSTALLING PROGRAMS D I 1 PC CONFIGURATION The SYNOR 4200 software can only run on a PC equipped with a WINDOWS XP operating system NB refer to the Microsoft manuals for how to use and choose these software programs D I 2 WINDOWS REGIONAL SETTINGS FOR WINPASS The WINPASS software is independent from WINDOWS however some WINDOWS settings may result in conflicts of interpretation in WINPASS The following regional settings must be modified and monitored In control panel Regional options date time and language Regional and language options ptions r gionales et linguistiques x 5 In the next window click on personalise Options r gionales Langues Options avanc es M Standards et formats Dette option modifie la facon dont certains programmes affichent les nombres les monnaies les d
38. The effects of a current passing through the human body are described in the text of EN 50191 of 20 January 2003 This text applies to the nstallation and operation of electronic test equipment B II 4 1 Safety loop From October 2007 a double safety loop will be integrated into testers allowing compliance with standards EN 61010 1 EN 60204 1 EN 954 1 and EN 5019 either directly or with the addition of external accessories emergency circuit breaker safety barrier light signalling etc See the connector wiring for implementation sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 17 79 This double loop acts by electromagnetic break in high voltage generators as soon as one of the loops is cut or earthed The software reacts by displaying a warning message and stopping the test sequence The test can only start running again if the loops are closed and the operator gives the order B II 4 2 Parts which are dangerous to touch It is taken as a point of departure that the human body possesses a non inductive resistance approaching 2 kQ B II 4 3 Alternating current 1 for voltages up to 25 V a current of 3 mA B II 4 4 Direct current 1 for voltages up to 60 V a current of 12 mA The discharge energy must never exceed 350 mJ NOTE A current peaking at a maximum of 0 7 mA although not dangerous in any way is perceptible by certain people B II 4 5 Optimization of safety on the SYNOR 4200 Th
39. a E 36 B VIL1 1 Characteristics of connectors on the interface side sese 36 B VIL1 2 Some advice for implementing the interfaces seseeeeeeeeeeneennen 37 B VILIS View Of tester Outputs 222 cet e tree terea depen Deep est ese vea prone eene NER epar eeu ad 38 B VII 2 Switching cards 40417 and 40427 sese eee nennen eren nennen 39 B VII 3 Switching cards 40418 and 40428 sees eee ener nennen nennen tnn 41 B VIL4 Switching cards 40570 and 40670 eee 44 B VIL5 SWITCHING CARDS 40675 essaie tete tree aeei ea pae ebbe saeva epe ceo o a 47 B VIIL G6 SWITCHING CARDS 40660 isses eene enne enne nne e trennen enses nnne nnnes 50 B VIL7 LIMITS OF INSULATION TEST UNDER NORMAL MEASUREMENT CONDITIONS 53 B VIIL S LIMITS OF CONTINUITY TEST UNDER NORMAL MEASUREMENT CONDITIONS 53 B VIIL 9 INTERFACE DURING 4 WIREs Kelvin methode MEASUREMENT of RESISTANCE 54 B VII IO layout of front SOCK cccecccccssccessseceesceceseceeaceceeceecceceaaeceeaaecseceeceaceeesaeceeaaecueneeceaeeseaaecneaeecsaes 55 C ANALYSIS OF THE TEST RESULTS eese esee esee tn stesse tastes sons tn seta stato seta sees sens snos sens enses 56 CI PRESENTATION OF THE ERROR LIST ss eeeeeeeee entente nenne nnne tnnt ense orante ne tetas esten ne ea rne eena 56 C I STUDY OF STANDARD WIRING ERRORS sise 57 C II CONNECTION FORGOTTEN OR BROKEN WIRE eese entent
40. add parts later on all he has to do is recall the number In this case the BATCH result file will be erased and replaced by the updated BATCH file The BATCH report is formatted by the TEXT H c n instructions between the BATCH and FLOT zone Variables may be associated see the variables chapter below This file is saved in the directory specified by the batch report path e g C sefelec lot A The batch name is given in alphanumerical characters 32 maximum but full stop and Y anti slash must not be used You can open this BATCH report from WORD or WORDPAD sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 111 179 Example Fromthe EDITOR LOT C sefelec lot H B 14 a aad HB16 BATCH REPORT HB 14 H B 14 Batch number amp LOT1 H B 14 Batch Serial number amp DIAL2 H B 14 eee HO H N 14 REPORT H N 12 Operatirs name amp DIAL1 H N 12 Number of sample tested in this batch amp LOT2 H N 12 This batch is composed to amp LOT3 pass sample and amp LOTA fail sample H N 12 Batch end time amp DATE H SEFELEC H Parc d activit s du Mandinet E LOT ssai lot1 UK AZ18 WordPad Bl xl Fichier Edition Affichage Insertion Format H 19 rue des campanules A EE x H 77185 Lognes France alr al alel Bl F2 z ocena z ez Am E Or ATE CE Ee E H www sefelec com FLOT FA 19425433 17 4 SR
41. an electrical connection is made a large number of times it can be observed that the resistance of this link is almost always centred around a mean value known as the typical value The degree of scatter around this value is a matter of only a few per cent tolerance on lengths cross sections etc B VI 3 DEVIATION If we suppose that an electrical link has a typical resistance of 100 mQ and that the functional tolerance is 500 mQ we shall normally find values such as 95 100 105 90 110 mQ If a test is performed and yields a measurement of 200 mQ the presence of an anomaly must be deduced There may be two reasons for this value e a stable non conformity error of cross section etc e anunstable non conformity bad contact etc In the first case the wire can be accepted if its cross section is greater than the value demanded In the second case it is known that a bad contact can evolve into a complete break This deterioration increases with time and as a function of environmental conditions It often takes the form of oxidation of the contact surface If we accept in our example that the resistance has doubled between two tests it is likely that the same law will continue to hold over time Thus the value of 200 mQ although lower than the functional value is indicative of a fault which with time will lead to a breakdown of the equipment B VI 4 CONCLUSION AERO 543 35 standards specify a tolerance threshold of 30
42. be made to appear on the screen with the possibility of replying YES or NO ow Gem In the second form it is possible to make another text appear depending on the reply YES or NO MB answer if YES answer if NO NOTE A NO answer in this dialogue box will lead to a FAILED test result even if all the other results have passed Example Fromthe EDITOR MB Is the LED red on LED is RED LED is not RED Fromthe TESTER the following dialogue box appears on the screen when the instruction is INFORMATION ET e k 1 Is the LED red on being carried out If the answer is YES the following text appears If the AR is NO the following text appears SEFELEC WINPASS Execution of the test program CA Doc Menu ae Tools Help Continuity meag A HAaN CC95 10 B DEUTSCH XX00 3 R 5 Ohm B DEUTSCH XX00 3 R 5 Ohm Is the LED reg on LED is RED LED is not RED Capacitance parameters Minimum capacitance 50 nF Maximum capacitance 150 nF imi Capacitance parameters Minimum capacitance 250 nF Maximum capacitance 400 nF Capacitance measurement A DEUTSCH XX00 1 B HAN CC95 4 xl Capacitance measurement error DEUTSCH XX00 1 B HAN CC95 4 xl H V 10 Is the LED red on al H V 10 Is the LED red on Al MB Is the LED red on LED is RED LED is not RED MB Is the LED red on
43. be scanned using the scroll box On the request Quit the window is refreshed but the test file remains open To change files test click on the Close icon E II 4 1 PROBES Machine Interface User To obtain this function click on the icon This function induces automatic scanning of the switching matrix and contact of the probe accessible on the front panel with any one of the points of the wiring system to be tested gives the address in user points and in tester points sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 172 79 This function is extremely useful for clearing breakdowns of the wiring system during the test or of the interface WARNING for reasons of safety regarding the equipment to be tested the probe is only accessible from the initial menu and the stop on fault E II 4 2 MANUAL MODE To obtain this function click on the icon This function gives access to measurement of the tester For security reasons this function is only accessible from the initial menu and stop on fault mode Using this it is possible to quit the test in progress while retaining its environment However while MANUAL MODE is in use it is possible to carry out measurements on demand using parameters other than those of the test file This function is primarily an aid to the constitution of a program and to the choice of the most specific test parameters Manual mode Multiple matrix E
44. be used for all tests including tests by groups of points One card uses two vertical connectors standard 41612 purple on the diagram on the front of the tester Columns A and C are used The tester addresses are shown on the diagram sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 44 179 sefelec Board 15 o TD c o a m Board 1 Board 2 2 Board 3 Board 4 Board 6 N PS ux a EN ias O Q an Ex lan C9 1 ane eae C15 1 tes TAM C12 C22 C32 C42 C52 C62 C72 C82 C9 2 C102 C11 2 C122 C132 C142 C15 2 C162 17 ILL HARTING reference of interface connectors A O CJ ss LM 33 Remote control Lc Lc 09 73 164 6907 Male connector 09 03 096 0501 Hood 09 02 000 9911 Grommet 09 02 000 9902 Left locking 09 02 000 9903 Right locking Wires recommended for wiring TYCO RAYCHEM 44A0111 24 n n colour code or choose an insulating material as flexible as possible corresponding to the measurement voltage and a 22 to 24 gauge Note it is not possible to use self stripping connectors at these voltages The most available connectors on the market are wrapping ones Each weld will be protected by the heat shrinkable cover It is advised to remove the marking ink between the connector pins risk of poor isolation The connector of the right figure is the male interface connector seen from the wiring side Ro
45. cold point aa i sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 103 179 In this case the A points described are connected to the hot point of the measurement and only the B points described are connected to the 0 V of the measurement The non described points are floating points There is no continuity test between A points or B points as these points are part of two groups and not nets The test conditions are identical except that the point addresses are replaced by the defined group names If you wish to run the same tests for alternating current AC dielectric option simply replace the letter I with J Example Fromthe EDITOR PI VAL 100M 500 1m 10m 30m PC VALO 5 500m 20 5m IU Af1 A 2 Af10 B 4 B 9 B 641 Group test in a STIMULI zone In a zone demarcated by STIMULI and FSTIMULI net tests must not be carried out as they may short circuit the command power supplies with the lower points This is the case of El tests or the other points in the case of IU or IM tests However IU can be used if B points are described Ex IU A P1 1 A P2 1 B TB1 5 If the points called are known short circuits of the stimuli power supplies are less probable However you are recommended as far as possible to run a complete wiring test of these points before any stimulus command To summarise EIU Tests short circuit DC dielectric insulation continuity between the points Insul
46. configuration at any time With the default settings previous codes produce a black text The size and font are set in the SOFTWARE CONFIGURATION This section is available in the TESTER menu However for instructions H HV HCM HCB and HM the colour and size can be programmed The command is only valid for the current instruction If these definitions are not entered the default colour and size are used Colour only four letters are recognised N black B blue R red and V green ie Size sizes 8 to 48 are available Example gt From the EDITOR Instruction H c n text om fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 73 79 SEIEIEC H V 10 Please connect the SUB D9 connector H V 10 Please connect the DEUTSCH connector H V 10 Please connect the HAN connector Instruction typewriter mode HM c n text HM R 14 Comments Fromthe TESTER Instruction H c n text SEFELEC WINPASS TESTER Execution of the test program C Documents and Settings begou Mes docun Menu Setup Tools Help HESSE Demo test of Winpass standard instruction Connect connectors SUB D9 Connect connectors DEUTSCH Connect connectors HAN H V 12 Demo test of Winpass standard instruction Hi HNi12 Lau LABEL Interface connection H V 10 Connect connectors SUB DS H V 10 Connect connectors DEUTSCH H V
47. created according to the source file format and the following information is added at the end of the line 112 M2 TESTEUR de c blage 128 Operateur255 08 12 2008 112 M2 is the source file columns 128 wiring TESTER is the name given to the tester upon commissioning Operator255 is the field entered in the dialogue box by the operator 08 12 2008 is the test date given by the computer s fe l SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 122 179 SCLEIEC If the same test is carried out the scroll down list appears The serial number 112 no longer appears in the scroll down list as it has already PASSED tests If the result of this new test is failed the results file is not modified This serial number will still be available for a new test After several tests the traceability results file takes the following form It displays all of the serial numbers tested only if the test program has been considered as PASSED P trace test results Bloc notes nmi xj Fichier Edition Format Affichage A11 ZA TESTEUR BEFELEC 112 M2 TESTEUR SEFELEC B99 ZD TESTEUR SEFELEC 224 M6 TESTEUR SEFELEC A12 ZB TESTEUR SEFELEC 113 M3 TESTEUR SEFELEC l user01555 17 07 2009 1 user01555 17 07 2009 1 user01555 17 07 2009 1 user55891 17 07 2009 1 user55891 17 07 2009 1 user55891 17 07 2009 N N N N N N Ln 1 Col 16 a f l SYNOR 4200 Manual Ref WINPASS Rev I
48. etc an uninterruptible power supply is recommended especially for the PC Maximum permissible deviation is 15 To sum up e Humidity 55 at 20 e Temperature 15 to 300 e Storage temperature 10 to 60 e 230 V mains supply 15 96 50 Hz 60 Hz possible on request e Earth lt 3 Q microbreak lt 10 ms e Atmospheric conditions dust ordinary wiring workshop Power consumption e PC about 200 VA depending on type e Central unit 300 VA e Back panel giving access to points 300 VA B II 3 ERGONOMICS OF THE WORKSTATION The tester is supplied as the instrument alone On demand furniture can be supplied or recommended The user must be able to move around the equipment to be tested but without losing sight of the screen Programming can be carried out on a micro computer installed in quieter surroundings With the SYNOR 1202 version in a case the tester can be set up on the work table for capacities less than 256 points at 500V B II 4 SAFETY OF PERSONNEL The voltages and currents employed in a wiring tester and in the wiring itself can be dangerous if touched The voltages and currents present in the wiring tester and in the wiring itself may be dangerous if touched Personnel protection is the responsibility of the site where the tester is installed SEFELEC can only provide recommendations the safety manager of the company using the device must ensure that safety requirements are met
49. following pages we shall describe a library of two connectors by way of example The first will be a 25 point connector with numerical pins the second a 50 point connector with alphanumerical pins of types A B C aa ab ac ba bb be To do this open the Editor and carry out the operations below In the menu of the Editor open the connector table FILE NEW In the dialogue box click on CONNECTOR The window contains a column in which we shall enter the names of the different connectors in the library In the grid on the right we shall describe the pins of these different connectors ET Fie Edi Connector le x Dea ee Fa ple EE LIH j onnector creation tool Numberofpoints 20 l 0 100 A Z Tew 14 Select all Unselect all v 18 OK D see d ifliD mauer zj amp AY 4j Eisetetec Editeur SF WINPASS ind B English d Nu ous s fe l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 156 179 SEIEIEC EI Creation of connector tables To create the first connector Click on NEW1 then on CONNECTOR TYPE Click on RENAME Type CONNECTOR for example to name the type of connector to be described Validate by pressing ENTER Click on TOOLS then on DEFINE CONNECTOR Drag the window DEFINE Number ofpaints 5 CNT to the right
50. four unit relays See relays K11 to K14 on card 40403 Opening fault on AU n Relay n unit A remains closed en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 27 79 SEIEIEC Opening fault on BU n Relay n unit B remains closed Opening fault on BPU n Relay n unit BP remains closed The fault is detected using an ohmmeter between the contacts of these relays see table below They must all be open when de energized Tests on switching cards 40418 Closing fault on A n Closing fault on A n 1 Closing fault on A n 2 etc These four faults indicate a failure of an A relay coil coil diode or filter cut off Closing fault on B n Closing fault on B n 1 Closing fault on B n 2 etc These four faults indicate a failure on a B relay coil coil diode or filter cut off Closing fault on A n or Closing fault on B n These two faults indicate that the A or B contact with address n does not close Opening fault on A n This fault indicates that the A contact with address n remains closed This message is always displayed with a series of insulation faults on the higher upper points modulo 4 This is because bus A is forced to the same line This fault drops on changing to a new module cut off relay Only the first error message must be taken into account SEFELEC WINPASS TESTER Self test Menu Setup Help Ieee Insulation test Switching board control test End address 64 Test voltag
51. icon e Stop the test and quit the tester function and return to the desktop To do this click in succession on the icons Bottom screen bar F1 Close Top screen bar This button is only active if the tester has returned to the main menu i e all applications are closed This documentation has no contractual validity and the SEFELEC company reserves the right to modify any characteristic sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 175 179 F QUICK START This chapter is not a summary of this manual and don t let you off reading the entire manual A It s a short list of the key recommendations for train operator ENVIRONNEMENT for further information see chapter B II 1 of this manual e Humidity 55 at 20 C e Temperature 15C to 30C e Storage temperature 10 to 60C e 230 V mains supply 15 96 50 Hz 60 Hz possible on request e Earth lt 3 Q microbreak lt 10 ms Connection to the main supply for further information see chapter B II 2 of this manual The plugs are 16A single phase earth and must be protected by a 16A magneto thermal circuit breaker and a differential of 30mA minimum INSTALLATING PROGRAMS for further information see chapter D of this manual The software of the SYNOR 4200 can only be used on a PC equipped with the operating system WINDOWS 2000 or XP When installing for the first time WINPASS must be installed before the PCI
52. information power supply are always in rack 1 Example Programmable power supply nr 1 at 32 V 1 A on connector C2 Pus1 32 1 Us1 ON RPC12 deactivation of programmable power supply are made with command code Shut down of power supply are made with command code Example Programmable power supply nr 2 at 5V 100mA on connector C4 Pus2 5 100m us2 ON RP C 1 4 Command code for cable testing between two points RP A 1 4 us2 OFF sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 143 179 e Programming of channels In order to to select and control each channel one has to open or close each corresponding relay cabled on the output connector 1 Closing relay to activate the corresponding channel 2 Opening relay to desactivate the corresponding channel General resetting all power supply and all channels in the rack RX The RX command code allows to reset all relay and all power supply activate previously The command code FINSTIMULI do the same nevertheless you can do a general reset ting without closing STIMULI zone D III 4 EXAMPLE PROGRAM D III 4 1 The test program REM First parterre HN H Test of chassis S3400 ind 3 diagram 40300 3 Connect tools Check absence of components H H I aS nm lt DIAL dialogue1 REM Second parts PC VAL 0 5 2 5 20 0 005 PI VAL 100 M 500 1000p 0 01 0 1 REM resistance of tools 3 7Q
53. interface card 40528 is loaded The PC must then be unplugged from the mains the card loaded into its connector and the tester connection cable plugged in Restart the PC WINDOWS will install the interface card automatically WINPASS is now ready for use C PROGRAM FILES V SEFELEC WINPASS This directory contains the tester operation software CASEFELECWINPASS This directory contains configuration files likely to be modified by the operator The test files will be saved to directories chosen by the user WARNING Test files must never be saved to C PROGRAM FILES SEFELEC WINPASS as they may be deleted during updates SET UP for further information see chapter B II 4 of this manual A key switch and an emergency circuit breaker controls supply of power to the whole instrument A signal tower allows tester is power on green light and tester is in test red light CALIBRATION for further information see chapter B II 5 4 of this manual We recommend to calibrate our units each year The calibration must be performed by qualified people having the complete procedure as well as correctly checked standards SELF TESTS for further information see chapter B III 5 of this manual Automatic self tests As soon as the tester is switched on or a when a function test self learning or self test is initialized the measurement units used by the function called are automatically tested en fe l 3 SYNOR 4200 Manual
54. message Test n 1 The insulation test provides a general picture of the insulation of the tester Indeed the relays may work perfectly but bad humidity or poor cleaning of the instrument may cause a drop in quality of the insulation of the whole tester It is necessary to be aware of this so that either the environment of the tester can be modified interfaces humidity of the premises etc or the parameters of test can be lowered NOTE t is impossible to perform this self test without disconnecting the wiring to be tested but it is advisable to leave the interface as the insulation test performed during the self test can give useful information about its condition Under the best conditions test voltage 2000 V and low humidity it is possible to test to 2000 MO but the self test can be requested at 3000 MO in order to ensure that the tester will not be included in the measurement As a general rule the 2000 V modules will always have better impedance than the 500 V ones because the quality of the relays and the distance between the tracks enable better performance en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 30 179 SEIEIEC B III 5 5 Selftest of 4 wire interfaces KELVIN An additional function is available for testers fitted with a 4 wire interface KELVIN method the even and odd points continuity and isolation link test The selftest is organised as follows Close A odd Close B od
55. model and keeping the ventilation apertures of the instrument clear In dusty environments it is advisable to clean the interior of the apparatus from time to time with a vacuum cleaner compressed air must not be used In workshops with cold floors or which are washed with water it is advisable to install the tester on a pedestal to limit condensation The electronic operation of the apparatus is checked in the following cases a Automatically when the functions TEST AUTOPROGRAM or SELF TEST are called up by a check of the measurement units b On demand by running the SELF TEST to check the relays of the switching matrix c During the tests by analysis of the coherency of the measurements d It is advisable to verify the test parameters twice a year After this period we cannot guarantee the accuracy of measurements and correct operation of the equipment components T fe l 5 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 49 179 sciciec Frequency Weekly or at each self programming SELF TEST Long shutdown SELF TEST Monthly CLEAN FILTERS Yearly CHECK MEASUREMENT PARAMETERS Yearly CLEAN TESTER It is also advisable to make a backup copy of the system disks on a medium other than the hard disc of the PC used with tester B II 6 PRECAUTIONS DURING USE The tester must never switch or receive external electrical power supplies that it does not control via
56. multiple test measuring one point with respect to a group of points B III 3 1 The test between two points The switching matrix chooses 2 points in the wiring and directs them towards the measurement unit By programming it is possible to choose the hot point and the cold point This configuration can be used for all measurements Measurement of continuity consists in injecting a programmable current and measuring voltage and current at the terminals of the resistance to be tested Ohm s law will give the exact value Measurement of continuity by 4 wires Kelvin method divides the switching matrix into two internal buses the first directing the test current the second conveying the voltage of the terminals of the element under measurement Even addressed points are allocated to the SENSE of the measurement odd points to injection of the current This arrangement is possible throughout the switching matrix and can be combined with 2 wire tests see appendix Measurement of resistances covers measurements from 10 O to 10 MQ in two wires using currents of 1 pA to 10 mA It is possible to program the time in order to charge the condensers in parallel sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 22 179 With 4 wires Kelvin methode it is possible to measure resistances from 100 mQ to 10 MQ The system of measurement chooses its ranges of current automatically 1 uA to 10 mA It is obvious that for l
57. net insulation and PC for the continuity of the net points and the short circuit test sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 101 179 D II 3 11 Multiple tests of one point in relation with the others A global test puts the point to be tested in the hot point of the measurement and all the other points at OV of the measurement A low voltage test is carried out to detect the short circuits and then a high voltage test for breakdowns or poor insulation Test of one point in relation with the others in DC The PI and PC parameters are required This programming can be done in tester points but not in a list of points Test of one point in relation with the others in AC The PJ and PC parameters are required This programming can be done in tester points but not in a list of points IM Tests short circuit DC dielectric insulation Insulation and continuity parameters PI and PC required JM Tests short circuit AC dielectric Insulation and continuity parameters PJ and PC required sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 102 179 D II 3 12 Multiple tests for unitary relay testers Net test in relation to all the other points On a net the tester conducts 1 A global test between the points described by the B points which will be connected to the hot point of the tester and all the other points which will be connected to the cold poi
