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profitest 204|+ - GMC

1. ve d 10 0 12 0 V 0 1 V 10 rdg 3 digits 0 999 KQ 1kQ ts 0 050 100 250 500 2 5 rdg 4 digits a 1 00 9 99 MQ 10 kQ from 0 05 MQ to 3 rdg 2 digits 50 MQ 1000 V 50 MQ 10 0 99 9 MQ 100 kQ Insulation max max Resistance 250V 13e U 1 mA 1 6 mA 8 rdg 2 digits 1200V cont R 100 499 MQ 1MQ 3 Uy 6m iA INS 500 1000 V 5 rdg 2 digits 500 999 MO 1MO 500 1000V 10 rdg 2 digits 1 3GQ 10 MQ 1000 V 20 rdg 2 digits Leakage Current 000 g99ma 0 2 9 9ma OO m 2kQ 8 6 rdg 9 digits 6 rdg 5 digits 250V cont 0 0 99 9 V 0 1 V vonage 100 999V 1 0 1000V 1V 20MQ 8 6 rdg 9 digits 5 rdg 5 digits 1 00 1 2 kV 0 01 kV 1200V cont 8 0 99 9 Hz 0 1 Hz 7 Frequency f 100 999H 10 1000 Hz TH 20MQ 8 6 rdg 2 digits 2 rdg 1 digit 13 z z J up to a maximum of 330 mQ 2 With reference to 10 A nominal current GMC I Messtechnik GmbH 55 PROFITEST 204HP Nominal Range of Reso Measuring Intrinsic Uncertainty Use lution Uncertainty Test dug 250 V 2 00 kV 5 rdg 5 digits 2 5 rdg 5 digits Measured Qty Current AC 10 0 250 mA PROFITEST 204HP 2 5kV Test Voltage UAC Nominal Range of Use 250 V 2 5 kV Reso lution Measuring Uncertainty 5 96 rdg 5 digits 5 rdg 5 digits
2. The following symbol appears A Danger High Voltage g 36 Touch neither the test probes nor the device under test during the voltage test A life endangering high voltage of up to 5 KV is present at the high voltage module test probes Pull the trigger at the marked high voltage pistol with switch to its limit stop and hold depressed The following values are displayed at the LCD U selected value Ir 00 0 mA or 0 00 mA Voltage is switched off automatically after the selected test duration has elapsed The following symbol appears Release the trigger switch c Shutdown Functions o o Short circuit the two high voltage pistols Pull the trigger at the marked high voltage pistol with switch to its limit stop and hold depressed The instrument is shut down immediately The green signal lamps must light up and the red signal lamps may not light up The following values are displayed at the LCD Ur XXX V lr gt XXX mA The last measured voltage value before breaking current was exceeded is displayed along with breaking current Imax A Tp Tmax The following symbol appears GMC I Messtechnik GmbH d Signal Lamps Two lamps are arranged diagonally at the test instrument and are used to signal operating states If both lamps go out when the instrument is in the ready to activate operating state RED test voltage is no longer generated Do not start
3. sess 60 9 1 2 Interface Definition and Protocol sse 60 9 1 3 Connector Pin Assignments As 9 2 Parallel Interface printer port 60 9 2 1 Connector Pin Assignments sss 60 10 Signals Error Messages Causes and Remedies 61 11 Mairitenance erinnerte tbe 11 1 Replacing Fuses 11 1 1 Replacing the Mains Fuse 11 1 2 Replacing the Measuring Circuit Fuse in the Test Probe at the PROFITEST 204 sse 66 11 2 Housing and Test Probes sem 66 11 3 PROFITEST 204 Measurement Cables 66 11 4 PROFITEST 204HP HV Test Cables n s 67 11 5 Repair Parts Replacement and Instrument Balancing 67 11 5 1 Cleaning the Transmitter and Receiver Diodes 67 1 5 2 Replacing Signal Lamp Bulbs Disconnecting the High Voltage Module eee 67 GMC I Messtechnik GmbH Contents Page 11 5 3 Replacing Bulbs at the External Signal Lamps ses 68 KROS SOftWale aient tide ttbetecte eine fett tede 68 TVA Recallbration eee se onion ene 69 11 8 Device Return and Environmentally Compatible Disposal 69 12 Appendix 2 reete e te ite 70 12 1 Checklist for the High Voltage Test oo 70 12 2 Minimum Display Values in Consideration of Operating Error ene Ti 12 3 List of Abbrev
4. Intrinsic Uncertainty 12 5 rdg 5 digits Measured Qty Current AC 10 0 200 mA PROFITEST 204HV Test Voltage UAC Nominal Range of Use 650 V 1 00 kV 1 00 kV 5 00 kV lution 7 rdg 5 digits Measuring Uncertainty 2 7 rdg 2 5 rdg 5 rdg 5 digits Intrinsic Uncertainty 0 596 rdg 0 3 rdg Measured Qty 1 0 10 0 mA 0 01mA 7 rdg 5 digits 5 rdg 5 digits Current AC 0 1 mA PROFITEST 204HV 5 4kV Nominal Range of Reso Use lution 650 V 1 00 kV 1V 10V 0 01mA 0 1 mA Measuring Intrinsic Uncertainty Uncertainty 2 7 rdg 0 5 rdg 2 5 rdg 0 396 rdg 7 rdg 5 digits 5 96 rdg 5 digits Test Voltage UAC 1 00 kV 5 35 kV Measured Qty Current AC 1 0 10 0 mA 56 GMC I Messtechnik GmbH 8 Setting Ranges for Parameters and Standard Values per DIN VDE PROFITEST 204 Measurement Parameters Charact Cross Section Lower Limit Standard Value Upper Limit Special Setting Options Protective Conductor Mea Test duration 1s Continuous measurement surement Limit value for protective 1 5 square mm 427 MQ conductor resistance based 2 5 square mm 293 mQ on phase conductor cross 4 0 square mm 187 MQ section and characteristics 6 0 square mm 141 MQ ofthe overvoltage protection 10 square mm 73 1 MQ device
5. RS 232 Interface Type Format Connector ohmic 207 V 253 V 45 Hz 65 Hz sine 0 C 40 C 20 C 60 C 5 C 40 C 0 C 40 C 75 no condensation allowed to 2000 m 207 V 253 V 45 Hz 65 Hz 204 approx 180 VA without accessories 204HP max 700 VA 204HV max 100 VA 0 5 mA basic device and 204HP or HV max 6 A basic device and 204HP or HV RS 232C serial per DIN 19241 9600 8 N 1 9 pin sub miniature socket 58 GMC I Messtechnik GmbH Electrical Safety Safety Class Line Voltage Test Voltage 204 Test Voltage 204HP HV Measuring Category Contamination Degree Safety Shutdown Fuses GMC I Messtechnik GmbH 204 Il 204HP HV per IEC 61010 1 EN 61010 1 VDE 0411 1 230 V 5 55 kV 50 Hz mains PE key switch external signal lamps to high voltage measuring terminals 204HP 5 kV AC 50 Hz 204HV 8 kV AC 50 Hz mains to PE 1 5 kV AC mains to external signal lamps 1 5 kV AC 2 if instrument overheats 204 mains T 1 6 250 test probe T16 1000 204HP HV mains F3 15 250 Electromagnetic Compatibility EMC PROFITEST 204 Product Standard Interference Emission EN 55022 Interference Immunity EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 EN 61000 4 11 ag Note Test Value EN 61326 1 2006 Class A Performance Feature Contact atmos 4 kV 8 kV 10 V m Mains Connection 2
6. 3 712 007 10 o Wind the two cables from the safety test probes at the cud i 9 HexNu 6 3 730 119 12 high voltage module onto the lower cable reel 2 bottom 10 Screw 2 3 716 018 24 gt Then wind the two cables from the test probes at the basic e 1 FM 1 3 421 111 01 instrument onto the upper cable reel 2 top i Ve q2 Rubber gt 9 326 607 01 gt Secure the cables and test probes with the included rubber RA ed Band bands 12 D Protective 13 Cover 1 3 171 302 01 A A Attention NM Observe regulations for portable testing systems as set forth in DIN VDE 0104 3 6 ess 67 ag Note Wind the cables from the safety test probes onto the Transport Caddy 204 reels included for this purpose at the back of the caddy after each use The test cables may not under any circumstances be mechanically stressed or kinked A because this may result in impaired insulation IN characteristics Remember that damage may L N Attention not always be externally recognizable Always inspect the test cables for mechanical damage before starting up the high voltage module each time it is used 16 GMC I Messtechnik GmbH 3 3 Connecting the PROFITEST 204 to 230 V Mains Power U y 230V o Li o N o PE green yellow o L1 o L2 o L3 LIE r e o PE green yellow o L1 o 12 o L3 ie ia Se ec Se iF N green yellow GMC I Messtechnik GmbH
7. CONVENE 1i incedo Tua ect fe 70 neutral conductor 00 70 PELV CiIrCUitS fon Aine ican Ade nes 70 personnel uero acer atr es 70 TIN SYSTEMS kem em 70 PSS ca d EG eel Rete da ose 9 Pulse control mode 00 005 41 GMC I Messtechnik GmbH R Residual voltage determination of value 33 incliGatiori 5 2 6a 11 34 61 65 S Self test serrana eee e pa 21 Signal generator acoustic acoustic sequences 37 configuration llis 20 Optical ainera rnt ede Cg 37 Signal lamps external description anr an 15 replacement of bulbs 68 T Temperature inside test instrument 21 Time and date lussuss 20 V Voltage measurement iussus 33 Voltage test Checklists era uc e ce ERES Nate 70 indication error message 64 procede iocari rr a ats Rod 35 safety precautions 05 12 setting ranges lisse 57 58 symbols at the display 11 technical data 000 56 W WinProfi installation and program start 23 transmission and print out of report data 25 GMC I Messtechnik GmbH 73 13 Repair and Replacement Parts Service Calibration Center and Rental Instrument Service When you need service please contact GMC I Service GmbH Service Center Thomas Mann Strasse 20 90471 N rnberg e Germany Phone 49 911 817718 0 Fax 449 911 817718 253 E Mail service8gossenmetrawat
8. High Voltage Test Up 205kV I 0 20mA Test OK t No values are saved to memory for Uy and ly during continuous operation with test duration set to gt gt gt gt gt gt gt 40 Premature Interruption of the Test The test can be interrupted prematurely at any time by releasing the trigger at the high voltage pistol with switch If testing is interrupted by releasing the trigger at the high voltage pistol before the pre selected test duration has elapsed the val ues displayed for Ur and may deviate from the last measured values ag Note Regarding Breakdown Voltage If the selected breaking current Imax is A exceeded before the selected test voltage IDI value has been reached the test voltage Aiia measured at this point in time is preceded with the gt symbol at the display and is stored to memory The corresponding symbol appears as well GMC I Messtechnik GmbH 4 5 4 Pulse Control Mode The pulse control mode is recommended for troubleshooting locating the point of flashover Breaking current Imax is set to a fixed value of approximately 125 mA for the 204HP and 5 mA for the 204HV in the pulse control mode If this value is exceeded test voltage is switched off within 0 5 ms After approximately 0 6 s test voltage is increased from O to the selected maximum value within a period of 0 2 s or is switched off again if breaking current is exceeded 0 6 s x Rise P
9. gt Connect the test instrument to 230 V mains power with the attached mains connection line connection 22 at the instru ment If an earthing contact outlet is unavailable or if only a 3 phase outlet is available the phase conductor the neutral conductor and the protective conductor can be connected with the help of the socket adapter The socket adapter is equipped with three permanently attached cables and is included as part of the KS13 cable set which is available as an accessory A Attention If a connection via earthing contact outlet is not possible disconnect the mains from all sources of voltage before connecting the cables of the coupling socket via pick up clips with the mains connections as shown in the draw ing A Attention The recessed outlet at the basic instrument is used to supply power to the HP HV high voltage module If this outlet is used for any other purpose current consumption may not exceed 6 A 3 4 Connecting the High Voltage Module to 230 V Mains Power Connect the recessed outlet at the basic instrument to the inlet plug at the high voltage module with the included power cable The high voltage module can also be connected directly to 230 V mains power 17 3 5 Operating Software Measuring and testing is quick and easy with the PROFITEST 204 The integrated operating software informs the user concerning all necessary operating procedures errors and measuring results etc regardless of
10. 25 50 75 100 used MENU Main menu START Continue 5 4 Clearing Memory This command deletes stored data from all existing systems Full memory capacity is made available in this way A ZN menon _ Attention Transmit and save all data to a PC before clearing the memory Select the desired command Sub menu START Execute the command PROFITEST 204 Select machine Browse data Organize data Delete data Transnit data Delete data The complete data storage will be deleted All saved machine data and measure ments will be lost MENU Main menu HELP ERT Delete data storage A security query must be acknowledged before all data records are deleted Permanent deletion is executed with the i STORE key 45 5 Data Transmission Measurement data the entire contents of the memory at the PROFITEST 204 can be transmitted to a PC with the function Selector switch in the data management position where it can be subsequently analyzed Measurement data can also be transmitted back to the test instrument 3g Note WinProfi software which is included with the PROFITEST 204 can be used for the transmission of data from the test instrument to the PC and vice versa This software encompasses all functions required for communications between the PROFITEST 204 and the PC A program description can queried from the online handbook included with the WinPr
11. 67 regarding signal lamp replacement External Signal Lamps The external signal lamps indicate the same operating states as the signal lamps integrated into the high voltage module They are used for additional security at the measuring site and must be plainly recognizable beyond the boundaries of the danger zone The external signal lamps can be directly connected to the respective terminals at the high voltage module Note For reasons of safety only Z504D signal lamps by GMC I Messtechnik GmbH may be used See chapter 11 5 3 page 68 regarding signal lamp replacement 15 3 2 Mounting the Instruments to the Optional Caddy o Place the unit consisting of the basic unit and the high voltage rn item Designation Qty Order No module onto the caddy platform 1 such that the lid of the 1 Platform 1 3 117 193 01 basic unit can still be opened 1H 2 Cable Reel 2 3 326 653 01 gt Secure the handle of the basic unit with the handle fixtures 3 3 ae 2 3 326 652 01 on the vertical posts as follows T 7 Tover 3 316460901 gt First loosen the screws at handle fixtures 9 with a 4 mm hex 5 Wheel 2 3 419 038 01 socket wrench 6 Disk 4 3 740 013 01 gt Push the handle fixtures 3 onto the handle and retighten the d 7 Circlip 2 3 743 024 59 screws 9 E n 8 Screw 6
12. desired in which case a Separate report is created for each system GMC I Messtechnik GmbH Printing the Report gt Select the desired printer in Windows The standard printer is always used Printer settings can be changed to suit your specific needs with the printer setup function in the System menu o Select a report template and start printing by clicking the OK button IProfokollauswahl Available Protocol Files Print List 1 HAUSOT 001 3645 2 Zoo lage Grabber Output to CFom i Font Standard J GET Read protocols from file tput gt Add to print list Printer lt Remove from print list CFile ALL Add all protocols to print list Cancel b e L le Selection CForm 2 of form CfForm 3 Note If the print out does not fit into the page as desired the font can be enlarged or reduced in size With some printers the printer driver included with Windows must be used instead of the driver provided by the printer manufacturer 51 Print the report to a file and edit o gt 52 Select the Output to File function instead of Output to printer The NAME XXX file is created automatically XXX stands for the System number which is entered automatically Start the WinProfi editor from the Windows start menu Open the NAME XXX file The file can be edited or as desired with the editor Save your changes to the previously created file name or to a new file with a diff
