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ATi user manual master

1. r Additional Low Terminals High Terminal Low Terminal Available Used mE Y 8 E r Secondary Terminals D High Terminal Low Terminal Hu xl Add gt lt Remove r Leakage Inductance Limits C gt lt Minimum Jo nH uk mH CH E Maximum 0 5 uy mH CH User Offset User Offset Enabled nH gk Measure Cancel Choose the integration period normally Medium and enter the terminals to be measured The Primary Terminals are where the test signal will be applied the Secondary Terminals will be short circuited together Note that more than one secondary can be short circuited at the same time by adding more of the available terminals to the used section of the dialogue NOTE Because leakage inductance is measured with a secondary winding shorted out be careful to choose a test signal that will not cause excessive currents to flow This is particularly significant in transformers where the turns ratio is very high and the shorted winding has only a few turns If for example the primary winding has 300 turns and the secondary 3 turns a test current of 10mA flowing through the leakage inductance on the primary side will give rise to a current of 1 Amp flowing in the shorted secondary winding PAGE 7 48 VOLTECH ATI USER MANUAL In order to protect transformer windings the test current when measuring leakage inductance i
2. Overall Pass Fail Analysis PAGE 4 28 VOLTECH ATI USER MANUAL AT SERIES SERVER ChartRunner Example Database Connection The chart will show the trend of inductance measurements over time an Individuals chart type See the ChartRunner help system for how to set up control limits change the display appearance or set up any of the other available chart types In the ChartRunner software create a new chart 254 CHARTrunner Inductance psuence L4 9 9 2 s L 2 L 9 VOLTECH ATI USER MANUAL PAGE 4 29 AT SERIES SERVER Enter a chart type the refresh rate for on line analysis and the chart type Click on the Data Source tab to choose the results database CHARTrunner Inductance Chartname type Data source Data definition Limits Control chart Titles Misc Help CAProgram FilesXvoltech Instruments Voltech AT Server Sample Access Datab areas Keep current column mappings and allow for non existing file Database or file name Under the Data Definition tab CHARTrunner Inductance Chart neme type Data source Data definition Limits Control chart Titles Mise m Source for data records Table Table Iv Keep columns itb ValtechResults X Column to use for Order By Filtering SQL settings Advanced The Filter is disabled Result records to include EMI C Query or view C Stored procedure C Custom q
3. eeeeeeeenee eene 5 12 5 4 FIXTURE PARTS 5 13 5 4 1 Fixture Plate Voltech Part Number 91 184 seen 5 15 5 4 2 Custom Fixture Kit Voltech Part Number 91 185 5 16 5 4 3 Socket Fixture Voltech Part Number 91 186 5 16 5 4 4 Connection Lead Set Voltech Part Number 78 090 5 17 5 4 5 Clamp Voltech Part Number 91 187 sse 5 17 5 4 6 Tooling iii nnde en no she eed nIBSI IIa 5 17 5 5 KELVIN CONNECTIONS eeeseeeneeen nennt nn nnne nn nna n sna sinn ennnen na 5 18 VOLTECH ATI USER MANUAL PAGE 5 3 FIXTURES PAGE 5 4 VOLTECH ATI USER MANUAL FIXTURES 5 1 INTRODUCTION AT Series Testers are able to perform an extremely comprehensive series of tests on a wide variety of transformers To utilize this capability fully it is recommended that test fixtures be constructed to suit each particular type of transformer to be tested Test fixtures are based on a fixture board containing connector pins They provide the interface to the tester via the tester node pins allowing transformers to be quickly inserted and removed in a reliable manner taking full advantage of the high speed testing capability of the tester A broad range of basic fixturing parts and fixture kits are availabl
4. The value of Ar is given in the section 8 1 of this chapter The values of the other factors are given below Ac 0 03 0 001 x Fy 0 03 0 001 Vu Where Fy is the measurement frequency Hz Vu is the measured voltage V PAGE 8 14 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 8 TRL TEST The accuracy for the test is given as Ar Apt As Where Ar is the total accuracy Ap is the accuracy of the primary winding measurement As is the accuracy of the secondary winding measurement To determine the values of Ap and use the accuracy specification for series inductance VOLTECH ATI USER MANUAL PAGE 8 15 SPECIFICATIONS 8 2 9 IR TEST The accuracy is based on the test conditions chosen to measure the insulation resistance and is given as Ar Where Ar Ar Ac Az Ap tActA t Az is the total accuracy is the basic relative accuracy is the calibration accuracy is the correction for current level is the correction for impedance level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 03 A 3 2 0 000002 Az 0 5 0 001 X Zy Where Iu Zm PAGE 8 16 is the measured current A is the measured IR value MQ VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 10 L2 C2 AND R2 TESTS The accuracy is dependent on the accuracy of the two
5. The results listing screen displays all completed tests giving test number type result in both value and pass or fail and status error for a description of status error codes see chapter 3 The listing may be printed by pressing the PRINT soft key in the same style as the standard results VOLTECH ATI USER MANUAL PAGE 2 43 GETTING STARTED After several program runs press the Finish softkey to return the tester to the top level display This is the end of the step by step tutorial which forms only a very brief introduction to the features available on your ATi Please study and browse through the rest of this manual or the on line help for the Windows software to get the best from your transformer tester The next section lists more features of the tester that you may wish to investigate yourself at this point before you try to create real programs for production use PAGE 2 44 VOLTECH ATI USER MANUAL GETTING STARTED 2 3 7 Storing Programs For everyday production use programs should be stored either e ona PC running the server software which will be permanently connected to the AT e in the tester s own memory Method 1 Using a permanently connected PC server has been described in the previous Getting Started section Method 2 Using the ATi s own internal memory as described here The programs can be stored within the tester even when it is switched off Once a program is stored the tester may be u
6. Fart number TUTORIAL Executing test 1 At the end of program execution the PASS indicator the green LED to the left of the display should be illuminated and the display should show VOLTECH ATI USER MANUAL PAGE 2 41 GETTING STARTED Fart number Fun TUTORIAL Settings Total 1 Failed 8 Results Last transformer P A 5 Finish 7 Press the RUN softkey several times to repeat the program execution On each run of the program the test results should be passed back to the Server where they may be viewed in the On line Monitor window iBixi l CTY 624 02 mOhm PASS 0000 2 15 1 1846 mH PASS 0000 3 TR 2 7096 PASS 0000 1 POL PASS If batch statistics have been enabled within the Server you will see the summary batch results window PAGE 2 42 VOLTECH ATI USER MANUAL GETTING STARTED at on com2 51581 x ATi Part Name Operator 1135 PART NUMBER Transformer Serial No Last Part Pas S Tested 18 PASS 18 FAIL 0 AQL 1 RE TRIES 0 FAIL 0 000 Last 10 Tx 0 Failed Test Min Max Last Result FAILS Polarity PolFAILS 1 CTY 10 000 kOhm 524 24 MOhm 2LS 1 1640 mH 1 2360 mH 1 1847 mH 0 3TR 2 6450 2 7540 2 7094 0 Test results may also be reviewed at any time via the tester s front panel results listing screen which is accessible from the Run Finish display by pressing the Results softkey see below 2 LS 3B8 3 mH 3 TR r2 361 4 LS 383 mH FAIL aaa
7. Self Test Two LCR modes are available LCR BNC mode uses the flexible leads attached to the four connectors on the control panel of the ATi to perform LCR Inductance Capacitance Resistance type measurements on a single winding or component LCR FIX mode uses nodes 13 14 15 and 16 of the fixture bay to perform LCR type measurements plus Turns Ratio Leakage Inductance and Interwinding Capacitance on two windings of a transformer The LCR fixture supplied with your ATi provides full Kelvin four wire connections to these nodes for convenient testing In LCR FIX mode nodes 13 and 15 are assumed to connect to the primary or energized winding of the transformer nodes 14 and 16 to the secondary PAGE 6 6 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 1 1 LCR BNC MODE Press the LCR BNC softkey and the ATi immediately begins to make measurements Ensure that DC Bias current is switched off before connecting and disconnecting component under test 3 4556mH 1 4427 CBHC mode AUTO Ws AUTO Hz 18m 3 78mH 188 Hz EMIT The upper measurement is that of the parameter selected by the 1st upper softkey In this case Ls the series equivalent inductance is 3 4556mH The second measurement is that of the parameter selected by the 3rd softkey In this case Q the quality factor is 1 4427 The next line shows the LCR mode that you are using This may be either BNC mode or Fixture mode
8. Test Conditions To measure DC resistance match the tester makes two DC resistance measurements see the R test and compares the two results Limits for the match of the two measured resistances may be set in terms of the ratio between them e g 1 1 5 By adding further DC resistance match tests to the test program any number of DC resistances can be tested for match PAGE 7 16 VOLTECH ATI USER MANUAL Choosing Test Conditions For optimum accuracy and performance use the test conditions shown in the DC resistance section of this chapter for each of the two windings Programming the Test Using the PC Test Editor Resistance Match Voltech e Select the integration time required e Enter the terminal names between which the X resistance is to be measured e Enter the terminal names between which the Y resistance is to be measured e Set the specific resistance for both X and Y terminals and then set the negative and positive percentage 96 limits VOLTECH ATI USER MANUAL PAGE 7 17 TESTS AND TEST CONDITIONS e Ifthe User Offset Enabled check box is checked a value can be entered into the edit box The value entered in the units shown is then added to any results returned from the AT tester e Select OK The test specification will now be displayed in the program window Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test condition
9. Ue e etu ans 4 24 4 3 7 On line Analysis via OLE sessi rne nnne nnns 4 35 4 3 8 Additional Notes for the Above Example eee 4 43 4 3 9 Off line Analysis esses sess eines einn ih nennen thanh e ati 4 45 4 4 LICENSE REGISTRATION eere eee nennen nnn nnn nn nnmnnn nnmnnn nnmnnn nnman nenene nnna 4 50 4 4 1 Enabling the Licensed Features seen 4 50 4 4 2 Transferring the License to Another 4 52 VOLTECH ATI USER MANUAL PAGE 4 3 AT SERIES SERVER PAGE 4 4 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 1 INTRODUCTION The Server program supplied with your AT Series Tester may be considered as an on line storage system The server will handle two types of data e TEST PROGRAMS e TEST RESULTS Test programs that are created using the Editor application may be uploaded into the Server central file store All testers connected to the Server then have access to the central store Programs are called up from the Server sent to and then executed within the tester The features of the Server include e MS Windows application style dialogues and tools e Storage of all previously created test programs e Transfer of test programs to the tester on request e Viewing of test programs outside the test program Editor environment e Test results may be received and stored in a da
10. Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Test limits should be set as close as possible to detect assembly faults If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester PAGE 7 110 VOLTECH ATI USER MANUAL 7 1 28 TRIM PAUSE TESTING IN ORDER TO TRIM A COMPONENT VALUE Trimmable Inductance AT Series Capacitance Resistance Tester Impedance Longitudinal Balance The TRIM test is used on signal audio and telecommunications transformers and other components where a means of physically adjusting a parameter is provided For example the Q factor of a coil may be tuned to within specified limits by adjusting a trimmable core Test Conditions A TRIM test may be used after any low voltage test on the tester If the desired parameter is outside the limits specified by that previous test the tester halts and provides a live display indicating which way ve or ve the operator should adjust the part Once trimming is complete the tester will continue with the rest of the tests in the sequence once the run pad is touched the Run softkey is pressed or the foot switch if fitted is closed VOLTECH ATI USER MANUAL PAGE 7 111 TESTS AND TEST CONDITIONS Tests that may be TRIMmed include R RLS RLP LS LP LSP LSB Q C TR LL LLO
11. reports and finally produce a printout for records Refer to your own application handbook for details of importing and manipulating data VOLTECH ATI USER MANUAL PAGE 4 45 AT SERIES SERVER Example of Off line Analysis The spreadsheet used in the example is Microsoft Excel 97 From the Excel top level menu bar select File Open X Microsoft Excel Book1 s Fie Edit View Insert Format Tools Data a New Ari lose L Save Ctrl S Excel will then bring up the Open File dialogue box Select the results file you wish to view and click on Open Open Lookin C Server z fs v lar C5200697 ESSE 20 06 97 10 51 2 n 20 06 37 10 44 Cancel Advanced T Read Only Find files that match these criteria File name at vj Text of property hs Find Now Files of type Microsoft Excel Files Last modified fany time El New Search 2 file s found After clicking Open the Text Import Wizard dialog box will appear PAGE 4 46 VOLTECH ATI USER MANUAL AT SERIES SERVER Text Import Wizard Step 1 of 3 windows ANS H i Ensure that the De limited option is checked and click on Next gt to move to step two Text Import Wizard Step 2 of 3 OLTECH AT3600 RESULTS FILE Server Program Version 2 04Communication Channel 6 71 VOLTECH ATI USER MANUAL PAGE 4 47 AT SERIES SERVE
12. GETTING STARTED To download a group of programs at the tester s top level display press the Set Up softkey Then at the Set Up mode display press the Groups softkey The next display will then prompt you for the name of the program group that you wish to use Enter the group name As with other names the group name can now be typed in from the keypad entered using a bar code reader connected to the bar code port of the ATi or selected from a list using the List option Again the cursor softkeys and the Delete softkey may be used to correct errors After pressing the Enter softkey or the download will commence and after a few seconds you will see the following display VOLTECH ATI USER MANUAL PAGE 2 85 GETTING STARTED Group successfully downloaded Continue Press Continue to return to the top level display Your program group has now been loaded into the tester s internal store and the Server PC may be disconnected These programs will be saved during power off and will only be overwritten by another group download Group Download Error Messages The following is a list of possible error messages that may occur if there is a fault in the group download process together with suggestions for the possible cause a Error Server not responding Continue PAGE 2 86 VOLTECH ATI USER MANUAL GETTING STARTED Possible Causes Faulty cable The cable from the
13. Fit the Fixture display and before the RUN FINISH display PAGE 2 62 VOLTECH ATI USER MANUAL GETTING STARTED The following flow diagram summarizes the possibilities Y Top level Display Y Select Programs Soft key y Select Test Program to Run lt 4 v Fit and Compensate Fixture gt Enter Operator Name 4 Enter Batch Number gt Enter Serial Number y RUN FINISH Now Batai New Operator Menu R Re compensate RUN FINISH Y Measurements v Enter New Serial Number VOLTECH ATI USER MANUAL PAGE 2 63 GETTING STARTED Additional displays after entering the part number Enter the operator name aa Enter the batch number 2 64 VOLTECH ATI USER MANUAL GETTING STARTED Enter the serial number Delete Abort Shift Use either the keypad or a barcode reader to enter the operator batch serial number then press the ENTER key on the keypad or the Enter softkey Cursor softkeys appear in context and may be used with the Delete softkey to correct mistakes Serial Number Entry After the First Transformer When the serial number option is enabled after the measurements for each transformer have been completed the following display will be seen with the fourth displ
14. Long Terminals High Terminal Low Terminal El Inductance Limits CX gt lt Minimum 100 rH f uh mH 9 9 Maximum 150 5 C uH mH User Offset User Offset Enabled mu PAGE 7 118 VOLTECH ATI USER MANUAL To program the test Enter the signal frequency and bias current required for the test Note that the signal is normally entered as a voltage by selecting the mV or V button but you may optionally enter it as a current by selecting the mA button If in doubt refer to the Test Conditions chapter of your AT user manual Note also that the measure button may be used here as outlined in your AT user manual with the combinations of test parameter specification shown in the following table Option 1 Option 2 Option 3 Option 4 Signal Specified Specified Auto Auto voltage current Frequency Specified Specified Specified Auto Bias Specified Specified Specified Specified 2 Select mouse click the button the integration time you require Medium is the default setting Long will give you more stable readings for tighter limits at the expense of test time and Short will test at the maximum speed but may give slightly noisier readings 3 Enter the terminal names between which the inductance will be measured By pulling down the menu along side the fill in box you may select the high and low te
15. Optional Program Tests eene 1 8 1 4 3 ATi LCR Mode Functions sessi eene 1 9 1 5 ATI FEATURES SUMMARY e esee en nenne nenas n nan n annu mana suas 1 11 1 6 TYPICAL PRODUCTION INSTALLATION e cere cere re eene nenne 1 12 1 7 USING THE ATI FOR DESIGN AND 1 14 1 9 OVERVIEW eue ratae i Dac exec T 1 15 1 8 1 Creating Programs The Editor sse 1 16 1 8 2 Storing Programs and Results The Server sss 1 17 1 8 3 Transferring Programs between Editor and Server 1 18 1 8 4 Executing Programs itt e i epe ERR SR RE enin 1 20 1 8 5 Test Fixt res i oie db T rei Uwe 1 23 1 8 6 Operating the AT Series Testers in Production 1 24 1 9 How DOES THE ATI TESTER 1 26 VOLTECH ATI USER MANUAL PAGE 1 3 INTRODUCTION PAGE 1 4 VOLTECH ATI USER MANUAL INTRODUCTION 1 1 How To USE THIS MANUAL Welcome to the Voltech ATi Please study this introductory chapter of the manual carefully It will help you to set up your tester quickly and safely The following symbol conventions are used throughout Important safety information To ensure operator safety all safety information must be
16. Pri EN v fE shez pee Enter U Sec AUTO V AUTO Hz Enter I Enter IBias L 4 8888 H Pri cec at Ws As Hz New settings are diplayed as above once they have been stored Since no measurements have been made with these new conditions measured values cannot be displayed on bottom line Having entered fixed values of voltage frequency and Ibias as required and pressed softkey 6 OK the screen will show 2 106 2mH 2 7712 CFixture modes AUTO Ws AUTO Hz s 98mJ llmBH 188 Hz The Bias level is only shown when its program value is not zero Press OK again to return to the normal measuring menu PAGE 6 26 VOLTECH ATI USER MANUAL FRONT PANEL MODES Note that com req is now displayed because a frequency has been chosen at which compensation measurements have not been made before For accurate measurements compensation should now be appiled See the compensation section in this chapter for details Press the Integration softkey on the settings menu to reveal the integration options Integration Short Medium Long The integration level controls details of the measurement method including the number of readings that are averaged together to provide the displayed measurements To achieve the specified accuracy of the ATi the default Medium measurement should be chosen Choosing Short integration will provide faster but less stable and accurate results For maximum stab
17. Resistor Test Nodes VOLTECH ATI USER MANUAL PAGE 8 31 SPECIFICATIONS Connector Details 9 pin female D type connector 5432 1 User Port Lm D see in eme 0 User Relay Drive 0 User Relay Drive 1 User Relay Drive 2 User Relay Drive 3 User Relay Drive 4 User Relay Drive 5 User Input 0 i User Input 1 12V User Relay Drive Outputs pins 1 2 3 6 7 and 8 All the user Relay Drive Outputs have the following equivalent circuit 12V m O0 Pin 5 Specification Relay coil resistance gt 1502 A Maximum sink current 80mA per output Relay o Drive Output A PAGE 8 32 VOLTECH ATI USER MANUAL SPECIFICATIONS User Inputs pins 4 and 9 The User Inputs have the following equivalent circuit 5V kQ User Input Specification Maximum input voltage 5V Minimum input voltage OV Minimum logic 1 input 4V Maximum logic O input 0 25V The zero reference voltage for these inputs is the OV ground 4mm socket situated on the right of the ATi unit The user inputs have no function at present and should be left unconnected 12V pin 5 Total maximum current User port pin 5 Remote port pin 3 100mA VOLTECH ATI USER MANUAL PAGE 8 33 SPECIFICATIONS 8 3 7 ENVIRONMENTAL CONDITIONS Line Input IEC 3 pin socket 87 to 265V ac 47 or 440Hz 100VA Fuse 1 6AT Dielectric Strength 2kV ac 50Hz for 1 minute line input to case Storage Temperature 40 to 70
18. See Chapter 7 Tests and Test Conditions for a guidance on Asc PAGE 8 10 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 4 C CS AND CP TESTS The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test and is given as Ar Ap Ay Aj t Ax Where Ar is the total accuracy is the basic relative accuracy 60 Ac is the calibration accuracy 96 Ay is the correction for voltage level 96 is the correction for current level Ao is the correction for Q factor Ar is the correction for C 96 The value of Ag is given in the section 1 1 of this chapter The values of the other factors are given below Ac 0 0896 0 00001 x F A 0 08 0 001 V A 0 08 0 0001 I Ag 0 08 2 On A F sum M x Where Fy is the measurement frequency Hz Vm is the measured voltage V Im is the measured current A Qm is the Q factor of the measured impedance Cm is the capacitance of the measured impedance VOLTECH ATI USER MANUAL PAGE 8 11 SPECIFICATIONS 8 2 5 QL ANDD TESTS The accuracy of measuring Q factor and D factor is given as At Ar Aap Where Ar is the basic total accuracy Ar is the basic relative accuracy is the correction for current level 96 Aap is the correction for Q or D factor The value of Ag is given in the table in section 8 1 of this chapter The values of the