58. of tester points that will have to be taken into account The number of switching points of the tester is indicated to inform the operator of the number that cannot be displaced Example gt From the EDITOR an initial electrical test will be carried out between points 1 and 2 Following the DEP 20 instruction the following test will not be carried out between points 1 and 2 but 21 and 22 C A 1 BE Aj4 B 6 DEP 20 C A 1 BE A 4 B 6 Fromthe TESTER SEFELEC WINPASS TESTER Execution of the test program C SEFELEC WINPASS4200 DEMO test DEP TESI Menu Setup Tools Help While the program is being executed no Alo e information is provided Insulation measurement during the test to say ALA BL6 R 150 HOhm that the equivalence Continuity measurement table has been shifted 4 1 B 2 R 5 Ohm by the number of points given by the DEP instruction al Insulation measurement A 4 B 6 R 150 MOhm I a 4 B 6 DEP 20 C Ai B 2 I A 4 B 6 C SEFELEC F2 Execute F3 Step by step Tester points shifting x Maximum tester point 256 If the DEP use was used a dialogue box opens asking the operator for the shift value required sefelec cance SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 110 179 D II 3 17 Batch management Batch management occurs when testing several id
59. of the tester name operator name and test date at the end of the line Instructions TRACE Fichier client Fichier sortie Label du champs de r f rence Nombre de champs d crivant un mat riel Index du champ de r f rence s parateur de champs FINTRACE The TRACE instruction opens a dialogue box asking the operator to select the equipment to be tested equipment having already PASSED tests no longer appear in the list The output file is automatically stored in the same directory as the Customer file Moreover if no directory is specified in the Customer file the latter must be stored in the same directory as the test program NOTE To indicate the operator name in the output X xi file the Operator name option must be ticked in sss F7 Test timefiate th e Test Configuration window Iv bs ien message display nan mener Compulsory input Limited research at pa points Im iDelste at each use A piece of equipment is considered to have f research oF points oroup faires PASSED if all the tests carried out in the TRACE essuenent te adjustment ges ane FINTRACE zone PASSED Result printing Delete at each use Pers IV Edition of the parameters The FAILED tests outside of the TRACE zone are p savetheresuts not taken into account in the TRACE instruction L Savedconfguaton result the global test result can be FAILED TEST su when the TRACE zone result is a PASSED Seved c
60. or an inconsistency low voltage in an open circuit for example an error message is displayed The following messages are blocked Acquisition system failure Acquisition system fail GAIN This message indicates that there is no dialogue between the tester and the PC Check that The tester is switched on mains supply present 4A fuse correct etc The tester PC connection cable is correctly connected Measuring card 40372 is correctly installed on the backplane and the flat bus info cable is properly connected Cards 40403 and 40404 are correctly installed on the backplane and the flat bus info cable is properly connected Current generator failure Check that Measuring card 40372 is properly connected Relay contacts K15 K16 and K17 for routing card 40403 are open DC voltage generator failure GoNoGo Microbreak measurement failure sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 26 179 Insulation Breakdown measurement failure Check that HV generator card 40371 is properly connected Fuse F1 100mA has not been tripped Relay contacts K15 K16 and K17 for routing card 40403 are open Insulation measurement failure Insulation voltage generator failure The following messages are not blocked Capacitance measurement failure Check that Measuring card 40372 is properly connected Relay contacts K15 K16 and K17 for routing card 40403 are open Resistance measurement fai
61. points gives Insulation measurement error A 6589 B 110 B 111 B 113 B 114 LIMITED SEARCH In this example we see that the faulty additional wire connected to the connection chain only appears when the insulation of the single point 6589 is tested i e after the chain has been tested with a passed result This confirms the rule requiring that all the points appear in a test program C 11 13 INSULATION TEST BETWEEN TWO POINTS Wiring 200 0O 15 M 0 300 Test requested A 200 B 300 If the programmed insulation value is less than 15 MQ the test is passed If the programmed value is greater than 15 MQ the test is failed In the second case the test result is en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 65 179 SEIEIEC Insulation measurement error A 200 B 300 C II 14 CASE OF RESISTORS WHOSE VALUE IS BETWEEN THE CONTINUITY RANGE AND THE INSULATION RANGE Wiring 200 0O 22 KQ 300 Test requested EI B 200 B 300 Test result Continuity measurement error A 200 B 300 Insulation measurement error A 300 B 200 The continuity test of 200 in relation to 300 is failed even if 100 is programmed After this failed test point 300 becomes the generator for an insulation test in relation to the lower address points This insulation test is failed even if 01 MQ is programmed This is the only case when the same points are listed as faulty fo
62. system document which remains the sole standard of reference sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 171 179 After self learning it is essential to go back to the EDITOR to insert the texts giving instructions to the operator or constituting the verification report WARNING during self learning all other functions machine configuration probes and manual mode are invalidated for security reasons E II 4 TESTING Once the program has been drawn up either by self learning or by input using the editor the wiring System must be tested by the test function accessible by selecting MENU TEST or the icon The dialogue box requests the name of the test program After the program is validated the bottom of the window indicates the start of the program This window scrolls during the test to display its progression To start the test click on the icon Dente If STEP BY STEP execution of the program is required click on the icon To stop the test without quitting the function click on the icon DAC e To modify the test configuration click on the icon Sq Set up For this last function see chapter on configuration During the test it is possible to modify the configuration The probe and manual mode are accessible via stop on fault At the end of a test it is possible to retest the equipment connected In this case the test window is not refreshed Preceding tests can
63. terminals b Naming of points Hot points cold points The hot points will always be A points on which the positive voltages of the measurement will be applied The B points are connected to the 0 V of the measurement There are two ways to reference a point Lue 1 5 3o MS SN By putting the name given in the equivalence table in brackets user point transcoded point The name is made up of a maximum of 24 characters blanks signs or letters It generally comprises the connector and pin names By putting the number giving its address in machine points tester output number in square brackets A f l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 91 179 SETEIEC D II 3 9 Type of test There is a specific instruction for each type of test There is a corresponding parameter associated with each test instruction a Syntax Example x gt From the EDITOR Relay commands Test one point others Commodity Here for a continuity or resistance measurement To Tests between two points Nettests Parameters call up a equivalence table simply select open a Cni x equivalence table and select the table you want The points no longer show up in the tester address DEN but at the transcoded point Select Add the line to Operator sanction write the corresponding instruction Inconditional posting x LIRE Relay commands Test one point others Commodity Tests between two p
64. tester will use DEMO TES file containing the test program in user points DEMO COR file containing the equivalence table Machine points gt User points DEMO n RES file containing the test results for processing elsewhere NOTE The TES and COR files are in text format and can be processed by text processing or a conventional spreadsheet The system s operation files are stored in the sub directory C PROGRAM FILES SEFELEC WINPASS it is strongly advised not to carry out any operation in this zone DEMO CNT file containing a library of connectors D II 3 SYNTAX In what follows the following convention is taken the instructions are symbolised by rectangle assemblies in which the key words used by the SYNOR 4200 software are written in bold SEFELEC tries as far as possible to ensure the compatibility of its software programs with previous versions Some codes no longer appearing in the following description are in principle always interpreted ATTENTION The keywords are case sensitive so upper and lower case must be correctly used The editor operates one line at a time so it is essential to only programme one instruction per line NB When writing the program it is important to only write one instruction per line irrespective of the editor used From version 6 01 the WinPass EDITOR is equipped with automatic syntax colouring This colouring has no effect on the programming Its purpose is to help with the presentat
65. to uncover the grid for creation of the pins 0 100 a z Text Then click on the tab 0 100 in order to describe the numerical pins of CONNECTOR 1 In NUMBER OF POINTS give the total number of pins of the connector First number n 8 that is 25 oo E When the box DEFINE CNT is completed correctly click on Ok This operation completes the grid of the pins of CONNECTOR 1 E I 2 2 Creating an alphanumerical connector To define the second connector as described at the start click on CONNECTOR TYPE and on NEW then on RENAME On the keyboard type out the name of the new connector to be described It will be CONNECTOR 2 in our example With the box DEFINE CNT still open click on tab A Z Enter the number of points 22 which will enable us to describe the first 22 pins in capital letters Since the first pins are in capital letters tick the box UPPER CASE M Number of poi sz dads The letters designating the pins do not include the letters J O and Q 0 100 A Z Te Deselect the four letters excluded their boxes must be empty O Click on Ok to complete the first 22 boxes in the grid Each of the following pins has two characters in its name Both columns must be completed The first column contains the letter a 23 times The second contains all the letters in alphabetical order except l o q i e 23 letters In the grid click in the box on the left under the Z In the box DEFINE CNT click on upper case
66. word processing program D V 3 TEST REPORT RES The test report RES is a file of type RTF It can be consulted using any word processing program D V 4 TEST PROGRAM TES The test program in user points TES is a text type file It can be generated on any kind of equipment and can be modified by any word processing program D V 5 TABLE OF CORRESPONDENCES COR The table of correspondences COR is a text type file it can be generated on any kind of equipment and can be modified by any word processing program Warning use of the editor takes into account the configuration of the tester number of points and position of the high voltage or low voltage modules It is therefore necessary to open the tester function see ch II 1 before any programming operation sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 154 179 Warning The use of the editor takes into account the tester configuration number of points and position of the high voltage and low voltage modules You must therefore go into the configuration function before any programming In the installation instructions we shall describe all the functions of the two parts of the WINPASS software The first part will deal with the Editor which will provide the opportunity to compose a program The second part will describe the operation of the tester Everything that follows is based on the supposition that the user is familiar
67. 009 Edition 136 179 SEIEIEC The programming can affect the polarity of output channels by using the same principle as the tests between two points point A hot point of the power supply point B cold point 2 Switching of two power supplies It is possible to use two power supplies In this case power supply 1 is addressable on the odd points and power supply 2 on the even points For example command of a relay control with power supply 1 between points 5 and 21 and with power supply 2 between points 12 and 14 The programming can affect the polarity of output channels by using the same principle as the tests between two points point A hot point of the power supply point B cold point Note depending on the construction of the tester the status of a power supply can change from one rack to another as well as the number For example a tester with 2 racks 2 times 16 slots can control 4 different power supplies or a single one with two cards 40680 placed in each rack 3 Programming What follows assumes knowledge of WINPASS programming see the programming sheet that comes with the tester b Power supply control RP680 C 10 2 Number of power supply 1 or 2 Row of the stimuli card Command activation of the power supply Command of a power supply on a 40680 card RP680 A 10 2 Number of power supply 1 or 2 Row of the stimuli card Stop deactivation of the power supply Command of a p
68. 1 1 C121 C13 1 C141 C15 1 C16 1 n O N e Q5 pes zo N N BEEHENHBNEHNHREBEHNEHHEHEHNEHERHBENERN Remote control 1 First tester adress HARTING reference of interface connectors 09 73 164 6907 Male connector 09 03 096 0501 Hood 09 02 000 9911 Grommet 09 02 000 9902 Left locking 09 02 000 9903 Right locking Because these cards are intended to route currents up to 10 A the sections must be chosen on the basis of these currents Note it is not possible to use self stripping connectors at these voltages and currents The most available connectors on the market are wrapping ones Each weld will be protected by the heat shrinkable cover It is advised to remove the marking ink between the connector pins risk of poor isolation The connector of the right figure is the male interface connector seen from the wiring side Row b is never used For all the other pins one in every four is wired see wiring list below This list gives the wiring of the first connector of the first switching card The other connectors are organised in the same way sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 51 179 pow ow cg a ae s 30 s ae First address f gt z male interface connector see cabling side E mE E mE f mE g mE g mE E mE E mE E mE E jE BH g mE g mE f mE mm Wa A E a a O E a O a E E a a E E H L a E L a a L1
69. 10 B 11 B 13 B 14 B 20 B 21 B 23 B 24 EI B 12 sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 61 179 Test result Continuity measurement error A 10 B 20 Insulation measurement error A 20 B 12 C II 8 UNCONNECTED WIRES IN A CHAIN Correct wiring 10 11 13 14 2021 23 24 Wiring produced 10 11 13 14 2021 23 24 O O 0 0O O O O Test requested EI B 10 B 11 B 13 B 14 B 20 B 21 B 23 B 24 Test result Continuity measurement error A 10 B 14 Continuity measurement error A 14 B 20 Insulation measurement error A 20 B 10 B 11 B 13 When a continuity error is encountered in a connection chain the test artificially divides the chain in two or more chains marked with an insulation test at the start Correct wiring 10 11 13 14 2021 23 24 O O 0 O O O O O Wiring produced 10 11 13 14 20 21 23 24 O O O O O O O O Test requested El B 10 B 11 B 13 B 14 B 20 B 21 B 23 B 24 Test result Continuity measurement error A 10 B 11 Continuity measurement error A 11 B 14 C II 9 TWO CHAINS CONNECTED TOGETHER Correct wiring 2 3 6 7 9 10 11 13 14 20 21 23 24 O O 0 O 0O O O O Wiring produced en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 62 179 SEIEIEC Test requested EI B 2 B 3 B 6 B 7 B 9 EI B 10 B 11 B 13 B 14 B 20 B 21
70. 27 NO7 28 COM7 29 NC 30 DI1 gip 32 c Dia 33 D14 34 DI5 35 DI6 86 DI7 37 DI8 SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition CPIESAMAZH of the card 134 179 D III 2 5 Syntax RELAY COMMANDS SO1 n The n relay is placed in the work position SO0 n The n relay is placed in the rest position SOM n The n relay is placed in the work position if at least one of the previous tests is failed SOB n The n relay is placed in the work position if all of the previous tests are passed SOC n The n relay is placed in the work position if the previous test is failed VOLTAGE DETECTION If the input output card is used to direct the relays in the wiring routing of a power supply the following rules must be followed e Do not carry out any other measurement than the voltage measurement on the multiplexer connected to the wiring power supply points e Do not carry out multiple tests El ED EN if a power supply is routed e Carry out tests to check that the wiring is correct before directing the relays e Use the voltage detection option in the test zones where the relays are directed The voltage detection option is programmed by two instructions STIMULI to indicate the start of a test zone with relay steering and FINSTIMULI to indicate that all the power supplies are deactivated In the test zones where the voltage detection opt
71. 8 mE Oo o e Ways 15 C29 m o ol A29 Ways 15 c30 m o Of 30 Ways 16 C31 m o ol A3 Ways 16 C32 EU o 2 e Relay and power supply have to be in rack 1 e The ways numbering is made as shown program drawing Power supply setup is made in the order of connectors according previous picture Connector C1 power supply has the address 1 Connector C2 power supply has the address 2 Connector C6 power supply have the address 6 e For relay for connector C1 ways addresses are from 1 to 16 for C2 from 17 to 32 for C6 from 80 to 96 c Syntax Define STIMULI area STIMULI Test instructions FINSTIMULI The area using power supplies shall be bracketed by STIMULI and FINSTIMULI command codes They replace command code PRESENCETENSION and ARRETTENSION old command code sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 142 179 They forbid the use of following command code net tests voltage detection disable probe and manual mode d Power supply instruction This is made in two time 1 Program and activate power supply Pusn Voltage Volts Current A n is the power supply number Example Programmable power supply 3 at 25V and 500mA and activation Pus3 25 500m us3 ON Activation may be anytime it s the last power supply parameter which is used 2 Switching of the external power supply this power supply can be programmable or not RP C Rak Power supply number For
72. 96 The SYNOR 4200 tester can carry out 4 wires Kelvin methode measurements starting at 1 mQ which enables it to carry out measurements of this type on wires of 50 cm length and 5 10 mm cross section between 7 and 13 mQ with good resolution en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 35 179 SEIEIEC B VI T USEFUL INFORMATION B VII 1 INTERFACE FOR SYNOR 4202 The measuring channels of the SYNOR 4200 are available on 64 pin connectors of the 41612 series HE 10 The switching cards can be mixed between 500 V and 2000 V Each switching card has two output connectors see photo arranged vertically The 500 V cards have two times 64 output channels and the 2000 V cards two times 32 see diagram B VIT 1 1 Characteristics of connectors on the interface side a 500 V outputs male connectors type 41612 64 pin R a c class 1 e SOURIAU reference 8609 464 78 09 755 000 E1 solder eyelets 8609 464 78 14 755 000 E1 wrapping pins e HARTING reference 09 73 164 6907 wrapping pins 09 73 164 6903 straight pins for printed circuit e 3M reference 3695 0000 self stripping e HARTING hood 09 03 096 0501 with M2 5 x 30 screw e HARTING grommet 09 02 000 99 11 On 40417 C cards the screws are replaced by two locking levers Right locking 09 02 000 99 03 Left locking 09 02 000 99 02 Warning Connectors with solder eyelets have very long delivery times We recommend A wrapping pins provided a few wiri
73. B 8 Test result Continuity measurement error A 2 B 9 Insulation measurement error A 8 B 2 B 3 B 6 B 7 Correct wiring 1 O 2 3679 Wiring produced 1 2 3 6 7 9 O Test requested EI Bf1 EI B 2 B 3 B 6 B 7 B 9 Test result Insulation measurement error A 2 B 1 Continuity measurement error A 2 B 9 C II 12 ISOLATED POINT WIRED ON A LONG CHAIN Correct wiring 110 111 113 114 120 121 122 123 124 130 131 133 127 o Wiring produced ot fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 64 179 SCIEIEC 110 111 113 114 120 121 122 123 124 130 131 133 127 Test requested EI B 110 B 111 B 113 B 114 B 120 B 121 B 123 B 124 B 130 B 131 B 133 EI B 127 Test result Insulation measurement error A 127 B 110 B 111 B 114 B 120 B 121 B 123 B 124 This example shows that the tester never goes beyond the faulty point in its search Correct wiring 110 111 113 114 120 121 123 124 130 131 133 134 6589 O Wiring produced 110 111 113 114 120 121 123 124 130 131 133 134 6589 Test requested EI B 110 B 111 B 113 B 120 B 121 B 123 B 124 B 130 B 131 B 133 B 134 EI B 6589 Test result without limited search Insulation measurement error A 6589 B 110 B 111 B 113 B 114 B 120 B 121 B 123 B 124 B 130 B 131 B 133 B 134 The same test on the same wiring with limited search programmed to 4
74. HIBIT THE EFFECT OF THE NOISE ELEMENTS B V 2 1 Effect of the capacitance c1 The capacitance C1 is due to the interlink capacitances in the tester the interface and the wire to be tested Its value is relatively high about 4 to 5 nF but it is easy using the low impedance of the source of the measurement circuits to charge and discharge it quickly Its effects on the measurement cycle are negligible B V 2 2 Effect of the resistance r1 This resistance which is very high in value makes practically no difference to the measurement However at high humidity levels this value can fall until it forms in parallel with Rx a by no means negligible element which can disrupt the measurement In this case as the equivalent resistance is weaker the solution is to lower the rejection parameters so that the test can be conducted under identical conditions B V 2 3 Effect of the series network r2 c2 This serial RC network made up of the total of stray capacitances of the open relay contacts and leakage resistances exerts a considerable influence as a function of the speed of the tester It introduces a parallel element of impedance that varies as a function of time at the terminals of Rx all the time that C2 is charging The deterioration in accuracy of measurement at high speeds is due to this phenomenon B V 2 4 Effect of 5O Hz radiation The assembly to be tested is bathed in 50 Hz radiation which can be significant and can affect the
75. I Pid PJ PC PR Pb PF P4 Pd Pdz PS PVA PVC PLR PCR PZL PZC PGM Pu Pue TARE n n TEST OF NETS El Eld EJ ED TEST BETWEEN 2 POINTS sefelec Measurement hot point in tester address test between two points or unitary relays Measurement hot point in user address test between two points or unitary relays List of Points in measurement hot point unitary relays Definition of points of a net or measurement cold point in tester address test between two points or unitary relays Definition of points of a net or measurement cold point in user address test between two points or unitary relays Definition of points of a net by List of Points or measurement cold points unitary relays measurement parameters Short circuit insulation highpot measurement parameters Short circuit highpot measurement parameters for dielectric strength option measurement parameters for continuity measurement parameters for resistance measurement parameters for shielding measurement parameters for capacitance measurement parameters for 4 wires Kelvin methode measurement parameters for diodes lt 20V measurement parameters for diodes gt 20V Measurement variable element and application time measurement parameters for alternating current option measurement parameters for direct current option measurement parameters for self inductance option measurement parameters for condensers on AC
76. LOTABR Only counts good parts a batch may be completed or reopened LOTAT Counts all parts a batch may not be completed or reopened LOTATC Counts all parts a batch may be completed LOTATR Counts all parts a batch may be completed or reopened Complete means a batch that has not been closed and the batch report not published as the number of parts desired has not been obtained It is possible to complete this batch until the number of desired parts is obtained Once the batch is completed and the batch report published it is no longer possible to modify or reopen it Reopen means a BATCH that has been closed and you want to add more parts to it In this case a new BATCH report will be published under the same name as the old one The previous batch report will be erased B Running the program with LOTA xj When the LOTA function is present in a program the TESTER will Lotnumber ask what the BATCH number is when the program starts up irrespective of the LOTA position in the program These dialogue boxes will be the first instructions asked during the test Annuler Then either the number of good parts of the BATCH will be asked in the event of the LOTA B function or the number of parts in the BATCH in the event of the LOTA T function Automatic lot management x Automatic lot management x Lot parts quantity Good lot parts quantity po PO Annuler Annuler Then the program will be run in chronological order Th
77. MER idiote 171 IPIE TESTING 5 pne 172 E IL4 1 PROBES tee ease 172 E IL4 2 MANUAL MODE TEE 173 E II 4 3 Execute a test Tile part oai ente t i n ER E EG Ht LE Em TO 174 E IL4 4 Safety AUTINP TOSES RM TH 175 EJL5 QUITTING THE TESTER FUNCTION nr ren ren eren neen nennen 175 Le SCI START meme 176 T fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 8 179 Ssere1ec A PRESENTATION Since 1970 one of the major occupations of our team has been to design and manufacture wiring testers Our experience in this field has been recognised by most companies using leading edge technologies in military aeronautic and civilian fields Testers in the SYNOR 4200 series all have the same architecture a PC compatible CPU connected via an opto isolated interface to a measurement unit and relay matrix switching unit capable of receiving modules of 500 V to 2000 V This combination of technologies provides high performance insulation measurement and a test speed easily compliant with the conditions required for the most sophisticated wiring A suite of user friendly interactive software operating in WINDOWS environment makes the tester easy for the operator and programmer to use To maintain compatibility between all generations of our testers transfer software allows the test programs of this instrument to be used on SYNOR 4200 instr
78. NOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 7 179 SCIEIEC E L3 CREATING THE Equivalence TABLE eene eere nee rennen 158 E L3 Description of the interface sise 158 E L3 2 Completing the equivalence table ss 159 E L4 USER DIALOGUE BOX nece tiertit er eet ee Gees shan ce ke tereti ee tek e ee test e EE da Ea cones 159 E L5 COMPLETING The TEST FILE eain becas repe eese ie inepte eg 160 EL5 1 TestbebtweerntwOJpolls ine ten it tete PR EPI e nb imamate 161 le ME Egi 162 DSB SEX cunc see 162 E L6 A FEW LITTEE EXTRAS iae teet tte en Feet etti tte reves EE OE E EREE 165 E L6 1 Graphic display of test file alien eese iaei be eerta 165 E L6 2 Another solution for the parameters applicable to older versions using DOS 165 ELO MESSAGES ES nn d eei ie either utei dues lets iii 165 EL6 4 Controller commatids eiecit tede nnn Feed ia teen bo Ernest E OU ii Ro revera 165 EI THE TESTER 1r ecetee eden te Fen ert ene na Deae ten eurem AOT EAT d re be na su dde nee dt des dde de 166 E II 1 CONFIGURATION eitis to th erecto ede tuae e Rae expe be oru a eU Eo rescue cto gue 166 E IL1 1 Machine configuration i e terree Leite o a tige Lene ree ehe rae de eed aR ae avaa 166 E II 1 2 Test veribirucino REP 167 BALD SELE TEES Ts C esteso uiti Macias E fuite CoU epeb dep eU eiue ics tesiita cde tenete 170 EJL3 SELF EEARNING iacit tie e aeree O EE A iere rese
79. NOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 88 179 Reminder of the optional measurement parameters table MEASUREMENTS PARAMETERS MIN VALUE MAX VALUE dielectric strength AC AC voltage 50 Veff 1500 Veff Rise time 500 ms 99 s Application time 20 ms 99 s Breakdown 500 uA 10 mA Vcc MEASUREMENT Voltage 0 1000V Vca MEASUREMENT Voltage 0 750V INDUCTANCE Resistive 10uH 200 H CAPACITANCE IN AC Capacitance 100 pF 2 000 uF INDUCTOR COIL IMPEDANCE Inductor coil 100 uH 200 H CAPACITIVE IMPEDANCE 100 mQ 160 kQ GMOV Voltage 0 360V Series resistance nb 1 7 Time 2ms 99s Voltage generation Voltage 4V 100 V Current voltage generation Voltage 5V 25 V Current 10 mA 1A External power supply on Depending on the power measurement switching U amp I 0 supply characteristics External power supply 1 or 2 on Depending on the power Stimuli switching U amp I 0 supply characteristics sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 89 179 Examples gt From the EDITOR and using the test file writing tool Insulation PI Continuity PC E x Relay commands Test one point others Commodity Relay commands Test one point others Commodity Tests between two points Nettests i Tests between two points Net tests Parameters Insulation Resistance threshold po fun Resistance low limit p a gt Insulation voltage oo Yz Resistance high limit NEN 2 7 Breakdown curren
80. O IK EK OK OK CK OK OK OK OK OK OK OK OK BATCH REPORT gt From the TESTER Batch number AZ18 once the tests have been carried out the batch Batch Serial number 123456 report file will be saved automatically DKK OK OK OE OK OK OK OK OK KE OK OK OK OK OK A counter at the bottom left of the screen REPORT indicates the batch name and number of parts Operator s name Smith tested Number of sample tested in this batch 2 This batch is composed to 2 pass sample and 0 fail sample Batch end time 07 07 2009 13 38 20 537 SEFELEC WINPASS TESTER Execution of the test program Documents and Settings be Menu Setup Tools Help ECO FE Parc d activit s du Mandinet SRI rue des campanules RSS Lognes France PASS TEST Wwa Selec com End of test 07 07 2009 13 38 20 ic Appuyez sur F1 pour obtenir de l aide A H 19 rue des campanules H 77185 Lognes France H www sefelec com zs F1 Close F2 Execute F3 Step by step F10 Partiel test stFELEC S sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 112 179 b Batch function LOTA LOTA Option1 option2 Path of the source batch report A The different LOTA options The following options are programmable with the following combinations LOTA B Only counts good parts a batch may not be completed or reopened LOTABC Only counts good parts a batch may be completed
81. PASS software Parameter Minimum value Maximum value Threshold resistance in insulation 0 2 GO Test voltage 0 1500 Vdc Application time 0 99 s sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 124 179 D III 1 2 Command codes of the dielectrometer SEFELEC XS series Main measurements carried out by the XS series devices For the RXS models rigidity function For the DXS models rigidity function megohmmeter For the SXS models rigidity function megohmmeter ground continuity sequence function Rigidity generator of the XS series Type of device Rigidity function RXS DXS SXS 50 50VA AC RXS DXS SXS 56 50VA AC and DC RXS DXS SXS 500 500VA AC RXS DXS SXS 506 500VA AC and DC 50VA and 500VA generator characteristics Programmable test voltage 100 V to 4200Vcc by pitch of 10V 5 of the programmed value The maximum test voltage depends on the switching board equipping the tester Breakdown current detection 50VA generator 500 LA to 10 mA 10 of the value read 500VA generator 10 mA to 100 mA 10 of the value read Min current leakage detection 50VA generator 100 pA to 9 99 mA 10 of the value read 500VA generator 1 mA to 99 99 mA 10 of the value read Max current leakage detection 50VA generator 100 A to 9 99 mA 10 of the value read 500VA generator 1 mA to 99 99 mA 10 of the value read Rise time 1 s to 99 s 5 o
82. PRINCIPLE The tester must know in tester point order e the names of the connectors 1 to 20 characters e the names of the connector pins 1 to 10 characters e the number of pins per connector A set of points having the same characteristics is taken to constitute a connector Non wired points on the interfaces will be considered as connectors In order to simplify completion of the transcoding tables connectors are classified by family or type of connector D IV 2 DATA INPUT For the method of operation refer to the User s Manual W420CH5 Input of the data in principle consists in describing the connectors used by the technology of the equipment to be tested A CNT file will contain the descriptions of the connectors previously grouped together by the user in a library e g all the SUBD from 9 to 50 pins These libraries stored on the hard disk can be used for several programs Incidentally it is useful early on to create the libraries necessary to describe all the technology of a product Once the connectors have been entered all that is needed is to give the correspondences between tester points and equipment points If tester points are not connected to the equipment it is superfluous to give them a name The corresponding box can just be left blank In the input grid for the table of correspondences an interface column is interposed between the machine points and the user points It can be used to compose the program us
83. R 4200 Manual Ref WINPASS Rev I july 2009 Edition SETEIEC Wiring produced Test requested Test result 14 16 O15 140 16 0 O 15 El B 14 B 16 El B 15 Continuity measurement error A 14 B 16 Insulation measurement error A 15 B 16 The insulation test of 14 in relation to the other lower address points is passed The continuity test of point 14 in relation to point 16 is failed The type of error and the address of faulty points are listed Finally the insulation test of point 15 in relation to the lower address points is failed Correct wiring Wiring produced Test requested 14 gt Oo 160 15 16 El B 14 B 15 EI B 16 Test result Continuity measurement error A 14 B 15 Insulation measurement error A 15 B 13 C II 4 ISOLATED POINT MISTAKENLY CONNECTED TO ANOTHER ISOLATED POINT Correct wiring 130 14 o __ 15 160 17 O Wiring produced SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 59 179 sefelec 13 14 e 15 16 170 Test requested EI B 13 El B t4 B 15 EI B 16 EI B 17 Test result Insulation measurement error A 13 B 13 The insulation test of point 13 in relation to the lower address points is passed The insulation test of 14 in relation to the lower address points is passed The continuity test of point 14 in relation to point 15 is passed The insulation test of 16 in rel
84. REM break of 24 V on outputs 18 and 5 RO680 16 1 A 18 B 5 REM stop of the 24 V power supply RP680 A 16 1 e Example 2 Or rack 2 with power supply 1 at 24 V and power supply 2 at 72 V position 4 The relays are placed according to the table below The 40680 stimuli card is in Relay A 9 1 24V P1 2 P2 E Relay B 3 1 24 V P1 3 P2 K Relay C 2 4 72V P1 4 P2 A Relay D 8 22 72V P1 5 P2 M Note that relays A and B have a common cold point 1 REM Test of open contacts of all relays Pl VAL 10 M 100 1 m 10 m 100m PC VALO5100m205m B P2 E P1 3 B P2 K B P2 A P1 5 B P2 M REM power supply control A P1 2 A A P1 4 A RP680 C 4 1 sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 138 179 RP680 C 42 REM command of relays RF680 4 1 A 9 B 1 RF680 42 A 8 B 22 REM test of contacts C A P1 2 B P2 E C A P1 3 B P2 K A P1 4 B P2 A A P1 5 B P2 M REM command of relays RO680 4 1 A 9 B 1 RO680 4 2 A 8 B 22 RF680 4 1 A 3 B 1 RF680 4 2 A 2 B 4 REM test of contacts A P1 2 B P2 E A P1 3 B P2 K C A P1 4 B P2 A C A P1 5 B P2 M REM overall resetting RX B B s f l SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 139 179 SCIEIEC D III 3 2 Using card 40575 This card has two groups of relay allowing to orders power supply on 16 channels These power supply must be external or del
85. Ref WINPASS Rev I july 2009 Edition 176 179 SEIEIEC Acquisition system failure Acquisition system fail GAIN This message indicates that there is no dialogue between the tester and the PC Check that The tester is switched on mains supply present 4A fuse correct etc The tester PC connection cable is correctly connected Measuring card 40372 is correctly installed on the backplane and the flat bus info cable is properly connected Cards 40403 and 40404 are correctly installed on the backplane and the flat bus info cable is properly connected Current generator failure Check that Measuring card 40372 is properly connected Relay contacts K15 K16 and K17 for routing card 40403 are open DC voltage generator failure GoNoGo Microbreak measurement failure Insulation Breakdown measurement failure Check that HV generator card 40371 is properly connected Fuse F1 100mA has not been tripped Relay contacts K15 K16 and K17 for routing card 40403 are open Insulation measurement failure Insulation voltage generator failure Capacitance or Resistance measurement failure Check that Measuring card 40372 is properly connected Relay contacts K15 K16 and K17 for routing card 40403 are open All these precautions make the tester extremely reliable in the quality of its results Self tests on demand These self tests are designed to check the switching matrix As this operation takes a relatively long tim
86. The short circuit test or high voltage test can be programmed out of the test Measurement of dielectric strength under alternating current is performed using an alternating voltage 50Hz adjustable to an effective 50V to 1 500V As is the case with direct current it detects any sudden rise of current up to a programmed threshold The short circuit test is maintained by default The rise time is more than 500 ms and the application time at least one period Warning The test under alternating current is penalised by the capacitive value of the tested equipment It must be remembered that the generator power is limited to 5 mA Breakdown detection Chort circuit Rise time Application time Fall time Test Measurement of capacitance and shielding is a measurement that eliminates eddy currents allowing fine measurement with good resolution Measurement of shielding ranges from 100 pF to 10 pF it uses an adjustment system allowing interfering capacitors introduced by the tester and interface to be eliminated Capacitor measurement ranges from 100 pF to 100 000 uF A more powerful current generator is available for stronger capacitors Adjustment is also possible BY es Constant current Yt Charge time sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 24 179 B III 3 2 The multiple test e With the 4 contact switching box The switching matrix positions the weakest address point of a net o
87. To complete the test file click on FILE NEW TEST PROGRAM The window displays a page containing lines on which we shall write the test program Writing can be done in two ways by direct entry respecting the syntax described in the programming instructions e by using the programming tool In the example below we shall not discuss the first method but will use the programming tool by selecting TOOLS TEST TOOLS This box contains the following tabs fe l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 160 179 SEIEIEC e Test between two points Equipment e Parameters e Multiple test e Control of relays option The principle for the first two headings consists in giving the type of test and the points to be tested The third is used to program the parameters associated with the tests When the test tool box is correctly completed validating it writes a line on the screen in tester syntax E I 5 1 Test between two points The test between two points enables testing of all components as opposed to the net test which is restricted to wires In the top window choose from the list of Relay command l Test one point others Commodity tests Test between two points Test Equipotential Parameter me SSCS Continuity ar LENT e Non continuity I Incondiional posting Continuity 4 wires Loop test e Insulation continuity Points e Insulation alternating current Res
88. VCe 2 amp PVCe 3 amp PVCe 4 amp PF 1 amp PF 2 amp PMVDC 1 amp PMVDC 2 amp Pb 1 amp Pb 2 amp PMVAC 1 amp PMVAC 2 amp PLR 1 amp PLR 2 amp PMIDC 1 amp PMIDC 2 amp PCR 1 amp PCR 2 amp PMR 1 amp PMR 2 amp PZL 1 amp PZL 2 amp PMRA 1 amp PMR4 2 amp PZC_1 amp PZC 2 amp PMP 1 amp PMP 2 amp PGM 1 amp PGM 2 amp PGM 3 amp PGM 4 amp PGM 5 amp PMVDO I 1 amp PMVDC I 2 amp PMVDC I 3 amp PVC 1 amp PVC 2 amp PMVAO 1 amp PMVAC 2 amp PMVAC I 3 amp Pus1 1 amp Pus1_2 amp PM1500P 1 amp PM1500P 2 amp PM1500P 3 amp Pus2 1 amp Pus2 2 amp PS 1 amp PS 2 amp PS 3 sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 118 179 D II 4 SYNTAX OF SPECIFIC TESTS A list of specific instructions for certain applications is given below D II 4 1 COMPARE function Following two measurement tests between two points it is possible to compare these values and display the result of this comparison in the test report The different parameters to be specified during the call up of this function are the type of measurement to compare R C d F etc the comparator gt lt lt gt gt lt the tolerance value as a percentage between 0 0001 and 100 Example R A 8 Bf9 R A 12 B 15 COMPARE R lt 2 The programme will therefore test that the resistance value between points 8 9 is less than or equal to the resistance between point
89. alues measured is less than 500mQ Special case for the capacitive element test To measure the insulation between two points the test is used associated with parameter PI Should you wish to measure the insulation between two points connected by a capacitor above 100 nF the code Ic with the parameter PI must be used In this case the tester discharges the capacitor measures the insulation and recharges the capacitor The short circuit is not measured NB This function is only active if the tester is equipped with a voltmeter card 40535 or 40494 e fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 98 179 SEIEIEC D II 3 10 Net tests A net is a series of wiring points with the same potential and therefore connected by a wire also called chain or shaft An insulated point constitutes a net of 1 point for the tester Example of a net here between 2 points of the J1 connector and 1 point of the J3 connector and 1 point of the P4 connector Hd J3 Connector J1 B H P4 To test this net you have to test its insulation or non continuity with the other test points and the continuity between the net points On a net the tester conducts 1 A global test between the lowest tester address point and all of the lower address points This test is conducted at low voltage so as to detect short circuits and at high voltage for breakdown or poor insulation 2 Continuity tests between the
90. and FSER instructions will be carried out the first time the test program is launched If this program is run through again or relaunched at the end of the test the DIAL instruction will not be carried out again SER DIAL C Documents and SettingsWINPASS dialogue demo DIA FSER s fe l a SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 85 179 Ssere1ec D II 3 7 Test parameters To carry out a measurement the tester must be given the parameters controlling the different generators and the PASSED test criteria A parameter is given in the program before the test instructions It is possible to change parameters as many times as necessary in a test file However there is no need to repeat the parameter instruction before each test if it does not change The last programming is taken into account The main solution involves defining all of the values of a measurement parameter in the test file This possibility has the advantage of linking the parameters to the test file and enables it to be exported on to any tester of the same type In the old syntax modes it is possible to call on parameter libraries With this solution the parameters belong to the tester The test files cannot be exported without checking that the parameter tables are the same on both appliances this solution is used on the old modernised SYNOR testers In addition the parameters do not appear on the test results file Syntax of parameters pro
91. arget file will be managed as a results file Both files can be stored in the same directory but they must have different names In the source target file name of the test report it is possible to include the different variables described in the chapter Test variables Example Fromthe EDITOR CRT C WINPASS CR de test htm C WINPASS CR_ amp DIAL1_ amp DIAL2 htm Example of source file target file created by the WinPass TESTER vi Ty prg de test UK Microsoft Word Fichier Edition Affichage Insertion Format Outils Tableau Fen tre 2 C Documents and Settings begou Mes documents SEFELEC SYNOR WINPASS prg demi fe C Documents and Settingslbegou v X r7 Live Search Fichier Edition Affichage Favoris Outils 2 Normal 12 iG zii s E i Favoris ss f Sites sugg r s Hotmail D buter avec IE8 Plus de compl ments 7 SEE PNR CONTES AN ENERO TT GITE INT NE CI A apy m r r P t s n a C Documents and SettingslbegoulMes docume fu Gl o mp Page S curt r Outis sefelec Test report of program test amp FILE Test report of program test Test demo UK TES Date amp DATE Operator s name amp DIAL1 Serial number amp DIAL2 Designation amp DIAL3 Test result amp RESULTAT Date 17 07 2009 Operator s name Smith Serial number 654987 Designation AARRTT Test result FAIL TEST LABEL results LABEL results
92. ates et les heures Personnaliser les options r gionales 2 x Nombres Symbole mon taire Heure Date S lectionnez un l ment pour afficher ses param tres ou cliquez sur Personnaliser pour choisir vos propres formats Apercu Positif 23 456 783 00 N gatif F 23 456 789 00 Symbole d cimal Francais France Personnaliser Exemples Nombre fizssse7eg00 C C t CS Symbole mon taire 23456789308 t i i S ewes 160744 Nombre de d cimales 2 ba Date courte Fr 8 11 2008 Symbole de groupement des que Date longue mardi 18 novembre 2008 Groupement des chiffres 123 456 783 bal Symbole du signe n gatif Y T Format de nombre n gatif AA E Pour aider les services vous foumir des informations telles que les actualit s et la m t o s lectionnez votre emplacement actuel Afficher les z ros en en t te 0 7 bd France zi S parateur de listes he Syst me de mesure M trique I Annuler ARRIQUET Chiffres standard o 23456789 Substitution des chiffres aucun bd Annuler Eppiader fe l d SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 69 179 setelec In the numbers tab The value for Decimal symbof must be a comma The value for Figure grouping symbol must be a space D I 3 CARRYING OUT THE INSTALLATION Testers are deli
93. ation and continuity parameters PI and PC required ElUd Tests short circuit DC dielectric continuity between the points Rigidity and continuity parameters Pld and PC required EJU Tests short circuit AC dielectric continuity between the points Rigidity and continuity parameters PJ and PC required IU Tests short circuit DC dielectric insulation Insulation and continuity parameters PI and PC required lUd Tests short circuit DC dielectric Rigidity and continuity parameters Pld and PC required JU Tests short circuit AC dielectric Insulation and continuity parameters PJ and PC required m fi l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 104 179 SCICICC D II 3 13 TARE function In order to get away from interface and tooling resistance it is possible to programme a TARE so that the tester takes this value away at each 2 wire continuity or resistance measurement This function can be introduced several times in the test file It is valid for all the tests that follow wx The values will be given in ohms and tenth ohms Example Fromthe EDITOR PI VAL 100M 500 1m 10m 30m PC VAL 0 5 500m 20 5m PR VAL 4 6 10m Om El B 1 B 2 B 4 TARE 5 R A 5 B 6 TARE 0 R A 7 B 8 T fe l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 105 179 SEIEIEC D II 3 14 Event wait contact state The following instructions should be followed t
94. ation concerning setting up building the interfaces and using the tester T fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 9 179 SCIEIEC The section ANALYSING THE ERROR LIST gives the examples of the frequent test situations The PROGRAMMING INSTRUCTIONS explain the syntax and means required to produce the test program The OPERATING INSTRUCTIONS explain the various possibilities of the WINPASS software for each function This is done using straightforward examples and screen copies This manual should be read in front of the tester screen The GENERAL INFORMATION must be understood before going any further The PROGRAMMING INSTRUCTIONS are not essential reading for the user who probably only needs to understand the section ANALYSING ERROR LISTS The technician will need a thorough understanding of all the information A ITT CONCLUSION We hope that the following pages contain a maximum of information expressed as clearly as possible However despite our efforts this manual may have its faults because it is difficult to write a document that addresses all levels and condenses all the possibilities of a multiple resource system We would therefore be pleased to hear your opinions and criticisms so that we can improve the text At the same time our technicians are always available to answer your questions or refresh your training This document is available updated on our Internet site htt
95. ation of stimuli power supply n in rack n RF6680 x n A B Switch on power supply n between points A and B RO660 x n A B Switch off power supply n between points A and B RX reset of all relays 40680 and 40575 EXTERNAL CONTROL if option present PLE1 1 2 3 control to 1 of outputs 1 2 3 PLEO 1 2 3 control to 0 of outputs 1 2 3 PLEGL1 control to 1 of all outputs PLEGLO control to 0 of all outputs PLEDELAI nn order delay after each control operation PLECONST lt gt define a group of outputs for control PLE1 lt gt control to 1 of group definedin lt gt PLEO lt gt control to 0 of group definedin lt gt TEST WITH UNITARY RELAYS EIU test between the others points short circuit insulation highpot continuity ElUd test between the others points short circuit highpot continuity IU AC A unitary insulation test between points A hot point and all other points IU A B unitary insulation test between points A hot point et points B OV IU A lt 5 B gt unitary insulation test between nets A and nets B JU AC insulation test same rules as code IU SYSTEM VARIABLE amp LABELn show the n LABEL name amp DIALn show the n field from dialogue box amp DATE show date from computer amp FILE show name of the test file en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 150 179 SEIEIEC amp RESULTAT amp RESLABELn Test between 2
96. ation to the lower address points is failed The insulation test of 17 in relation to the lower address points is passed Correct wiring 130 14 0 O15 160 17 O Wiring produced 130 14 16 17 15 Test requested EI B 13 El B 14 B 15 EI B 16 El B 17 Test result Insulation measurement error A 17 B 16 You are now familiar with the various basic error cases so we will stop our analysis of the tester procedure here T fe l i SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 60 179 SEre1ec CIL INVERSION OF TWO WIRES Correct wiring 18 0 O 19 200 o2 i Wiring produced m o eeu E 20 21 El B 18 B 19 El B 20 B 21 Test requested Test result Continuity measurement error A 18 B 19 Insulation measurement error A 20 B 19 Continuity measurement error A 20 B 21 Insulation measurement error A 21 B 18 C II 6 BREAK IN A CONNECTION CHAIN Correct wiring 10 11 13 14 20 21 23 24 O O O O O O O O Wiring produced 10 11 13 14 20 21 23 24 O O O O O O O O Test requested EI B 10 B 11 B 13 B 14 B 20 B 21 B 23 B 24 Test result Continuity measurement error A 10 B 20 C II 7 BREAK IN A CONNECTION CHAIN WITH AN INCORRECT WIRE Correct wiring 10 11 13 14 2021 23 24 Wiring produced 10 11 13 14 2021 23 24 O O O O 12 Test requested EI B
97. b Ce tae sent 18 B IL4 4 Dart CUITE NE Oc 18 B IL 4 5 Optimization of safety on the SYNOR 4200 eene eee 18 B IL4 6 TO SUMMAT Ze E seal ie 18 BAILS MAINTENANCE OF THE INSTRUM ENT ener 19 BIG PRECAUTIONS DURING USE easiest re eben Fette aae td eae ra see sudo raa e oe eren uc e veu EER 20 B IL7 RELAYS CONTAINING MERCURY eesseeseeeseeeeeeee eene enne entente ente then trennen enne tne ne nenne 20 B M PRINCIPLE OF OPERATION 4 aieo n a a tb e Erat E E E E Ceo E a 21 BHII G N RAL PRINCIPLE sissies an tee ete EEA e TEE E EEEE i 21 B II 2 THE SWITCHING MATRIX ccccesccesscesscssecesneesseesseeeseeescecsaecaecsaecsecsseseseeeseeeseeseneeeaeeeeeeaaeenaes 21 DIPSA STD mm 22 B IIL3 1 The test between two points nennen nen rennen rennen erster 22 B E3 2 The multiple test iiie ierit rhet aea i Ae UR Ea e ede REY ante 25 B HI3 3 Special features ener ier P rr esae e Ye beer Linie ere Poe ERRORI LI REG 25 BIA SELF ICONO oE E E tern e E tree tendon E teen alates 25 BIS SELF TESTS asser Rite EAER edere EAEE ERE E EEAS 26 B H 5 Atomatic self TESTS eoe ee ted rrt etie Pa Toros Y oo ev Riu a een eto Hi Undo E ERNER 26 B IL5 2 Self testS on demand ii e uero aeter line exec e bo UR esae Page oeteg 27 B IIIL 5 3 Organization of a point in the switching matrix 29 B IIL5 4 Organization chart of the switching matrix self test 30 B IIL5 5 Selftest of 4 wire interfaces KELVIN sess ener