13. establish whether the measurement cables are disconnected at any point PROFITEST 204 A TEST Protective conductor VY v Insulation resistance Leakage current Select the desired test Voltage measurement High Voltage test MENU Open the sub menu 29 4 2 1 Configuring Test Parameters Select a test voltage of 500 V for the main circuit or 1000 V if required for extended testing A lower test voltage can also be Selected for testing voltage sensitive components The allowable limit value for insulation resistance can also be changed Select the desired parameter Adjust to the desired value 30 Insulation resistance Setting test parameters Nom volt 1 00 kU Linit 1 00MR MENU Cont ma Change val Start test HELP 4 2 2 Start the Test START Or O ag Note Insulation resistance Rins 1 28 GQ Ums 1 05 kV Hom volt 1 88kU Limit 11 885 Testing IN U 25V The test can only be started with the START key on the test instrument from the test parameters window a STORE Press briefly Store an event Press and hold Store an event and activate the entry field Up to 15 characters can be entered to the entry field or to the info field at the bottom left as a description for the measurement See chapter 5 1 1 regarding data entry or ec non STORE Press briefly Store an event The green
14. existing systems which contain no data can be deleted with this function PN Select machine machine Browse data Organize data Delete data Transnit data Select the desired command Sub menu Ba Delete data Organize data Deleting recorded machines error correction Memory O 25 50 75 100 used MENU Continue ERT Do it HELP A security query must be acknowledged before individual system data are deleted A message appears after data has been deleted from all systems for which reports have been printed After pressing the START key again a list is read out which includes all systems whose stored data have not yet been printed out GMC I Messtechnik GmbH 5 3 2 Memory Test Memory is tested for errors with this function Errors can be corrected in some cases Follow the instructions which appear at the display START Test the memory Organize data Deleting recorded machines Data storage test error correction Memory O 25 50 75 100 used MENU Continue ERT Do it HELP Memory Test Starting address Rddress sort E Block distance End address 1 I4 No error found in address link area Memory O 25 50 75 100 used MENUJMain menu START Continue AN GMC I Messtechnik GmbH Memory Test Address relationship 4 Checksum machines 4 Checksum data 4 complete storage range Memory O
15. file whose data are to be transmitted to the test instrument NAME DAT gt PC Start transmission by clicking the OK button ag Note In order to transmit data from the PC to the test instrument the data file to be transmitted must be in the same directory as the WinProfi program files Data transmission Transnitting data to or from a PC Connect the PROFI TEST 264 to PC with 9 pole SUB D extension cable Transmitting GMC I Messtechnik GmbH 47 6 Printing Uploading and Creating Reports The test instrument s report functions can be activated by setting the function selector switch to the Printer position The following functions are available e Print Values PSI only in conjunction with SECUTEST PSI Measured values from a selected system can be read out via the serial interface and printed out at the PSI module optional e Print Reports Report data from a selected system are read out via the printer port parallel interface Any commercially available printer with a CENTRONICS parallel port can be used Report number system number and description time and date as well as measured values and type of measurement are printed from the test instrument to the report form If several measurements were performed for each type of measurement they are numbered consecutively Select a Report Form The user can select from amongst three report forms which have been loaded to the ins
16. function has Switched the instrument to the stand by mode It is entirely possible that the displayed value for lr is less than Imax because the last measured value is always displayed Instrument is defective Transmission between PROFITEST 204 and 204HP HV interrupted Excessive temperature inside the test instrument high voltage test Allow instrument to cool down for approx 10 minutes 11 2 2 Special Safety Precautions and Instructions for the PROFITEST 204HP HV High Voltage Module Precautions for the prevention of unauthorized activation Key Switch Precautions for the prevention of unintentional activation e Multiple Key Operation It is only possible to activate test voltage with the trigger at the high voltage pistol with switch after pressing the start key at the basic instrument e Two Hand Operation Each of the high voltage pistols is equipped with its own trigger The test probes are only made accessible when both triggers are pulled and held simultaneously e High Voltage Pistol with Switch pistol with yellow marking Includes double safety feature The test probe is made accessible after the trigger at the high voltage pistol with switch has been pulled to its initial mechanical limit stop High voltage is not switched to the test probe until the trigger is pulled beyond this position assuming the instrument is in the ready to activate state 12 General Safety Precautions e Integrated sign
17. in the process Software updates can also be uploaded with the same program independent of the currently installed language ag Note WinProfi software can be used to upload the desired lan guage to the test instrument The software encompasses all of the functions required for establishing communica tions between the PROFITEST 204 and a PC A program description is contained in the online instructions included with the WinProfi software WinProfi software WinProfi is currently applicable up to Windows 7 32 Bit A Installing and Starting WinProfi Software at the PC gt Download the WinProfi software from our homepage http www gossenmetrawatt com 2 Products Software Software for Testers gt WinProfi gt Unzip the zip file winprofi zip gt Install the software on your PC by executing file Setup WinProfi Vx xx exe gt Select the desired language for the WinProfi software and for the user interface of the test instrument gt Follow the instructions which appear at the monitor The program is added to your start menu after installation gt Establish a connection between the PC and the PROFITEST 204 Use an appropriate interface cable to this end See page 5 o Start WinProfi again Switch the test instrument on Display or print out online user s manual The online manual contains information concerning the software which is not included in these operating instructions Win
18. key If discharge does not occur only the voltage value is saved ag Note If conductors are exposed when a machine is switched off which are not protected against direct contact e g if plug connections are interrupted the maximum allowable discharge period is 1 second 33 PROFITES 204 Protective conductor conductor TEST SH Insulation resistance Leakage current Voltage measurement Select the desired test High Voltage test Open the sub menu 44 1 Configuring Test Parameters The discharge period the time during which the voltage value must be reduced to a safe level of less than 60 V can be set within a range of O to 9 seconds Residual voltage less than 60 V is dis played when this threshold has been reached Uoltage measurement Setting the maximum discharge time Limit value 5 005 Cont Change val Set discharge period duration mj Cont fal Start test HELP 34 4 4 2 Start the Test START Uoltage measurement UE Sm f 5OOHz Cont measurem max 18BBU AC DC Testing AC Sg Note The voltage test can only be started with the START key on the test instrument a STORE Press briefly Store an event Press and hold Store an event and activate the entry field Up to 15 characters can be entered to the entry field or to the info field at the bottom left as a description for the measurement See ch
19. mains o Short circuit all electrical circuits to themselves gt Disconnect surge diverters from control current circuits if these would be triggered by test voltage gt Disconnect PELV circuits high voltage testing is not required here gt Test insulation at all circuits with 1000 V If insulation resis tance is OK with 1000 V the high voltage test should be Successful as well o Disconnect the converter 70 c Attention in TN systems In these systems the protective conductor is connected with the neutral conductor in the terminal box High voltage is therefore present between the phase conductors and the neu tral conductor If necessary the neutral conductor must be separated as it is not disconnected from the mains by any fuse Set Up the Test Instrument See chapter 8 Setting Ranges for Parameters and Standard Val ues per DIN VDE High Voltage Test gt Test all circuits conductors against the protective conductor all switches within the system circuit must be switched on and testing must be performed upstream and downstream from relays o Remove all short circuiting after the test Performing the Test without Short Circuiting gt Test all conductors from all circuits separately against the protective conductor if flashover occurs the machine may be damaged Functions Test gt The machine must be tested for correct functioning especially as regards safety functions after high volt
20. parameter Open parameters entry window All settings and changes entered via the menus which are made available when the selector switch is in the SETUP position are saved automatically and are retained even after the test instrument has been disconnected from mains power Exit function GMC I Messtechnik GmbH 3 7 1 Adjusting Contrast and LCD Illumination Contrast can be increased or reduced with this function Furthermore illumination can be activated or deactivated Only for devices with electroluminescence lighting PROFITES 204 AO 4 PDisplay contrast contrast Time and date Beeper Self test Language SETUP AV Adjust contrast Display contrast Setting display contrast fi eld Fla LighterDarker display START HENUJExit GTR Backlight Activate or deactivate illumination This function is only available for devices with electroluminescence lighting Background illumination is switched off automatically after 2 5 minutes as long as no keys are activated during this period of time Background illumination is reactivated for an additional 2 5 minutes each time a key is pressed 19 3 7 2 Setting Time and Date The test instrument s internal clock can be set with this function The clock continues to run even after the instrument has been disconnected from mains power Time and date are included in the printed test reports The date is enter
21. read out as well A description of the interface protocol as well as a list of commands and syntax is available upon request from GMC I Messtechnik GmbH 60 9 1 3 Connector Pin Assignments RxD TxD NC TxD view SI RxD view Sl 5 A4 312 NC 6 GND Oo NC 4 NC gt 8 NC 97 9V 9V O e c co co N D oousocgsom 9 2 Parallel Interface printer port Any commercial printer with a CENTRONICS parallel port can be connected to this interface 4 Prerequisite the printer includes internal character sets pure Windows printers do not work Comprehensive reports can be printed out which have been cre ated with the included software 9 2 1 Connector Pin Assignments T Strobe 2 9 DO D7 10 ACK 13 1 dE et OC C0 UU QUO DO OO ac PX d gd 020090 009 95 14 NC 25 15 Fault 14 16 Init printer 17 NC 18 25 GND GMC I Messtechnik GmbH 10 Signals Error Messages Causes and Remedies Signal Error Message Test Sequence Testing HGO Discharging the residual voltage Residual A T less than amp BHll M um Test OKt Test failed LCD is not illuminated Protective conductor and insulation measurement cannot be performed Temperature too high wait 14 min External voltage on probe tips VOLTAGE GMC I Messtechnik GmbH Mea
22. 2 The Key Switch The key switch protects the instrument against unauthorized use Keep the key in a safe place to which only authorized personnel have access Each time testing is completed turn the key to the O position and remove it from the lock 3 1 3 Indication of Operating States Signal Lamps The signal lamps integrated into the high voltage module indicate the two different operating states Stand By State Key switch is in the I position on Power supply to signal and control circuits at the high voltage module is switched on All test voltage circuits are switched off and are secured against inadvertent activation A A Attention All safety precautions which are required before entering the danger zone should now already be implemented including posting of warning signs WS1 and additional signs ZS2 in accordance with DIN 40008 part 3 GMC I Messtechnik GmbH Ready for Activation AN The menu used to start the voltage test has been opened and the start key has been activated No voltage has yet been applied to the safety test probe assuming the trigger at the high voltage pistol has not been pulled e The test probes are secured against unintentional contact assuming the triggers at the high voltage pistols have not been pulled y y Attention When the instrument is ready for activation all points of access to the danger zone must be secured See chapter 11 5 2 page
23. 34 Starbtlie TeSb cien ertt tent ae tn Voltage Test option PROFITEST 204HP HV onsas 35 Functions Test test preparation nmm 35 Configuring Test Parameters TEST Sequence neenon eren eatis enn ee d Pulse Control M d c i D e Penes Ending the Voltage Test ssseemnn En Da Da Processing Transmitting and Deleting Data Selecting a System ering a Description Copying Descriptions Deleting a Description a Processing viewing measured values a Reorganization Deleting Recorded Data Memory Test Clearing Memory esee eme 45 Data Transmission 2 25 Ea e ale e edere 46 GMC I Messtechnik GmbH Contents Page 6 Printing Uploading and Creating Reports 48 6 1 Print Values PSI Print a Report sn 48 6 2 Selecting a Form for Report Printing enne 49 6 3 Uploading a Report Form i 6 4 X Report Form Generating Program see 53 6 4 1 List of Code Words and their Meanings eese 53 6 4 2 Report Layouts a 6 4 3 Uploading a Report Form to the Test Instrument 54 7 Characteristic Values see 55 8 Setting Ranges for Parameters and Standard Values per DIN VDE 57 9 Data Interfaces 9 1 RS 232 Serial Interface m 9 1 1 Software Analysis of Measurement Results