19. X gt lt Nominal 2 CH CH Cm CH 5 Negative 5 ce Positive 5 52 User Offset User Offset Enabled PAGE 7 116 VOLTECH ATI USER MANUAL To program the test 1 Enter the signal frequency and bias current required for the test Note that the signal is normally entered as a voltage by selecting the mV or V button but you may optionally enter it as a current by selecting the mA button If in doubt refer to the Test Conditions chapter of your AT user manual Note also that the measure button may be used here as outlined in your AT user manual with the combinations of test parameter specification shown in the following table Option 1 Option 2 Option 3 Option 4 Signal Specified Specified Auto Auto voltage current Frequency Specified Specified Specified Auto Bias Specified Specified Specified Specified 2 Select mouse click the button the integration time you require Medium is the default setting Long will give you more stable readings for tighter limits at the expense of test time and Short will test at the maximum speed but may give slightly noisier readings 3 Enter the terminal names between which the inductance will be measured By pulling down the menu along side the fill in box you may select the high and low terminals for each test 4 Select mouse click the button the type of limits you require and enter the va
20. essent 5 12 5 4 Fixture Parts Available from Voltech seen 5 13 5 5 Kelvin Connections ite e i rhe i e nad 5 18 5 6 1 6 1 LCR Mode Basic Functions esses nnne 6 5 6 2 Tests Available in 6 5 6 17 6 3 ECH Men s oo deam Aem Ets 6 19 6 4 COMPENSATION ssi i ERE ER re EEUU MU Ee Ud eret opea Cows 6 29 6 5 LCR Mode Error 6558065 6 35 6 6 Programm MOOG asic e ti A rb rp rA e need 6 39 7 TESTS AND TEST CONDITIONS esee seen en nennen manna nenn snas nsn mana suas sauna 7 1 7 1 Introduction eei e Eo ge doe D ce reete ae 7 4 7 2 Series and Parallel Circuits esses 7 123 7 3 Capacitor Measurements sessi eene nnne nnne nnne 7 125 N Aaa aae aaa Tadaa aaa aa aa Aueue aaia da iia 8 1 8 1 Specifications Summary Available 8 5 8 2 Accuracy Specifications Available 5 8 8 6 3 Interface Details 2 ede t e pe ae 8 25 8 4 EMG Compliance ct pote i e v o ed s 8 35 9 WARRANTY AND SERVIC
21. following way Note The BNC connectors are also connected internally to nodes 20 P and S and 18 P and S of the fixture bay Program v Measured v PAGE 6 8 VOLTECH ATI USER MANUAL FRONT PANEL MODES Remove any fixture from the fixture bay and ensure these nodes 18 and 20 are clear before using the BNC terminals The top softkey number 1 allows you to move through the visible options Press softkey 1 and you will see 5 1202mH 1 4401 Ln modes m Peg AUTO AUTO Hz Mes 18ml 3 78mH 186 Hz EMIT Lp and Q The options for the second display line have changed as appropriate and can be changed by pressing the softkey 3 VOLTECH ATI USER MANUAL PAGE 6 9 FRONT PANEL MODES 5 1216mH 694 77m awe CBHC modes Settings Prq AUTO U AUTO Hz B Mes 9 99m 5 7 188 Hz ERIT Lp and D More tests are available by pressing More 1 3 softkey 2 2 6453 0 HR 55 212 d modes Settings Peg AUTO V AUTO Hz Mes 18ml 3 78mH 188 Hz ERIT Zand 0 Please see the sections following LCR FIX for details of how to use the front panel LCR modes of the ATi PAGE 6 10 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 1 2 LCR FIX MODE Press the LCR FIX softkey and the ATi immediately begins to make measurements Ensure that DC Bias current is switched off before connecting and disconnecting component under test 1 088
22. measurement circuits to the particular nodes required in the test PAGE 1 26 VOLTECH ATI USER MANUAL INTRODUCTION Test Sources The three sources are fully programmable in thousands of steps of voltage current and frequency Measurement Circuits Fully auto ranging the measurement circuits are capable of measuring from uV and nA to 500V and 4Apk with great precision Keyboard Display and Interfaces A broad range of programming results display and storage methods Processors The AT series testers are based on a two processor design 1 Astandard microprocessor that acts as controller and also drives the relay matrix the keyboard and display and the various interfaces 2 A fast digital signal processor that controls the test sources and performs the measurements The test sources relay matrix and measurement circuits are all under direct control of the processors to ensure optimum speed accuracy and reliability Running a Test When the test program is loaded into the tester each individual test is assembled into a sequence of operations involving the components in the functional block diagram shown previously The sequence is different for each test and in some cases it depends on which are the preceding and following tests in the program but in all cases it is optimised to give the best measurement speed and accuracy VOLTECH ATI USER MANUAL PAGE 1 27 INTRODUCTION As an example the sequence for mea
23. 08 0 001 Vy 0 08 0 000196 Im 0 03 x Ig im Aq 0 08 2 Qm LS LP LSP LPS and X 0 08 2 x Qu RLS and RLP Ag 0 03 x In ly Where Fm Vm lm In Qu is the measurement frequency Hz is the measured voltage V is the measured current A is the bias current A is the Q factor of the measured impedance VOLTECH ATI USER MANUAL PAGE 8 9 SPECIFICATIONS 8 2 3 LL ANDLLO TESTS The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test and is given as AT AR AC Av Aj AQ AB ASC Where Ar is the total accuracy 96 An is the basic relative accuracy 96 Ac is the calibration accuracy 96 Av is the correction for voltage level 96 is the correction for current level 96 Aa is the correction for Q factor Asc is the correction factor for the short circuit impedance The value of Ar is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 08 0 00001 x Av 0 08 0 001 Vy 0 08 0 0001 Iu 0 08 2 Qm Ag 0 03 x Ip Iu Asc Zsc x Turns Ratio x 100 Measured LL Where Fm is the measurement frequency Hz Vm is the measured voltage V Iu is the measured current A is the bias current A Qu is the Q factor of the measured impedance Zsc is the impedance of the applied short circuit
24. 3 4 p e Self Test Pri Sec Settings More 4 4 EXIT Sec Settings PHAS EXIT Sec Settings EXIT Mes Sec EXIT Signal Enter f Fix Integration Enter V Auto Compensate Enter I Delete Print Enter IBias Enter Sec Cancel OK OK Shift Short p IBias XBias ER Long Delete Enter Cancel Cancel y Short One All Open One A11 PAGE 6 20 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 3 3 LCR MODE SETTINGS For maximum convenience and ease of use the ATi automatically chooses the voltage and frequency at which the LCR mode tests are carried out The test conditions can also be programmed to fixed values to match the specification of a part or to ensure that a batch of parts are tested at exactly the same conditions The LCR mode settings screen allows you to Enter fixed voltage and frequency test conditions Compensate for the effect of stray inductance and capacitance from the connection to the part under test Change the level of integration applied to the measurements Print the current measurements to a standard printer Measure on the front panel using any of the tests that have been purchased This section describes the measurement settings that are available in both LCR BNC and LCR FIX modes VOLTECH ATI USER MANUAL PAGE 6 21 FRONT PANEL MODES 1 988 1 AA Mare 1241 11 791 CFixture made Prg AUTO U AUTO Hz Mes lem 1 46mA 1kHz Press the
25. 3 7 PROGRAMMING HINTS AND TIPS e eeeeeeee esee nnn nnn nnn 3 48 PAGE 3 4 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 1 CREATING A PROGRAM Using the Editor enables you to quickly and easily create test programs for your AT Series Tester without any specialized knowledge of computer programming The Editor will guide you through the programming of the tests you wish to carry out helping you ensure that programming errors are eliminated e The features of the Editor Software editor include e Full MS Windows application compatibility providing many visual aids for tailoring the test parameters to your needs e Schematic diagrams of the transformer under test showing pin to node connections These form the basis of your test program e Form fill in dialogue boxes to guide you through the programming of each test Atest program under development may be executed and the test results viewed on screen Test programs and results may be stored in a PC running the Server software Transfer of test programs to specified paths or floppy disk for backup Afull context sensitive and menu driven help system An additional function available through the test program editor is upgrading the firmware of your AT Series Tester See the Firmware Upgrades section in chapter 2 for details VOLTECH ATI USER MANUAL PAGE 3 5 PROGRAM EDITOR 3 2 CREATING THE TRANSFORMER SCHEMATIC The Voltech AT Serie
26. 50Hz 50Hz 50Hz 20Hz Ideal Test Conditions for Inductance Measurement The test conditions can also be determined automatically by the ATi according to this table Specified voltage Specified current Auto Specified Specified Frequency Specified Note that a fixed signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 21 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Winding Inductance Series Circuit Voltech Choose the integration period normally Medium and enter the terminals to be measured Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions PAGE 7 22 VOLTECH ATI USER MANUAL Notes When choosing test conditions the following potential problems should be considered a Current Levels The upper voltage limits should be chosen to give a maximum current level of about 50mA rms for the lowest inductance expected In some cases this current may cause core saturation and a lower voltage should be used The minimum voltage level must be chosen so that the test current does not become so low that it cannot be sensibly measured The lower voltage limits in the table above always give test currents higher than 3p A rms b Self resonant Frequency At lower frequencies the capacitance of the windings can normally be ignored because its impedance is much
27. 6 5 LCR Mode Error Messages 6 35 LEAKAGE INDUCTANCE 7 45 4 50 LONGITUDINAL BALANCE 7 80 7 85 Measure button 3 31 NODES ys CE 3 8 5 3 14 7 114 Package Contents 2 6 PASS Indicator 2 7 PC specification 2 12 7 105 brio eere earn 6 28 8 28 Program Edit 3 19 Program Mode 2 77 Quality Factor 7 26 Quick start tutorial 2 19 7 103 Registration ssusss 4 50 PAGE 10 1 INDEX 8 29 RENAMING A 3 9 7 13 7 34 RESP FREQUENCY RESPONSE 7 89 55 7 96 RUN Indicator 2 7 2 9 Schematic creating 3 6 SCREEN CONNECTION 3 12 Self Testte nin 2 49 self test during power on 2 10
28. AT tester This function can be used to adjust for measurement fixture effects that cannot be compensated for or to compensate the fixture manually so a compensation stage is not required to obtain the correct readings 4 Click on the OK button The test and its parameters will now appear in the Program window Low Terminal B Minimum Value 59 000 Ohms Maximum Value 73 000 Ohms 5 Again by double clicking the left mouse button select R Winding Resistance from the Available Tests window At the dialogue box enter the data as before this time for the second winding Integration Leave as the default Medium VOLTECH ATI USER MANUAL PAGE 2 25 GETTING STARTED PAGE 2 26 High terminal C Low terminal D Minimum 590 Maximum 730 Click on the OK button Again the test and its parameters will appear in the Program window 6 Now by double clicking the left mouse button select LS Inductance Series Circuit from the Available Tests window At the dialogue box enter the data required for the inductance test Signal 1V again choose the V units button by clicking with the mouse Frequency 50Hz Integration Leave as the default Medium High terminal A Low terminal B Click on the gt button to select a minimum limit only and enter Minimum 3H Winding Inductance Series Circuit NH Om ey c CM Cue C VOLTECH ATI USER MANUAL GETTING STARTED The User Offse