98. be connected to the tester so the interface is created and the table of correspondences is written To start self learning select MENU SELF LEARNING or the icon Before conducting any operation connect the equipment for the self learning to the tester The first dialogue box requests the table of correspondences This may have a name different from the test file Self learning setup x Self learning search criterias Test program parameters Stat address TS Endaddess 15 sj Continuity Resistance low limit p a Resistance high limit b ax Information conceming the program Test current po mA v Maximum voltage jo vz Test time ns After validation the second box requests the parameters to be used in the test file At the bottom of this box enter the addresses of the start and finish of the exploration These addresses comprise the first and last point connected to the tester even if this point is isolated Validation of this box initiates exploration of the wiring system This is displayed on the screen by the writing of the test file step by step as the tester creates the nets Once self learning is complete the program can be used immediately for tests This operation is an excellent way of confirming that the self learning process has bee carried out properly WARNING an autoprogram can only be validated if the listing of the test program is compared with the wiring
99. between points A and B It memorises the result If a timeframe in seconds whole value is given the second measurement is carried out automatically If the timeframe is not given in the parameter a dialogue box asks the operator a question When the operator replies YES or the timeframe a second measurement is made and compared with the percentages given in parameter PS D II 4 4 Measuring thermocouples It is possible to measure a type K thermocouple from the comparison of the measurement of 2 Chromel Alumel resistances of the thermocouple The comparison is made from the resistance values and not from a temperature threshold Measurement parameter PRCA VAL minR maxR T Ratio 96 Percentage of error Rchromel Ralumel Theoretical Rchromel Ralumel Application time Maximum resistance Minimum resistance Parameters for measuring the thermocouple Programming the measurement RCA A n1 B m1 A n2 B m2 E mca Alumel address Chromel address Thermocouple measurement instruction sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 120 179 D II 4 5 TRACE FINTRACE Instruction to trace equipment that has PASSED tests from a source file A text file comprising the list of equipment to be tested e g the equipment serial number must be created Winpass generates an output file in the same format as the customer input file in which the equipment that PASSED tests is stated with the addition
100. creen the number of net tested in continuity test displays on screen the number of net tested in continuity test with fail result compare the result of the 2 last tests between 2 points discharge or stop the discharge of points after their test COMMANDS FOR MULTIMETER AGILENT 34401 1 if option is present PMVDC MVDC PMVAC MVAC PMIDC MIDC PMR MR PMR4 MR4 PMP MP PMVDC MVDC PMVAC MVAC DC voltage measurement parameters DC voltage measurement AC voltage measurement parameters AC voltage measurement DC current measurement parameters DC current measurement resistance measurement parameters resistance measurement 4 wires Kelvin methode resistance measurement parameters 4 wires Kelvin methode resistance measurement period measurement parameters period measurement parameters for DC current calculation based on a shunt DC current calculation based on a shunt parameters for AC current calculation based on a shunt DC current calculation based on a shunt COMMANDS FOR PICOAMMETER M1500P if option is present PM1500P M1500P A B M1500PM A M1500PU A B M15000P parameters threshold resistance tension time test M1500P between two points test M1500P between A and all the others points test M1500P between points A and the B points COMMANDS FOR SEFELEC XS DIELECTROMETER PXSI sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition XS insulatio
101. d Close A odd Close B odd Error De DE Error OK d Open A odd Open A odd Close B odd Close B odd gt Error gt Error Bad Bad Close A odd Open B odd Close A odd Open B odd Error Error B VA e Close A odd Close B even Error Others points Insulation minor Error 1 i i o a o A A S Note This test cannot run the bus insulation test and unitary relay test on multiple relay testers This selftest is possible by disconnecting points 1 to 4 and running a normal selftest on these 4 points The request is made by selecting 4 WIRE INTERFACE on the CONFIGURATION tab of the selftest met f l G SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 31 179 SELEIEC B IV Using the TESTER B IV 1 BRIEF GLOSSARY Below we list a few words with their definitions in order to make the instruction manuals as clear as possible CHAIN another term for a net CONTINUITY function yielding the result good if the resistance measured lies within the range of thresholds programmed Low impedance function FILES set of instructions needed by the tester to explorer a wiring system and determine its defects INSULATION function designating as good a measurement greater than the threshold value programmed High impedance function LIST OF POINTS can be considered as a net but may also group together points possessing the same characteristics all insulated all tested at very hig
102. d out from the R programming code and amp RS RDEF returns the number of defective resistance tests amp RS amp RS d amp RS GM amp RS IDEF amp RS dDEF amp RS GMDEF amp RS NI amp RS dz amp RS VC amp RS NIDEF amp RS dzDEF amp RS VCDEF amp RS J_ amp RS F_ amp RS VA amp RS JDEF amp RS FDEF amp RS VADEF amp RS C amp RS b amp RS THTC amp RS CDEF amp RS bDEF amp RS THTCDEF amp RS NC amp RS LR amp RS THTA amp RS NCDEF amp RS LRDEF amp RS THTADEF amp RS 4 amp RS CR amp RS GU amp RS 4DEF amp RS CRDEF amp RS GUDEF amp RS R amp RS_ZL_ amp RS_u_ amp RS_RDEF_ amp RS_ZLDEF_ amp RS uDEF amp RS R4 amp RS ZC amp RS ue amp RS R4DEF amp RS ZCDEF amp RS ueDEF Net test only with the test report function amp RS EQUI returns the number of nets amp RS EQUIDEF returns the number of defective nets amp RS EQUICC returns the number of short circuit tested nets amp RS EQUICCDEF returns the number of defective short circuit tested nets amp RS EQUII returns the number of insulation tested nets amp RS EQUIIDEF returns the number of defective insulation tested nets amp RS EQUIJ returns the number of AC dielectric tested nets amp RS EQUIJDEF _ returns the number of defective AC dielectric tested nets sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 117 179 amp RS EQUIC returns the number of DC net points amp RS EQUICDEF returns the number of defecti
103. e it cannot be performed automatically These self tests must always be used before any self learning operation after a prolonged stoppage of the tester or in any case of doubt Their function is to check that all the relays of the switching matrix open and close properly NOTE It is impossible to perform this self test without disconnecting the wiring to be tested but it is advisable to leave the interface as the insulation test performed during the self test can give useful information about its condition Self tests frequency Weekly or at each self programming SELF TEST Long shutdown SELF TEST Monthly CLEAN FILTERS Yearly CHECK MEASUREMENT PARAMETERS Yearly CLEAN TESTER sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 177 179 Loop self test for further information see chapter E II 2 of this manual NOTA in Set up loop self test is recommended to heat progressively the electronic of the tester This function is efficient when a tester doesn t reach insulation resistance threshold because of high humidity or long shutdown PRECAUTION DURING USE for further information see chapter B II 6 of this manual The tester must never switch or receive external electrical power supplies that it does not control via its own software Such power supplies include induction coils not fitted with free wheel diodes or capacitors that are not discharg
104. e SYNOR 4200 reacts to a variation in current If the operator is in contact with the wiring the generator is inhibited and the energy stored in the wiring is discharged through a 1 kQ resistance The continuity generator does not exceed 20 V DC The high voltage DC generator is limited to 5 mA The high voltage AC generator is limited to 5 mA rms The system of protection applies both to the equipment under test and to the operator it is independent of the voltage applied and of the current injected for measurement purposes NOTE When the generator is inhibited the switching matrix remains in the same position as upon occurrence of the incident for 20 ms in order to ensure complete discharge of the wiring under test B II 4 6 To summarize access to the tester must be restricted to personnel made aware of electrical hazards It is strongly recommended not to handle the equipment being tested risk of faults and electric shocks A safety loop is proposed on testers fitted with the high voltage AC option For voltages greater than 1000 V suitable signalling available as an option must be set up T fe l a SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 18 179 sciciec B II 5 MAINTENANCE OF THE INSTRUMENT 1 PRELIMINARY Our warranty refer to the beginning of this manual attests the quality of materials and workmanship in our products If malfunction should be suspected or other information be desired call our
105. e according to the switching board type Points 1 256 500 V Opened error 41 Ar 1 Pa 1 Ca 1 Pt 41 R lt 2 Ohms Insulation measurement error 45 Ar 1 Pa 1 Ca 1 Pt 45 U lt Uprog 4L Ar L Pa tt Ce tot Pt 41 Insulation measurement error 49 Ar 1 Pa 1 Ca 1 Pt 49 U lt Uprog 41 Ar 1 Pa 1 Ca 1 Pt 41 Insulation measurement error 53 Ar 1 Pa 1 Ca 1 Pt 53 U lt Uprog 41 r 1 Pa 1 Ca 1 Pt 41 Insulation measurement error ST tae tle Pe ee ie ee PG 15 U lt Uprog 4L Ar to Fe LD OR He Pt or 41y Insulation measurement error 61 Ar 1 Pa 1 Ca 1 Pt 61 U lt Uprog 41 r 1 Pa 1 Ca 1 Pt 41 SELF TEST FAIL End of self test 23 06 2005 13 35 58 a F2 Execute u F1 Close D F3 Step by step F8 Parameters s fe l i SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition SeI Iec 28 179 Opening fautonBn This fault indicates that the B contact with address n remains closed This message is always accompanied by a single opening fault with the corresponding modulo 4 unit Example opening fault 41 with 1 5 9 etc SEFELEC WINPASS TESTER Self test Menu Setup Help ze lo E gt RENE Insulation parameters Resistance threshold 500 MOhms Insulation voltage 500 V Breakdown current 1 m HV rise time 10 ms HV hold time 10 ms Start address 40 Con
106. e nennen 57 C I 2 SINGLE CONNECTION WITH ONE INCORRECTLY CONNECTED TERMINATION WIRED TO AN ISOLATED LOWER ADDRESS TERMINAL entente enne nene en 58 CIL3 SINGLE CONNECTION WITH ONE INCORRECTLY CONNECTED TERMINATION WIRED TO AN ISOLATED HIGHER ADDRESS TERMINAL cesses ettet en nest sten nennen 58 CIL4 ISOLATED POINT MISTAKENLY CONNECTED TO ANOTHER ISOLATED POINT 59 CALS INVERSION OF TWO WIRBS eere erneute eee eh eene etre eee eoa eh neo adt ree reader dires 61 C IL6 BREAK IN A CONNECTION CHAIN Qisecssccssssesesesseeseeeeseeeceeeneceaeeeseecsuecauecaueceaecnaeeuseeeeseeeeeeeeteaes 61 C JIL7 BREAK IN A CONNECTION CHAIN WITH AN INCORRECT WIRE cessent 61 CILS UNCONNECTED WIRES IN A CHAIN eeesseesseeeeeseeeneen nene enne entren nent enne tenete sienne en 62 C JIL9 TWO CHAINS CONNECTED TOGETHER ener enne enne terrere en 62 C I 10 TWO CHAINS CONNECTED TOGETHER BY A FORGOTTEN WIRE ON ONE OF THEM 63 C IL 11 ISOLATED POINT WIRED IN A CHAIN POINT POSITION ren 64 C IL 12 ISOLATED POINT WIRED ON A LONG CHAIN eessseseseeeeeee nee ettet en nennen 64 C IL 13 INSULATION TEST BETWEEN TWO POINTSS esssseseseeeeeeeeee ener nennen ennt nn senten en 65 C I11 14 CASE OF RESISTORS WHOSE VALUE IS BETWEEN THE CONTINUITY RANGE AND THE INSULATION RANGE sees cesis keiten exea eue ined cubs va E Dodane R ea decet den rv D eate ERES a 66 C M DOCUMENTS FOR ANALYSING THE ERROR LIST 66 C
107. e points on the wiring to be tested under measurement This switching matrix works by means of relays giving it high performance on insulation and voltage The technology selected is the REED relay these components provide high commutation speed 300 us and very high insulation 210 MQ enabling thousands of points to by commuted in parallel and at a very high voltage 2150 V Two possibilities are available in application of this principle e A switching matrix with 4 contacts allowing all types of measurement between two points or by nets except for tests between groups of points e Aunitary relay switching matrix provides the additional possibility of testing one net against all the other points connected to the earth standards GAM EG 13 RC AERO 54335 PR EN 2283 NF F 67 001 5 Dec 91 and testing between groups of points B I 3 OPTIONS We shall restrict ourselves here to a list of these options each of which is the subject of a specific manual e measurement of dielectric strength under alternating voltage programmable between 20 V and 1500 V The breakdown detection threshold is programmable between 500 pA and 10 mA e measurement of inductance 10 uH to 10 H e measurement of impedance e low level measurement continuity and insulation at 200 mV e control of relays B TE CONDITIONS OF OPERATION B II 1 ENVIRONMENT A wiring tester is an instrument for carrying out several types of measurements and imposes certain
108. e program may be executed several times and when the number of parts is obtained either the number of good parts or the number of total parts then the BATCH report will be generated and closed s fe l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 113 179 setelec C Reopening or completing a LOTA To reopen or complete a batch launch the program x and when the batch number is requested simply C The lot already exist Would you add data to this lot enter the number of the batch that has already been J tested and a dialogue box will ask if you want to complete this BATCH You will then be asked the number of BATCH parts This number is the number of parts to be added to the previously tested batch x If this dialogue box appears it means that you are using an existing batch number and that the option to reopen or The lot already exist Enter an other lot number complete a BATCH has not been selected in the program You will not therefore be able to complete this batch D LOTA report When the BATCH has reached the number of parts defined the batch report is generated this number is defined by the number entered in the dialogue box The LOTA report is created from a source file in html format See the chapter below on the test report function for creating the source file In this file customer specific layout may be carried out with the addition of test variables The test variable fields
109. e writing tool and select the table you want The points no longer show up in the tester address but at the transcoded point Select Add the line to write the corresponding instruction What shows up in the test program PI VAL 100M 500 1m 10m 30m PC VALO 5 500m 20 5m El B J1 5 B J1 6 B J3 2 B P4 1 El B 10 B 11 f l SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 100 179 SETEIEC What the global test involves In all the following cases the continuity test s between the net points is are executed To summarise EI Tests short circuit DC dielectric insulation continuity between the points Insulation and continuity parameters PI and PC required Eld Tests short circuit DC dielectric continuity between the points Insulation and continuity parameters Pld and PC required EJ Tests short circuit AC dielectric continuity between the points Rigidity and continuity parameters PJ and PC required EN No insulation or short circuit test at the start of the net Only the continuity test is carried out A continuity parameter is required PC ED Short circuit continuity tests between the points Continuity parameters PC required Il DC dielectric insulation continuity tests between the points Insulation parameters PI required IJ AC dielectric continuity tests between the points Rigidity parameters PJ required Two parameters are necessary for a net PI for the
110. easurement instructions between two points tester option Type of measurement Option required Measurement syntax dielectric strength AC 34019 AC generator J A xx yy B ww zz DC voltage ZLC or 40535 VC A xx yy B ww zz AC voltage ZLC or 40535 VA A xx yy B ww zz Inductance ZLC LR A xx yy B ww zz Capacitance in alternating current ZLC CR A xx yy B ww zz Inductor coil impedance ZLC ZL A xx yy B ww zz Capacitive impedance ZLC ZC A xx yy B ww zz GMOV GMOV GM A xx yy B ww zz Voltage generation U generation GU A xx yy B ww zz Current voltage generation U generation card 40549 u A xx yy B ww zz External power supply on U generation external ps ue A xx yy B ww zz measurement switching External power supply 1 or 2 on Stimuli with Microlab ps UsnON or UsnOFF Stimuli switching n 1 or 2 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 93 179 sefelec b Options These are not compulsory and can be accumulated They are separated from the test code by a space OorS Operator decision Allows the operator to decide if the test has passed or failed Example Fromthe EDITOR PR VAL 10 100 Om Op RO A B 2 gt From the TESTER x A dialogue box appears The operator can Tet Resistor measurement then select PASSED or FAILED In this case the tester does not carry out any Point fi measurement This is up to the o
111. ed The tester is fitted with an external output function that can be programmed to connect two programmed points to a connector on the front panel An external measuring instrument can be connected to this for specific measurements or troubleshooting However the following conditions must be observed e The external device must NEVER exceed the MAXIMUM VOLTAGE and CURRENT values permissible on the relays of the tester e Dielectrimeters and breakdown meters are STRICTLY FORBIDDEN e The external output must not be used as a generator switch e Any external power supply is forbidden as the routing relays are unable to switch it e n the case of an external output on a multiple insulation test all or some of the points are short circuited because the relays remain in place Select STOP TEST to look for a fault on the equipment with an ohmmeter PRESENTATION OF THE ERROR LIST for further information see chapter C of this manual Errors appear in red PASSED test results in blue on a full display Error messages 1 If there is a continuity or broken circuit error Continuity measurement error A J1 12 B TB1 EARTH R gt 250 Ohms 2 f there is a continuity error due to a poor contact Continuity measurement error A P4 21 B J32 a R 15 Ohms 3 If there is an insulation error due to a short circuit in relation to the lower points Insulation measurement errorA P6 AA B J12 5 R 1 20 Ohms 4 f there
112. elec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 47 179 sefelec e 32 24 Board 3 Board 4 Board 6 o O z e O O e O a C10 1 C11 1 C12 1 C13 1 n d C16 1 C5 2 C62 C72 C8 2 C92 C10 2 C11 2 C12 2 C13 2 C142 C15 2 C162 POLLAN HARTING reference of interface connectors L Board 5 LLL CL Board 7 09 73 164 6907 Male connector 09 03 096 0501 Hood 09 02 000 9911 Grommet 09 02 000 9902 Left locking 09 02 000 9903 Right locking Wires recommended for wiring TYCO RAYCHEM 44A0111 24 n n colour code or choose an insulating material as flexible as possible corresponding to the measurement voltage and a 22 to 24 gauge Note it is not possible to use self stripping connectors at these voltages The most available connectors on the market are wrapping ones Each weld will be protected by the heat shrinkable cover It is advised to remove the marking ink between the connector pins risk of poor isolation The connector of the right figure is the male interface connector seen from the wiring side Row b is never used For all the other pins one in every four is wired see wiring list below This list gives the wiring of the first connector of the first switching card The other connectors are organised in the same way sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 48 179 puse ee ee MEM NN ENG
113. enne enne 3l B IV SING THE TESTER eee eerie reed EREE O mien else eed ee tees 32 BAVA BRIEF GLOSSARY oc sete cc etisncestcastinieer erene n EEIE eiee ET EEEE E E EE EES aE eS 32 BIS TOP 32 BAV 3 ERROR MESSAGES redi iet aa i ouo ane e e Reo eaten 32 BIVA THE TWO MODES se ere she e a eU e e nre A lite pde teens lente 33 B V PARAMETERS AFFECTING THE ACCURACY OF MEASUREMENTS OF INSULATION ener 33 B V 1 GENERAL E M M M 33 B V 2 INFLUENCES and SOLUTIONS ADOPTEd to inhibit the effect of the noise elements 34 B V 2 1 Efrect of the capacitance Cli iius rd eere ere reete te hara ede elo edere ede antes 34 ot fe l S SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 4 179 SCIEIEC B V 2 2 Effect of the resistance 11 cccscccccsecssssecsecccccecccseveccocceccescvsecescceseceescessececceserecssecseceees 34 B V 2 3 Effect of the series network 12 02 iii 34 B V 2 4 Effect of 50 Hz radiation seen 34 B V 3 CON CLUSION PEE 34 B VI IMPORTANCE OF THE MEASUREMENT OF LINE RESISTANCE eene 35 B VLT functional TOLERANCE eee tne idt et rre e as cedar ener einen 35 DR MEM PICGUVQUUES EE 35 B VELS deviations aceite tro Ee eei cedere rine eund een eter PER Pee ped bee PEE ed Enea eT eod APR Eee TS 35 BVIF CONCEUSION cR 35 B V USEFULINFORMATION ienien nunai E E E taies ide 36 B VILI Interface FOR SYNOR 4202er iernii
114. entical parts and wanting one report of all the parts together rather than one report per part a Batch function LOT If the BATCH function is introduced in the test file a result report common to all the products in a batch can be produced This function does not hide the test results for each part tested The BATCH function is placed after the different electrical tests intended to test the part making up the BATCH The instructions between BATCH and FLOT are intended solely for the layout of the BATCH report batch report path The test is carried out in chronological order of the test program implemented When the BATCH zone is executed dialogue boxes successively ask o forthe BATCH number o If the part is to be counted Answer YES to add the part for this batch number or NO to ignore this part for this batch number o If the BATCH is complete Answer Yes for a BATCH result file to be created called BATCH test file name BATCH no This file is formatted according to the texts written between BATCH and FLOT Answer NO for the BATCH to be completed at another time o The end of test dialogue box TEST PASSED or FAILED appears and suggests RETESTING or STOPPING It is possible to reopen a BATCH by running the program and recalling the same BATCH number It is possible to reopen a stopped batch for which a batch report has already been created For example if the operator has validated the batch end but would like to
115. ents we use mercury relays for some of our functions European Directive 2002 95 EC of 27 January 2003 concerning the restriction of certain substances for electrical and electronic equipment ROhS and European Directive 2002 96 EC of 27 January 2003 concerning waste from electrical and electronic equipment WEEE stipulate that from 1 July 2006 the use of mercury is restricted only for equipment relating to food electrical household appliances medical applications and toys Industrial equipment is not concerned um fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 20 179 SEIEIEC B EEE PRINCIPLE of operation B III 1 GENERAL PRINCIPLE The role of the PC is to dialogue with the operator It is used to process store and read the test programs It sends test commands to the measurement unit and the switching matrix The latter then selects the points to be tested in the wiring system under test and connects them to the measurement unit The results are sent to the PC which processes them B III 2 THE SWITCHING MATRIX The switching matrix is a steering device composed of REED relays which chooses points in the wiring system to be tested and links them to the measurement units Every point tested is either the departure point or the arrival point of a measurement In order that any terminal of the tester may be connected at will it is necessary to associate two contacts with it directing each point to the hot
116. f the value programmed Application time 1 s to 999 s 5 of the value programmed Fall time 1 s to 99 s 5 of the value programmed Detection mode P IMAX detection by current threshold DELTA DELTA detection by current variation I DELTA IMAX DELTA are activated at the same time FI FIMAX detection by current threshold rapid mode FI DELTA FIMAX DELTA are activated at the same time sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 125 179 The detection mode is automatically defined by the tester at the factory the default mode is DELTA A the end of the PXSRC and PXSRA parameters it is possible to specify the detection mode in this case the instruction becomes PXSRC VAL 500 1m 9 9m 1m 1 5 1 FI The detection mode must be written in commas depending on the syntax described in the detection modes at the beginning of this chapter This parameter is optional it is not specified the chosen mode will be the factory configuration one See the SEFELEC XS series manual for complete characteristics of the XS series devices Point programming follows the rules of tests between two points or tests per group unitary relays See the chapter on this subject in the manual attached e Insulation resistance measurement DXS dielectrimeter PXSI VAL 500 10M 15M 1 5 1 T Ty Fall time in seconds gt Application time in seconds gt Rise time in seconds Maxi
117. g material as flexible as possible corresponding to the measurement voltage and a 22 to 24 gauge Note it is not possible to use self stripping connectors at these voltages The most available connectors on the market are wrapping ones Each weld will be protected by the heat shrinkable cover It is advised to remove the marking ink between the connector pins risk of poor isolation The connector of the right figure is the male interface connector seen from the wiring side Row b is never used For all the other pins one in every two is wired see wiring list below This list gives the wiring of the first connector of the first switching card The other connectors are organised in the same way sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 42 179 BB RC Ll d trompeur a TT HE E EE A cd 3n Ss a i E atii a Lo qe ee aves RS a ee es E J SS S es E uam MEI MER SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 43 179 sefelec B VII 4 SWITCHING CARDS 40570 AND 40670 Switching cards 40570 or 40670 2000 Vdc 1500 Vac 2 A 64 points route the measurement of the SYNOR 4207 and 4208 They are placed in racks receiving a maximum of 16 cards each They are all identical only their position determines their address They are intermixable with 40675 cards see the technical datasheet Since the relays used are mono contact these cards may