24. 4 All measured data can be archived with the measuring and test report which can be printed out directly or at a PC This is especially important where product liability is concerned 1 2 PROFITEST 204L The PROFITEST 204L test instrument has been furnished with an extra long measurement and control cable allowing for comfortable use at large machines and machine components Please note that use of the LEADEX 204 extension cable is only possible to a restricted extent as a result of this extra long measurement cable Due to the additional relatively high ohmic resistance of the LEADEX 204 extension cable the minimum test current of 10 A AC as specified by EN 60204 may be fallen short of under certain circumstances causing the instrument to abort the test and display a corresponding message As a rule this does not occur during use of the LEADEX 204 extension cable until protective conductor resistance at the device under test has reached a value of 200 mQ or greater This effect may even occur with relatively low line voltage values less than 210 V If you require longer measurement cables than those supplied with the PROFITEST 204L for your application we recommend the use of extension cables with a significantly larger cross section Our product support team see address on page 74 would be happy to assist you with any questions you may have ff 4 Attention Protective conductor and high voltage test It is imper
25. Operating Instructions A GOSSEN METRAWATT PROFITEST 204 204 L 204HP 204HV Test Instrument for EN 60204 DIN VDE 0113 23 9 15 Test instrument may only be operated under supervision of a qualified electrician C f N 1 do tO 2 Ee oG N I 7 ET F bvwnen 22 204 8 ae CD Tine and date G 9 Self test C z 23 Language M a 10 11 o NS SZ CAT II 1000 V gt J Connector Panel PROFITEST 204 Basic Instrument GMC I Messtechnik GmbH 19 HR8O STORE START Roc 21 D START Rins Remote Control PROFITEST 204 Test Probes J N mem N Attention The ventilation slots at the bottom of the housing 24 and in the connector panel of the basic instrument must remain unobstructed GMC I Messtechnik GmbH o N OORA OUN Function selector switch Dey M key Printer port Connector socket for RS 232 interface LCD window Signal lamp test passed green test failed red MENU key Help key save key Start key for selected test Signal lamp test in progress yellow Push buttons left and right for releasing the handle from its snap in position Push buttons left and right for releasing the lid Lid Accessory input module SECUTEST P SI not included in standard equipment Carrying handle and til
26. PROFITEST 204 A Danger High Voltage If non specified fuses are used in the measuring circuit test probe operator error may be life endangering danger of short circuiting o Remove the cover with the 3 screws from the test probe with a suitable tool screwdriver gt Replace the blown fuse with a new fuse with the same characteristic values T16 1000 o Reassemble the test probe 11 2 Housing and Test Probes No special maintenance is required Keep outside surfaces clean and dry Use a slightly dampened cloth for cleaning Avoid the use of cleansers abrasives or solvents A A i L N Attention Condensation at the high voltage module the test cables and the device under test must be prevented because high voltage might otherwise result in surface leakage current Insulated components may also conduct high voltage if condensation is present 11 3 PROFITEST 204 Measurement Cables Inspect the measurement cables for mechanical damage at regular intervals GMC I Messtechnik GmbH 11 4 PROFITEST 204HP HV Test Cables Wind the test cables around the reels at the back of the transport caddy option after each use if the caddy is used The test cables may not under any circumstances be mechanically damaged or kinked because insulating capacity may otherwise be impaired Inspect the test cables and the high voltage pistols for mechani cal damage before placing the high voltage module into service each time
27. Profi ni xj GMC I Messtechnik GmbH 23 B Prerequisites for Software Update or Exchange of Data o Find the interface to which the PROFITEST 204 is connected File Protocol Update Help Search Device Calibration Info Time and Date Copyright Printer Setup Exit Note Always start this function first before performing an update or changing report templates After starting this function WinProfi loads the report files specifically necessary for the connected instrument Due to the fact that WinProfi has been created for use with several types of test instruments incorrect test reports may otherwise be loaded or erroneous options may be made available gt Query information regarding current software version File Protocol Update Help Search Device Calibration Info Time and Date Copyright Printer Setup Exit 24 C Transmitting a Software Update to the Test Instrument IN Attention Previously saved data are lost during the updating procedure Save the measured values to your PC before WinProfi System File Protocol Help Language Firmware Extended Function met ER Acme rete Update all gt PC Select Update all from the Update menu Follow the instruc tions which appear at the monitor Depending upon the utilized PC updating takes from 1 to 2 minutes The green LED indicates that the instrument is ready to receive data If the PC and the test instrument are
28. WinProfi for communication with PROFITEST 204 The free PC starter software WinProfi is used for communication with your PROFITEST 204 test instrument WinProfi is available on our homepage with the following content and functions up to date test instrument software for loading a different language for the user interface for loading an updated software version e Transmission of measurement data from the test instrument to the PC preparation and modification of templates for test reports at the PC and transmission of the templates to the test instrument e preparation printout and filing of test reports at the PC The following interface cables and or converters are required for communication between test instrument and PC Z3241 RS232 tester RS232 PC RS232 USB Converter 2501L RS232 tester USB PC not possible via the RS232 terminal of a connected SECUTEST SI Up to date PC software free of charge starter or demo software for data management report and list generation is available from our homepage for download WinProfi is currently applicable up to Windows 7 32 Bit GMC I Messtechnik GmbH Notes on SECUTEST SI Operating Instructions The SECUTEST SI module is used together with the PROFITEST 204 exclusively for entering comments at the alphanu meric keypad The following chapters from the operating instructions included with the SECUTEST SI 3 349 613 15 are relevant for oper
29. age measuremnt Stored FROFITEST 284HP max ZEW zB mH PR FITEST 284 HL max SEW iBmH PROFITEST 284 HU HP not found Transmission finished Green signal lamps are not illuminated PROFITEST 285 HU HP nat found Red signal lamps are not illuminated Defective instrument 64 capacitive resistive p Yo Error Meaning Cause The current value for the contact current measurement is not within the allowable measuring range The instrument is switched to voltage measurement it must be assumed that dangerous contact voltage is present The measuremen Data management message has been saved to memory Data transmission has been successfully completed PROFITEST 204HP HV High Voltage Module The displayed high voltage module has been detected The displayed high voltage module has been detected The displayed high voltage module has not been detected Cu Power cable no Key switch set to Blown fuse Defective signal lamp plugged in 0 Faulty data exchange between PROFITEST 204 and 204HP HV Defective signal lamp he dimension nder momen rrent measured during the test was capacitive to a given extent The larger capacitive current Current me S of the device under test the greater the asured during the test was primarily ohmic However it must neverth ent which se eless be assumed that leakage curr
30. age testing GMC I Messtechnik GmbH 12 2 Minimum Display Values 12 3 Listof Abbreviations in Consideration of Operating Error Table for the calculation of minimum display values for protective conductor resistance insulation resistance and differential current in consideration of instrument operating error Abbreviation Meaning Contact current for leakage current test Voltage drop during protective conductor test HecimO Bing MQ Alm Frequency of measuring voltage Limit Value Max Display Limit Value Min Display Limit Value Max Display Maximum permissible current before high voltage is switched off Nominal current Breaking current for high voltage test Protective Extra Low Voltage Safety Extra Low Voltage Insulation resistance Protective conductor resistance Test voltage Measuring voltage Voltage value prior to exceeding the breaking current during high voltage testing GMC I Messtechnik GmbH 71 12 4 Index B Breaking current exceeding cie Rn 36 in pulse control mode 41 indication 0 2 0 2c eee 11 Setting ox I Eee ween tsi 37 setting range llle ee eae 57 with regard to breakdown voltage 40 C Comment COPY x x vi De LE DR oe C 43 delete dawn era e tees 43 GRIEF eked tole d eot ela ado ans 43 entry opti
31. al lamps identify the operating status of the test in strument e Test voltage is electrically isolated from mains power This prevents heavy current from flowing to ground via the high voltage pistol with switch Current Limiting in the Event of Sparkover If the current limiting value entered as a parameter is exceeded in the event of sparkover the instrument is automatically switched to the stand by mode The instrument is automatically switched to the stand by mode when power is restored after a mains failure A Attention The ventilation slots at the bottom of the high voltage module and at the connector panel of the basic instrument must remain unobstructed GMC I Messtechnik GmbH A DN mem N Attention Observe regulations set forth in EN 50191 Erection and operation of electrical test equipment Attention If safety test probes are used the operator must make cer tain that the probe tips and the connector cables are in flawless condition before beginning work All utilized equipment must be inspected for visibly apparent external damage and defects before use see chapter 11 2 page 66 through chapter 11 4 page 67 A gt Attention It is imperative that the measuring cables are completely unwound prior to starting the high voltage test gt Attention Make sure that all points of access to the danger zone have been secured before testing is started and that no persons remain wit
32. and standard values is included in chapter 8 page 57 37 E MENU High Uoltage Test Select the desired parameter Parameter Setup Duration 1 00s Test volt 2 00kU VY v Imax 250mA Rise tine 1 00 s Adjust to the desired value MENU Cont Fa Change val Start test HELP A Test lm ec Voltage Ur Time Rise Test Decline me Test Time gt Constant 0 1 s 38 GMC I Messtechnik GmbH 4 5 3 Test Sequence A Attention Make sure before testing is started that the measuring cables are completely unwound that all points of access to the danger zone have been secured and that no persons remain within the danger zone when the system is made ready for activation o Turn the key switch to the position The test instrument is switch to the stand by mode The green signal lamps are illuminated gt Check the test parameters o Press the START key The instrument is switched from stand by to the ready for activation The red signal lamps are illuminated START GMC I Messtechnik GmbH High Uoltage Test Up 205kV I 020mA Test V 2 88kU Imax 258mA Testing HIGH VOLTAGE A Danger High Voltage Touch neither the test probes nor the device under test during the voltage test A life endangering high voltage of up to 5 kV is present at the high voltage module test probes o Position the high voltage pistol
33. apter 5 1 1 regarding data entry or eo O I STORE l Z Save results The green red signal lamp is extinguished briefly as acknowledgement Press briefly GMC I Messtechnik GmbH 4 5 Voltage Test option PROFITEST 204HP HV Electrical equipment at machinery must withstand a test voltage applied between the conductors of all electrical circuits and the protective conductor circuit for a period of at least 1 second with a value of twice the rated voltage of the equipment or 1000 V whichever is greater The test voltage must have a frequency of 50 Hz and must be generated by a transformer with a minimum power rating of 500 VA ag Note The PROFITEST 2044 must be used in combination with the PROFITEST 204HP HP 2 5kV high voltage module for testing in accordance with DIN VDE 0113 The PROFITEST 204HV HV 5 4KV is required for testing with up to 5 kV The PROFITEST 204 automatically recognizes which type of high voltage module has been connected Communication between the basic instrument and the high voltage module can be tested as described in chapter 3 7 4 A Attention Inspect the test instrument high voltage cables and high voltage pistols to assure flawless condition before beginning work see also chapter 11 4 page 67 Note Testing of measurement cables The first test should be conducted on test probes with short circuited measurement cables The instrument must indicate a value of approxi
34. ation with the PROFITEST 204 e Chapter 2 e Chapters 3 1 and 3 2 e Chapter 10 e Chapter 11 e Chapter 12 e Chapter 13 Safety Features and Precautions Inserting and activating the SI Module Characteristic Values Maintenance Repair and Replacement Parts Service Product Support The following functions are not active and are only sensible in combination with the SECUTEST test instrument Display and save reports e Statistics Utilization in combination with a barcode scanner Contents 1 1l 1 2 2 2 1 2 1 1 2 1 2 2 1 3 2 1 4 2 2 3 1 3 1 1 3 1 2 3 1 3 3 2 3 3 3 4 3 5 3 6 3 7 3 7 1 3 7 2 3 7 3 3 7 4 3 7 5 Page Applications s 7 t a 8 PROFITES T 204 oe ccrte hr i te coe sere tos 8 PROFITEST 2Q4L erre etes 8 Safety Features and Precautions sss 9 Meanings of Symbols Symbols on the Instrument ssennnes 10 Symbols in the Operating Instructions eeeee 10 Symbols which Appear at the PROFITEST 204 Display 10 Symbols which Appear at the Display of the PROFITEST 204HP HV High Voltage Module s 11 Special Safety Precautions and Instructions for the PROFITEST 204HP HV High Voltage Module s 12 Initial Start Up ssss Start Up of the Optional High Voltage Module Mounting the High Voltage Module to the Ba