29. CONDITIONS Primary Terminals High and Low The zero phase reference terminals that are often the same as the energized terminals Secondary Terminals High and Low The turns ratio and polarity measurement will be made between the primary and secondary terminals Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits mV or V when entering absolute values as limits Test limits should be set as close as possible to the nominal value in order to detect faults A typical tolerance would be 5 If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester PAGE 7 76 VOLTECH ATI USER MANUAL 7 1 18 IR INSULATION RESISTANCE Test Measurement Test Test Basic Range Voltage Frequency Accuracy IR 1MQ to 1GQ 100V to 500V DC 1 0 Insulation AT Series Tester Transformer windings are often insulated from each other and from the core by insulating tape enamel on the wire or by plastic moulding
30. If compensation is required see later this line will also say comp req Prg AUTO V AUTO Hz These are the programmed measurement conditions By default the ATi automatically chooses measurement conditions that optimize the measurement accuracy Sometimes these conditions may not be appropriate for the final application of the part under test or may be different to those VOLTECH ATI USER MANUAL PAGE 6 7 FRONT PANEL MODES chosen on other equipment See later sections of this chapter for how to program the measurement conditions of your choice Mes 10mV 3 78mA 100Hz These are the measured test conditions The voltage and frequency are measured at the sense terminals of the ATi If you are using Kelvin 4 wire connections then these are the conditions measured on the connectors of the part under test Usually the voltage and frequency will be identical to the programmed voltage and frequency because the ATi always attempts to trim its output voltage across the part to be equal to the desired or program voltage see below If the impedance of the part is very low the ATi might not be able to supply sufficient current to maintain the programmed voltage In this case the voltage measured will be less than the program voltage The current passing through the part is also displayed on this line A constant current can be programmed for some tests The ATi is applying the test signal to BNC terminals on the control panel in the
31. In general all tests have restrictions on which test parameters may be or have to be specified and which may be chosen automatically In the case of the LS Winding Inductance series circuit test the valid combinations are summarized in the following table The combination that is not allowed is to specify the voltage or current and ask the AT to find the frequency If you have entered a non permitted combination the editor will display a warning message when you click on the measure button and there will be no measurement until you correct the error PAGE 3 38 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 4 4 VERIFYING YOUR PROGRAM Typically in production use your program would be downloaded to an AT Series Tester from the Server which is a PC resident software package described in detail in chapter 4 However before you transfer your program to the Server archive you should always verify it by running it on an actual transformer The Editor software will enable you to download a program directly to the tester and to execute it from the PC keyboard Before you attempt to run the program 2 Make sure you have connected your tester s Auxiliary Port on the rear panel to a suitable COM port on your PC This may be COM2 if your mouse is already using COM 3 Set up the COM Port on the PC Setup Communications Ea select pe eo Setup gt Communications Cancel From the top level menu In the
32. Insulati esistance L2 Inductance 1 10000 10000 1 ImV 5V 20Hz 3MHz 0 1 Match Interwinding Capacitance 1 1000 1000 1 ImV 5V 20Hz 3MHz 0 296 Match General GBAL Longitudinal OdB 100dB ImV 5V 20Hz 3MHz 0 5dB Balance Longitudinal LBAL OdB 100dB ImV 5V 20Hz 3MHz 0 5dB Balance ILOS 100dB 100dB ImV 5V 20Hz 3MHz 0 548 C pee RLOS EN F RESP 100dB 100dB ImV 5V 20Hz 3MHz 1 0dB Response RLOS 100dB 100dB ImV 5V 20Hz 3MHz 0 2 1m2 IMQ ImV 5V 20Hz 3MHz 0 2 Impedance Z Z B ImQ IMQ ImV 5V 20Hz 3MHz 0 2 with Bias Impedance 9 ANGL K 360 360 ImV 5V 20Hz 3MHz 0 05 Phase Angle Int d E 3 3 PHAS 360 360 ImV 5V 20Hz 3MHz 0 05 Phase Test Trimming n a n a Adjustment Output to User n a n n a n Port 1mV to 5V or Meier 100nH to 100H 20A to 20Hzto3MHz 0 2 100mA DC Bias Inductance with External Bias 1mV to 5V or Parallel 100nH to 100H 20 to 20Hz to 3MHz 0 296 Circuit DC 100mA Bias PAGE 8 6 VOLTECH ATI USER MANUAL TRIM n a n a UT a a SPECIFICATIONS cd di 1mV to 5V or 1mQ to IMQ 20 to 20Hzto3MHz 0 2 External Bias 100mA Notes 1 Ag basic relative accuracy full specifications follow Specification at 23 C 5 C after one hour warm up and long integration 2 Absolute maximum ratings for all tests 5Vrms and 0 4Apeak except IR 500VDC 3 Where used the bias current ac
33. L C Z D Q Rac X Z 0 Rdc Insulation Resistance Turns Ratio Leakage Inductance Bias current up to 1A Fully programmable 5V 3MHz or AUTOMATIC test conditions 0 05 basic accuracy e 4 terminal Kelvin connections using high quality leads supplied e Easy to use Compensation for stray resistance inductance and capacitance 161 86PH ite tc Mare 1 3 PAGE 1 14 1 6646 BHC made Pegi AUTO U AUTO Hz _ Mes 9 91ml 2 23mBH 1kHz EIT 365 57M TRL LL C More cega IL uu I n CFixture modes Set Np EEE Prq AUTO U AUTO Hz a uh jy a m 11 Mes 2 84 U 1 85mA m x H VOLTECH ATI USER MANUAL INTRODUCTION 1 8 OVERVIEW This section gives a more detailed overview of your ATi and how to use it It is recommended that you read this section before attempting to use your tester Topics covered in this overview e The features and functionality of the ATi in a production environment e What appears in a test program e How programs are created archived and then used in actual test e Test fixtures e Typical manual and robotic test situations e Internal functionality How the tester executes each test Note This overview is intended as an introduction to each of the above topics so that you may quickly understand what may be possible If further detail
34. MANUAL GETTING STARTED Then use the following sequence of key presses to run the test program for the part TUTORIAL 1 Press the softkey Programs to display Server programs Hew program EXAMPLE 1 FAHA 1 4 FART NUMBER PROGRAM 1 2 The program name can now be chosen from the list of programs available on the PC Server If the list of programs fails to appear after a few seconds check that the AT Server is running the COM port and file folder are configured correctly and that the cable from the AT Server port is correctly fitted to the PC 3 Use the T and 4 keys to select the program and press the Run softkey VOLTECH ATI USER MANUAL PAGE 2 39 GETTING STARTED Server programs FROGEHM 1 TUTOR TAL Delete 4 When the download has been successfully completed you will see a message to fit the fixture similar to the following LL gri Fit the fixture Compenzate FISTURE ID 5 Asthe fixture is already fitted and compensation is not required with the sample transformer simply press the No Comp softkey to move on to the Run Finish display PAGE 2 40 VOLTECH ATI USER MANUAL GETTING STARTED Fart number TUTOR TAL Settings Finish 6 Press the Run softkey to start program execution As the program is running the RUN indicator the yellow LED to the left of the display will be illuminated and the display will indicate the test currently being executed ps
35. Self iei tov NR e e d 2 49 2 5 Production Mode ie pe ep 2 52 2 6 Stop ON Fall i E E e tate etus 2 69 2 Timo essa etur atum ducem st E 2 71 2 8 Fixture Compensation esses sisse einsehen nennt inanis iE 2 73 2 9 Setup MOO6 ione eie au en 2 77 3 PROGRAM EDITOR aaar a raaa aaa a aa aa aa paaa aaan aaa aaa aaa aa daa dadia iadaaa 3 1 3 1 Creating a Program dci ic a pn dl naa 3 5 3 2 Creating the Transformer Schematic sees 3 6 3 3 Creating the Test Program eene einen nnn nnne nnne 3 13 3 4 Using the Measure Button ssssseee eene 3 31 3 9 EMO COOCS 15a vik soot RO o ack des totes 3 42 PAGE IV VOLTECH ATI USER MANUAL 3 6 Fixture Compensation see also section 2 8 3 46 3 7 Programming Hints and TIps 3 iut eter tai epe teda 3 48 4 AT SERIES SERVER 1 cene teret rinm encect enuereetec Eakas iaiia ainnir Eass 4 1 41 Introduction i e EBENE erit Ha 4 5 4 2 Test Program Handgun istics it ett teret det ea 4 6 4 3 Test Results Hanaling retini de ipsa ta penaa iniia Sea Eni 4 11 4 4 License Registration assesses A AE Eie a eE T EREET 4 50 5 FIXTURES E E E E en ete ek See eA id 5 1 o T Introd CtlOn s alee ees eet htt he Se a ees 5 5 9 2 DO SCIIDLION ue oiv aaa 5 6 5 3 Fixture System Specification
36. Sense Where Used Ideal for developing test programs or testing small batches of different wound components The 40 Socket Fixture consists of 20 pairs of red and black 4mm shrouded safety sockets mounted and wired into a blank fixture A variety of clips and posts can be used to enable connection to the component under test When testing larger quantities of the same component 50 or more then a custom fixture solution is strongly recommended Ask your Voltech supplier for details of the Custom Fixture Kit VOLTECH ATI USER MANUAL PAGE 5 11 FIXTURES 5 3 FIXTURE SYSTEM SPECIFICATION The Voltech custom fixture is designed to connect to wound components with the following characteristics Size A footprint of up to 63 5mm square A height of up to 63 5mm A connection matrix up to 60mm square Connection types Surface mount Pin connection Blade connection Flying leads Pitches of 1 27mm 2 00mm 2 50mm 2 54mm 0 1 3 81mm 0 15 There are some application limitations to the above for example the minimum pitch of the blade type that can be connected to is determined by the minimum pitch that the necessary connector can be put on Also though a 1 27mm pitch is available it is only anticipated that component connections will be on multiples of this pitch and there will not be two connections only 1 27mm apart PAGE 5 12 VOLTECH ATI USER MANUAL FIXTURES Compatible connection types Kelvin clips Ke
37. Settings softkey to reveal the settings menu 2 106 2mH 2 7712 CFixture modes Prq AUTO Ws AUTO Hz Mest 9 928mJ 11mBH 188 Hz Press the Signal softkey to show the signal settings PAGE 6 22 VOLTECH ATI USER MANUAL FRONT PANEL MODES Signal settings Enter f Pri U Hz Enter WJ Sec AUTO Y AUTO Hz mAb Enter I Enter IBias 161 623JH Sec at 4 928 U 1 35mH Z2BBkHz Note that in LCR BNC mode there is only one set of conditions to choose and that the Pri Sec softkey is thus not shown On the bottom line of this display the last measurement and its measurement conditions are displayed if they are available ENTER f ENTER V and ENTER Ibias These keys allow you to enter fixed values of voltage frequency and DC bias current using the 12 key numeric keypad The combination of AUTO f and a fixed value of voltage is NOT allowed Hence you must always enter a fixed frequency before entering a fixed voltage You may enter a DC bias current when any measurement is displayed but bias is not applied during C Cs or Cp measurements To enter for example a fixed frequency press ENTER f softkey 1 on the previous screen and you will see VOLTECH ATI USER MANUAL PAGE 6 23 FRONT PANEL MODES Enter value Pri U Hz Auto Sect AUTO Y AUTO Hz mAb Delete f Enter L 1 1 5 Cancel at 4 98 U 1 35mA Shift Press Fix to enter the value currently bei