118. g to the measurement voltage and a 22 to 24 gauge Note Self stripping connectors can be used but with a heat bonded not extruded flat cable pitch 1 27 mm 64 wire AWG 28 gauge ur fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 39 179 SEIEIEC Thomas amp Betts reference 201 64 100 Tyco AMP reference 6 57643 4 In this case remember that the points are wired in column arrangement and not zigzag Because the hoods cannot be used the locking parts must be dismantled on the switching cards The most available connectors on the market are wrapping ones Each weld will be protected by the heat shrinkable cover It is advised to remove the marking ink between the connector pins risk of poor isolation The connector of the right figure is the male interface connector seen from the wiring side Row b is never used All the other pins are wired see wiring list below This list gives the wiring of the first connector of the first switching card The other connectors are organised in the same way Tester address male interface connector Customer connector d trompeur male interface connector see cabling side BN BH BH BH BH BH BH BH BN BH BH BH BH BH BH BH BN BH BH BH BH BH BH ot fe l n SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 40 179 SCIEIEC gt V V AR a O1 a C1 V o V o
119. grammed in the test file e Value per range X type of parameter see list below The minimum and maximum values are given in scientific notation e g 100 10E1 and in the standard units of the IS system Q F s etc with the indicators p n u m k M and G Syntax of the old setting modes The two following modes although obsolete are still valid to ensure the compatibility of the old Tester generation program The parameter library can only be used for the old DOS versions The parameter number must lie between 0 and 99 A section of the EDITOR can be used to fill in 100 different tables per measurement group LE Ed Table number X type of parameter see list below e value per percentage The nominal value is given in scientific notation while the tolerance is in a direct value between 1 and 100 en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 86 179 SEIEIEC The different standard measurement parameters of the tester Parameter type Parameter syntax DC insulation PI VAL R threshold insulation U I breakdown HV rise t HV application t DC dielectric strengh Pld VAL insulation U breakdown HV riset HV application t Continuity PC VAL minimum R maximum R I test maximum U application t Resistance PR VAL minimum R maximum R application t test range Capacitance PF VAL minimum capacitance maximum capacitance Shielding Pb VAL minimum capacitance max
120. h voltage etc NET Sequence of points in a wiring system having the same potential and therefore connected by a wire also known as a chain or tree An isolated point constitutes a net of 1 point as far as the tester is concerned SELF LEARNING OR SPONTANEOUS LEARNING a function whereby a test program can be created automatically from a calibration wiring system SWITCHING MATRIX control system operating through relays or semi conductors with which the points to be tested in the wiring system are selected TRANSCODING software with which the tester translates machine address points into user points including the names of the connectors and their pins B IV 2 MENUS for further details see Instructions for use and WINDOWS on line help The tester s software uses the WINDOWS environment with its dialogue boxes buttons and scroll boxes We shall not go any further into these concepts in the remainder of this document B IV 3 ERROR MESSAGES e Major defects detected by the system are displayed in clear on the screen e They show the problems encountered in the electronic operation of the tester e defective measurement e no printer available e disk unit absent or faulty e fault in the connection between the PC and the tester e etc Most of these messages inhibit operation of the tester as a precautionary measure risk of misinterpretation of the test en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I
121. his system makes 4 wires Kelvin methode operation possible without much modification of the interface but respecting the odd even layout A1 A2 A3 M Relay A controls Joo fra fafa UE Point n Point n 1 Point n 2 Point n 3 Relay B controls UY Global B1 B2 B3 B4 control SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 21 179 sefelec This switching matrix is available either in modules of 128 points accepting a current of 2A and a voltage of 500 V and equipped with 2 type 41 612 64 point connectors or in modules of 64 points accepting 2A and 2000 V equipped with 2 type 41 612 32 point connectors b Switching matrix with unitary relays Another switching matrix is also available It is made up of unitary relays giving greater testing flexibility with unlimited combinations It is equipped with unitary relays accepting 2A 2000 V A1 A2 A3 A4 B1 B2 B3 B4 This switching matrix can test a net with respect to lower ranking addresses or one point among others The second switching matrix can also test a net among all the other points Point n Point n 1 Point n 2 Point n 3 This switching matrix is ideal for functional tests because any points in a wiring system can be routed or protected if they are likely to be damaged or impede the test B III 3 THE TEST Two major families of tests are possible by the positioning of the switching matrix de commutation the test between two points and the
122. imum capacitance 4 wire continuity P4 VAL minimum R maximum R test maximum U application t 4 wire resistance PR4 VAL minimum R maximum R application t test range Diode Pd VAL minimum U maximum U test Zener diode Pdz VAL minimum U maximum U test NB For the 2 and 4 wire resistance measurement PR and PR4 if the value entered for I test range current range is 0 the tester will use an automatic current range Reminder of the measurement parameters table MEASUREMENTS PARAMETERS MIN VALUE MAX VALUE Threshold INSULATION resistance 50 kQ 2000 MO INSULATION amp dielectric strengh Insulation U 20V 2000 V INSULATION amp dielectric strengh Rise time 10 ms 99s INSULATION amp dielectric strengh Application time 10 ms 99s INSULATION amp dielectric strengh breakdown 500 HA 10 mA 2 amp 4 wire CONTINUITY test 10 mA 2A 2 amp 4 wire CONTINUITY Maximum U 5V 20 V 2 amp 4 wire CONTINUITY Time 3 ms 99 s 2 wire CONTINUITY min max R 0 5 Q 250 Q 4 wire CONTINUITY min max R 1mQ21A 250 Q 2 amp 4 wire RESISTANCE Time 3 ms 99s 2 amp 4 wire RESISTANCE Current range 1 uA 10 mA 2 wire RESISTANCE Resistance 10 Q 10 MQ 4 wire RESISTANCE Resistance 100 m 10 MO DC CAPACITANCE Capacitance 100 pF 100 000 uF SHIELDING Capacitance 50 pF 1 uF DIODES Current 10 mA 2A Voltage 100 mV 20 V ZENER DIODES Test voltage 20 V 100V Zener voltage 20 V 90 V
123. ing the interface as a reference and thus ignoring the tester The table of correspondences will then be written by inserting the connectors one by one as they are connected to the tester DV FORMAT OF THE PROGRAM FILE In order to function the tester needs several working files in which all the information for a set of tests is provided The name of each of these files is made up of not more than 31 alphanumerical characters and an extension of 3 characters imposed by the tester software in accordance with the description above The name of a test program will be written in the form TES D V 1 CONNECTOR TABLE CNT The connector table CNT is a text file in which each record corresponds to a connector and is made up as follows en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 153 79 seciciec name of connector name of pin y of pin J where the opening curly bracket represents the beginning of a record and therefore of a connector The name of the connector is made up of 30 characters and must be followed by a line ending LF CR The names of pins must be made up of 10 characters and must be followed by a line ending LF CR The maximum number of pins is limited to 1000 A record must be terminated with a closing curly bracket The number of connectors contained in a file is unlimited D V 2 ERROR REPORT ERR The error report ERR is a text file It can be consulted using any
124. ion and reading of a program The choice of colours cannot be set sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 71 179 D II 3 1 Commodities text image and dialogue box functions a Comment OUR et a L A comment is not registered in the wiring test program It does not appear on the screen or on the printer during the test It simply allows the programmer to enter comments into his program which are visible when editing the test file Example Fromthe EDITOR REM tester demonstration program sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 72 179 b Text function Messages for the operator The text is displayed on the screen sent to the printer and saved in a results file if requested I lt text The text is only displayed on the screen ext The text concerns the previous tests It is edited if one of the previous tests fails It is written on the screen and printer This code remains compatible with the old HC WINPASS versions earlier than 4 00 H text O The text concerns the previous tests It is only edited if all of the previous tests are correct It is written on the screen and printer HCB text il This keyword allows the operator to enter a text from the keyboard during the test The text may be for example the operator s name or a test report text is NB During the test the printer can be disabled in the
125. ion is programmed the multiple tests El ED EN are prohibited and a voltage absence test is carried out systematically before each test between two points COMMAND OF DIGITAL INPUTS SE n This command blocks the test programme awaiting transfer to the logic value 1 on the input n SE1 n Is equivalent to the SE n command SE0 n Blocks the test program awaiting a low level on the input n It is possible to interrupt the wait for the SExx instructions by clicking on the button located at the bottom of the WINPASS Tester screen STOP INTERROGATION INPUT The program then resumes as normal en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 135 79 SEIEIEC D III 3 FUNCTIONAL TESTS STIMULI CARD 40680 AND 40575 Functional tests use power supplies outside the tester measurement so as to stimulate the devices relays etc in the equipment being tested These external sources often stay on while the tester carries out a cycle of measurements state of contacts indicator lamps etc Precautions must therefore be taken to ensure there are no conflicts between the measurement current and stimuli or worse short circuits in the power supplies For this the zones using power supplies shall be bracketed by STIMULI and FINSTIMULI codes In these zones WINPASS bans all tests by global groups i e closes off all cold points El EIU ED Il IU EJ etc The only one allowed is IU A
126. is an insulation error due to low resistance in relation to the lower points Insulation measurement errorA FRAME EARTH B J24 1 R lt 50k Ohms 5 f there is an insulation point with a long net limited search is requested Insulation measurement errorA J4 T B J1 25 R 1 25 Ohms B J2 28 LIMITED SEARCH 6 If there is an insulation error between 2 points Insulation measurement errorA point 34 B point 237 R 60MQ 7 If there is a breakdown or dielectric error on a point in relation to a net Insulation measurement errorA PRISE 12 B J4 37 U xxV B J4 39 or T xxxms or fe l 3 SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 178 79 SEIEIEC The time is given if the breakdown occurs during the application time The voltage is given if there is a breakdown during the rise time 8 If the insulation test voltage was not reached by the end of the rise time the error is close to a short circuit Insulation measurement errorA J45 12 B P12 1 U lt Uprog 9 If there is a error during a test between 2 points for all options FLT xxxxx A TB1 5V B TB1 0V xx nnnn ADVICE FOR REPAIR for further information see chapter C V of this manual Do not forget the role of the probe This shows the points affected on the wiring on a table matching the tester point intermediate interface point and user point NOTE There are two restrictions to using the probe low level and stimuli
127. istance Diode Cable tester point Opening an equivalence table Condenser e Shielding e Self inductance Condenser alternating current Then choose the test options by tick the boxes M Finally specify the two points to be tested by choosing them from the list called up in the table of correspondences of the wiring system to be tested click on CORRESPONDENCES Note some of tests proposed are only available if the options are present sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 161 179 E I 5 2 Net test To create a test net between more than 2 points select the command code Test file creation tool x Relay commands Test one point others Commodity Tests between two points Net tests Parameters SUED 02 LI L CL M s L E LI e High voltage insulation test and continuity El Low voltage short circuit test and continuity ED Continuity test on the net EN e Alternative high voltage insulation test and continuity EJ Next step is to select the different points of the net tick the box M near the point Points marked with are points which are already used in the program it s only an information you could select this point more than once if needed As explained in previous chapter the name of the point must be peace E transcoded from equivalence table In this case select OPENING eum me AN EQUIVALENCE TABLE For
128. ition 75h79 SEIEIEC d Dialogue box DIAL EZ Dialogue box file name Used to compile a dialogue box of 1 to 10 fields Filled in at each test by the operator these fields are printed on the test list Some fields can be used to fill in the results file name see user s manual The text can be added in one of the fields 1 to 9 of a dialogue box in a text of the type H The dialogue box used will be the last one programmed in the test sequence Code n 1 to 9 gives the text of the corresponding field of the dialogue box SEFELEC WINPASS EDITOR Dialogue box CDO Example Eile Edit Tools Window Help x Bg gt Creation of the dialogue box from the EDITOR j D i m and the creation of the dialogue box tool demo DIAL perator s name Serial number Designation Sete a N SEFELEC Call up the dialogue box when writing the test program from Winpass editor DIAL C sefelecDEMOW INPASS dial demo DIA H B 12 Op rateur amp DIAL1 start test From the TESTER the following dialogue box x appears to allow the operator to fill in the different fields Operator s name Serial number s fe l i SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 76 179 SCICICC WINPASS TESTER Execution of the test program C Doc Menu eee Tools ce Start test 06 07 2009 10 15 Operator s name Smith Serial number 115577 Resignation AAEES5 O
129. its own software Such power supplies include induction coils not fitted with free wheel diodes or capacitors that are not discharged The external output must not be used as a generator switch As the SYNOR tester is a measuring instrument SEFELEC cannot be held liable under its guarantee or otherwise for any damage to the device or lost production resulting from failure to comply with the operating conditions set out above environment mains power supply and utilization conditions The tester is fitted with an external output function that can be programmed to connect two programmed points to a connector on the front panel An external measuring instrument can be connected to this for specific measurements or troubleshooting However the following conditions must be observed e The external device must NEVER exceed the MAXIMUM VOLTAGE and CURRENT values permissible on the relays of the tester e Dielectrimeters and breakdown meters are STRICTLY FORBIDDEN e The external output must not be used as a generator switch e Any external power supply is forbidden as the routing relays are unable to switch it e Inthe case of an external output on a multiple insulation test all or some of the points are short circuited because the relays remain in place Select STOP TEST to look for a fault on the equipment with an ohmmeter B II 7 RELAYS CONTAINING MERCURY You are reminded that to guarantee high quality performance from our instrum
130. ivered from Tester e e d e Power supply 1 o e 16 linked channels to r power supply 1 2 equal parts in each card Power supply 2 i 7 e 16 linked channels to power supply 2 a Installation These cards are still installed at the end of the rack their setup is manually made automatic setup only recognize standard cards Only SEFELEC technician have to do this setup The setup is visible from matrix 4200 setup cards 40575 are in yellow sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 140 179 Matrix 4200 setup Xi C1 Matrix 4200 Version 5 02 build 74 f l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition SETEIEC 141 179 b Program The ways numbering is made as follows Ways 1 C1 BH O m Power1 Ways ie C2 mg UH A2 Power 1 Ways 2 C3 EUR AS Power 1 Ways 2 C4 HUN A4 Power 1 0V indt Ge E O E d Power 1 0V Ways 3 bid US A6 Power 1 0V Ways 4 C7 Bog A7 Ways 4 C8 Bod A8 Ways 5 C9 Hod AQ Ways 5 C10 Bodo A10 Ways 6 C11 Bod A11 Ways 6 C12 Bod A12 Ways 7 C13 Hooda A13 Ways 7 C14 mE O O A4 Ways 8 C15 Hog A15 Ways 8 C16 BH O O A16 Ways 9 C17 E O O A17 Ways 9 C18 BH Oo O A18 Ways 10 C19 E Oo O A19 Ways 10 C20 m O O A20 Ways 11 C21 Bog A21 Ways 11 C22 Bod A22 Ways 12 C23 Bodog A23 Ways 12 C24 E DO O 24 Ways 13 C25 m o o 25 Ways 13 C26 m o o A26 Ways 14 C27 BE Oo O Az Ways 14 C2
131. l Ref WINPASS Rev I july 2009 Edition 83 179 SCICICC D II 3 6 Conditional zones a Zone executed if all tests have PASSED A series of instructions may be inserted between TESTB and FTEST that will only be carried out if all the tests preceding this zone have passed Example Fromthe EDITOR TESTB PF VAL 50 n 150 n F A 4 B 6 FTEST The tester will carry out the instructions between the zone marked out by TESTB and FTEST only if all the tests preceding this zone have PASSED If just one test fails these instructions will not be carried out b Zone executed if one of the tests has FAILED A series of instructions may be inserted between TESTM and FTEST that will only be carried out if one of the previous tests has FAILED For example STOP instruction Example Fromthe EDITOR TESTM PF VAL 50 n 150 n F A 4 B 6 STOP FTEST If all the tests preceding this zone have PASSED the tester will continue the test by ignoring the instructions in this zone If one of the tests preceding this zone has failed the instructions in the zone will be carried out sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 84 179 C Zone executed only in the first test A series of instructions may be inserted between SER and FSER that will only be carried out once during the first test after a file is loaded Example Fromthe EDITOR The DIAL instruction between the SER
132. l a SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 14 179 setelec TABLE OF THE DIFFERENT PROGRAMMABLE PARAMETERS option MEASUREMENTS PARAMETERS MIN VALUE MAX VALUE ACCURACY CONTINUITY 2 wires R min 250 Q 5 R max 250 Q 5 Courant 2A 5 Voltage 20 V 5 Time 99 s 1msoris 4 wires Kelvin methode R min 2500 5 R max 250 Q t5 Current 2A 5 Voltage 20 V 5 Time 99 s 1msoris INSULATION Resistance 2000 MQ 5 DC voltage 500 V 5 2000 V 5 Rise time 99 s 1msoris Application time 99s 1msoris Breakdown 10mA 10 DIELECTRIC STRENGTH AC voltage 1500 V t596 Rise time 99 s msoris Application time 99 s 1msoris Breakdown 10mA 10 DIODES Current 2A 5 Voltage 20 V 5 ZENERS Test voltage 100V 5 Zener voltage 90 V 5 RESISTORS 2 wires Resistance 10 MQ t596 Time 99 s 1msoris 4 wires Kelvin methode Resistance 10 MQ 5 Current 10 mA SHIELDING Capacitance 1 uF 5 pF 5 DC CAPACITORS Capacitance 100 000 uF 5 pF 10 AC CAPACITORS Capacitance 2 000 UF 5 pF t 10 96 INDUCTION COIL Self induction 200 H t596 The tolerance values are given for the read or programmed value as the case may be These are guaranteed values on the measuring unit but the connection interfaces have a considerable effect on measurement quality sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 15 179 The switching matrix The switching matrix is the element which brings th
133. lick on the button AUTOMATIC CONFIGURATION READ OUT E II 1 2 Test setup Unlike the machine configuration test configuration can be changed at any time It is a set of tools facilitating the use of the tester to carry out tests Using the icon at the bottom right of the test screen access can be had to this box during the test and the contents can be modified It is the usual principle the function is activated by the presence of M Test setup x v Stop on fail v Test time date Operator intervention message display Mlle care Stop on first Fail Limited research at bs points Research of points group failures Compulsory input Delete at each use Measurement offset adjustment T Serial number Compulsory input Result printing 7 Delete at eachiuse oo oPheshp v Edition of the parameters IV Save the results M Full edition 0 Savedoomiguatin v Measurement report Excel report Operator report Saved configuration Looping test program Simplified report printing Clear didlog boves DIAL HTML report printing CRT Save the statistics OK f l SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 167 179 SEIEIEC Panel at top left test conditions e STOP ON FAIL in the event of a test fault gives access to a control box which will define the problem or correct it immediately OPERATOR INTERVENTION MESSAGE DISPLAY
134. lled on your PC proceed as follows Uninstall WINPASS from Windows and the add delete a program option situated in the control panel Then delete the control liv file situated in C WINDOWS SYSTEM32 manually You are now ready to install the new version of WINPASS From WINPASS 5 04 version installed on your PC proceed as follows Insert the installation CD select remove to delete the previous version and follow the instructions for deleting the previous version Relaunch the installation program Follow the instructions for installing the new version sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 70 179 D IT DESCRIPTION OF THE SOFTWARE The SYNOR 4200 tester is delivered with a pack containing the files required for installing the tester software and its editor D II 1 FILE MANAGEMENT The PC is delivered with specific documentation see suppliers manual recalling how it works The WINDOWS operating systems are supplied with educational software All actions on files copy delete etc and floppy disks formatting will be carried out using WINDOWS utility programs D II 2 OPERATING FILES The tester needs several files to function in which all the information is provided for a series of tests The file names are composed of alphanumerical characters and a 3 character extension imposed by the tester software according to the description below For a series called DEMO the
135. long enough to allow easy access to the equipment being tested handling for repair without disconnecting Jumper technology must be chosen so that the whole is as flexible as possible Rilsan jackets are a good solution but should not be tightened too much or have strands with too many wires 64 is the correct maximum To make connections easier the tester addresses may be left free if the number of tester points makes this possible For example if you have a tester for a 64 pin connector that you are going to use to test a 50 pin connector 14 addresses can be left free if the tester cannot be completed with a smaller connector All of the pins of a connector on the equipment to be tested must be connected to the tester without fail Otherwise the tester risks not seeing certain defects or poorly interpreting an inversion However free addresses on a tester can be left unprogrammed saves time during the test The voltages used by measurements routed by these cards must be insulated properly jacket spacing cleaning etc the conductor sections will only be dependent on continuity measurements T fe l SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 37 179 SEIEIEC View of tester outputs B VII 1 3 The connector described in this document is the tester connector For reasons of electrical safety it is a female connector ZY elele i Bug 38 179 SYNOR 4200 Manual Ref WINPASS
136. long list it s possible to sort the ee aaa connectors in alphabetic order select SORT THE CONNECTORS Opening an equivalence table Multiple test Add the line E I 5 3 Example The example described below use all the step described in this chapter creating connector creating equivalence table and use some net test and some components test The first net is testing with the following parameters insulation 500V hold time 100ms rise time 10ms The breakdown current is 1mA and the resistance threshold is 100MO The net is made from two points linking by a wire which has a resistance value less than 2Q The test current used for this pi J 3 test is 1A Test file creation tool xj Relay commands Test one point others l Commodity l Tests between two points Net tests Parameters Resistance threshold fo fua Insulation voltage o v Breakdown current ju na gt HV rise time Fo sz HV hold time Fo sz ex o Operingan eaivanestabie an equivalence o Operingan eaivanestabie Multiple test Add the line sefelec Test file creation tool xi Relay commands Test one point others l Commodity Tests between two points Net tests Parameters Resistance low limit p Jaz Resistance high limit p as Test current m 4 2 Maximum voltage o vs Test re B sz Deering an eaiveene ttle an equivalence Deering an eai
137. lure Check that Measuring card 40372 is properly connected Relay contacts K15 K16 and K17 for routing card 40408 are open All these precautions make the tester extremely reliable in the quality of its results B III 5 2 Self tests on demand These self tests are designed to check the switching matrix As this operation takes a relatively long time it cannot be performed automatically Furthermore it does not entail unavoidable errors of interpretation prejudicial to the proper operation of the tester These self tests must always be used before any self learning operation after a prolonged stoppage of the tester or in any case of doubt Their function is to check that all the relays of the switching matrix open and close properly 4 tests are performed on each point Each of the 2 contacts is tested open then closed The point is then tested for insulation from lower ranking points This last test is designed to assess the insulation of the apparatus the preliminary tests having eliminated any doubt regarding the mechanical operation of the relays Switching failures are indicated by the self test after the switching matrix parameters and components are displayed Unitary relay tests Closing fault on AU or BPU n Relay n unit A or Relay n unit BP does not close There are four AU unit relays and four BPU relays See relays K1 to K4 and K6 to K9 on card 40403 Closing fault on BU n Relay n unit B does not close Each BU has