35. ative that the measuring cables are completely unwound prior to starting the tests GMC I Messtechnik GmbH 2 Safety Features and Precautions This instrument fulfills the requirements of the applicable Euro pean and national EC guidelines We confirm this with the CE marking The relevant declaration of conformity can be obtained from GMC I Messtechnik GmbH The PROFITEST 204 204 HP and 204 HV test instruments have been manufactured and tested in accordance with the following safety regulations IEC 61010 1 DIN EN 61010 1 VDE 041 1 1 DIN VDE 0413 part 1 and EN 60204 DIN VDE 0113 If used for their intended purpose the safety of the user the instrument and the device under test is assured Read the operating instructions thoroughly and carefully before using your instrument and follow all instructions included therein Make sure that the operating instructions are readily available to all oper ators Observe the following safety precautions The instrument may only be connected to electrical supply Systems with 230 V 240 V which conform to the valid safety regulations e g IEC 60364 VDE 0100 and are protected with a fuse or circuit breaker with a maximum rating of 16 A Be prepared for the occurrence of unexpected voltages at devices under test for example capacitors may be dangerously charged e Make certain that connector cables measurement cables and test cables are in flawless condition e g no damag
36. ause gt Set Imax to gt gt gt gt gt gt gt for selection of the pulse control mode see chapter 4 5 2 page 37 c If continuous operation is required set test duration to gt gt gt gt gt gt gt as well see chapter 4 5 2 page 37 GMC I Messtechnik GmbH 4 5 5 Ending the Voltage Test gt Release the triggers at the high voltage pistols gt Press the MENU key gt The signal lamps switch from red to green o If the test system is left unattended it must be switched to the out of service mode signal lamps off Turn the key switch to the O positions and remove the key Secure the instrument against unauthorized use g 41 9 Processing Transmitting and Deleting Data Previously stored data or data records can be processed with the function selector switch in the data management position The following functions are available Select a System A system number can be selected with this function to which measurement results can then be stored A description of the System can be entered as well Data Processing Individual data from a previous measurement e g protective conductor test can be displayed for the selected system and can be deleted if desired Data Reorganization Previously added systems can be deleted from memory and a memory test can be performed Clear Memory This command deletes data records which have been saved for all existing systems Full memory capacity
37. breaker All cross sections see following tables phase cond a 8 x In break time 0 1 s GMC I Messtechnik GmbH 57 PROFITEST 204HP 2 5kV Parameter Lower Limit Test Duration Standard Value Upper Limit Special Setting Options Continuous Test Voltage Breaking Current Imax Pulse control mode Rise Time Recommended The highest value applies PROFITEST 204HV Parameter Lower Limit Upper Limit Special Setting Options Test Duration 1s 120s Continuous Test Voltage 650V 5kV Breaking Current Imax 1mA xx 10 mA Pulse control mode Rise Time 100 ms 1s 99 9 s Recommended PROFITEST 204HV 5 4kV Parameter Lower Limit Test Duration Upper Limit Special Setting Options Continuous Test Voltage Breaking Current Imax Pulse control mode Rise Time Recommended Reference Conditions Line Voltage Line Frequency Waveshape Ambient Temperature Relative Humidity 230 V 196 50 Hz 0 196 sine deviation between effective and rectified values 196 23 C t2K 40 6096 Load Impedance Nominal Ranges of Use Line Voltage Line Frequency Line Voltage Waveshape Temperature Range Ambient Conditions Storage Temperature Operating Temperature Accuracy Max Relative Humidity Elevation Power Supply Line Voltage Line Frequency Power Consumption Max Leakage Current Power Consumption
38. calculated value 16 square mm 73 1 MQ 25 square mm 89 2 MQ 35 square mm 114 MQ 50 square mm 85 3 MQ 70 square mm 48 5 MQ 95 square mm 47 7 m 120sq mm 34 3 mQ Insulation Resistance Mea Nominal voltage 100 V surement Resistance limit value 10 KQ Leakage Current Measure Leakage current 0 1 mA ment Voltage Measurement Discharge time 1s Voltage Test Test duration 1s Continuous measurement Test voltage 250 V 650 V Breaking current 10 mA 0 5 mA Pulse control mode Rise time 100 ms Depending upon high voltage module HP or HV Overvoltage Protection Device Characteristics PROFITEST 204HP for Limit Value Selection for Protective Conductor Testing Parameter Lower Limit Standard Value Upper Limit mu Setting ptions Test Duration Continuous Display in Selection Menu Explanation Available for Cross Section Fuse ty 5s Fuse break time 5 s All cross sections Siphase cond Fuse ty Bis Fuse break time 0 4 s 1 5 through 16 square mm Siphase cond Tape B SelyOds Circuit breaker characteristic B 1 5 through 16 square mm phase cond a 5 x In break time 0 1 s Test Voltage Breaking Current Imax Pulse control mode Rise Time Type C18HI yO Circuit breaker characteristic C 1 5 through 16 square mm Recommended phase cond a 10 x In break time 0 1 s The highest value applies Mj CB B IyO 1s Adjustable circuit
39. correctly synchronized the yel low LED lights up and the green LED goes out The red LED lights up during programming sequences After transmission has been com pleted the LED goes out and the instrument is restarted The message Transmission done appears at the PC A DN ntm _ Attention The instrument may not under any circumstances be switched off during transmission nor may the connec tion to the PC be interrupted e Subsequently select Language loading the respective lan guage if applicable WinProfi System File Protocol Update Help Language GMC I Messtechnik GmbH D Organizing Report Data gt Connect the test instrument directly with the PC via an appro prate interface cable ag Note Do not connect the PC to the SI module e Send or receive a data file System 5 Protocol Update Help Receive File Send File Print Data e Print data System gt Protocol Update Help Receive File Send File Protokollauswaht Available Protocol Files T HAUSUT 001 3645 ei GET 2 oop Lage Grabber GET Read protocols trom tile T Output to LB Fom 1 Font Add to print list Stondord j lt Remove from print list Printer OK Selection 4 c FSD Em Form 2 ALL Add all protocols to print list 4 Cancel Form 3 GMC I Messtechnik GmbH Egit or transmit report templates WinProfi System File Update Help Edit Protocol Forms For
40. cross section and nom current of the protective device 128mm TBmm 256A Due to the fact that according to EN60204 1 2006 overcurrent protection devices with varying tripping characteristics are permissible for each phase conductor cross section 5 different types are offered for cross sections of up to 16 square mm and two for cross sections of greater than 16 mm when selecting the limit value 27 Select the parameter Set the value Protective conductor Setting the test parameters Duration 10 0 s Limit value 238mft Mese 16mm MENU Cont ma Change val Start test HELP Proceed as follows in order to select the limit value gt Ascertain the phase conductor cross section of your connector cable gt If applicable check to see whether or not the nominal current of the utilized overcurrent protection device is allocated to the phase conductor cross section If an overcurrent protection device with low nominal current is used you can determine the limit value on the basis of the phase conductor current assigned to this nominal current o Select the limit value on the basis of the triggering characteristics offered for the various overcurrent protection devices If your machine system includes components with different power cable cross sections e g fans pumps etc and if these are equipped with their own overcurrent protection devices the limit value for the protectiv
41. e conductor test must be selected in accordance with the power cable cross section of these components or with the overcurrent protection devices which have been installed for them A Attention It is imperative that the measuring cables are completely unwound prior to starting the protective conductor test 28 4 1 2 Start the Test START Or ag Note Protective conductor AUO5S3 V Rs 53 mOQ Duration 18 85 3 Limit amp amp mR te Testing The test can only be started with the START key on the test instrument from the test parameters window see picture on page 27 STORE Press briefly Store an event Press and hold Store an event and activate the entry field Up to 15 characters can be entered to the entry field or to the info field at the bottom left as a description for the measurement See chapter 5 1 1 regarding data entry Press briefly Save results The green red signal lamp is extinguished briefly as acknowledgement GMC I Messtechnik GmbH 4 2 insulation Resistance Test In accordance with EN 60204 DIN VDE 0113 insulation resis tance measured between the phases of all current circuits and the protective conductor circuit with 500 V direct voltage may not be less than 1 MQ Four nominal voltage ranges are included with the PROFITEST 204 for this test 100 V 250 V 500 V and 1000 V These can be con figured as test parameters as is a
42. e at the test probes is displayed for resistance values of 1 00 Q to 25 0 Q and for over ranging gt 25 0 Q because calculated voltage drop AU based upon 10 A would lead to unrealistically high results in this case After expiration of the test duration the highest measured protective conductor resistance value and the corresponding voltage drop value are displayed Always assure that adequately good contact has been estab lished with the device under test before starting the test The test can be started with the key 20 on the test probe 17 if preferred If test current drops to a value of less than 10 A during the selected test duration a corresponding message appears at the display However testing is continued normally In the event of poor contact or if the test probes are not connected testing is aborted If voltage is present at the test probes after measurement has begun no measurement is performed Interference voltage at test probes appears at the display and a STOP signal is displayed simul taneously this message may be displayed in the case of interrupted protective conductor connections as well as external voltages have been included capacitively here GMC I Messtechnik GmbH TEST A Select the desired test Open the parameters entry window 4 1 1 Configuring Test Parameters PROFITEST 204 P Protective conductor Insulation resistance Leakage current Uoltage measurement High Uo
43. e to insulation no interruptions in cables or plugs no kinks etc mpulse withstand voltages of up to 2 5 kV may occur in overvoltage category Il systems with 230 400 V GMC I Messtechnik GmbH The PROFITEST 204 basic instrument and the PROFITEST 204HP and HV high voltage modules may not be operated f visible damage is apparent f connector measuring or test cables are damaged e f they no longer function correctly e f the signal lamps are defective e f the functions test is not passed see chapter 4 5 1 page 35 In such cases the instrument must be removed from service and secured against unintentional use Send the instrument to the Repair and Replacement Parts Service Department see chapter 13 Opening of Equipment Repair The equipment may be opened only by authorized service per sonnel to ensure the safe and correct operation of the equipment and to keep the warranty valid Even original spare parts may be installed only by authorized service personnel In case the equipment was opened by unauthorized personnel no warranty regarding personal safety measurement accuracy conformity with applicable safety measures or any consequential damage is granted by the manufacturer Data Backup The measurement report and input data are stored and secured in the test instrument RAM as long as the associated battery sup plies the required voltage Please note that the data will be lost during a software update We t
44. ed as follows DD MM YYYY Day Month Year SETUP av Select time or date START Select cursor position for data entry Change values 20 PROFITES 204 O 4 Display contrast contrast P Time and date Beeper Self test Language Date and Time Setting date and time Date 07 07 1995 Time 14 57 Ma Change val srRRT Pos MENU Select Return 3 7 3 Configuring the Signal Generator If Measuring mode or On is selected various acoustic signal sequences are generated during operation of the high voltage module which identify its operating state Measuring Mode A good measurement is indicated with a single long acoustic signal and a bad measurement with three short acoustic signals On Same as Measuring mode plus each key activation is acknowledged with an acoustic Signal as well Off No acoustic signals are generated SETUP A Select On Off or Measuring mode PROFITES 204 O 4 Display contrast contrast Time and date Beeper Self test Language Beeper Beeper function On Off Meas mode measuring Fla Select mode menu START Exit function GMC I Messtechnik GmbH 3 7 4 Performing the Self Test Display lamp and relay functions as well as options are automatically tested and results are displayed ag Note Before starting the self test both test probes must be disconnected from an
45. ent is pres tary conditions does not exceed the lected limit value However this situation may change over a period of time Faulty data exchange be ween PROFITEST 204 and 204HP HV nstruments mounted After a lamp has been 0 one another incorrectly replaced The reflectors were no re installed Remedy Switch the device on with the key switch Switch the device on with the key switch Connect the high voltage module Plug in power cable see chapter 3 4 page 17 Set key switch to I Replace fuse Replace signal lamp Refer to following error message Defective instrument Replace signal lamp see chapter 11 5 2 page 67 Check connections at both instruments Check to see if the signal tubes are covered Install the reflectors Clean dust or contamination from the transmitter and receiver diodes at the bottom of the basic instrument see chapter 11 5 1 page 67 GMC I Messtechnik GmbH Signal Error Message E Meaning Cause High voltage module can be switched on x High voltage present at the test probes during measurement Do not touch the test probes 2d A Tp Inns The specified limit value Imax has been exceeded The current limiting function has switched the instrument to the standby mode Test completed successfully residual voltage less than 25 V Temperature too high wait 14 min Continuous op