38. Up Self Test The tester is now at the top level menu and the softkeys allow you to select which of the five main functions you require PAGE 2 10 VOLTECH ATI USER MANUAL GETTING STARTED Programs is used when running test programs in production test mode LCR BNC FIX enable the tester to behave like a component analyzer continuously updating front panel readings See chapter 6 for more information no the LCR front panel mode Set Up is used to group download programs from a Server PC to the permanent store of the tester and to set up the options within the tester Self Test is used to perform a thorough self test A detailed explanation of the operation of the ATi that follows pressing the Execute Program and Self Test keys is given later in this chapter VOLTECH ATI USER MANUAL PAGE 2 11 GETTING STARTED 2 22 Installing the PC Editor Connect the tester s auxiliary port to a spare COM port on the PC as shown The type of connector on the PC will determine the cable that you use For most PC s this will be a 9 pin female PC to 9 pin female ATi Auxiliary port COM port Switch on the power supply to the PC Before attempting to install the Editor check that your PC satisfies the following hardware requirements PC processor 486 or better Memory 4MB minimum Hard disk space 2MB minimum Operating system Windows 95 or newer Supported screen resolutions 640 x 480 800 x 600 1024 x 768 1280 x 1
39. a list of programs available on the PC Server or in the ATi s own memory i e local programs entered by swiping a barcode or created directly from the front panel by selecting New program and pressing the Set Up softkey see chapter 6 Local programs Heu program 3 PROGRAM 1 Delete TUTORIAL Once the test program to be executed has been selected pressing softkey 1 Run produces the following display PAGE 2 54 VOLTECH ATI USER MANUAL GETTING STARTED Fit the fixture Compenzate FIXTURE For connect all used terminals together FIXTURE1 is the name given as the Fixture ID in the Editor software Program options dialogue see chapter 3 or under program options in front panel program mode see chapter 6 Press Compensate or No Comp as required Note For fixture compensation see later in this chapter Fart number PROGRAM 1 Settings Place the component to be tested in the fixture and press the Run softkey touch one of the run pads or press the footswitch VOLTECH ATI USER MANUAL PAGE 2 55 GETTING STARTED After the measurement remove the component and place it in the Pass or Fail bin as appropriate Continue in this way until each component in the batch has been tested then press Finish 2 5 2 Error Messages Server Program Store Error Server not responding Continue Possible Causes Faulty cable The cable f
40. angle of the complex impedance at a specified frequency is tan X R Where R and X are the real and imaginary parts of the complex impedance See also the impedance test Z which measures the magnitude of the impedance z R X Where Used An impedance phase angle test may be performed on any ferrite or iron cored winding but it is an especially important test of audio telecommunication and other signal components where the angle of the impedance is important VOLTECH ATI USER MANUAL PAGE 7 105 TESTS AND TEST CONDITIONS Measuring the phase angle of the impedance will help to determine that the part has been properly assembled using the correct cores and the right gauge of wire Measurement Conditions The AT Series Tester applies the specified AC voltage to the winding under test Using harmonic analysis the phase angle of the impedance is determined from the measured voltage and the current flowing through the winding Inductive Capacitive ANGL is the angle of the complex impedance tan X R Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test PAGE 7 106 VOLTECH ATI USER MANUAL Programming the Test Using the PC Test Editor Impedance Phase Angle lh cmi e b Choose the integration period normally Medium and enter the High and Low Terminal names Note that the PC Editor s Meas
41. entered before the program can be saved Enter the password on the instrument keypad using the Shift key to enter letters if necessary and press Enter Confirmation Enter the AT Password YTEDD Delete Abort Shift PAGE 6 46 VOLTECH ATI USER MANUAL FRONT PANEL MODES A Password Valid screen will confirm the correct password entry and return you to the program screen which now lists the new test program that has been created Local programs FREOGERHM 1 TUTORIAL Delete 6 6 3 RUNNING A TEST PROGRAM To run the program use the arrow keys to select it and choose the Run softkey This will run the test program that has been created from the front panel of the instrument in exactly the same way that a program created by and downloaded from the AT Editor would be run i e you will be prompted to fit the fixture choose compensation or no compensation and then run the chosen program by selecting Run VOLTECH ATI USER MANUAL PAGE 6 47 FRONT PANEL MODES Fart number TUTORIAL Settings Running the program will take you to the PASS FAIL display where pressing Finish will return you to the program selection screen where you may choose to re run the test program run a different test program change the set up of am existing test program delete a program or create another new program from the front panel 6 6 4 PASSWORD PROTECTION The ATi s front panel program mode allow
42. entered the limits in one form you may change to another form of limits by clicking with the mouse on another one of the radio buttons Note If you are using minimum and maximum limits gt lt the values of your minimum and maximum limit cannot be the same or you will be prompted by an error message to change one or both of your limit values PAGE 3 30 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 4 UsiNG THE MEASURE BUTTON While working through the Quick Start Tutorial chapter 2 you may have noticed that the dialogue box for the test R Winding Resistance contained a button labeled Measure In fact most tests have a Measure button within the dialogue box It is included there to allow you to fill in various fields in the dialogue box by using the AT to measure the value from a sample transformer All tests with a Measure button will allow you to enter a value into the test limits section of the dialogue box In addition some tests can also make use of the Measure button to select the test conditions The programming details for each test in section 7 Tests and Test Conditions specify which tests allow the Measure button to enter the test parameter values 3 4 1 HARDWARE CONNECTIONS FOR USING THE MEASURE BUTTON Before attempting to use the Measure button 1 Make sure you have connected your tester s Auxiliary Port on the rear panel to a suitable COM Port on your PC This may be COM Port 2 if your mouse is alre
43. exactly 1 000 Q Notice also that the voltage applied to the resistor is NOT exactly 100mV because of the voltage drops across and Rc In a Kelvin or 4 terminal connection the voltage is applied in exactly the same way through a pair of Power leads but the voltage is MEASURED using an extra pair of Sense leads The voltage measuring circuit is designed to have a very high input impedance 10MQ on the ATi and so negligible current flows in the Sense leads there being a negligible error in the voltage measurement VOLTECH ATI USER MANUAL PAGE 5 19 FIXTURES V 100mV Vm RL 2mO RL i 2mO RL l 2mO RL 2 RC 5mo RC i 5mQ Rc Rc Smo R 1 0002 4 wire measurement circuit The current flowing is the same 100 0mV 1014mQ 98 62mA But the voltage measured is now 1 0000 x 98 6mA 98 6mV And the dc resistance calculated is 98 6mV 98 6mA 1 0000 4 wire R 21 0000 The correct result In general a true Kelvin connection provides the most accurate means of sensing the voltage across any impedance AC or DC and hence helps to produce an accurate measurement of that impedance without errors due to lead and contact resistance The voltage measured can also be used to trim Vm to the desired voltage PAGE 5 20 VOLTECH ATI USER MANUAL FIXTURES Ideally all impedance measurements would be made using Kelvin connections However many te
44. for direct indirect special incidental or consequential damages arising out of the use of or inability to use software or documentation even if advised of the possibility of such damage In particular Voltech is not responsible for any lost profits or revenue loss of use of software loss of data cost of substitute software claims by third parties or for other similar costs In no case shall Voltech s liability exceed the amount of the license fee 9 3 SERVICE AND CALIBRATION To confirm the accuracy of your AT series tester a calibration check should be carried out every 12 months Calibration is carried out using a special fixture as described in the next section The calibration can be performed by an authorized Voltech service center or at your own facility if you have the required equipment For details of calibration facilities and any other service request please contact your Voltech supplier Voltech strongly recommends that you discuss your service requirements with your supplier before service is needed Extended warranty and full service agreements are available 9 4 OBTAINING SERVICE AND APPLICATIONS SUPPORT Voltech personnel will be happy to help you with any query that you may have Please telephone fax or e mail your local supplier or your regional Voltech service center as listed at the front of this manual To ensure we provide the fastest possible support we may ask you for e The serial number of the AT
45. for modifying an existing program if you needed to append further tests at the end However if you wish to add an extra test somewhere in the middle of an existing program a different procedure is required 1 In the Available Tests window click with the left button of the mouse to highlight the test you wish to insert 2 In the Program window click with the left mouse button to highlight one of the existing tests in the list This will become the point of insertion the new test will be inserted in front of the one you have selected PAGE 3 22 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 From the top level menu bar select Program gt Insert Test E CTHOBES Md E07 ELO Editor New Part 8 x Part Schematic Tester Server Setup Help Erw Options Edit esses o i CTY Continuity Edit Test 5 R Winding Resistance LS Inductance Series Circ LP Inductance Parallel Cit Delete Test aL Q Factor RLS Equivalent Series Resi RLP Equivalent Parallel Res LL Leakage Inductance LLO Leakage Inductance wi 5 Interwinding Capacitant TR Turns Ratio MAGI Magnetising Current voc Open Circuit Voltage IR Insulation Resistance Program List Maximize HPDC High Pot de High Terminal C Low Terminal D gj HPAC High Potac 80 00 mOhms Maximum Value 200 00 mOhms LSB Inductance with Bias S LPB Inductance with Bias P WATT Wattage SURG Stress Test Surge de BSE ds TRIM Trimming Adjustment OUT Output to User P
46. for use in production The code at the end of each result line should normally be zero any other code signifies that an error occurred in the measurement PAGE 3 40 VOLTECH ATI USER MANUAL PROGRAM EDITOR At this point you may want to protect your test program by setting an AT password To do this select Part TUTORIAL File TUTORIAL atp Voltech Tester Set Password Part Schematic Program Tester Server Setup Help The resulting dialogue see x Download Program below allows the AT password iui s Upload Program to be set If a password is set Fisture this password will need to be entered into the AT whenever a 5 poems Eee Set Password test program is changed or Ga deleted Set AT Password x Note that this Editor Only the following characters can be used in the dialogue also allows password max 25 characters the password to be ABCDEFGHIJKLMNOPQRSTUMWAYZ reset The old 1234567890 SPACE password is not required to do this All New Password that is required is for USE i the new password to oniy be entered and verified VOLTECH ATI USER MANUAL PAGE 3 41 PROGRAM EDITOR 3 5 ERROR CODES Voltech AT Series testers provide the operator with two types of error detection Anelectrically sound hardware integrity test called self test with the provision of error codes should an electrical fault be detected e Return of a