138. mum R threshold Minimum R threshold Test voltage DXS test parameters XSI A P1 1 B J4 58 E NN 2 component tip cold point 1 component tip hot point DXS measurement between two points XSI_U A P1 1 B J4 58 EE m NN group of B points cold points group of A points hot points DXS measurement per group Table of limit parameters for the DXS depending on the Insulation resistance function Parameter Minimum value Maximum value Test voltage 10 Vdc 500 Vdc Threshold resistance 0 200 GO Rise fall time 0 999 s Application time 0 999 s SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 126 179 sefelec e Ground continuity measurement SXS ground continuity mode PXSCM V VAL 12 5 10m 10 15 E PXSCM O VAL 6 1 10m 1 5 15 E XSCM A P1 1 B J4 58 T XSCM U A P1 1 B J4 58 Fall time in seconds Application time in seconds Rise time in seconds Maximum R threshold Minimum R threshold Test current Test voltage Test parameters of the SXS per voltage drop Fall time in seconds Application time in seconds Rise time in seconds Maximum R threshold Minimum R threshold Test current Test voltage Test parameters of the SXS per Ohm value gna component tip cold point 1 component tip hot point SXS measurement between two points group of B points cold points group of A points hot points SXS measurement per gr
139. n Hz Current Voltage Test parameters of the CHROMA power supply CHROMA ON OFF activation deactivation of the CHROMA 6404 sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 131 179 D III 1 6 Commands of the AGILENT 34401A multimeter See the AGILENT multimeter manual e DC voltage measurement PMVDOC VAL Vdc min Vdc max MVDC A B e AC voltage measurement PMVAC VAL Vac min Vac max MVAC A B e Two wire resistance measurement PMR VAL R min R max MR A B e Four wire resistance measurement PMRA VAL R min R max MR4 A B e Measurement of direct current at the terminals of a shunt PMVDOC VAL Idc min Idc max R shunt MVDO A B e Measurement of alternating current at the terminals of a shunt PMVAC VAL lac min lac max R shunt MVAC A B Table of limit parameters for the AGILENT 344101A multimeter in the WINPASS software Parameter Minimum value Maximum value PMVDC 0 500Vdc PMVAC 0 500Vac PMR amp PMR4 0 10 MO Current for PMVDC amp PMVAC Min current 0 Max current 2A Rshunt for PMVDC amp PMVAC 0 10 MO en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 132 179 SEIEIEC D III INPUTS OUTPUTS OF THE PCI 7250 AND PCI 7251 LOGIC CONTROL CARD Card inserted in the computer on a PCI slot Connection is made directly o
140. n resistance parameter U maximum R threshold minimum R threshold T rise T hold T fall 151 179 XSI A B XSI U A B PXSCM V or PXSCM XSCM A B PXSRA or PXSRC XSRA or XSRC A B insulation XS test between two points insulation XS test between group of points see rule for group of point test Ground continuity parameters in Volt or Ohm U I R low limit R high limit T rise T hold T fall XS ground continuity test between two points XS Alternative or Continuous hipot parameter U low leakage limit high leakage limit Delta T rise T hold T fall Hipot XS test Alternative or Continuous between 2 points XSRA U or XSRC U A B sefelec Hipot XS test Alternative or Continuous between group of points SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 152 179 D IV TRANSCODING The purpose of transcoding is to transform machine addresses given by the tester output terminals into user addresses The operator is thus able to read the list of faults without having to refer to a table of correspondences this tedious task being performed for him by the tester However the programmer has to give the tester the information required to carry out this conversion An input help dialogue box enables the operator to enter these data without having to worry about syntax The Editor is used for entering the data D IV 1 THE
141. n the hot point side of the measurement On the cold point side are brought together all the address points lower than the hot point The process is carried out in a single operation with no scanning so that the test of point 5 will take the same time as that of point 5 000 for example This advantage was made possible by the choice of the relay technology of the switching matrix The measurement unit then determines the resistance between one point and a group of points In case of a defect a search is carried out to determine which points are really defective in order to facilitate repairs There is only one constraint on this procedure it forces all the net points to appear in the test programme the defect however will appear once only thus weeding the error list see analysing results e With the unitary relay switching box This switching matrix is able to direct each point independently either to the cold point or to the hot point of the measurement In this way it is possible to test a net among all the other points but also to prevent the tester from obtaining access to certain points fragile components relay switching etc B III 3 3 Special features As mentioned earlier the test between 2 points is accessible by programming to all the measurement units standard measurements and all the options The choice of the hot point is possible in all these cases see Programming Instructions In case of defects
142. n the card on a female SUB D37 connector The card is controlled by the WINPASS software D III 2 1 Card characteristics Relay outputs Number 8 4 reversing relays 4 Normally Open relays Interrupting capacity 120 Vac dc 0 5A 24Vdc 1A Switching time 8ms Contact insulation resistance 100MO Digital inputs Number 8 Input current 10mA Input voltage 24Vdc or 24Vac 50 1000Hz low logic state 0 1 V high logic state 5 24V Input impedance 2 2kO D III 2 2 Schematic diagram of the relay outputs This format concerns relay numbers 1 to 4 NO1 COM1 NC1 on the connector diagram Normally open epp em 7 Normally closed This format applies to relay numbers 5 to 8 NO5 COMB on the connector diagram p Normally open Po sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 133 179 DI1 DI1 DI2 Diez D III 2 3 D III 2 4 Front view sefelec Schematic diagram of the optocoupled inputs on the connector diagram Diagram of the female SUB D37 connector NOl COM1 2 NF1 3 NO2 4 COM2 5 NF2 6 NO3 7 COMS 8 NFS 20 NO8 10 COM8 11 Dii 12 DIS 13 DIS 14 Did 15 DI5 16 DI6 17 Digs 18 DIg 19 R2 e v xe Padi S JF n CJILIHPER gt CAS FILTER q3 20 NO4 21 COM4 22 NF4 23 NO5 24 COMS5 25 NO6 26 COM6
143. n time The voltage is given if there is a breakdown during the rise time 8 If the insulation test voltage was not reached by the end of the rise time the error is close to a short circuit Insulation measurement error A J45 12 B P12 1 U Uprog 9 If there is a error during a test between 2 points for all options FLT xxxxx A TB1 5V B TB1 0V xx nnnn C IT STUDY OF STANDARD WIRING ERRORS Using a few straightforward examples we will examine all the types of error encountered For a thorough understanding of the test results the operator must think like the tester In other words e Always test the points in a chain in relation to the original point i e first point described Example EI B 5 B 6 B 12 B 18 1 test 2 test 3 test 4 test Insulation with Continuity Continuity Continuity lower points with 5 with 5 with 5 e if there is a break in a net and an El test multiple insulation is requested at the start of the chain this test is only valid for the second part of the chain The tester therefore repeats an El test on the 1 point of what it considers to be a second net see example 8 C II 1 CONNECTION FORGOTTEN OR BROKEN WIRE Correct wiring 14 15 Wiring produced 140 O 15 Test requested EI B 14 B 15 Test result Continuity measurement error A 14 B 15 or fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 57 179 SEIEIEC The insulati
144. nce option measurement of condenser on AC option measurement of AC voltage option measurement of DC voltage option measurement of self inductance impedance option measurement of capacitance impedance option measurement of GMOV option generation of voltage generation of voltage current associated with the letter S or O option external power supply control associated with the letter S or O option no test test of insulation of one point among all the others in direct current IM A nnnn test of insulation of one point among all the others in alternating current JM A nnnn option test of continuity of one point among all the others CM A nnnn test of a 4 wires point others being parallel test of insulation of one 4 wires point among all the others Resistance DELTA During a 4M test compare DELTA of measures PROGRAMMING OPTIONS presented as standard only as a test between two points W Oor S l u WAITING FOR EVENTS sefelec external output operator ratification display of test value loop test detection of microcuts continuity SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 148 179 PCe Ce NCe PVCe continuity event parameters contact opening or closing waiting for contact opening waiting for contact closing voltage event parameters appearance or disappearance of a voltage if voltage measuring option is present VCe NVCe COMMODITIES REM text
145. ndard Te we Tools He HNAEm ISNG cs Demo test of Winpass standard instruction The image specified in the instruction arborescence appears he operator must validate by clicking OK to continue the test Connect connectors SUB D9 Connect connectors DEUTSCH Connect connectors HAN REM programme de demonstration Testeurfi4 DIAL C Documents and Settings begoufles H B 12 Operator amp DIAL1 test is sfartinc PI VAL 100 M 500 1 m 10 m 30 PC VALO 5 S00m20 5m E HV 12 Demo test of Winpass stfndard ins Y Connect connectors SUB D94 HAN DEUTE C A SUBD9 AA28 1 B SUBD9 AA28 C A HAN CC95 1 B HAN CC95 2 C A DEUTSCH XX00 1 B DEUTSCH XXON 2 H V 10 Do you connect all interfac conr MB Did you connect all interface coMnect TESTM I A DEUTSCH XX00 3 B HAN CCS5 7 HR 12 There is a fail in interface conr STOP FTEST FLABEL LABEL SUB D9 HAN Test HN 10 cabling test between connector St EI B SUBDS AA28 1 B SUBD9 A428 2 B HAN CC95 3 B HAN CC95 4 B HAN CC95 5 PF VAL 50 n 100 n F A HAN CC95 6 B SUBD9 AA28 4 EI B SUBDS AA28 3 B SUBD9 AA28 4 B SUBD9 AA28 5 B HAN CC95 1 B HAN CC95 2 B HAN CC95 6 EI B SUBD9 AA28 6 B SUBD9 AA28 7 miemmno i108 8 RiHAM CCOR 7 fe gg md FZ Execute sac s fe l i SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 78 179 SCICICC f Message box question for the operator A message box can
146. nfiguration and number of points are no longer the same the breakdown is not repeated and the tester does not detect it as a fault In such cases if the test is repeated at a lower voltage the fault is often no longer detected because there is no longer breakdown e If incorrect insulation parameters are selected or the insulation materials of the equipment to be tested are of poor quality the tester as above cannot find the second faulty point poor insulation on a group of 1000 points but good on a few points In this case the message point not found or parameters too high appears n every case it is important to distinguish between short circuit insulation fault or breakdown C V ADVICE FOR REPAIRS A It is possible to carry out repairs with the equipment connected In some cases the time required to connect and disconnect the interface is such that it is best to immobilise the tester and carry out repairs on the spot To do this the external output programmed or manual is useful as the tester can be stopped on 2 test points and their status can be established using an ohmmeter until the repair is finished The measuring device must NEVER exceed the tester characteristics i e MAXIMUM VOLTAGE and CURRENT allowed by the switching matrix Dielectrimeters and breakdown meters are STRICTLY FORBIDDEN In the case of an external output on a multiple insulation test all or some of the points are short circuited as the
147. ng precautions are taken Note Self stripping connectors can be used but with a heat bonded not extruded flat cable pitch 1 27 mm 64 wire AWG 28 e Thomas amp Betts reference 201 64 100 e Tyco AMP reference 6 57643 4 In this case remember that the points are wired in column arrangement and not zigzag b 2000 V outputs male connectors type 41612 64 pin R a c body class 1 only even pins are mounted i e 32 pins e SOURIAU reference 8609 432 78 09 755 000 E1 solder eyelets e HARTING reference 09 73 132 6907 wrapping pins e HARTING hood 09 03 096 0501 with M2 5 x 30 screw e HARTING grommet 09 02 000 99 11 On 40418 C cards the screws are replaced by two locking levers Right locking 09 02 000 99 03 Left locking 09 02 000 99 02 Warning Connectors with solder eyelets have very long delivery times We recommend wrapping pins provided a few wiring precautions are taken The voltages used are too high for flat cables en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 36 179 SEIEIEC B VII 1 2 Some advice for implementing the interfaces For easier writing of the correspondence table between tester points and user points connectors and pins of the wiring to be tested it is important to connect the connectors in the same order as the tester addresses As electrical wire resistance is negligible compared with contact resistance there is no reason not to create connection jumpers
148. nits can supply voltages and currents which could be lethal Comply with the safety regulations related to the use of high voltage devices ALWAYS MAKE SURE THE HIGH VOLTAGE INDICATOR IS OFF WHEN CONNECTING OR DISCONNECTING THE SPECIMENS T fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 3 179 SEre1ec CONTENTS A PRESENTATION e 9 AL HOW TOUSE THIS MANUAL teret terere tete eet eee tet ee ete RS etw 9 A W THE CHAPTERS is E 9 A II CONCLUSION RER PE ET EE ENERE 10 B GENERAL INFORMATION ssennnenneneneneeeenenenenennnenennenenenesesenensese 11 BI CHARACTERISTICS ss smilies tent pesi pP EE italie De ERR Ro EE ERR pea EE TRE e a PE PER ae be ERR o eue 11 B I 1 BASIC VERSIONS 3 edt ite etica iret ate ec ao ese Radon tnt DE Ev tetes 11 B 12 The compatible PC 4 iet sens tte pda tete tai atteste eee a 13 B 13 OPTIONS ae 16 BIL CONDITIONS OF OPERATION screen iate Donee pee Lese ern less EK EERS nine edit 16 BALL ENVIRONMENT pP 16 B II 2 CONNECTION TO THE MAINS SUPPLY esseeseeeeeeeeeeen eene 16 BIL3 ERGONOMICS OF THE WORKSTATION csscessseessessseessetesecesecnseceseeeseeeeneeeseeeaeeeaeeeaaeeaaes 17 BUA SAFETY OF PERSONNEL animes io E dU eit rat bo EE eee c eee 17 B IL4 1 Satety LOOP CE 17 B IL4 2 Parts which are dangerous to touch 18 B II 4 3 Alt rnating Current dre est een et ag Le esee Ege exe edo r
149. nt of the tester This test is initially conducted at low voltage so as to detect short circuits and then at high voltage for breakdown or poor insulation 2 Continuity tests between the points described pu forum ere H The net test with unitary relays connects the B points described to the hot point of the measurement and carries out the insulation test with all the other points not described at OV Then the continuity test between the B points is carried out like with the El code E Ha CCE This test associated with the Pld parameter does not carry out an insulation test only DC rigidity To replace the DC rigidity test with an AC rigidity test the code J replaces I Insulation test between the A points described and all the other points m opem Any number of A points can be described by their address They will be connected to the hot point of the measurement All other non described points will without exception be connected to the 0 V of the measurement There is no continuity test between A points as these points are part of a group and not a net In AC the code J replaces I CRC This test associated with the Pld parameter does not carry out an insulation test only DC rigidity Insulation or AC dielectric test between the A and B points described MA a The A points will be connected to the hot point the points indicated by the code N will be floating points The other points will be connected to the
150. o detect the moment of contact closing or opening Parameters a Hee He The measurement used is continuity A generator current and voltage must therefore be entered If the test is PASSED the tester moves automatically to the next measurement If the test is failed in the event that the contact never closes for example the message no event appears Limit of event wait parameters contact state Parameter Min value Max value R Threshold 0 250 O I 10 mA 2A V 5V 20V time 0 1000 s SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 106 179 sefelec a Waiting for contact opening At the start of the test the contact is made The tester will wait for the measured resistance to be greater than the R threshold For the test to PASS this event must occur between min t and max t R Contact state Bi E un adeceandletenmeedeindemsm a Em gt t min t maxt Example The diagram above must be programmed as follows PCe VAL 5 500m 201 5 Ce A P1 2 B P5 12 The event is correct if the contact opens R gt 5Q within 1 to 5 seconds The chosen current is 500 mA and the generator is limited to 20 V b Waiting for contact closing At the start of the test the contact is not made The tester will wait for the measured resistance to be smaller than the R threshold For the test to PASS this event must occur between min t and max t
151. oe SE tlesn teh ales Mawel 146 d origi pee 146 D Ill 5 SUMMARY OF PROGRAMMING CODES rennes 147 D IV TRANSCODING PT 153 DIV THE PRINCIPLE iic tnt esae RE fee oies in ne D aea Dep 153 DIV2 DEATAJINPUT iir ertet eerie HER eee elena opt dE ipe reprae iesus ruo REGE Nes gd 153 D V FORMAT OF THE PROGRAM FILE iii 153 DVA CONNECTOR TABLE SONT tte tete degree ete ie ades aged eaae eese s ge se a 153 D V2 ERROR REPORT M ERR uiua iube e e treo Sere delete nent el 154 D V 3 IEST REPORT RES iicet edicere ee Be tenore eek dee tr annee eden epe bn bed uot gea 154 I V4 TESTE PROGRAM TES tei ee tait eto dee owe deuce 154 D V 5 TABLE OF CORRESPONDENCES COR eessesseeeseeeeeeeeneen eene rennen nennen trennen nenne 154 E OPERATING INSTRUCTIONS eere eese esee eee stesse seta stessa tuse osinon ssi S tepesi tasses sene to seta sens enses 155 EX EDITOR meer nain farei adivit tement tres etae ivi iet eris 155 E I 1 PASS WORDS vei aso tee eae dn fees leuita e Pret Pda ines vega eto EEEE E inerte latente 156 E L2 CREATION OF CONNECTOR TABLES eese etes etienne E E a teta TREERE 156 B L2 Creation of connector t bl s icone tete tegit ae einen Up a ei oa ga etn 157 E L2 2 Creating an alphanumerical connector eeeessesseeseeeeeeeeeene eee nre 157 T fe l 3 SY
152. oints Net tests Parameters Optio J Operator sanction J Inconditional posting Loop test Opening an equivalence table Multiple test Add the line What shows up in the test file PR VAL10 100 Om R A 1 B 2 Fromthe TESTER SEFELEC WINPASS TESTER Execution of the test program C SEFELEC WINPi Menu Setup Tools Help In the test results the test parameters show up in black The I8 B f LE test results appear for each measurement in blue if the result Start test 06 07 2009 13 39 48 has passed and in red if the result has failed In the event of a failed Resistor parcmbtera result the measured value is shown Resistance low limit 10 Ohm in the test results Resistance high limit 100 Ohm Test time ms sefelec Resistor measurement error A P1 B P1 B R 10 KOhm gt SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 92 179 The different measurement instructions between two points standard function of the tester Type of measurement Measurement syntax Continuous insulation A xx yy B ww zz Continuity C A xx yy B ww zz Resistance R A xx yy B ww zz Capacitance F A xx yy B ww zz Shielding b A xx yy B ww zz 4 wire continuity 4 A xx yy B ww zz 4 wire resistance R4 A xx yy B ww zz Diode d A xx yy B ww zz Zener diode dz A xx yy B ww zz The different m
153. on see programming instructions Ch Il 3 2 3 it displays the results of the parameter encountered in clear on the screen and in the listing FULL EDITION used to display all the measurements whatever the result of the test good or bad In the list of results the word fault is nevertheless clearly shown sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 168 179 MEASUREMENT REPORT at the end of the test displays the total of measurements taken and the number of faults for each type of measurement OPERATOR REPORT displays a screen at the end of the test to enter comments LOOPING TEST PROGRAM at the end of program restart it automatically you need to stop it with manual action on STOP button CLEAR DIALOGUE BOXES reset dialogue boxes every time we execute the TES program Panel at bottom left e RESULT PRINTING the results are sent to the printer Select printer setup to set the different parameters of the printer e SAVE THE RESULTS The results are recorded at the end of each test in a TES file Select Saved configuration for the configuration of the saved result file Ask confirmation the resulis are only recorded after confirmation by the operator Saving option Ask confirmation Save in Acrobat file format pdf adding to TES file the same file will be created to pdf format Hd oe ees das eie Directory e Directory Two solutions are proposed
154. on test of 14 in relation to all the other lower address points is passed Only the break between 14 and 15 is reported by a continuity error message C II 2 SINGLE CONNECTION WITH ONE INCORRECTLY CONNECTED TERMINATION WIRED TO AN ISOLATED LOWER ADDRESS TERMINAL Correct wiring 13 O 14 0 O 15 I3 2 LL 140 15 El B 13 El B 14 B 15 Wiring produced Test requested Test result Continuity measurement error A 14 B 15 Insulation measurement error A 15 B 13 The insulation test of 14 in relation to the other lower address points is passed The continuity test of point 14 in relation to point 15 is failed The continuity error is therefore reported Point 15 becomes the generator and the insulation test of point 15 in relation to the lower address points is therefore failed as 15 is connected by mistake to 13 The faulty points and the insulation error are reported Correct wiring 13 O 14 0 O 15 Wiring produced 13 14 O15 Test requested El B 13 El B 14 B 15 Test result Insulation measurement error A 14 B 13 Continuity measurement error A 14 B 15 The insulation test of 14 in relation to the other lower address points is failed point 13 The continuity test between point 14 and point 15 is failed C IL 3 SINGLE CONNECTION WITH ONE INCORRECTLY CONNECTED TERMINATION WIRED TO AN ISOLATED HIGHER ADDRESS TERMINAL Correct wiring 58 179 oe f l 3 SYNO
155. option measurement parameters for self inductance impedance option measurement parameters for capacitance impedance option measurement parameters for GMOV option voltage current generation parameters option external power supply control parameters option resistance of tool for deduction short circuit highpot insulation continuity short circuit highpot continuity dielectric strength short circuit highpot continuity option short circuit continuity highpot insulation continuity dielectric strength highpot insulation continuity no overall test continuity SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 147 179 bm unitary relays d dz S LR CR VA VC ZL ZC GM GU u ue N MULTIPLE TESTS JM CM SLIPS RING TESTING 4M IM4 DELTA measurement of insulation measurement of insulation capacitive load measurement of non insulation measurement of dielectric strength AC option measurement of continuity measurement of non continuity measurement of continuity 4 wires Kelvin method measurement of resistance measurement of resistance 4 wires Kelvin method measurement of capacity measurement of shielding measurement of shielding by the three measurements method option on measurement of diodes lt 20V current test measurement of diodes gt 20 V set voltage test measurement of variable test before and after variation measurement of inducta
156. or MEVS J TEST MENU I Clear dialog boxes DIAL HTML report printing CRT IV Full edition v Measurement report Operator report Save the statistics The FINTRACE instruction is optional if it is not present in the test program the TRACE zone x stops at the end of the test program Example PI VAL100M 500 1m 10m 30m PC VALO 5 500m20 5m TRACE C sefelec liste reference txt C sefelec resultat trace test txt serie 2 1 H N 12 Part test A 1 B 2 C A 3 B 5 FINTRACE a fe l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 121 179 SCLEIEC The reference list file comprises the following serial numbers 2 fields are listed in this table Field no 1 is the serial number of the parts that must be tested Field no 2 is a specific customer code other columns may be added 111 M1 112 M2 113 M3 222 M4 223 M5 224 M6 225 M7 A11 ZA A12 ZB A13 ZC B99 ZD B101 ZC UserName fuserO1S55 0000 When the test starts WINPASS asks the operator for his name or username if the option was chosen CANCEL A 2 dialogue box appears This presents the serial numbers available in the source file in a scroll down list The test resumes here a continuity test between points 1 and 2 and an insulation test between points 3 and 5 of the tester If all the program tests are PASSED the results file is
157. oup Table of limit parameters for the SXS in ground continuity mode Parameter Minimum value Maximum value Test voltage fixed value 6 Vdc fixed 12 Vdc fixed Test current 5A 30 A depending on the switching board Threshold resistance 0 1 50 Rise fall time 0 999 s Application time 0 999 s sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 127 179 e Hipot AC measurement RXS in hipot mode PXSRA VAL 500 1m 99m 1m 1 5 1 l F XSRA A P1 1 B J4 58 XSRA U A P1 1 B J4 58 Fall time in seconds Application time in seconds Rise time in seconds AI High threshold leakage current Low threshold leakage current Test voltage Test parameters of the RXS in AC p component tip cold point 1 component tip hot point XSRA measurement between two points group of B points cold points group of A points hot points XSRA measurement per group Table of limit parameters for the SXS depending on the Hipot AC mode Parameter Minimum value Maximum value Test voltage 100 Vac 5 KVac Leakage current 0 9 99 mA AI 1 mA 10 mA Rise fall time 0 999 s Application time 0 999 s SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 128 179 sefelec e Hipot DC measurement RXS in hipot mode PXSRC VAL 500 1m 9m XSRC A P1 1 B J4 58 XSRC U A P1 1 B J4 58 1m 1 35
158. ower supply on a 40680 card c Programming of channels The channel addresses cannot be transcoded RF680 21 2 A xx B xx Address of the cold point 1 to 22 Address of the hot point 1 to 22 Number of power supply Row of the stimuli card Closing activation of the channel RO680 21 2 A xx B xx Address of the cold point 1 to 22 Address of the hot point 1 to 22 Number of power supply Row of the stimuli card Opening deactivation of the channel RX General resetting all power supplies and all channels of all racks Note if there is only one power supply it will always be power supply 1 and points A and B will run from 1 to 22 sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 137 179 WARNING for power supply 1 1 3 5 WINPASS syntaxic corrector controls these addresses e Example 1 If there are two power supplies A and B will be chosen in the odd addresses 19 21 and even for power supply 2 2 4 6 20 22 The Either rack 1 with a single power supply 24 V and a 40680 stimuli card in row 16 The relay coil is connected between outputs 5 and 18 the 24 V being in 18 REM command of the 24 V power supply RP680 C 16 1 REM Test of open contacts PI VAL 10 M 200 1 m 10m 100m A P1 A B TB4 8 REM dispatch of 24 V on outputs 18 and 5 RF680 16 1 A 18 B 5 REM Test of closed contacts PC VALO5500m205m C A P1 A B TB4 8