46. eration with high power during high voltage testing Allow the instrument to cool down for approximately 10 minutes Internal temperature monitoring is defective Errer in temperat detection circuit PEERUICE Hardware error Send the high voltage module to the GMC I Service GmbH Repair and Service Department Fed lamp defect Flease replace E One of the signal lamps at the high voltage module is defective Refer to chapter 11 5 2 page 67 regarding replacement GMC I Messtechnik GmbH 65 11 Maintenance Safety features should be inspected and documented at least once a year by the repair department at GMC I Service GmbH to assure flawless functioning and efficiency 11 1 IN Attention Disconnect the instrument at all poles from the measur ing circuit before opening any of the fuse cartridges Disconnect the instrument from the mains Replacing Fuses A y Attention Use specified original fuses only Short circuiting or repairing fuses is prohibited The instrument may be damaged if fuses with other current ratings breaking capacities or triggering characteristics are used 11 1 1 Replacing the Mains Fuse gt Open the fuse cartridge with a suitable tool e g a screwdriver gt Replace the blown fuse with a new fuse with the same characteristic values gt Close the fuse cartridge 66 11 1 2 Replacing the Measuring Circuit Fuse in the Test Probe at the
47. erent name The report can be printed out with the print file function in the WinProfi editor Close the editor with the Exit function in the file menu GMC I Messtechnik GmbH 6 4 Report Form Generating Program Report forms can be created and edited with WinProfi or any other editor The contents may also include functional characters for the utilized printer tabs margins etc All three report forms can be subsequently uploaded to the test instrument with the help of WinProfi software VAL 6 4 1 List of Code Words and their Meanings The positions at which measured values and other device information appear in the report are determined with place holder code words These code words always start with the symbol for the purpose of identification DATE Prints the test date at the corresponding position within the text in European format i e DD MM YYYY TIME Prints the time testing was performed at the corresponding position within the text in 24 hour format i e HH MM QNAME Prints the device ID at the corresponding position PROFITEST 204 or OEM designation SER Prints the device serial number at the corresponding position in the following format M 1234 5678 MAC Prints out the system or machine number 8 digits DESC Prints out the system or machine description up to 255 characters GMC I Messtechnik GmbH All measured values from a selected test for a given system which have been defined w
48. face with the help of a PC with a CD ROM drive and an interface cable The software update is loaded to the flash EPROM at the PROFITEST 204 basic instrument The file containing the desired software version can be uploaded to the test instrument via the serial interface with the help of the update function included with WinProfi software The previously installed software is overwritten Data Transmission Prerequisites o Establish a connection between the PC and the PROFITEST 204 gt Switch both devices on Proceed as described in chapter 3 7 5 page 23 GMC I Messtechnik GmbH 11 7 Recalibration The respective measuring task and the stress to which your mea suring instrument is subjected affect the ageing of the components and may result in deviations from the guaranteed accuracy If high measuring accuracy is required and the instrument is fre quently used in field applications combined with transport stress and great temperature fluctuations we recommend a relatively short calibration interval of 1 year If your measuring instrument is mainly used in the laboratory and indoors without being exposed to any major climatic or mechanical stress a calibration interval of 2 3 years is usually sufficient During recalibration in an accredited calibration laboratory DIN EN ISO IEC 17025 the deviations of your instrument in rela tion to traceable standards are measured and documented The deviations determined in the p
49. herefore advise you to regularly transmit your stored data to a PC in order to prevent potential loss of data in the test instrument We assume no responsibility for any data loss For data processing and management we recommend the following PC software programs e ETC e PS3 documentation management report generation and monitoring of deadlines e PC doc WORD EXCEL report and list generation e PC doc ACCESS test data management e ELEKTROmanager for PROFITEST 204 2 1 Meanings of Symbols 2 1 1 Symbols on the Instrument The symbols on the instrument have the following meanings Ce Indicates CE conformity Warning concerning a point of danger Attention observe documentation Report functions Data management This device may not be disposed of with the trash Further information regarding the WEEE mark can be accessed on the Internet at www gossen metrawatt com by entering the search term WEEE 2 1 2 Symbols in the Operating Instructions A A Life endangering for the operator if instructions identified with this symbol are not observed Danger for the operator and the instrument if instructions identified with this symbol are not observed 2 1 3 Symbols which Appear at the PROFITEST 204 Display Inz imA U gt 25 Warning concerning a point of danger e g voltage at the test probe is greater than 25 V Timer function indicates test duration P
50. hin the danger zone when the system is made ready for activation GMC I Messtechnik GmbH A Danger High Voltage The test probe is made accessible after the trigger at the high voltage pistol with switch has been pulled to its initial mechanical limit stop High voltage is not switched to the test probe until the trigger is pulled beyond this position assuming the instrument is in the ready to activate state A Danger High Voltage Touch neither the test probes nor the device under test during the voltage test A life endangering high voltage of up to 5 kV is present at the high voltage module test probes Exclusion of Liability In the event of a sparkover PCs which are operated in proximity may crash causing data loss in the process Please therefore ensure prior to conducting the high voltage test that all data and programs are saved appropriately and that the computer is Switched off if necessary This phenomenon may even occur without an RS232 connection The manufacturer of the test instrument assumes no liability for any direct or indirect damage to computers peripheral equipment or data stocks in connection with the execution of high voltage tests Furthermore the manufacturer assumes no liability for defects in DUTs caused by high voltage tests This applies especially for electronic components within devices Please also observe the checklist for high voltage tests given in chapter 12 1 18 3 Init
51. ial Start Up 3 1 Start Up of the Optional High Voltage Module 3 1 1 Mounting the High Voltage Module to the Basic Instrument The HP or the HV high voltage module must be mounted to the PROFITEST 204 test instrument before initial start up When correctly mounted reliable data exchange is assured between the two devices by means of LED transmission see chapter 3 7 4 Performing the Self Test IN Attention The basic instrument and the high voltage module must both be disconnected from the mains and from the measuring circuit prior to mounting Close the lid of the basic instrument gt Turn the basic instrument upside down Place it onto a soft surface in order to avoid scratching the lid gt Pull the two rubber feet from the bottom of the basic instrument behind which the through holes are concealed o Position the high voltage module such that the connector terminals and cables from both devices are on the same side gt Pull the two rubber feet from the bottom of the high voltage module behind which the through holes are concealed gt Set the four threaded rods into the through holes see sketch gt Tighten the threaded rods with a screwdriver 4 5 mm 14 Remove rubber feet e K A Rear Panel High Voltage Module o Insert the two previously removed rubber feet into the holes at the high voltage module GMC I Messtechnik GmbH 3 1
52. iations eee ere 71 TAA ulDBeX zx reote ae te te RB eee rette ene 72 13 Repair and Replacement Parts Service Calibration Center and Rental Instrument Service 74 14 Product Support ee esee 74 z 1 Applications 1 1 PROFITEST 204 The PROFITEST 204 test instrument is used for quick and safe testing of electrical and electronic equipment and systems at machinery in accordance with DIN VDE 0113 EN 60204 1 The following initial and periodic tests must be performed in accordance with these regulations e Testing for continuity of the protective conductor circuit with a test current of at least 10 A e Insulation resistance test e Voltage test optional PROFITEST 204HP HV e Testing for residual voltage Beyond this other tests can be performed which are not required for the safety of electrical equipment at machinery but which nevertheless supplement the instrument in a practical fashion e Measurement of electrostatic discharge capacity for floor coverings in accordance with DIN 51953 e Leakage current test for the substantiation of the absence of voltage e Voltage and frequency measurements All values required for approval reports can be measured with this instrument The optional SECUTEST SI module an input module which can be Set into the lid of the instrument and which is equipped with an integrated interface and keypad expands the applications range of the PROFITEST 20
53. in proximity to the device under test gt Pull both triggers but only pull the trigger at the high voltage pistol with switch to its initial limit stop The test probes are exposed gt Establish contact with the test circuit o Pull the trigger at the high voltage pistol with switch to its final limit stop High voltage is now switched to the test probes Testing continues until the selected rise time and the test duration have elapsed An acoustic signal is generated by an internal buzzer for the duration of the test application of high voltage including rise and decline gt For subsequent testing of neighboring circuits release the trigger until it reaches its initial limit stop establish contact with the next test circuit and pull the trigger to its final limit stop Testing is started again 39 Storing Measured Values to Memory After the test sequence has been completed the last measured values for Uy and ly remain at the display These results can be saved with or without a comment and a consecutive number is assigned to the test automatically Up to 15 characters can be entered to the entry field or to the info field at the bottom left as a description for the measurement See chapter 5 1 1 page 43 regarding data entry The values at the display are overwritten when the next test is executed Press briefly Save results Press and hold Store an event and activate the entry field
54. ing and Starting WinProfi at the PC Install the software as described in chapter 3 7 5 part A if not already installed Start WinProfi from the Windows start menu B Data Transmission Prerequisites gt Establish a connection between the PC and the test instrument Use the Z3241 cable to this end which is included with the test instrument Switch both devices on GMC I Messtechnik GmbH C Uploading Report Forms from the PC to the Test Instrument Note Forms can only be uploaded from the PC to the test instru ment if they are located in the same directory as the WinProfi program files gt PC Select Upload forms in the Reports menu Follow the instructions which appear at the monitor D Generating Reports at the PC Load form from PC Dounloading protocol forms via the serial interface Note The desired measurement val ues from the test instrument must be stored to the PC hard disc before reports can be generated at Please follow the PC instruction manua The following steps are performed at exactly the PC Transnitting o Select Print data in the File menu gt Select the desired file and acknowledge with OK gt Click the Get button in order to display all of the systems which have been saved to the selected file o Click the system to be printed out and then click the but ton The selected system appears in the print list Several or all Systems can be printed at once if
55. inter has no paper Please insert paper TRRT Your printer does not work Check connection eih Busy printing data Hbort bu turning zwitch GMC I Messtechnik GmbH Meaning Cause Printing is not possible Data are being transferred to the printer The printer may not start printing until data transmission has been completed A data box with records indicates that measurement data have already been saved for the selected system The prin The prin The prin The prin The prin The prin The prin er does not f er is function er is function er does not f er does not f er does not f The data record for a given system has been deleted nction ing incorrectly ing correctly nction nction nction er is functioni ng correctly Remedy Check the printer connector cable and make sure that there is paper in the printer Check to see if an error has occurred at the printer Check the data record Check the connection between the printer and the PROFITEST 204 and then press the START key Press the MENU key in order to abort printing Switch the printer to online and then press the START key Add paper to the printer and then press the START key Check the connection between the printer and the PROFITEST 204 and then press the START key Turn the switch in order to abort printing 63 Signal Error Message Change to wol t
56. is made available in this way Data Transmission Measurement data the entire contents of the memory at the PROFITEST 204 can be transmitted to a PC with this function where they can be subsequently analyzed e g with the programs WinProfi PS3 or EXCEL Data records which have been saved to the PC can be transmitted back to the test in strument Memory Capacity Current memory capacity is continuously displayed as a bar graph in the first three functions listed above Depending upon how many systems have been entered max 254 up to 2800 measurements can be stored to memory 42 5 1 Selecting a System 7e n Select the desired command Sub menu System No Select a number Status PROFITEST 204 Select machine Browse data Organize data Delete data Transnit data Select Machine Selecting a machi M No Status d Description Memory O 25 50 75 100 used MENU Cont Fa Change value TART Return OERE Delete A filled in file cabinet indicates that measurement data have already been stored for the selected system GMC I Messtechnik GmbH 5 1 1 Entering a Description Select Machine m MENU Selecting a machine E Deseto No 001 Status Description ceCa car cleanc Lh Memory Ox 25 50 75 100 rians used Description MENU Cont Fa Change value Descriptions can be entered for the TART Return Gare Delete various system