47. higher than that of the inductance However at very high frequencies this is not so the capacitance dominates and inductance cannot be measured The self resonant frequency of the transformer is the changeover point between these two regions Normally to get a good measurement of inductance the test frequency should be less than 20 of the resonant frequency of the transformer In general high values of inductance will have a high inter turn capacitance and hence a low resonant frequency Where there is a choice of test frequencies always use the lower value to minimise any problems due to self resonance c Non linear Inductance Normally inductance measurements should be used for transformers where the B H characteristics are linear However if inductance measurements are attempted for instance with line frequency transformers where the core material is non linear even at low signal levels the measured results can be highly dependant on the applied test signal VOLTECH ATI USER MANUAL PAGE 7 23 TESTS AND TEST CONDITIONS This can be a problem when trying to compare measurements made on commercially available impedance bridges or component testers with measurements made using the ATi The test signal in such bridges is usually determined within the instrument and is often at a fixed frequency and at a voltage level that is not guaranteed to be constant for all value of inductance Usually if the actual test conditions of the br
48. initiate testing and enter data Run pads Two stainless steel discs at the front of each side of the ATi Lightly touching the programmable run pads will start the programmed test sequence Footswitch The Run input of the Remote Port on the tester s rear panel can be optionally connected to a footswitch Barcode Input A barcode reader connected to the Barcode Port on the tester s rear panel can optionally be used to input text data such the name of the test program or the transformer batch or serial number of the transformer VOLTECH ATI USER MANUAL PAGE 2 9 GETTING STARTED 2 2 INSTALLATION 2 2 1 Switching on the ATi Place the tester on a stable level work surface in the position where it is to be used Ensure that the top surface of the tester is not fitted with any test fixture and nothing is touching any of the test nodes Connect the tester s line input to the available supply and switch on using the switch next to the line input at the back of the ATi 0 off You must connect the power lead to a socket with a safety ground contact When the ATi tester is switched on it performs a self test which lasts for about 10 seconds During power on self test you will see on information concerning your ATi s configuration on the display including the firmware version When the power on self test has finished you should see the following display Fower On Test Pragrans PASS LCR CBHC LOR Set
49. keypad PAGE 6 42 VOLTECH ATI USER MANUAL FRONT PANEL MODES Set up R Minimum limit 53 Maximum limit Hi nade Lo nodes Then scroll down again to choose your high and low nodes Set up R Hi node 3 Delete Hext Shift Choose Next At the following display see below you may choose to Measure if the test that is being set up supports this functionality Pressing Measure will update the limits as well as signal and frequency if those parameters are set to Auto similar to the Measure button in the AT Editor program VOLTECH ATI USER MANUAL PAGE 6 43 FRONT PANEL MODES Measure Lo nodes Choosing OK will return you to the program test selection screen which should now correctly display the test parameters that have been entered ina table format see below Note The Ok softkey does not allow you to exit the test set up screen until all required test parameters have been entered E Type Energise Measure Set Up Program options 6 6 2 SETTING UP TEST PROGRAM OPTIONS To set up program options for the test that has been created select Set Up This will take you to the program options screen where you can now change or PAGE 6 44 VOLTECH ATI USER MANUAL FRONT PANEL MODES set the test program name fixture ID and all other program options that are also available in the AT Editor software For example under Name en
50. measure low voltage open circuit the test signal is applied to one winding called the energized winding The voltages across another winding or the same energized winding are measured The low voltage open circuit measurement is the rms value of the voltage measured and can be an AC or a DC voltage It is recommended that you choose the winding with the highest number of turns as the one to be energized Choosing Test Conditions The recommended test conditions depend on the inductance of the energized winding they are given in the table below assuming that the energized winding is the one with the highest number of turns Inductance of the Preferred Test Signal Energized Winding Frequency Voltage 300kHz 100kHz 30kHz 10kHz 1kHz 100Hz 100Hz 50Hz 50Hz 50Hz 20Hz E 3 zs 4 3 23 zs ed 9 PAGE 7 74 VOLTECH ATI USER MANUAL The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency Programming the Test Using the PC Test Editor Low Open Circuit Voltage Voltech Choose the integration period normally Medium Energized Terminals The terminals where the test signal will be applied This is normally the winding with the greatest number of turns VOLTECH ATI USER MANUAL PAGE 7 75 TESTS AND TEST
51. next screen shown is the test selection screen initially with the absence of any tests PAGE 6 40 VOLTECH ATI USER MANUAL FRONT PANEL MODES E Type Energise Measure Set Up Program options To create a new test select Add which will take you to the test selection screen for the standard measure mode see below Select measurement CTY Continuity Winding Resistance Series Inductance Parallel Inductance Use the arrow key softkey 2 to select a test to be set up For example scroll down one line to R Winding Resistance and press Enter to set up a winding resistance test on your ATi tester The next screen that you will see is the set up screen for the selected test In this example the Set up R screen see below VOLTECH ATI USER MANUAL PAGE 6 41 FRONT PANEL MODES Integration Medium Limit type Percentage Hominal limit Hegatiuve Use the arrow key to scroll through and set up the test parameters For example to set up limits scroll to the Limit type line and press softkey 3 three times to enter both minimum and maximum limit values Set up R Integration Medium pet Hin amp Max Percentage Minimum limit Delete Maximum limit Hext Hi nade Shift Use the down arrow key again to scroll to the Minimum limit and Maximum limit lines and enter your limit values from the instrument keypad For example enter 59 and 73 using the numeric
52. other factors are given below 0 08 0 000 1 Im Aap 0 2 x Qu 1 Qu Q factor Aap 0 2 x Du 1 Dy D factor Where Qu is the Q factor of the measured impedance Dm is the D factor of the measurement impedance Iu is the measured current A PAGE 8 12 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 6 TR TEST The accuracy is based on the test conditions chosen to measure the turns ratio and is given as Ar Ap t ActApytA svtAy Where Ar is the total accuracy Ar is the basic relative accuracy Ac is the calibration accuracy is the correction for primary voltage level 96 Asv is the correction for secondary voltage level 96 AN is the correction for the turns ratio value 96 The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 1 0 00003 x Fm Apv 0 1 0 01 Vem Asv 0 1 0 01 An 0 1 0 1 Ny Where is the measurement frequency Hz Vem is the measured primary voltage V Vsm is the measured secondary voltage V Nm is the measured turns ratio primary secondary VOLTECH ATI USER MANUAL PAGE 8 13 SPECIFICATIONS 8 2 7 LVOC TEST The accuracy for measuring open circuit voltage is given as A Ag Ay Where Ar isthe total accuracy Ag is the basic relative accuracy Ac isthe calibration accuracy Ay isthe correction for voltage level
53. parasitic components on the fixture board itself These are usually a combination of parallel capacitance between adjacent wires sockets or pins and series resistance and inductance along the lengths of wires It is best to try fixture compensation when performing trial runs on the program as it is being developed using the Editor As a guide if fixture compensation changes the test results then it should be applied whenever the program is run in a production situation For optimum accuracy in production test fixture compensation measurements should be made 1 Whenever the test fixture is changed 2 Atthe beginning of each day or work period 3 Whenever a new test program is loaded into the AT for execution Performing compensation on a fixture consists of making TWO measurements Short circuit S C compensation will compensate for the effects of stray connection lead resistance and inductance Open circuit O C compensation will compensate for the effects of stray lead capacitance See also the description of 4 terminal Kelvin connections in the fixture section of this manual for how to eradicate the effects of CONTACT impedance between the test part and the fixture To Perform Fixture Compensation Once a program is ready to run you will have the option of pressing the COMPENSATE softkey on the panel Press COMPENSATE and you will be given the option to perform S C or O C compensation BOTH types of compensation should
54. programs are archived in the Server which is connected to the tester and running and the tester has been set up to use the Server as the Program Store or the programs have been downloaded into the tester which has been set up to use its internal memory as the Program Store 3 Fixtures have been created for the transformers you wish to test Note If you have a footswitch fitted to the remote port on the tester pressing it will take the same action in production mode as pressing the upper softkey For text entry such as the name of a program or the serial number of the transformer under test you may optionally use a barcode reader connected to the tester s rear panel barcode port PAGE 2 52 VOLTECH ATI USER MANUAL GETTING STARTED 2 5 1 Production Mode With No Options Enabled For simple test programs where Top level Display none of the following options are enabled batch number operator number or serial number the flow diagram shown on the left Select Programs Soft key summarizes production mode operation Select Test Program to Run Fit Fixture Compensate Fixture COMP Fixture Compensation RUN FINISH Menu FINISH RUN Measurements VOLTECH ATI USER MANUAL PAGE 2 53 GETTING STARTED At the top level display press softkey 1 Programs Programs LCR amp BHC LCR FIRN2 Set Up Self Test The program to be run may now be chosen from
55. rest of the batch When a new batch is started the AQL level is reset according to the level entered for the part using the Voltech AT Editor PAGE 4 16 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 3 5 ON LINE ANALYSIS VIA A DATABASE The AT Server software can store test results in an electronic database This provides a very powerful and versatile method of recording and analysing test results historically or on line The Server uses standard Windows methods including OLE DB and ODBO to connect to a variety of databases that conform to these specifications Once stored in a database the data may then be analysed using tools available in the database application or tools provided by specialist software packages such as those available for SPC Statistical Process Control One example of this is to monitor in real time the trend in a winding resistance to identify a defective drum of copper You would then be able to rectify the fault during production rather than producing a large stock of QA failed transformers all wound with the defective wire Setting Up Database Results Storage From the Set up menu select Results to see the following dialogue Standard Results Saving CSV Display Basic Statistics Database Results Saving Advanced Cancel Select Database Results Saving to save results to a database For this feature to operate properly a connection to the database must be set up first and a l