159. ower values the accuracy and resolution is less good than at strong currents see continuity 4 wires However for fragile components unable to support such currents it is preferable to use this mode of measurement Measurements of continuity and resistances can work with two types of calibration The first is automatic see configuration it consists in measuring the internal resistance of the tester and bringing it down to the measurement The second consists in entering in the test programme the value of the interconnection interface which will then be adjusted to the measurement This will thus give 0 Q at the input connectors of the equipment to be tested Measurement of diodes enables injection of a current of 10 mA to 2A into a diode and measurement of the voltage at its terminals It is possible to measure diodes from 100 mV to 20 V this measurement is performed in 2 wire mode A second range of 20 V to 90 V operates with a test voltage of 20 V to 100 V The generator used is limited to 5 mA Measurement of insulation combines several functions It can perform e measurement of insulation resistances from 50 kQ to 2000 MQ at high voltage 20 V to 2000 V depending on the switching matrix e measurement of dielectric strength and detection of short circuits This measurement proceeds as follows e An initial test at low voltage continuity measurement to detect any short circuit 1 If a short circuit is found the test sto
160. p www sefelec com T fe l a SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 10 179 scleiec B GENERAL INFORMATION B I CHARACTERISTICS B I 1 BASIC VERSIONS The basic versions of the SYNOR 4200 are made up as follows e a common measurement unit a set of software utilizing Microsoft WINDOWS e a central processing unit based on a PC e facilities for mixing 500 V and 2 000 V modules of access to points The SYNOR 1202 Small table top tester supplied in a case limited to 256 points at 500 V or 128 at 2 000V The PC is external This instrument is not extensible The SYNOR 4202 Tester supplied in case but with external PC without terminal or front insertion printer e This tester can be equipped with 16 switching matrix modules e Additional racks of 16 modules can be connected The SYNOR 4203 fe l G SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 11 179 seleiec Identical tester to the SYNOR 4202 but supplied in a cabinet and able to receive up to 384 switching cards i e 49152 points at 500 V or 24576 points at 2000 V The SYNOR 4204 Tester resulting from modernization of SYNOR testers of the previous generation SYNOR 9400 SYNOR 3400 It is equipped with the same basic constituent elements as the 4200 measurement and software only the switching matrix units of these older versions is kept The SYNOR 4207 4208 Basic SYNOR 4200 tester to which a uni
161. perator who will determine if the test has PASSED or PB po FAILED FAIL W External output Allows 2 switching points to be routed on outputs located on the front panel The operator can then carry out further measurements Example Fromthe EDITOR PR VAL 10 100 Om Op RW Ali B 2 gt From the TESTER A dialogue box appears and the 2 switching points designated by the instruction are routed towards the external output The operator may carry out a verification measurement with an external appliance s f l G SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 94 179 SC Le C H power line disturbance Only associated with a continuity test detects power line disturbances during the test current application time Example gt From the EDITOR PC VALO 5 500m 20 5m C u Alt BE gt From the TESTER SEFELEC WINPASS TESTER Execution of the test program C SEFELEC WINPASS4200 DEMO TES LR EST Menu Setup Tools Help Ar EE 9 ERAH Continuity parameters Resistance low limit 0 Ohm Resistance high limit 5 Ohm Test current 500 mA Maximum voltage 20 V Test time 10 ms Continuity measurement error BET B 2 Micro cut m PC VAL O 5 500 m 20 10 m Al Cp Ali B 2 F DD F3 Step by step F10 Partie test F L SEFELEC F S fe l G SYNOR 4200 Manual Ref WINPASS Rev j
162. perator Smith test is starting H B 12 Operator amp DIALIi SEFELEC Once the dialogue box has been validated by the operator the fields filled in by the operator appear in the test results The text instruction H B 12 Operator amp DIAL1 test is starting with variable appears in the test results The variable is replaced by the value filled in in the dialogue box see the test variable chapter for more information The NDIAL function is used to display the dialogue box as DIAL but its content is not visible in the results list To use the various fields modify the amp DIALn codes in the brackets of text codes H c t where n is the field number The results file configuration is unchanged NDIAL EX Dialogue box file name S fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition SC ICICC 77 179 e Screen image function This function is used to display TXT HTM BMP and JPG files During the test when this instruction is being carried out the Winpass tester moves into the background and the desired file appears The operator validates by clicking OK to resume the test SCREEN File name and path Example Fromthe EDITOR SCREEN C Documents and settings WINPASS connecteur interface JPG Fromthe TESTER ISEFELEC WINPASS TESTER Execution of the test program C Documents and Settings begou Mes documents SEFELEC SYNOR WINPASS prg demainpass sta
163. point point A or the cold point point B of the measurement The measurement and control bus of this switching matrix allows up to 49152 test points to be connected at 500 V This is possible because of the modular construction of the equipment This means that the smallest tester has only one module As the modules are identical only their geographical position determines their address The racks are identical in the case of SYNOR 4203 but switches allow them to be addressed individually The equipment is specially designed to allow two types of module to be combined in the same tester provided that the same technology is used multi or mono contact relays Each rack has its mains power supply and control interface allowing the CPU to control any number of backplanes without modification Extensions are possible on any basic version The address of each point is given by the position of the tester output terminal This position is unchangeable in each rack The first card is always located on the left of the rack seen from the output side Two types of switching system are available a Switching matrix with multiple relays To simplify operation by reducing the number of bus command signals and to reach a compromise between cost and size the relays have 4 contacts This makes it necessary to bring two measurement buses with 4 wires Kelvin methode each into the tester Unitary relays will select the unit requested However t
164. points amp RS amp RS CDEF amp RS IDEF amp RS NC amp RS NI amp RS NCDEF amp RS_NIDEF_ amp RS 4 amp RS J amp RS 4DEF amp RS JDEF amp RS R_ amp RS C amp RS RDEF Net tests amp RS EQUI amp RS EQUIDEF amp RS EQUICC amp RS EQUICCDEF amp RS EQUI amp RS EQUIIDEF amp RS EQUIJ_ amp RS EQUIJDEF amp RS EQUIC amp RS EQUICDEF _ SPECIFIC TEST COMPARE DECHARGE ON or OFF show GOOD or BAD test result show result of LABELn show the number of good or bad test amp RS R4 amp RS FDEF amp RS ZL amp RS GMDEF amp RS GU amp RS R4DEF amp RS b amp RS ZLDEF amp RS VC amp RS GUDEF amp RS d amp RS bDEF amp RS ZL_ amp RS VCDEF_ amp RS_u_ amp RS dDEF_ amp RS LR amp RS ZLDEF amp RS VA amp RS uDEF amp RS dz amp RS LRDEF amp RS ZC amp RS VADEF amp RS ue amp RS dzDEF amp RS CR amp RS ZCDEF amp RS THTC amp RS ueDEF amp RS F_ amp RS CRDEF amp RS GM amp RS THTCDEF displays on screen the number of net displays on screen the number of failed net test displays on screen the number of net short circuit tested displays on screen the number of net short circuit tested with fail result displays on screen the number of net tested in insulation test displays on screen the number of net tested in insultation test with fail result displays on screen the number of net tested in AC hipot test displays on screen the number of net tested in AC hipot test with fail result displays on s
165. points described Programming syntax TEST i TEST TEST i i Name of points list j EX The number of points per net is unlimited As stated above the machine address points are in square brackets and the transcoded points in brackets In the latter case the connector name is generally separated from the pin name by a separator or The description of a net always ends with a en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 99 179 SEIEIEC b Naming of points 1 Programming in tester points it is possible to give as many B points as there are tester points 2 Programming in user points from an equivalence table it is possible to give as many B points as tester points 3 Programming in list of points a list of points gathers together all of the points of a net Only the name of this list between and is to be given in the programming Example El B lt equipo1 gt B equipo2 c Type of test Example of programming a net With the test fible creation tool Writing from tester points Writing from user points xf F Relay commands Test one point others Commodity Relay commands Test one point others Commodity Tests between two points Netlests Parameters Tests between two points Nettests Parameters E 1E III E JE YE YE YE IE 1E JE To call up a equivalence table simply select open an equivalence table in th
166. ps in the table of correspondences These gaps in the tester represent points which have not been allocated so that there will be no description an empty box opposite these points en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 158 179 seciciec E I 3 2 Completing the equivalence table Click in the User column against machine point 1 Call up the programming tool INSERT CONNECTOR Drag the dialogue box to the right hand side of the screen and click in the LIBRARY window to call up the CONNECTOR library in which we stored the connectors of this wiring system Click on CONNECTOR 1 and in the window NAME give the name of the connector of the wiring system P1 in our example If necessary choose a separator between name of connector and pins then click on INSERT The first 25 points are defined automatically I SEFELEC WINPASS EDITOR Equivalence table als Window Heip E Fie Edt To oe a e aE Machine Interface User iss elm E onnect ition tool EE C1440 P1 10 pita GEL cia P112 c13 P113 cia Pisa cias Pr 15 MERE i7 GET i118 GE CERTES cian 120 CHENE c12 P1 22 ciaza P123 C124 P1 24 c1a 25 P1 25 E To enter P2 click on point 32 and in the box INSERT CONNECTOR click on CONNECTOR2 Type P2 in the window NAME then click on INSERT The 50 tester points from 32 to 82 are then defined
167. ps the message SHORT CIRCUIT appears in the error list e f there is no short circuit the high voltage is applied During the programmable rise time 2 if breakdown occurs the voltage is displayed and the test stops the breakdown voltage is given in the error list e f no breakdown occurs and if the voltage does not reach the required value 10 the message U Uprog appears in the error list e Next the voltage is applied for the duration of the programmed application time 3 If breakdown occurs during this period the moment when the fault appears is displayed in the error list and the test stops e Lastly if all goes well at the end of the application time 4 the insulation resistance is measured The tester will add a measurement time as a function of the range requested The measurement time varies from 20ms to 240ms according to range e To end the sequence the tester reduces the high voltage and then discharges the unit tested to an earth resistance total time 20ms This procedure is identical at the end of every measurement of insulation Ieee eee ee ee ee ee ee ee ee meee eee ee ee ee ee eee lt _ gt OS Short circuit Rise time Application time Measurement Discharge test time time SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 23 179 sefelec The test of dielectric strength detects any sudden variation in the increase of the test current outside the programmed limit
168. r continuity and insulation If the same resistor 22 KO is tested with the program A 200 B 300 The test result is Insulation measurement error A 200 B 300 regardless of the reject value If you need to measure this resistance more accurately it can be tested either with the program NW A 200 B 300 or with the program A 200 B 300 with stopping on error F5 The second case requires a failed test result In both cases points 200 and 300 will be available on the EXTERNAL OUTPUT socket The resistance can then be measured manually with an ohmmeter For more exact measurements there is a resistance measurement option C IIE DOCUMENTS FOR ANALYSING THE ERROR LIST To analyse a results list the operator should always forget the tester The list showing tester points is only useful to the programmer when debugging is necessary as the transcoding allows him to interpret errors directly by reading the wiring diagram Put briefly this requires 1 the error list showing user points 2 the equipment wiring diagram en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 66 179 SEIEIEC IV ANALYSIS OF THE RESULTS The error list reported by the tester cannot generally be used directly by the wirer responsible for repairs unless he she has received a minimum of training The operator must therefore proceed as described below if he she has the documents referred to in the previous chapter
169. relays remain in place Select STOP TEST to look for a fault on the equipment with an ohmmeter e fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 67 179 SEIEIEC After each repair it is wise to carry out manual continuity and insulation tests on the chain s affected by the fault During repairs be sure to clean the equipment to be repaired before reconnecting it to the tester especially if the required insulation test involves high quantities However carefully repairs are carried out they still sometimes produce new faults The equipment must therefore be checked on the tester until it produces a fault free list In this case a partial test using the address search is not enough All the tests must be repeated B Do not forget the role of the probe This shows the points affected on the wiring on a table matching the tester point intermediate interface point and user point NOTE There are two restrictions to using the probe low level and stimuli C In the case of breakdown as a general rule if the error result for a breakdown is in Volts the fault will have occurred during the voltage rise time You should therefore look for a surface defects or a elements placed too close to each other damaged wire poor solder etc If the result is in milliseconds and therefore seen during the application time look for substrate contamination printed circuit cleaning trace of flux etc T fe l
170. rent Only the result of the last measurement will be taken into account in the test results e fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 97 179 SEIEIEC C Special case Special case of resistance measurement The setting of the resistance measurement can give rise to two possibilities e Test per range case PR VAL 990 1100 5m Op R A P1 1 B P3 8 The resistance will pass if it lies between 990Q and 110090 possible values between 1 Q and 10MQ e Test from a threshold case PR VAL 990 10T 5mOpg R A P1 1 B P3 8 The 10 TQ value expresses a value above 10 MQ i e infinite The value measured will pass if R gt 990 Q Special case for the slip rings Instruction 4M associated with parameter P4 Carries out a 4 wire resistance measurement for the time shown in parameter P4 and checks that the resistance values lie between the min and max values selected in parameter P4 Option DELTA value Inserted between P4 and 4M checks during the 4M test that the delta between the maxR and minR measured is less than the value indicated in the DELTA instruction Example P4 VAL 10m 10 1 20 5 DELTA 500m 4M 1 S Checks during a 4 wire continuity measurement between points 1 and 3 that the resistance values lie between 10mQ and 100 under a voltage of 20V 1A for 5 seconds of test The DELTA instruction checks in the measurement sampling that the difference between the max and min v
171. rol card 133 DIT 21 Card characteristics ueneno Pa el eoa veda y ee geo E EEEE aeneae te 133 D IL2 2 Schematic diagram of the relay outputs ss 133 D IL2 3 Schematic diagram of the optocoupled inputs eese 134 D IIL2 4 Diagram of the female SUB D37 connector of the card sese 134 DU23 M irm qe 135 D IIL 3 FUNCTIONAL Tests STIMULI card 40680 and 40575 136 DAIL3 A Using card 40680 diee eerte eit EC erit Leib ee epe be Evo Lene revo PEE Ue 136 a Principle diagrammes esi Ratte eem epe Eee pe Ee re ean ie RE Pee LES PARU a 136 b Power supply control inei RR eti n DER EE ea nnn EA Ru 137 c Programming of channels ss 137 DIH32 Using card Rh M M 140 g nstallattOniz oid scewss EE EAE EEEE E EE ede bes EEUU a e Ode node 140 b PrOgram eeesdir cene terere Steuer e epe Ue otc e EE REC Ee ee ke be ERE Led e epe Reno o 142 G Syta ects ie ie ieu e ns 142 d Power supply INSTUCUON 55 Hennebont SE SUL Lea BUNTEN he 143 e Programming of channels ss 144 DIA EXAMPLE PROGRAM ieri ee Een d te eee orale en Feud tue latte era arenae beta 144 D HL4l Thetest prOPEFatns suere reete rero Ta prae pede soa Cedar tego EEEE aoa tr terne 144 D42 Comments on test prOBram one tieeete iacente tt ende trie Lat rh a err eb o toa eh p ed eH ae bI aeui 146 a ipii m 146 De Second Part oc EE 146 MM nico
172. s 12 15 by around 2 D II 4 2 Charge Discharge It is possible to validate or stop the discharge function of the tester systematically from the DISCHARGE ON or DISCHARGE OFF command Or it is possible to force a discharge between two points only and to indicate the desired discharge time In this case in addition to the two points to be discharged the discharge time must also be given in ms Discharges are done via resistances of 1kQ Example DECHARGE OFF from this command after each measurement test there will be no discharge of these points R A 2 B 4 R A 3 B 5 DECHARGE A 3 B 5 10 points 3 and 5 are discharged on resistances of 1kO for 10ms R A 6 B 8 DECHARGE ON from this command after each measurement test a discharge of the named points will be carried out F A 9 B 10 T fe l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 119 179 scleiec D II 4 3 Variable element test For elements with an imprecise nominal value The variable element test probe strain gauge thermistors etc takes the resistance measurement at rest and repeats the measurement after variation to assess the percentage deviation Simply enter the percentage range and the measurement current application time see Resistance measurement Min percentage Max percentage Application time Second measure timeframe optional s rama jrone When reading code S the tester carries out a resistance measurement
173. same Whenever there is a wiring error a message appears on the screen and on request on the printer according to the criterion chosen in configuration Errors appear in red PASSED test results in blue on a full display Error messages 1 If there is a continuity or broken circuit error Continuity measurement error A J1 12 B TB1 EARTH R gt 250 Ohms 2 If there is a continuity error due to a poor contact Continuity measurement error A P4 21 B J32 a R 15 Ohms 3 If there is an insulation error due to a short circuit in relation to the lower points Insulation measurement error A P6 AA B 12 5 R 1 20 Ohms 4 f there is an insulation error due to low resistance in relation to the lower points Insulation measurement error A FRAME EARTH B J24 1 R lt 50k Ohms 5 If there is an insulation point with a long net limited search is requested Insulation measurement error A J4 T B J1 25 R 1 25 Ohms B J2 28 B J2 30 B J3 5 s fe l G SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 56 179 SCICICC B J4 1 LIMITED SEARCH 6 If there is an insulation error between 2 points Insulation measurement error A point 34 B point 237 R 60MO 7 If there is a breakdown or dielectric error on a point in relation to a net Insulation measurement error A PRISE 12 B J4 37 U xxV B J4 39 or T xxxms The time is given if the breakdown occurs during the applicatio
174. se B 3 4 4 Measure B O O 5 Sense A Warning light 1 Green light 2 Common 3 Red light O O Probe 3 Probe 1 Remote switch 2 Safety loop 1A 3 Safety loop 2A 4 NC 5 Safety loop 1B 6 Safety loop 2B 7 Remote switch Remote switch The points not mentioned are not connected Note The safety loop originally equips all testers as from October 2007 en fe l 3 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 55 179 SCICICC C ANALYSIS OF THE TEST RESULTS The following instructions are intended more especially for the user of the tester Once the technician has set up the test programs interfaces and connections the user checker or wirer has to interpret the error list correctly in order to save precious time and improve the test operations Recommendations The operator should avoid cluttering his work space with unnecessary documents The recommended documents are e the tool connection document e the wiring diagram e the transcoded error list provided by the tester C I PRESENTATION OF THE ERROR LIST For transcoded errors the connector names are separated from the pins by a full stop or depending on the selection all between round brackets A J1 5 In the non transcoded version the same point is written with square brackets A 344 During transcoding only the point address is modified the other texts and indications remain exactly the
175. t The choice of self test types is a function of the options of your tester Self test setup x Self test details IV Search limited to Dg points Self test looping Parameters reset v Save self test result Self test type v Continuity 4 wires interface IV Insulation MN Switching board control Start address g End address pe B After choosing the general settings you will need to parameterize the values of the different measurements which will go to make up your self test s fe l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 170 179 setelec The parameters selected will be the strictest possible in order to ensure that the tester does not bias the measurements on the wiring through its own characteristics By way of example the settings of the parameters for continuity and insulation are shown below The self test parameters are automatically saved and proposed afresh after any stoppage of WINPASS There is an icon to return to the factory parameters NOTA in Set up loop self test is recommended to heat progressively the electronic of the tester This function is efficient when a tester doesn t reach insulation resistance threshold because of high humidity or long shutdown EI SELF LEARNING Self learning is used to create a test file on the basis of a wiring system taken as representative This operation is only possible when the equipment to be tested can
176. t Code for a go no go test at maximum speed Erg This is not a quality test sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 82 179 D II 3 5 Chapter Label For long programs requiring operations such as connections switching or stimuli commands it is possible to divide the test into several zones each with its own name or LABEL If LABELS are present in the test file the zone s to be tested in the same test program can be selected using a button on the PARTIAL TEST Winpass Tester screen By default the tester executes the complete file The syntax is as follows LABEL Name Label FINLABEL Example Fromthe EDITOR LABEL connection of interfaces H V 10 Please connect the SUB D9 connector H V 10 Please connect the DEUTSCH connector H V 10 Please connect the HAN connector ENDLABEL Fromthe TESTER Once the test program is loaded it is possible to HOS gw ERI select PARTIAL TEST in Pies the test control bar Then Run the complete test program in the PARTIAL TEST ma or s Run the following sections of the test program dialogue box it is possible INTE to view the list of LABELS SUB DS HAN Test created in the program CHAN DEUTSCH test and to select a combination of them Once validated only the instructions included in the selected LABELS will be carried out F2 Execute fe l i SYNOR 4200 Manua
177. t a na Test current oo na HV rise time fio ns Maximum voltage foo Yz HV hold time Fo fsz Test time B fsz What shows up in the test program or in writing on the keyboard PI VAL 100M 500 1m 10m 30m PC VALO 5 500m 20 5m Resistance PR Inductance PLR Test file creation tool E x Relay commands Test one point others Commodity Relay commands Test one point others Commodity Tests between two points Net tests Parameters Tests between two points Net tests Parameters Inductance m Resistance low limit Do 2 gt SIRET E H n Resistance high limit po Fax Maximum inductance po ng Test time p ns Test current oid pa What shows up in the test program PR VAL 10 100 Om Op PLR VAL 8m 10m s fi 2 SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 90 179 SCLEIEC D II 3 8 Test between two points To carry out a test between 2 points the application parameters must first be defined see previous chapter Once these parameters are entered a test instruction needs defining that will apply these parameters and define the 2 points where the test will be applied a Programming syntax Test points can be named in 2 different ways TEST TYPE EL A c b B c b Test written in transcoded points c connector b pin An equivalence table must be created beforehand ee ee eer ee Test written in machine points number of tester output
178. t file exists The self test function is accessible under the same conditions The autoprogram function enables spontaneous learning by the tester of wiring for which no test program exists The sensitive functions file modification and manual operations on the measurements are protected by a configurable password The Editor is used to write and modify test files and transcode them It includes a checking function to identify any errors of syntax that may have crept into a test program The sensitive functions file modification and manual operations on the measurements are protected by a configurable password The measurement unit This comprises the following functions depending on options e Measurement of insulation resistance e Measurement of dielectric strength DC Hipot DC measurement e Measurement of dielectric strength AC option fe l G SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 13 179 Se Le C Measurement of continuity 2 wires This measurement is used to detect microbreaks e Measurement of continuity 4 wires Kelvin methode e Measurement of capacitances e Measurement of shielding e Measurement of diodes e Measurement of resistances with protection point e Detection of transients e GO NO GO production test e Measurement of self inductance option e Measurement of inductances option e Astimulus generating system can be adapted to the tester s fe