57. it is used A Attention Test cables and high voltage pistols which demonstrate even minimal damage should be sent immediately to the Repair and Replacement Parts Department at GMC I Service GmbH 11 5 Repair Parts Replacement and Instrument Balancing When the instrument is opened voltage conducting parts may be exposed The instrument must be disconnected from the measur ing circuit for repair replacement of parts or balancing If repair or balancing of a live open instrument is required this may only be carried out by trained personnel who are familiar with the dangers involved 11 5 1 Cleaning the Transmitter and Receiver Diodes If the PROFITEST 204 basic instrument is operated for a lengthy period of time without a high voltage module the transmitter and receiver diodes may become dusty Before mounting a high voltage module to the basic instrument unscrew and remove the bottom cover 2 Phillips head screws in the middle and clean the four diodes with a soft brush Replace the bottom cover and retighten the screws GMC I Messtechnik GmbH 11 5 2 Replacing Signal Lamp Bulbs Disconnecting the High Voltage Module In order to replace the signal lamp bulbs the high voltage module must first be disconnected from the basic instrument N Attention Before dismantling the basic instrument and the high voltage module both must be disconnected from the mains and from the measuring circuit o Close the lid at
58. ith MAC The following assignments apply to the type of mea surement which must be indicated in parentheses 1 Protective conductor test 2 Insulation test 3 Leakage current test 4 Voltage measurement 5 AC high voltage test The measured values and the parameters from the individual tests are printed out next to each other in a single line in the following order Additional text cannot be entered to the line i e explanation or descriptions must be entered to the report either before or after the measured values Protective conductor test 1 Max voltage drop at the protective conductor 2 Max protective conductor resistance value 3 Test duration for protective conductor test 4 Limit value for protective conductor voltage drop Insulation test 1 Insulation resistance value 2 Nominal test voltage 3 Insulation resistance limit value Leakage current test 1 Leakage current 2 Voltage at the test probes during measurement 3 Leakage current limit value 53 BAD QNUM 54 Voltage measurement 1 Voltage at the test probes 2 Frequency 3 Time in seconds until discharge to less than 60 V 4 Time limit for discharge to less than 60 V Voltage test 1 Test voltage measured value 2 Test current 3 Test duration 4 Nominal test voltage Any entered comment for the respective portion of the test is read out in the same line after the code words Bad measured va
59. kV Mains Connection 3 V 0 5 period 10096 A B B Mains Connection 1 kV A A A This is a class A device This device may cause radio interference in residential areas If this is the case the owner may be required to imple ment appropriate corrective measures Mechanical Design Protection Dimensions Weight IP 40 per DIN VDE 0470 part 1 EN 60529 Basic instrument 204 WxDxH 255 mm x 133 mm x 240 mm Basic instrument 204 and high voltage module HP or HV mounted on caddy WxDxH 380 mm x 250 mm x 650 mm 204 approx 5 1 kg 204HP HV approx 8 kg 59 9 Data Interfaces 9 1 RS 232 Serial Interface The data interface socket 5 is used to connect the SECUTEST SI module accessory which can be set into the lid of the PROFITEST 204 The same interface can be used to exchange data with an IBM compatible PC Pin 9 may not be short circuited with pin 5 9 1 1 Software Analysis of Measurement Results The included software allows for the convenient generation of reports forms at the PC and uploading to the test instrument 9 1 2 Interface Definition and Protocol The PROFITEST 204 interface complies with the RS 232 standard Technical Data Baud Rate 9600 baud fixed Character Length 8 bits Parity none Stop Bits 1 Data Protocol per DIN 19244 X_ON X_OFF All PROFITEST 204 operating functions can be remote controlled via this interface Signal and display values can be
60. lect the system with the description to be copied and press the MENU key three times gt Select the new system and press the MENU key The copied text appears and can be edited as desired 5 1 3 Deleting a Description gt Simultaneously press the i STORE and the START keys The description is deleted and the cursor jumps to the first entry position in the respective description entry field 43 5 2 Data Processing viewing measured values Measured values can be viewed and individual measurements can be deleted if desired PROFITES 204 y Select machine nachine Browse data Organize data Delete data Transnit data Select the desired command Select the desired measurement Delete the measurement Data record deleted appears at the display after deletion of the selected measurement has been started The i STORE key must be pressed and held for approximately 1 second in order to delete a data record thus preventing inadver tent deletion of data If the key is not released after deletion of the selected data record all following data records are deleted sequentially at a rate of 1 record per second Browse Data Machine Data No data present ee Memory O 25 50 75 100 used Menu START Main menu GyraRE Delete VT amp forw back 44 5 3 Data Reorganization 5 3 1 Deleting Recorded Data Data from individual systems which have already been printed out and
61. lized report layouts Beyond this the positions at which the measured values appear can be determined by the user and these can be supplemented with the worst value thus providing an improved overview Time date utilized test instrument etc can also be added at any desired position within the report The layout of the list which includes the measurement series is fixed and cannot be changed 6 4 3 Uploading a Report Form to the Test Instrument The various report forms have different maximum lengths Report form 1 Full report 16 kB File name PROTO V1 PRN Report forms 2 and 3 Condensed report 8 kB each File name PROTO V2 PRN and PROTO V3 PRN See chapter 6 3 for uploading instructions GMC I Messtechnik GmbH 7 Characteristic Values PROFITEST 204 Measured Measuring Nominal Range Reso Nominal Voltage Nominal Short Internal Measuring Intrinsic Uncertainty Overload Quantity Range of Use lution Un Current Circuit Resis Uncertainty Current Ik 0 85 MQ 100 yQ 85 10 330 MQ 10A 12A 3 rdg 5 digits Protective 999 mQ imo Conductor 12V 8 6 rdg 6 digits Fuse Resistance Rpg 1 00 9 990 1 00 9 999 0 10 MQ A 16 A 1 000 V T SER loom SELV 3 rdg 10 digits Breaking capacity i Q ungrounded SKA AU for Protec 0 9 99 V 0 01 V 10A 12A 2 rdg 3 digits tive Conductor
62. lso the case with the allowable limit value for insulation resistance The measurement can be started in an ideal fashion with the key 21 on the test probe 17 For capacitive devices under test or for DUTs with relatively long cables press and hold the key 21 or 10 until stabilized display values have been obtained When the START key is pressed and held the instrument performs continuous instead of an individual measurement Voltage at the device under test appears at the LCD in addition to measured insulation resistance Discharge Upon completion of the measurement the device under test is automatically discharged in order to assure absence of voltage The falling voltage value can be observed at the display during discharging The measured insulation resistance value remains in memory during this period of time WOLTAGE Interference voltage If voltage is present at the test probes after measurement has begun no measurement is performed Interference voltage at test probes appears at the display and a STOP signal is displayed simultaneously GMC I Messtechnik GmbH N j Attention Do not touch the test probes during this measurement A direct voltage of up to 1000 V is present between the test probes Note Testing of measurement cables The first test should be conducted on test probes with short circuited measurement cables The instrument must indicate a value of approximately zero Q This serves to
63. ltage test Test duration can be adapted to local circumstances Recommended test duration 10 s The limit value for protective conductor resistance can be changed depending upon conductor cross section and the characteristics of the overvoltage protection device which is used with the machine Select the parameter Set the value GMC I Messtechnik GmbH Protective conductor Setting the test parameters Duration 10 0 s Limit value 238mft Type B S8IyO 1s phase cond 16 mm MENU Cont ma Change val Start test HELP The limit value setting for protective conductor resistance is based upon the cross section of phase conductor L and if applicable neutral conductor N and not the cross section of protective conductor PE This is necessary because cables with phase conductor cross sections of greater than 16 square mm are equipped with protective conductors of reduced cross section and selection on the basis of protective conductor cross section would not be unequivocal A rated current nominal current is assigned to the phase conductor cross section for the respectively utilized overcurrent protection device as shown in the following table The table can be displayed from the TEST menu in order to simplify selection as an aide to the protective conductor test function i Query help rot conductor e Limit value for PE test based on conductor
64. lues only including all of their parameters and limit values in the same order as indicated under VAL The user must decide whether or not testing was successful based upon this information As is also the case with VAL the parameter in parentheses indi cates the type of measurement The worst value with reference to the limit value is always indicated i e the bad values are not necessarily the highest or lowest values but rather the worst with reference to the respective limit values for measurements with various limit values BAD can appear after VAL and can be used for a simple GO NO GO evaluation Any entered comment for the respective portion of the test is read out in the same line after the code words Number of stored measurements per type of measurement The type of measurement is indicated in parentheses The different types of measurement appear in the same order as is the case with VAL RESULT This code adds the word bad to the text if at least one bad value has been measured for a given type of measurement see VAL RESULT 0 This code adds the word bad to the text if at least one bad value has been measured for a given system Fully automated reports analysis is possible with the two RESULT place holder code words 6 4 2 Report Layouts The report header the texts which appear between the measure ment series and the footer can all be freely changed for the creation of individua
65. m d Send Protocol Forms Form 2 Form 3 L lal TURBO DRIVE Machine Inc Industrial Equipment and Support P 0 Box 666 Hellhoundsuille TW5 9RT England CERTIFICATE FOR PROOF OF COMPLIANCE FOR INDUSTRIAL MACHINES Verification of safety for the electrical equipment of industrial machines according EN 60204 1 IEC 264 1 DIN VDE 6113 Common data of machine under test Description Number DESC Number of protocol MAC Equipment used for tests NAHE SER Date of tests GDRTE Responsible person R Schweiger The following protocol confirms that all tests for proof of electrical safety of the described machine according to the standards mentioned above have been carried out with great care The tests have been carried out by skilled persons according DIN UDE 8185 Part 1 5 75 Subclause 3 2 1 The machine under test does GRESULT 8 meet the requirements of EN 60204 1 IEC 205 1 DIN UDE 8113 Comment eee nnn nnn 25 4 Testing Machines in Accordance with DIN VDE 0113 and EN 60 204 Each of the following tests is automatically allocated to the currently selected system number If the respective test results are saved with the STORE key they are assigned to this number The System number can be entered in the Select system menu see chapter 5 1 page 42 The following sequence applies to the measuring mode e Select the desired test Enter test parameters if requi
66. mately zero Q This serves to establish whether the measurement cables are disconnected at any point GMC I Messtechnik GmbH 4 5 1 Functions Test test preparation Perform the following functions test in the indicated order from a through e a Key Switch gt Set the key switch to O Neither the green nor the red signal lamps may light up b Voltage Test gt Set the key switch to e The green signal lamps must light up Select the voltage test with the ZNM keys e 204 EIE g Protective conductor conductor Insulation resistance Leakage current Voltage measurement Select the desired test PHigh Voltage RA Initialisation of high voltage module as a prerequisite for correct parameter input gt Press the START key The corresponding high voltage module is recognized and dis played in the bottom left corner of the LCD provided it has been correctly connected and the key switch is in the l position The initialisation ensures that the parameter values that are sub sequently entered are within the limits applicable to the respective high voltage module 35 o gt Select the desired values for test duration test voltage breaking current Imax and rise time chapter 4 5 2 page 37 ag Note Do not set Imax to pulse control Press the START key The red signal lamps must light up The following values are displayed at the LCD U V amp lj 2 mA O K