56. secondary Lm Lin 4 Lp x Ls Look up the recommended test signal for this inductance Enter the recommended frequency for this inductance as the test frequency The primary and secondary voltages can be calculated from the following Ns N Vs Vin a V Vin A Np Ns Where Lm Intermediate inductance Lp Primary inductance Ls Secondary inductance Vo Primary voltage Vs Secondary voltage Vm Intermediate voltage Np Primary turns Ns Secondary turns If you calculate V or Vp to be greater than 5V you should set 5V as your test signal If you calculate V or Vp to be less than 1mV you should set 1mV as your test signal VOLTECH ATI USER MANUAL PAGE 7 71 TESTS AND TEST CONDITIONS Choosing the Test Conditions Based on Vm Interm diate Inductance Preferre Test Signal Lm Frequency Voltage Vi 300KHz 100KHz 30KHz 10KHz 1KHz 100Hz 100Hz 50Hz 50Hz 50Hz 20Hz ES E gt E m ds EN E E The ATi can automatically determine the test conditions according to the following table Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency Choosing Test Limits When specifying turns ratio tests it is preferable to avoid limits which are unnecessarily tight and which may therefore lead to measurement difficulties For example if two equal secondary windings should have 10 turns each the
57. switch As the measurements proceed the test number will increment PAGE 2 58 VOLTECH ATI USER MANUAL GETTING STARTED Fart number zu 3 TUTORIAL Settings Total 1 Failed 8 Results Last transformer FP A 5 od E Fart number zu z a TUTORIAL Settings Total 1 Failed 1 168 Results Last transformer Finish 1 The Run Finish display is seen after a component has been tested The front panel LED green Pass red Fail the output lines of the remote port and the LCD indicate the pass or fail result of the previously tested transformer so that the operator may place it in the appropriate Pass or Fail bin Results are also sent to the Server at this time if so enabled in the Editor program options and all previous test results may be reviewed on the results listing screen which is accessible directly on the front panel via the Results softkey see below VOLTECH ATI USER MANUAL PAGE 2 59 GETTING STARTED Status 5383 mH FAIL aad r2 361 FAIL 383 mH FAIL aaa Results listing screen Note that the total and failed number of transformers tested displayed are reset when the test batch number is changed or a new test program is run If the STOP softkey is pressed or the STOP input of the remote port is held low the ATi will immediately stop testing STOP will be shown on the display all LED s will be off and no results will be reported back to
58. the Server 2 5 4 Re measuring Fixture Compensation Fart number Ru TUTORIAL Settings Total 1 Failed 1 Results Last transformer Finish PAGE 2 60 VOLTECH ATI USER MANUAL GETTING STARTED If you think that fixture compensation needs to be re measured at any time at the above display press the Settings softkey to reveal Fart number Compensate TUTORIAL Total 1 Failed 1 1 Last transformer F A I L Press Compensate to repeat the fixture compensation measurements or Back to return to the RUN FINISH display without re compensating 2 5 5 Execute Mode With Options Enabled As stated in the following chapter of this user manual test programs may be created with any of the following three options enabled or disabled e Operator name 9 Batch number 9 Serial number In each case if an option is enabled the data entered by the operator for that option is included with the results that are sent back to the Server This additional data is then available to be used as you wish for example it may be included in your production reports Note that these options are part of the program not global settings of the ATi allowing you to enable different options for each transformer as required VOLTECH ATI USER MANUAL PAGE 2 61 GETTING STARTED When running programs with any of the above options enabled there will be additional displays depending on which options are enabled after the
59. to configure the HBSW 8300 Plug the barcode reader into the port and switch the AT on The barcode reader is configured correctly as supplied by HP If the settings have been changed reset the wand by plugging it in into the tester switching the tester on and swiping the codes below 9600 Baud FAIA 0 s Parity none 1 Stop bit PAGE 8 26 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 3 2 SERVER PORT RS232 interface for connection to a PC Server running the Voltech AT Series Server software 25 pin male D type connector E WNE Ground Earth No connection RX OV TX No connection No connection 8 3 3 AUXILIARY PORT RS232 interface for connection to a PC running the Voltech AT Series Editor software 9 pin male D type connector Cr summae Pin Signal mame No connection No connection TX i CTS RX RTS No connection No connection 0V VOLTECH ATI USER MANUAL PAGE 8 27 SPECIFICATIONS 8 3 4 PRINTER PORT Standard parallel printer interface 25 pin female D type connector E CENE I EE Tw ISTROBE BUSY DO i PE D1 No connection D2 AUTOFD D3 i ERROR D4 D5 ISLCTIN D6 0V D7 ACKNLG OV 1 2 3 4 5 6 7 8 9 Signals with a name starting with are active Lo Printing options can be chosen from the Options dialogue of the Editor software If you intend to print all results for each program you will need a high speed ther
60. top surface of the tester In particular remove all test fixtures and transformers and anything connected to the four BNC terminals VOLTECH ATI USER MANUAL PAGE 2 49 GETTING STARTED As the self test is running the front panel display will indicate progress using a horizontal bar Self Test At the end of the self test you should see the following screen Self Test Pragrans LCR CBHC LOR Set Up qus Self Test PAGE 2 50 VOLTECH ATI USER MANUAL GETTING STARTED If there is a failure at any point in the self test you will see a display similar to the one below Self Test Repeat FAIL Continue Measure bus relay fail Lo Details Made 16 The message shown on the lower two display lines will depend on what caused the failure In the unlikely event that your tester continues to fail please make a careful note of the failure message and error codes which may be accessed by pressing Details at the above display and contact your Voltech supplier immediately For more detail on AT error codes see chapter 3 VOLTECH ATI USER MANUAL PAGE 2 51 GETTING STARTED 2 5 PRODUCTION MODE This is the normal operating mode of the ATi when used for production testing of transformers Before you try to use the tester in production mode make sure that all of the following have been carried out 1 Test programs have been created for the transformers that you wish to test 2 Either the
61. voltage to fall with increasing load Where Used A DC resistance test should be used to check each winding to ensure that the correct wire gauge has been wound with the correct tension and that the winding is terminated properly Test Conditions The winding resistance is calculated by measuring the DC voltage across a winding and the current flowing through it The test signal is chosen automatically by the AT and may be a constant current or voltage VOLTECH ATI USER MANUAL PAGE 7 13 TESTS AND TEST CONDITIONS Choosing the Test Signal The DC test signal is set automatically according to the value specified as maximum in the test limits Maximum Resistance 10 100 1000 1kQ 10kO gt 10kQ 400mA 200mA 100mA 30mA 3mA 3004A 8 0V Programming the Test Using the PC Test Editor Winding Resistance eA pu eme 9 e Choose the integration period normally Medium and enter the terminals for the resistance measurement PAGE 7 14 VOLTECH ATI USER MANUAL If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered in the units shown is then added to any results returned from the AT tester This function can be used to adjust for measurement fixture effects that cannot be compensated for or to compensate the fixture manually so a compensation stage is not required to obtain the correct readings Choosing Test Limits T
62. with DC bias the tester first applies and stabilises the DC bias current and then applies an AC voltage across the selected winding The tester measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain the complex impedance from which the inductance is extracted Generally it is not necessary to measure the inductance at the normal operating conditions of the transformer which could involve for example hundreds of volts or several amps of bias This is because the core material can normally be assumed to behave linearly in the operating region and the inductance measured at a low level represents the inductance that will appear in use Choosing Test Conditions For optimum accuracy and performance use the test conditions chosen for inductance without bias in the previous section of this chapter The test conditions can also be determined automatically by the ATi according to this table Sigma Specified voltage Specified current Auto Auto Specified Specified Specified Auto Specified Specified Specified Specified Note that a fixed signal cannot be used with an Auto frequency The DC bias current level must always be specified VOLTECH ATI USER MANUAL PAGE 7 39 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Winding Inductance with Bias Series Circuit Choose the integration p
63. 01 Pass 3 3 13E40 4 10 44 26 Pass 59 73 6 78E401 Pass 3 3 14E40 5 10 44 27 Pass 59 73 6 78E 01 Pass 3 3 19E40 6 10 44 29 Pass 59 73 6 78E401 Pass 3 3 15E40 Pih C6200697 Isl Ready ees pese o vise em nd A You may need to adjust the cell number format of the spreadsheet and the width of the columns in order to display the required number of decimal places Using functions built into the spreadsheet the data obtained may now be used to create graphs and bar charts for a visual representation of your results As an example to produce a graph select a group of results from one column then click the Chart Wizard button and use this to create the graph you require in the normal way For additional help on what may be possible please refer to your spreadsheet user manuals VOLTECH ATI USER MANUAL PAGE 4 49 AT SERIES SERVER 4 4 LICENSE REGISTRATION 4 4 1 ENABLING THE LICENSED FEATURES The Server software is supplied to you under the terms of our current license agreement and is for use on a single PC only It is not necessary to register the software to use the program storage CSV results storage or OLE features of the Server software The software must be registered however before you can use the database and basic batch statistics features The software may be registered in either trial or demo or full mode A FREE trial of the software may be obtained your Voltech supplier and will enable you to make full u