179. t management area print on the screen a HTML JPG TXT or BMP file zone executed only in the first test zone executed only if the preceding tests are all GOOD zone executed only if the preceding tests are all BAD Event parameters for continuity relay open or close waiting contact opening waiting contact closing event parameters for voltage voltage appears or disappears waiting for voltage shut down waiting for voltage presence 149 179 CONTROLLER COMMANDS if option present SE n command beginning of test if n at 1 SO1 n Set output n to 1 SO0 n set output n to 0 SOM n n at 1 if one of the preceding tests is BAD SOB n n at 1 if all the preceding tests are GOOD SOC n n at 1 if all the preceding tests are BAD STIMULI COMMANDS if option present STIMULI test zone using power supplies other than the measurement FINSTIMULI end of test zone using stimuli general reset PRESENCETENSION zone disabling measurement if a voltage is present replaced by STIMULI ARRETTENSION end of PRESENCETENSION zone replaced by FINSTIMULI usn ON activation of stimuli power supply n if option is present usn OFF de activation of stimuli power supply n if option is present RO n xx opening of relay xx in rack n RF n xx closing of relay xx in rack n RP C n x control of power supply x in rack n RP A n x shutdown of power supply x in rack n RP6680 C x n activation of stimuli power supply n in rack n RP680 A x n de activ
180. t will have this star in this dialogue box Select Add the line to create the corresponding command LI O LI L Opening an mm file Sort the connectors Cable tester point Opening an equivalence table Multiple test Add the line s fe l SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 163 179 SCIEIEC To finish this program file we will create a component test one 10 O resistance between points P1 6 and P1 10 First step we need to describe resistance parameter Until now we only create parameters for continuity and insulation to test nets Test file creation tool xi Relay commands Test one point others Commodity l In TEST FILE CREATION TOOL select PARAMETERS and then nd EXPERS espe RR Complete parameters as the picture beside We only need to have minimum and maximum resistance value we choose for Resistance low li BF fax the 10 Q resistance a limit between 9 and 11 Ohm COC DE An adjustable hold time is convenient when capacitive Test time 5 zi components are present An adapted hold time has to be ene p choosen in order to charge the parasite capacitor Here we choose a 5ms test time The test current is programmed at 0 in order to indicate that the tester is working in automatic ranging A Opening an equivalence table Still in TEST FILE CREATION TOOL select TESTS BETWEEN TWO POINTS to program resistance point test PES i
181. tary relay switching system has been added The SYNOR 4207 is the case version of the SYNOR 4208 cabinet model The SYNOR 4209 Basic SYNOR 4200 tester designed to test large dimension wiring as found in railway automotive and aeronautic systems The central measuring unit of this tester is in a cabinet containing the PC with its screen keyboard and printer The switching matrix is in units powered by the central processing unit This allows the tester assembly to be arranged around the item to be tested and thus reduce the number of connection interfaces fe l G SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 12 179 Se Le C B I 2 THE COMPATIBLE PC According to the version this may or may not be built into the tester box rackable industrial PC To create transcoding and test files it is possible to use a programming station to enter the different data without monopolizing the tester Nevertheless the tester can perform both these functions on its own The PC whether or not it is incorporated is insulated electrically from the measurement unit and the switching matrix to which it is connected by a special cable An optical barrier separates the two assemblies in order to ensure a high degree of immunity from noise The external PC must operate on WINDOWS 2000 or XP The interface uses a PCI slot The software The TESTER includes the test function accessible to any operator if the tes
182. technical assistance 33 1 64 11 83 40 for FRANCE or contact your local distributor 2 INSTRUMENT RETURN Before returning an instrument to our Service Department please call them at the above phone number for shipment instructions Use packaging that is adequate to protect it from damage 3 MAINTENANCE Our units don t need particular maintenance except an annual calibration If problems please follow the brief check list here after If the problem continues call our service department at the above number The other possibilities for a bad functioning need an intervention inside the unit by qualified people However we can supply a service manual including schematics of our units Please get in contact with our Service department in order to know price and delivery time 4 CALIBRATION We recommend to calibrate our units each year The calibration must be performed by qualified people having the complete procedure as well as correctly checked standards Our Maintenance department is at your service to perform the annual calibration Please get in contact with our Maintenance department in order to know the price and the delivery time 5 Cleaning and checking Only clean the instrument with a mild rag or slighly soaked with water Our own teams are specially qualified for the checking and periodic maintenance of the tester However the cleaning services should be responsible for cleaning and changing the dust filters according to
183. test file by a simple code PI 5 this means that for the measurements to follow the DC insulation parameters will be those given in list no 5 of the table of parameters To complete this table select TOOLS LIBRARY OF PARAMETERS This method has the advantage of simplifying definition but the disadvantage of assigning the parameters to the tester and not to the test file This can also be inconvenient if the file is used on another tester Note 7he particular advantage if this method is its compatibility with older systems operating on DOS SYNOR 3400 SYNOR 9400 etc E I 6 3 MESSAGES Since messages have no programming tool just click on the line of the program and type the message on the keyboard respecting the syntax for example H start of test or HV end of test E I 6 4 Controller commands The controller commands can be written with the test tool TooL TEST TOOL In the test tool click on tab CMD RELAY It is then possible in the Rack in question either to direct or deactivate the power supplies or to control the relays Note do not forget to perform a zero reset at end of program sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 165 179 E II The tester E IT 1 CONFIGURATION In the operation of the tester two configurations must be distinguished e machine configuration e test configuration E IL1 1 Machine configuration This depends on the electronic structure of the tester
184. the table Point Point Passed P Label Type of test A B Measurement Failed F Value R gt 150 Part One Insulation Measurement P1 A MOhms P 150000000 Continuity Measurement P1 A P1 C R 5 Ohms P 5 R gt 150 Part One Insulation Measurement P1 D MOhms P 150000000 R gt 150 Part One Insulation Measurement P1 E MOhms P 150000000 Continuity Measurement PIE J42 R 5 Ohms P 5 Continuity Measurement P1 E J47 R 5 Ohms P 5 Continuity Measurement PIE J49 R 5 Ohms P 5 R gt 150 Part One Insulation Measurement P1 F MOhms P 150000000 Def Continuity Measurement P1 F J4 5 R 5 Ohms F 5 R gt 150 Part One Insulation Measurement J4 5 MOhms P 150000000 The function is implemented by selecting the option in the results save configuration The Excel report is not a test instruction It is a configuration option that can be accessed from the WINPASS Tester menu test setup sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 115 179 D II 3 19 Test report function The test report instruction calls up a prepared test report file in which texts images logos or variables from the test results file can be added This format defined by the user creates a summary of the tests carried out by the tester CRT Source file path Target file path The source file will contain the basic report in HTML form images text logos or tables or TEXT form The t
185. this line An information box informs you that you are in manual mode Click OK to confirm the test Click on EXECUTE to start the test Warning This operation always results in a failed test It is forbidden to start a partial test in the middle of a net INFORMATION ok ame H Program of demonstration of the sofware WINPASS DIAL dialoguel LABEL First part H Equipotential test PC VAL O 6 500 m 20 5m PI VAL 100 M 500 1m 10 m 100 m EI B P1 1 B P1 3 B P1 6 B J4 2 B J4 5 B P1 2 B P1 4 e sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 174 179 E II 4 4 Safety during tests In order to ensure that false moves are as far as possible avoided certain functions are prohibited in the particular cases shown in the table below Self test Self learning Test Stop on fault Starting screen Probe no no no yes yes Manual mode no no no yes yes Switching matrix no no no no yes configuration Test configuration yes yes yes yes yes Quit WINPASS no no no no yes WARNING use of manual mode can be dangerous for the equipment to be tested if the operator is not trained in its use E II 5 QUITTING THE TESTER FUNCTION When the tester has completed its task the operator has two options before him e e Stop the test of the reference in progress in order to access another test file In this case the tester function remains open Just click on the
186. tinuity test Insulation test Switching board control test End address 75 Test voltage according to the switching board type Points 1 256 500 V Opened error B 4L Ar L Pa Le On Lo Pt i AT R lt 2 Ohms Insulation measurement error 41 Ar 1 Pa 1 Ca 1 Pt 41 U Uprog i r 1 Pa 1 Ca 1 Pe 1 5 Ar 1 Pa 1 Ca 1 Pt 5 9 Ar 1 Pa 1 Ca 1 Pt 9 Limited search SELF TEST FAIL End of self test 23 06 2005 13 52 52 u F1 Close o F8 Parameters F3 Step by step Note To optimise the self test time the short circuit test is not carried out Consequently a short circuit will be detected by the high voltage generator which will display the message U Uprog Likewise a relay fault impedes the operation of the search algorithms and often the message point not found or test earth is given after the search this should be ignored B III 5 3 Measurement hot point Measuremen t cold point sefelec Organization of a point in the switching matrix An Switching matrix Bn output SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 29 179 B III 5 4 Organization chart of the switching matrix self test An close Bn close OK NO error message An close Bn open NO OK error message An open Bn close OK error message An close Bn open Bn minor close Insulation OK NO scan and error
187. tor The last instruction in this part calls up a dialogue box file dialogue1 DIA in which the programmer asks the operator for information such as his name the serial number etc as mentioned earlier the fields in this box can be attached to the name of the result file b Second part This part carries out the wiring test excluding the components i e wires only The codes used are those of the net tests so the parameters for continuity and insulation PC and PI have to be described first In order to refine the measurements of continuity the programmer has added the value of the interface TARE VALUE 3 7 C Third part Here the condition test bad is used The text will not be printed unless one of the preceding tests is bad If all the tests are good this part will not be executed and the test will go on to the fourth part If this is not the case the test will stop here d Fourth part Unlike the third part the following tests are only possible if the wiring test in the first part is satisfactory Fitting of the components is therefore requested and the tester with the appropriate parameters will test three resistances a condenser a diode and switches sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 146 179 D III 5 SUMMARY OF PROGRAMMING CODES PROGRAMMING ADDRESSES A nnnn A c b A lt List of Points gt B nnnn B c b B lt List of Points gt PARAMETERS P
188. uly 2009 Edition 95 179 SETEIEC l Display of the measured value Systematically shows the value of the size measured In the test setup see corresponding chapter it is possible to select FULL EDITION In this case all the test results are displayed If this option is not active only the fail tests will be displayed in the test results Example gt From the EDITOR PR VAL 9K 11K Om Op RI Ali B 2 gt From the TESTER Despite the tester being configured to display only the default test results thanks to this option on the instruction the results of this measurement are displayed in the test results SEFELEC WINPASS TESTER Execution of the test program C SEFELEC WINPASS4200 DEMDO test R TES Menu Setup Tools Help Ar 9 Start test 06 07 2009 14 16 13 Xl Resistor parameters Resistance low limit 9 KOhm Resistance high limit 11 KOhm Test time D ms Resistor measurement Apt B 2 R 10 KOhm s fe l d SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 96 179 SCICICC B Run the test again Example Fromthe EDITOR PR VAL 9K 11K Om Op RB A 1 BE Fromthe TESTER opens the manual mode window The x requested test is then rerun RSS continuously p A 1 Resistor parameters The operator ns required to press Pointa Resistance low limit STOP to stop the measurement n ee Pressing on CLOSE then resumes Poimp 7 TERIS the test Test cur
189. uments and vice versa Upward compatibility between SYNOR 3400 and SYNOR 4200 is guaranteed AI HOW TO USE THIS MANUAL If you have never used a SYNOR wiring tester read the general information at the beginning through to File management After this using a straightforward wiring arrangement on which you can create faults such as a dummy box practice with the tester referring to the Operating instructions and the Analysing the error list instructions for help Finally you should read the Programming instructions and transcoding information to gain total control of the system If you are already familiar with older generations of SYNOR testers you should read Programming instructions but it will be useful to read all the manuals If you have to train operator level personnel use the Operating instructions and Analysing the error list Finally if you are short of time or your usual operator is absent use the Operating instructions WARNING A device of this kind is designed to improve quality it cannot therefore be used without a basic minimum of training A TE THE CHAPTERS Each tester is delivered with a manual containing four sections e General information e Instructions for analysing the results Programming instructions Operating instructions In addition there are instructions concerning the PC and the use of WINDOWS not supplied by SEFELEC The GENERAL INFORMATION gives all the inform
190. use Example Name of test file DEMO TES Configuration Name Name of result file DEMO RES Configuration Name Dial2 Name of result file DEMO101 RES sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 169 179 bearing in mind that in the dialogue box called up by DIAL in the test program the designation 2 requests the serial number and received the reply 101 SIMPLIFIED REPORT PRINTING prints a report at the end of the test with the date the name of the operator the serial number the total faults and the operator s report e SAVE THE STATISTICS Records the date the name of the operator the serial number the total faults in a common file for all tests bearing the same reference For use of this option see chapter 3 User dialogue box E II SELF TEST A tester is a device whose purpose is to check the quality of the wiring system of a product It cannot yield a reliable diagnosis unless its own wiring is faultless For this reason it is necessary always to self test the apparatus before using it see General Description The self test can be accessed by selecting SELF TEST or clicking on the button f MENU This dialogue box enables you to configure your self test It is made up of a number of pages which will appear as a function of the configuration of the machine Options The first page gives you the opportunity to carry out the general settings of your self tes
191. ve DC net points D II 3 21 Test variables specific to the BATCH The variables that can be used from the BATCH function are described below All the other variables described previously are still valid Batch name amp LOT1 Total number of parts amp LOT2 Number of good parts amp LOT3 Number of bad parts amp LOTA Enter the batch end time amp HEURE Enter the operator name used when opening a WINDOWS session amp OPE The following variables are only valid with the LOTA function Recopy the test parameters clearly amp Px n gives the value of field n in the Px parameter used during the test PI VAL 100M 500 1m 10m 30m Example amp PI 2 will be replaced with 500V amp P 1 will be replaced with 100MO amp PI 1 amp PI 2 amp PI 3 amp PI 4 amp PI 5 amp PVA 1 amp PVA 2 amp PC 1 amp PC 2 amp PC 3 amp PC 4 amp PC 5 amp PJ 1 amp PJ 2 amp PJ 3 amp PJ 4 amp PTHTC_1 amp PTHTC 2 amp PTHTC 3 amp PTHTC 4 amp PTHTA 1 amp PTHTA 2 amp PTHTA 3 amp PTHTA 4 amp PTHTC 5 amp PTHTA 5 amp P4 1 amp P4 2 amp P4 3 amp P4 4 amp P4 5 amp PQGU 1 amp PR 1 amp PR 2 amp PR 3 amp PR 4 amp Pu 1 amp Pu 2 amp PRA4 1 amp PR4 2 amp PR4_3 amp Pue 1 amp Pue 2 amp Pd 1 amp Pd 2 amp Pd 3 amp PCe 1 amp Pce 2 amp PCe 3 amp PCe 4 amp PCe 5 amp Pdz 1 amp Pdz 2 amp Pdz 3 amp PVCe 1 amp P
192. veene ttle Multiple test Add the line SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 162 179 First step in EDITOR FILE NEW CREATE TEST PROGRAM Now on the screen we can add the different instruction to create the testing program To help us we use the test file creation tool select TOOL TEST FILE CREATION TOOL Now select PARAMETERS and INSULATION Complete parameters as described in picture upside select ADD THE LINE to create the command code in the program In the same dialogue box in PARAMETERS select CONTINUITY Complete parameters as described in picture upside like insulation parameter select ADD THE LINE to create the corresponding command code Now parameters have been created From TEST FILE CREATION TOOL select net tests and tick the box P1 1 and P1 3 To have points name from equivalence table Select OPENING AN EQUIVALENCE TABLE and choose the file TRANSCO COR The second net is as described below with the same parameters P1 2 P1 4 P1 5 P1 7 P1 9 P1 12 x You don t need to write parameters program will use those Relay commands Test one point others Commodity Tests between two points Net tests Parameters writing before For second net tick the boxes for each point as the picture There is a star in front of P1 1 and P1 3 because they are already use in a net In a full program you need to describe every points for safety reason So at the end every poin
193. vered with a CD ROM containing the WINPASS software options and tester configuration Simply insert the CD ROM in the drive and the program loads automatically The installation software lets you choose the work directories To accept the default directories click on NEXT in each prompt NB ff the testers are in network you must be in administrator mode and the operation files must be on the PC disk D I 4 DESCRIPTION OF THE INSTALLATION The installation program copies the whole SYNOR 4200 software into a particular directory of your PC In standard mode the following directories are proposed C PROGRAM FILES SEFELEC WINPASS This directory contains the tester operation software C SEFELEC WINPASS This directory contains configuration files likely to be modified by the operator The test files will be saved to directories chosen by the user A ATTENTION Test files must never be saved to C PROGRAM FILES SEFELEC WINPASS as they may be deleted during updates ATTENTION When installing for the first time WINPASS must be installed before the PCI 40528 interface card is inserted Then unplug the PC from the mains insert the card in the PCI slot and plug in the tester connection cable Start the PC up again and WINDOWS will install the interface card automatically WINPASS is ready to operate with the TESTER D I 5 UPDATING WINPASS Before updating WINPASS the previous version must be deleted Up to WINPASS 5 03 version insta
194. w b is never used For all the other pins one in every two is wired see wiring list below This list gives the wiring of the first connector of the first switching card The other connectors are organised in the same way sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 45 179 d trompeur o Q o o c c fo o o E S g a o o 2 o o c c e o o d 2 c o o E o o o L o o o g o Lr LDBODBDBUDLBIBIbBiIImiubiipipiiuuuiilliuutbypLc a BLIONBUBUBUBLUBUBUBUBUBUBUBUBUBUBN UM 32 31 30 29 0 o iv D E oO E connector see cabling side Fist address HH cabled pin 46 179 july 2009 Edition Rev SYNOR 4200 Manual Ref WINPASS sefelec B VII 5 SWITCHING CARDS 40675 Switching cards 40675 3000 Vdc 2000 Vac 2 A 32 points route the measurement of the SYNOR 4207 and 4208 They are placed in racks receiving a maximum of 16 cards each They are all identical only their position determines their address They are intermixable with 40670 cards see the technical datasheet Since the relays used are mono contact these cards may be used for all tests including tests by groups of points One card uses two vertical connectors standard 41612 orange on the diagram on the front of the tester Columns A and C are used The tester addresses are shown on the diagram sef
195. will be replaced in the BATCH report by their respective values during tests The directory where this report is created is the same as the source report The batch report is saved under the name source file name batch no This file is an html format You can open it from TESTER MENU OPEN a results file or from an html editor 21x Regarder dans E WINPASS4200 DEMO gt 3 P Er A RES essai rpt soc Mes documents RES nom testeur r cents RES_test DEP RES_test R RES test soc rpt Bureau RES test Y Tests Demo Mes documents PE an Paste de travail 3 victim Nom du fichier Fichiers de type Lot result file LOT Annuler Z RES_demo imprimante cab A The batch report name is given in alphanumerical characters 32 maximum but full stop and anti slash must not be used s fe l SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 114 179 SCLEIEC D II 3 18 Test result in the form of an EXCEL file The test result can be obtained in the form of an EXCEL file This file only processes the code LABEL if the test has to be divided into chapters Texts Hct are not taken into account Only tests appearing in the test result on the screen are copied into the EXCEL table A column indicates PASS or FAIL for the test of each line The XLS file is stored in the directory RES xxxx of the test file The total printout function copies all the measurements into
196. with the basics of the Microsoft WINDOWS operating system If this is not the case it is essential to study the instructions for use described with that software When creating a new test file after clicking on the blank page the screen proposes a logical sequence to assist preparation of the information to be entered in the tester I SEFELEC WINPASS EDITOR File Edit Tools Window Help Create a new file e Create Connector list Create Equivalence table EJ Create Dialogue windows H Create Test program sefelec SYNOR 4200 Manual Ref WINPASS Rev july 2009 Edition 155 179 E I 1 PASSWORDS The following functions are controlled by password Access to the editor 3 Access to the tester id Access to the test configuration Access to self learning Use of the self test without parameter changes Access to manual mode Use of stop on fault without changing the parameters measurement or points The administrator has all rights access to names passwords and choice of user rights Users do not have access to the control panel They must enter their name and password to access protected functions User names and passwords are limited to 16 characters In the basic tester configuration this function can be disabled only by a SEFELEC technician By default when the WINPASS software is first installed the user is SEFELEC and the password is SEFELEC E I 2 CREATION OF CONNECTOR TABLES In the
197. write a message in a test result in the event of the operator stop the test with or do a manual action before the end of the test STOP ON FIRST FAIL the test is stopped and moved on to the next test as soon as a fault appears LIMITED RESEARCH where there is an insulation fault with a large number of points it is possible to limit the search for points to a number defined in the window on the right In the error list the indication LIMITED SEARCH is shown MEASUREMENT OFFSET ADJUSTEMENT the tester is capable of measuring its own internal resistance and of bringing it down to the level of measurements of low resistance in continuity and resistance measurements Panel on the right configuration of the print out of the results e TEST TIME DATE marks the date and time of the test USERNAME to enter the name of the operator at start of test e Obligatory field as its name suggest makes it obligatory to complete the Operator s name field This option does not allow for validation of one name among others e SERIAL NO to enter a serial number at start of test Obligatory field makes it obligatory to enter the serial number of the assembly to be tested This option checks that the serial number field is not empty but does not verify the coherence of the number Input box x USER Name stee SERIAL NUMBER 123458 Cancel e Edition of the parameters as soon as the tester encounters a parameter instructi
198. x Menu Testtype Test of 1 point towards The dialogue box below gives Points Continuity parameters a toolbar offering a choice of Point APIA 7 Resistance low limit p ez available measurements Resistance high lini p iH The right hand window is used e po LI to choose the points to be st 2 EA tested The left hand window x pas gives access to the choice of the parameters of the test to be performed LES gt D a Z ia F2 Test F4 Looping F5 Stop F6 Ext output F Touch point F1 Close Finally the control bar at the bottom of the window enables the operator to start the test loop it and stop it Access to the probe and the external output is always possible from this function bar Finally the result of the measurement is displayed in large characters in the middle of the window o F1 Close Return to the test by clicking on the icon sefelec SYNOR 4200 Manual Ref WINPASS Rev I july 2009 Edition 173 179 E II 4 3 Execute a test file part It is possible to execute only part of a test file To select this click on CONFIGURATION SOFTWARE CONFIGURATION Select TEST PROGRAM LIST VISIBLE MANUAL SELECTION OF START OF PROGRAM and PROGRAM VISIBLE AFTER SELECTION or not as required Software set up Click OK expand the bottom window and using the scroll box look for the program line from which you wish to start the test Click on

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