67. ment until the temperature error has been cleared High Voltage Module An installed high voltage module is recognized automatically Proceed as follows if an error message is read out for this portion of the self test even though a high voltage module has been con nected Check the connections at both instruments and above all make sure that the signal tubes at the high voltage module have not been obstructed or covered 21 LCD Test In the following two tests neighboring horizontal and vertical Self Test elements at the LCD are activated separately If individual cells do LED RUN yellows E not become active send the instrument to an authorized service Continue testing LED OK green B center for repair LED FAILED red Relais 1 E Relais 2 Li me B LE gt L 34 elals H SSS Relais 5 El D START Continue testing START MENU Stop testing ag Note The LEDs must first blink and the relays must be Switched before they can be checked off as OK START Continue testing 22 GMC I Messtechnik GmbH 3 7 5 Uploading the Desired Language or a Software Update If a language other than the one included with the instrument is desired it can be uploaded with the help of the WinProfi PC pro gram The file with the desired language is transmitted to the test instrument via the serial interface The previously installed language is overwritten
68. ning Cause Remedy PROFITEST 204 Basic Instrument The stopwatch is displayed during protective conductor measurement The falling voltage value is continuously displayed until residual voltage has reached a value of less than 60 V All clear signal after insulation testing Voltage at test probe is less than 25 V or 60 V depending on measuring function The test was passed Test results are not within allowable limit values Power cable not plugged in Plug in power cable see chapter 3 3 page 17 Mains fuse is blown Replace mains fuse see chapter 11 1 1 page 66 Fuse integrated into test probe is blown Replace fuse in test probe see chapter 11 1 2 page 66 Continuous operation during protective conductor test Allow instrument to cool for approximately 10 minutes Indicates type of voltage applied alternating voltage superimposed with direct voltage direct voltage alternating voltage Protective conductor and insulation measurements Interference voltage is present at the test probes and the measurement will be aborted If protective conductor testing is started with an interrupted protective conductor a voltage may be induced capacitively This voltage is recognized as an interference voltage by the instrument 61 Signal Error Message MAX 250U A Ip lt i0A Inc ima U 25V DATA HOLD Database Operations Storing makes no sense Error in data st
69. ofi program A Installing and Starting WinProfi at the PC gt Install the program as described in chapter 3 7 5 part A if not already installed o Start WinProfi from the Windows start menu B Data Transmission Prerequisites gt Establish a connection between the PC and the test instrument Use the Z3241 cable to this end Switch on both devices 46 C Transmitting Data from the Test Instrument to the PC gt PC Select Receive data in the File menu Follow the instructions which appear at the monitor gt PC Select the directory to which the file is to be transmitted o PC Enter a file name The data file extension DAT is added automatically gt PC Start transmission by clicking the OK button Three files are generated which can only be differentiated by means of their data formats and the corresponding data file extensions NAME DAT Machine readable data file NAME TAB Data file in ASCII format NAME XLK EXCEL data file ag Note Transmitting measurement data back to the test instrument is only possible with the DAT file Data transmission Transnitting data to or from a PC Connect the PROFI TEST 264 to PC with 9 pole SUB D extension cable Transnitting GMC I Messtechnik GmbH D Transmitting Data from the PC to the Test Instrument gt PC Select Transmit data in the File menu Follow the instructions which appear at the monitor o PC Enter the name of the
70. ons 0000 43 Contrast ics mar ute deu xu X uA 19 Current limiting in the event of sparkover 12 D Data transmission liess 46 Deletion entirememory sess 45 individual measurements 44 recorded data 000 44 Discharge after insulation test l i 29 measurement of discharge time 33 E Electrical isolation 00 00005 12 72 ELEKTROmanager ssssse 9 EIO inis aret dd e Rete t ie ah 9 F Fuses GAA sick TE 59 replacement 00 cee eae 66 H High voltage module assembly have a ted ibn RD Yes 14 description 6 eee 4 initialisation 0 llle 35 High voltage test see voltage test 2 eee 35 l Insulation resistance test Lis 29 Interference voltage during insulation resistance test 29 during leakage current test 31 indications reis p teu 10 26 61 L LCD contrast and illumination 19 EE CD RUE 22 Leakage current test 000 31 M Mains connection 0 00 c eee eee 17 Mains failure 2 6 ee eee 12 Memory deletion deae Se Panties 45 OCCUPATION 2 52 ena Dno aa E 42 storing of an event iliius 28 testing 2 2 cee eee eee 45 0 Operating error 0 eee eee 71 P PC doc ACCESS 2 0 2 cee eee 9 PC doc WORD EXCEL 000 9 Protective conductor test 26 Protective measures control current circuits 70
71. orage Press to repair Error cannot be repaired Please delete data memory Error in data storage Press to repair Memory full Data storage full Hew machines cannot be entered 62 Meaning Cause Remedy Warning for leakage current test Voltage may not exceed 250 V Indication that test current is less than 10 A Warning regarding a source of danger e g voltage at the test probe is greater than 25 V This symbol appears after the measured voltage value has been frozen at the display see chapter 4 4 page 33 No measurement has been performed Measurement results have already been saved The remote control key 7 was pressed and held longer than required See displayed tex See displayed text An error has occurred while saving data to memory Save data to a PC and then clear the memory See displayed tex See displayed text The memory is not longer able to store additional measurement data Save data to a PC and then clear the memory See displayed text Transmit data to a PC or print data out and then delete any unnecessary systems or clear the memory entirely No data have yet been saved to this data record GMC I Messtechnik GmbH Signal Error Message Data record deleted Ho usable data in memory Error printing to the FSI Check connection TART Busy printing please wait To abort press MENN The printer is offline Turn to online Your pr
72. red e Start measurement or return to the initial menu e Save measured values to memory and enter a description if desired The protective conductor test the insulation test and saving mea sured values to memory can be triggered from the test probe 17 Test Parameters and Limit Values per DIN VDE ag Note If test parameters and limit values have been changed we recommend resetting these to the default settings in accordance with DIN VDE before testing a new system Switch the test instrument on to this end Press the MENU key and then turn the function selector switch to the TEST position This restores default values in accordance with DIN VDE Standard values in accordance with DIN VDE are included in the table in chapter 8 page 57 Setting Ranges for PROFITEST 204 Parameters The lower and upper limit values for all adjustable parameters are included in the table in chapter 8 page 57 26 4 1 Protective Conductor Test Uninterrupted connection of a protective conductor system is tested here by using an alternating current of approximately 10 A with a line frequency of 50 Hz Testing must be conducted between the PE terminal and various points within the protective conductor system If resistance values of less than 1 00 Q occur voltage drop AU for respective protective conductor resistance is displayed This is the calculated voltage value based upon a 10 A test current in accordance with DIN VDE 0113 Voltag
73. red signal lamp is extinguished briefly as acknowledgement GMC I Messtechnik GmbH 4 3 Leakage Current Test This test is required by DIN VDE 0701 0702 It can be used to test devices machines and systems for the observance of limit values for leakage current contact current Leakage current and voltage drop resulting from this current at a 2 kQ load are measured and displayed ag Note If a voltage of greater than 20 V occurs at the test probes leakage current measurement is stopped The 2 kQ load is also deactivated in this case Display of measured voltage AU nevertheless continues A Attention Interference voltage may not exceed 250 V e 2041 al Protective conductor conductor Insulation resistance Leakage current Voltage measurement Select the desired test High Voltage inet Open the sub menu GMC I Messtechnik GmbH 4 3 1 Configuring Test Parameters The limit value maximum leakage current can be changed Select the desired parameter Adjust to the desired value 4 3 2 Start the Test START ag Note Leakage current Setting test parameters Limit value 2 0mA MENU Cont Ma Change value Start test HELP Leakage current AI 1 bmA AUSSOEN A MAX 250V Test OK The leakage current test can only be started with the START key on the test instrument 31 Press briefly Store an event Press and hold Store an e
74. rocess are used for correction of the readings during subsequent application We are pleased to perform DAkkS or factory calibrations for you in our calibration laboratory Please visit our website at www gossenmetrawatt com Company DAkkS Calibration Center or FAQs Calibration questions and answers By having your measuring instrument calibrated regularly you fulfill the requirements of a quality management system per DIN EN ISO 9001 Verification of specifications or adjustment services are not part of the calibration For products from our factory however any necessary adjustment is frequently performed and the observance of the relevant specification is confirmed GMC I Messtechnik GmbH 11 8 Device Return and Environmentally Compatible Disposal The instrument is a category 9 product monitoring and control instrument in accordance with ElektroG German Electrical and Electronic Device Law This device is subject to the RoHS direc tive Furthermore we make reference to the fact that the current status in this regard can be accessed on the Internet at www gossenmetrawatt com by entering the search term WEEE We identify our electrical and electronic devices in accor dance with WEEE 2012 19 EU and ElektroG with the K symbol shown to the right per DIN EN 50419 These devices may not be disposed of with the trash Please con tact our service department regarding the return of old devices If you use ba
75. rotective conductor and insulation measurement interference voltage present at the test probes Indication that test current is less than 10 A during protective conductor measurement Indicates all clear after insulation test voltage at the test probe is less than 25 V Warning for leakage current test voltage may not exceed 250 V GMC I Messtechnik GmbH e Transmission TA finished T Errer in temperat detection circuit PSERWICE DATA HOLD Data management message data transmission successfully completed Excessive temperature inside the test instrument protective conductor test Allow instrument to cool down for approx 10 minutes Internal temperature monitoring is defective Send the high voltage module to the Repair Department at GMC I Service GmbH This symbol appears after the measured voltage value has been frozen at the display see chapter 4 4 page 33 GMC I Messtechnik GmbH 2 1 4 Symbols which Appear at the Display of the PROFITEST 204HP HV High Voltage Module O K j HIGH VOLTAGE amp U lt 25 A Tp Tmax Error T High voltage module ready for activation A life endangering high voltage of up to 5 kV is present at the test probes of the high voltage module Test completed successfully residual voltage less than 25 V The predefined limit value lax has been exceeded The current limiting
76. rox 0 7 s time measurement for the testing of protection against residual voltage is started automatically Elapsed time can be observed in the symbol field at the display Time measurement is stopped as soon as the measured value drops to below the 60 V threshold Elapsed time required for discharge to 60 V now appears at the display Voltage measurement continues until maximum allowable discharge time has elapsed normally 5 s The measured voltage value is then frozen and the DATA HOLD symbol appears at the display If the 60 V limit is not reached within the allowable discharge period the voltage value measured at the end of this period is frozen and time measurement continues until 10 seconds have elapsed If the voltage value is still above 60 V the test is aborted and the instrument resumes voltage measurement GMC I Messtechnik GmbH If a value has been frozen at the display voltage measurement is not resumed by the instrument until The START key is pressed The measurement is stored to memory with the i STORE key Voltage measurement is restarted from the menu Voltage at the test probes climbs again to a value of greater than 60 V or assuming the last measured voltage value was greater than 60 V the following measured value is even higher i e if rising voltage can be observed Elapsed time and the measured voltage value at the end of the allowable discharge period are stored to memory by activating the i STORE
77. s The description is displayed and subsequently printed out when the respective sys tem is selected Note An ID number should be entered for each system if PS3 software is used Enter the number in parentheses The system description appears to the right of the ID number see illustration above Parentheses are entered by pressing and holding the shift key and simultaneously pressing the number keys 8 and 9 Descriptions can be entered in two different ways Convenient Entry with the SI Module optional Descriptions can be entered with the alphanumeric keypad at the SI module see operating instructions included with the SECUTEST SI Entry with the Keys at the PROFITEST 2044 Select letters numbers or characters Move the entry cursor left GMC I Messtechnik GmbH Move the entry cursor right Entered data must be acknowledged with the MENU key The previously entered data are then saved to memory Alternatively data can be saved by pressing the STORE key at the SI module Up to 250 characters can be entered The entry field scrolls automatically from one line of text to the next Apart from the SI module data can also be entered via the PC keyboard requires adapter PROFI MF II article number Z504H A comment can be entered for each test procedure in the same way immediately after completion of the test However the length of these comments is limited to 15 characters 5 1 2 Copying Descriptions gt Se
78. s address is printed into the header of these forms Refer to the following chapter in order to modify these report forms GMC I Messtechnik GmbH S nu Select the desired command Select a report form START Acknowledge the selected report form PROFITES 204r 4 Print results PST Print protocol P Select protocol Load form from PC Select protocol Protocol according to formi form Z form 3 MENU Select form GHELP TART Confirm 6 3 Uploading a Report Form Report and print out forms can be generated and modified with the help of WinProfi software and can be uploaded to the PROFITEST 204 WinProfi software provides the user with a high performance editor to this end ag Note Before uploading a report form the header should be edited to fulfill your needs see chapter 6 4 2 page 54 GMC I Messtechnik GmbH s name and address are included in the header upon shipment from the factory N Attention All measurement data stored to the test instrument are deleted when a print form is uploaded There are two recommended procedures for uploading report forms 1 Upload the report form 2 Perform measurements 3 Print the report or e 1 Perform measurements 2 Transmit and save measured values to a PC 3 Upload the report form 4 Transmit measured values back to the PROFITEST 204 5 Print the report 50 Install
79. se contact GMC I Messtechnik GmbH Product Support Hotline Phone 49 911 8602 0 Fax 49 911 8602 709 E mail support gossenmetrawatt com GMC I Messtechnik GmbH GMC I Messtechnik GmbH 75 Edited in Germany e Subject to change without notice e A pdf version is available on the internet A GOSSEN METRAWATT Telefon 49 911 8602 111 GMC I Messtechnik GmbH Telefax 49 911 8602 777 S dwestpark 15 E Mail info gossenmetrawatt com 90449 N rnberg e Germany www gossenmetrawatt com
80. sic Instrument 14 TheKey SWITCH deett ocetsec tora eter E a 15 Indication of Operating States sss 15 Mounting the Instruments to the Optional Caddy 16 Connecting the PROFITEST204 to 230 V Mains Power 17 Connecting the High Voltage Module to 230 V Mains Power 7 Operating SoftWare i te erre err rere ri EEG 18 Onine Helps oct precoce t DEOR ERR ERR EDT 18 Setpa a ed edd co RM EAR Mx ice soc 19 Adjusting Contrast and LCD Illumination 19 Setting Time and Date netter ntes Configuring the Signal Generator Performing the Self Test Uploading the Desired Language or a Software Update 23 Contents Testing Machines in Accordance with DIN VDE 0113 and EN 60 204 26 gt n2 n2 Ex do a a uq dme ge gs qme qe qz N Oo RPBRROUUNMNv AA Page Protective Conductor TeSt gisis 5 m thereto 26 Configuring Test Parameters ssseem 27 Start the Test Insulation Resist Configuring Test Parameters ssseme 30 Start the Test Leakage Current Test ssssssseeeneenennmnnnn 31 Configuring Test Parameters ssssemm 31 Start the Test Mores diu Ur e Me a tent anne 31 Voltage Measurement protection against residual voltage 33 Configuring Test Parameters ssseemmm
81. t com www gmci service com This address is only valid in Germany Please contact our representatives or subsidiaries for service in other countries DAKKS Calibration Laboratory for Electrical Quantities D K 15080 01 01 accredited per DIN EN ISO IEC 17025 2005 Accredited measured quantities direct voltage direct current values DC resistance alternating voltage alternating current values AC active power AC apparent power DC power capacitance frequency and temperature Competent Partner GMC I Messtechnik GmbH is certified in accordance with DIN EN ISO 9001 2008 Our DAkkS calibration laboratory is accredited by the Deutsche Akkreditierungsstelle GmbH National accreditation body for the Republic of Germany in accordance with DIN EN ISO IEC 17025 2005 under registration number D K 15080 01 01 74 We offer a complete range of expertise in the field of metrology from test reports and proprietary calibration certificates right on up to DAKKS calibration certificates Our spectrum of offerings is rounded out with free test equipment management An on site DAKKS calibration station is an integral part of our service department If errors are discovered during calibration our spe cialized personnel are capable of completing repairs using original replacement parts As a full service calibration laboratory we can calibrate instru ments from other manufacturers as well 14 Product Support When you need support plea
82. t stand Test probe with integrated controls Test probe with integrated fuse Key for saving measurement value Key for starting protective conductor measurement Key for starting insulation measurement Mains connector Power supply connector for high voltage module max 6 A Ventilation slots PROFITEST 204 HP HV High Voltage Module Connector Panel High Voltage Pistol with Switch Inlet connector for power supply to high voltage module with insert for fuse Key switch for the prevention of unauthorized use Terminals for external signal lamps see chapter 3 1 3 page 15 When green signal lamp is illuminated high voltage module is ready for operation When red signal lamp is illuminated high voltage module is ready to be activated Caution danger Permanently attached measurement cable Trigger switch As opposed to high voltage pistols without switch the high voltage switch ing pistol is identified with a red clamping ring on the connector cable un derneath the handle Recessed safety test probe GMC I Messtechnik GmbH Items Shipped with the Instrument If you have two sets of operating instructions with different issue dates Use only the newest operating instructions The issue date appears on the title page underneath the order number 3 348 781 xx e g 17 9 10 means 17 revision September 2010 PC Program
83. the basic instrument gt Turn the instrument combination upside down and set it onto a Soft surface in order to avoid scratching the lid gt Unscrew the four threaded rods with a 4 5 mm screwdriver remove two rubber feet first see chapter 3 1 1 gt The high voltage module can now be lifted away gt Set the high voltage module onto the floor on its feet gt Loosen the hex nut inside the instrument at the respective reflector 8 mm width across the flats o Remove the reflector gt Remove the defective bulb from the bayonet fixture and install a new bulb 12 to 15V 2W with BAQs base e g OSRAM Miniwatt T10 no 3453B gt Replace the reflector gt Mount the high voltage module to the basic instrument as described in chapter 3 1 1 67 11 5 3 Replacing Bulbs at the External Signal Lamps A Attention Before replacing bulbs at the external signal lamps Disconnect the external signal lamps from the terminals 3 at the high voltage module or Disconnect the high voltage module from the mains and from the measuring circuit gt Unscrew the red or the green cap by turning counterclockwise gt Remove the defective bulb from the bayonet fixture and install a new bulb 12 to 15V 2W with BAQs base e g OSRAM Miniwatt T10 no 3453B gt Replace the cap and tighten by turning clockwise 68 11 6 Software Device software for the test instrument can be updated via the RS 232 inter
84. the selected measuring function All information and measurement results are displayed at the dot matrix LCD in clear text The integrated operating software is sufficient for most tests and measurements However the operator should nevertheless read and observe the contents of these operating instructions 3 6 Online Help Online help can be queried and displayed at the LCD for all measuring and test functions and for practically all settings Example Display Contrast Function SETUP PROFITEST 204 Display contrast Time and date Beeper Self test Switch position Language 18 o Press the STORE key in order to query online help e STORE Display contrast CEF Press A to increase contrast CEP Press F to decrease contrast Press to toggle backlight Light is turned off aut after 2 5 min in idle mode MENU Exit HELP Start adjustment Query online help o Press the same key once again or the MENU key in order to exit the online help function Exit online help or o Start the selected function directly from the online help menu with the START key START Start the selected function GMC I Messtechnik GmbH 3 7 Setup Various basic settings can be configured for the test instrument with the selector switch in the SETUP position y PROFITES 204 4 Display contrast Time and date Beeper Self test Language Select the desired
85. the voltage test unless all signal lamps indicate correct functioning Defective lamps must be replaced as described in chapter 11 5 2 page 67 Acoustic Signals signals for On or Measuring mode Ready to Activate 4 Repetitive Sequence gt 0 1 2 3 t s During Test A Repetitive Sequence fs E B l 5 0 1 2 3 t s lr Imax A Single Sequence gt 0 1 2 3 t s See chapter 3 7 3 page 20 regarding activation of this function GMC I Messtechnik GmbH 4 5 2 Configuring Test Parameters The following parameters can be configured with the green signal lamps illuminated in the stand by state Test Duration Time period during which test voltage is applied Setting range 1 00 to 120 s the continuous operation symbol gt gt gt gt gt gt gt can be selected with the M key by scrolling to below 1 00 s Test Voltage Test voltage level Setting range HP 250 V 2 00 kV HP 2 5kV 250 V 2 50 kV HV 650 V 5 00 kV HV 5 4kV 650 V 5 35 kV Imax Maximum allowable current before high voltage is switched off Setting range HP 10 075427 250 mA HP 2 5kV 10 0 200 mA HV 0 50 10 0 mA HV 5 4kV 0 50 10 0 mA Control symbol gt gt gt gt gt gt gt can be selected with the M key by scrolling to below 10 0 or 0 5 mA Rise Time Period of time during which test voltage rises to the selected value Setting range 100 ms to 99 9 s At table showing all setting ranges
86. trument Upload a Report Form from the PC The user can create personalized report forms Report tem plates include header text and footers Report forms can be created at the PC and uploaded to the test instrument via the serial interface 48 6 1 Print Values PSI Print a Report e PROFITEST N 2041 n i Print results PSI P Print protocol Select the desired command Select protocol Load form from PC I MENU Select the desired system no START Start printing Print results PSD Printing the machine No 001 Status Description Memory O 25 50 75 100 used Ma Change value G HELP MENU Escape START Printout Status A filled in file cabinet indicates that measurement data have already been stored for the selected system The printer symbol appears during transmission of data to the printer Once a print job has been started it can only be aborted by turning the function selector switch An error message is read out if the printer does not work The print job must be restarted in this case GMC I Messtechnik GmbH 6 2 Selecting a Form for Report Printing Selection can be made from amongst three previously stored report or print out forms Data are then laid out in accordance with the selected form and are read out to an external printer ag Note Three report forms are included with the instrument as a standard feature GMC I Messtechnik GmbH
87. tteries or rechargeable batteries in your instrument or accessories which no longer function properly they must be duly disposed of in compliance with the applicable national regula tions Batteries or rechargeable batteries may contain harmful sub stances or heavy metal such as lead PB cadmium CD or mer cury Hg They symbol shown to the right indicates that batteries or rechargeable batteries may not be disposed of with the K trash but must be delivered to collection points specially provided for this purpose Pb Cd Hg 69 12 Appendix 121 Checklist for the High Voltage Test Protective Measures for Personnel gt Switch the machine off and secure against switching back on o Perform protective conductor and insulation resistance tests gt Make sure that the system is grounded o Secure the danger zone with barriers Even narrow points of access must be blocked Post warning signs in a clearly visible fashion Set up warning lamps in a clearly visible fashion o o gt Attach the emergency stop switch in a clearly visible fashion gt Warn personnel working in the area of possible danger o If the operator leaves the work area the test instrument must be switched off with the key switch and the key must be removed from the lock Protective Measures for the Machine recommended gt Review the electrical diagram and make a note of all electrical circuits o Disconnect the neutral conductor from the
88. vent and activate the entry field Up to 15 characters can be entered to the entry field or to the info field at the bottom left as a description for the measurement See chapter 5 1 1 regarding data entry or eo non STORE HL i Press briefly Store an event The green red signal lamp is extinguished briefly as acknowledgement 32 GMC I Messtechnik GmbH 4 4 Voltage Measurement protection against residual voltage EN 60204 requires that voltages in excess of 60 V occurring at all accessible machine components during operation must drop to a residual voltage value of 60 V or less within a period of 5 seconds after supply power has been switched off Testing for the absence of voltage is conducted with the PROFITEST 204 by means of a voltage measurement which mea sures discharge time as well During discharge elapsed time is continuously displayed at the LCD after supply power has been switched off until the limit value of 60 V has been reached In addition to the type of voltage AC DC or AC DC the respective frequency is measured and displayed as well The mean value is always read out In addition to voltage and frequency type of voltage AC DC or AC DC is displayed in the symbol field at the bottom right hand portion of the display If during a voltage measurement with a measured value of more than 60 V the voltage value drops by more than 596 of the measured value during one measuring period app
89. y devices under test and must be kept separate from one another It is also essential to assure that no voltage is present at the test probes SETUP PROFITEST 204 Display contrast Time and date Beeper Self test Language Self Test Type GTMSe27eeeReee1 Software version 161 61AE Date of creation 61 87 96 Calibration date 17 87 96 ROM check sum CRL check sum Device temp High voltage deu AAAA Start testing MENU Main menu GMC I Messtechnik GmbH Error Messages and their Meanings Test results OK or option installed high voltage module Error message Test failed device under test defective or option not installed ROM Checksum A software error may have occurred Install the included system software to the test instrument again If problems persist we recommend calling our product support hotline CAL Checksum This portion of the self test examines the calibration subassembly Even if the CAL checksum is OK this does not mean that the PROFITEST 204 need not be calibrated in accordance with the prescribed schedule If this portion of the self test is failed the instrument must be returned to the manufacturer for re calibration Temperature Inside the Test Instrument The temperature limit has been intermittently exceeded inside the instrument The measuring mode is disabled until the temperature drops back into the allowable range Do not start the next measure

profitest 204|+ - GMC

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