64. 024 CD ROM drive x2 minimum speed To install the Editor software place the ATi CD ROM supplied with your tester into the CD ROM drive of the computer and follow the on screen instructions PAGE 2 12 VOLTECH ATI USER MANUAL GETTING STARTED 1 The set up program will suggest a directory in which to place the Editor files C Program Files WVoltech Instruments WVoltech AT Editor This directory will be created if it does not already exist If you want to place the files elsewhere browse to another directory If you have a previous version of the Editor software already installed on your PC the procedure outlined above may also be used to install a new version None of your program files will be lost The same Editor program is used for all AT Series testers excluding the discontinued AT3500 and AT1000 PC COM Port Configuration When the installation of the Editor has been completed you will see the Editor icon in the program group Voltech Software Double click with the left mouse button on the Editor icon to start the program Initially configure the Editor to use the chosen COM port Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Communications x 1 From the top level Commi nications Setup menu select Communications 2 In the dialogue box shown here COM Port select he PC ie Cancel communications port that is connected to th
65. 18 Voy 0 00000001 x E 398 is the common mode voltage measured VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 12 LBAL ILOS AND RESP TESTS The accuracy is given as Ar Apt0 87 ActAytAyo Where Ar is the total accuracy dB Ar is the basic relative accuracy dB Ac is the correction for calibration Avi is the correction for the input voltage level Avo is the correction for the output voltage level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 1 0 0000001 X Fy Ag 0 001 Vy Ag 00001 Vi yo Where FM is the measurement frequency Hz Vmi is the measured input voltage V Vmo is the measured output voltage V VOLTECH ATI USER MANUAL PAGE 8 19 SPECIFICATIONS 8 2 13 RLOS TEST The accuracy is given as A 0 174x ndi a zx Z Where Ar is the total accuracy dB Az is the total accuracy for the Z test 96 Z is Vy Iu zo kd 22 Where Vm is the measured voltage V Iu is the measured current A Zreal is the real part of the reference impedance Q Zimag is the imaginary part of the reference impedance Q PAGE 8 20 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 14 Z AND ZB TEST The accuracy is given as Ar AptActAytA Where Ar is the total accuracy Ar is the basic relative accuracy Ac is the calibration accuracy Av is the correction for voltage level 96 is t
66. 1mH More C145 11 791 ELS CFixture made Settings Prg AUTO U AUTO Hz D Mes lem 1 46mA 1kHz ERIT The ATi is making measurements on nodes 13 and 15 the primary and nodes 14 and 16 the secondary The LCR fixture supplied with your ATi has four Kelvin leads already connected to these nodes VOLTECH ATI USER MANUAL PAGE 6 11 FRONT PANEL MODES To change from measurements on the primary nodes 13 15 to measurements on the secondary nodes 14 16 press softkey 5 Pri Sec 161 63H 1 7888 Lor CFixture made Settings Peg AUTO V AUTO Hz Mes lem 8 45mA kHz For measurements of TR turns ratio and TRL turns ratio by inductance softkey 5 toggles the display of measured test conditions It does NOT alter the designation of primary 13 15 and secondary 14 16 Turns ratio is always displayed as the ratio between primary 13 15 and secondary 14 16 windings 365 32M Hp NES Fixture mode Prg AUTO Wa AUTO Hz Mes 2 84 lU 1 38GkHz PAGE 6 12 VOLTECH ATI USER MANUAL FRONT PANEL MODES By default the number of primary turns is assumed to be 1 In this example Np Ns 1 0 965 To display the actual number of turns as measured enter the number of primary turns by pressing the appropriate buttons on the numeric keypad Note Only numbers and a decimal place can be entered for Np E g Np 1000 Np Ns 1000 365 365 47 TRL LL C More
67. 2 3 GETTING STARTED 2 9 SET UP MODE 2 77 29 SoflKey ie e n ER 2 78 e 2 83 Resetting Tester Set Up Options sse 2 83 2 9 2 GtOups SOflkey a 2 84 2 4 VOLTECH ATI USER MANUAL GETTING STARTED 2 1 INTRODUCTION This chapter is designed to introduce you to the basic facilities of the ATi and help you to realize the benefits of automated transformer testing in the shortest possible time If you are reasonably familiar with the testing of transformers and how to install and use Windows programs this chapter may be all that you need but you are nevertheless urged to read and understand the complete contents of this manual in order to achieve the maximum benefits that the ATi can bring For production testing the use of good quality test fixtures is very important Please see the fixturing section of this manual for details of parts that are available from Voltech If you have any questions or are unsure of what to do at any point please do not hesitate to contact your Voltech supplier Once installed The ATi will enable you to rapidly accurately and reliably test wound components in your production or goods inwards environment The PC Editor will enable you to quickly and easily create test programs for your tester without any specialized knowledge of computer programming The PC Server wi
68. 5 Guides 12 off Fixings for above 5 4 3 SOCKET FIXTURE VoL TECH PART NUMBER 91 186 A fixture board fitted with 40 4mm sockets 20 red power and 20 black sense The sockets are wired to the 40 contacts which align with the tester s 40 nodes This fixture may be used for convenient wiring to existing fixtures or as a means of connecting flying leads and clips for use in developing test programs or testing parts in a design laboratory PAGE 5 16 VOLTECH ATI USER MANUAL FIXTURES 5 4 4 CONNECTION LEAD SET VoL TECH PART NUMBER 78 030 A selection of Kelvin and non Kelvin crocodile clips and spring loaded posts are available from Voltech called the Connection Lead Set Each of the clips is finished with 200mm red and black leads terminated in 4mm plugs The connection lead set consists of 10 Spring loaded connection posts 10 Kelvin crocodile clips 10 Non Kelvin crocodile clips 10 Fine non Kelvin clips 5 4 5 CLAMP VOLTECH PART NUMBER 91 187 The hand clamp is supplied with 7 height blocks and fixings 5 4 6 TOOLING Drilling templates are available in a variety of sizes 1 27mm 2 00mm 2 50mm 2 54mm 3 81mm and are sold as a pack Pack of 5 1 of each pitch drilling templates Voltech Part No 50 307 VOLTECH ATI USER MANUAL PAGE 5 17 FIXTURES 5 5 KELVIN CONNECTIONS Kelvin or 4 terminal connections are commonly used in precision measurement systems to obtain accurate measu
69. 50 VOLTECH ATI USER MANUAL Test Conditions To measure capacitance the tester applies an AC voltage between the windings to be tested usually with all taps on each winding shorted together It then measures the voltage between the windings and the resulting current Dividing the voltage by the current gives the interwinding impedance from which the capacitance is extracted using harmonic analyses Capacitance is measured as part of a complex impedance The AT Series C test uses a parallel equivalent circuit for capacitance measurements CS series circuit capacitance is also available Choosing the Test Signal Recommended test conditions for different values of capacitance Caj acitance Range Prefe ed Test Signal Frequer gt y Voltage 100KHz 100KHz 10KHz 1KHz 100Hz 100Hz Test Conditions for Capacitance Measurement The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 51 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Capacitance Voltech Choose the integration period normally Medium and enter the terminals to be measured More than one terminal can be High and more than one terminal can be Low This is to allow testing of the complete primary to seco
70. 6 AT Series Tester The equivalent AC resistance of a winding may be different to that measured at DC The resistive part of the complex winding impedance will be modified by in phase core losses and skin and proximity effects The transformer FR losses will then be different to those calculated using the DC resistance Where Used The equivalent series or parallel resistance test is used to determine the AC equivalent resistances of a transformer As opposed to the DC resistance test R which uses DC voltages the RLS and RLP tests apply AC voltages at a specified voltage and frequency The measurement of AC resistance at a particular frequency helps to ensure that the winding has been correctly wound with the correct gauge of wire and correctly assembled onto the correct type of core material Normally the equivalent resistance test would follow an inductance test on the same winding Using the same test conditions for both tests will speed the execution of the program PAGE 7 34 VOLTECH ATI USER MANUAL Test Conditions To measure equivalent resistances the AT applies an AC voltage across the selected winding and measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain a complex impedance from which the equivalent series and parallel resistances are obtained Choosing the Test Signal For optimum accuracy and performance use the te
71. 7 1 13 CS and CP Capacitance Test Series and Parallel Circuit 7 55 7 1 14 C2 Capacitance Match sss eese enne nnns 7 57 7 1 15 Turns Ratio and Phasing eee 7 60 7 1 16 TRL Turns Ratio by Inductance eee nnne 7 68 7 1 17 LVOC Low Voltage Open Circuit essen 7 73 7 1 18 IR Insulation Resistance sse 7 77 7 1 19 GBAL General Longitudinal Balance essen 7 80 7 1 20 LBAL Longitudinal Balance seen 7 85 7 1 21 RESP Frequency Response sse etnies 7 89 7 1 22 ILOS Insertion LosS esses essent innate nnns 7 93 7 1 23 ALOS uiui t en ted t uta 7 96 7 1 24 Z ZB Impedance Impedance with 85 7 100 25 X Reacltancea i ee dete et etate 7 103 PAGE 7 2 VOLTECH ATI USER MANUAL 7 1 26 ANGL Phase Angle of 6 6 7 105 7 1 27 PHAS Interwinding Phase Angle sese 7 108 7 1 28 TRIM Pause Testing in Order to Trim a Component Value 7 111 7 1 29 OUT Control External 7 113 7 1 30 LSBX Inductance with External Bias Series Circuit 7 116 7 1 31 LPBX I
72. AGE 3 34 VOLTECH ATI USER MANUAL PROGRAM EDITOR Remember to remove the short circuit header before performing short circuit compensation You may still select No on either of the above dialogues to perform just one type of fixture compensation or none at all VOLTECH ATI USER MANUAL PAGE 3 35 PROGRAM EDITOR Assuming no errors when the tester has finished the compensation measurement you will be prompted to remove the shorting links and fit the sample transformer After you have clicked on the OK button the tester will be commanded to make its measurements and you will see the following message Editor Windows Application G Fixture Compensation Successful Re connect the component to measure the test parameters When the measurements have finished the display will return to the dialogue box for the LS test with values entered for the test signal the frequency and the nominal inductance Winding Inductance Series Circuit r Test Parameters Integration Signal 300 my CY C mA C Short Medium Frequency f1 CHz kHz MHz C Long r Terminals High Terminal Low Terminal A x B r Inductance Limits CX C Nominal 4 55051 CH CuH mH CH CkH 9 Negative x Positive x From this point it is very easy for you to complete the dialogue box by simply entering the values you require for the Negative and Positive percentage limits PAGE 3 36 VOLTECH ATI USER MAN
73. ATi UnitID Text 10 Unit Serial Number FirmwareID Text 10 Unit Firmware Version PAGE 4 24 VOLTECH ATI USER MANUAL AT SERIES SERVER Table tbl VoltechResults Field Format Notes ResultID Text 25 Index ID RunID Text 25 As tb VoltechRunID RunID TestID Text 25 As tbl VoltechTestID TestID TestNo Number Long Integer Test number as in test program OC_Comp Text 5 YES NO N AOpen Circuit Compensation status SC Comp Text 5 YES NO N AShort Circuit Compensation status Load Comp Text 5 YES NO N ALoad Compensation future development Result Number Single Actual test result TestStatus Text 5 DSP Status for test PassFail Text 5 PASS FAIL Individual test pass or fail result Table tbIVoltechRunID Field Format Notes RunID Text 25 Index ID Date Date Time Short Date Date of Test Run Time Date Time Long Time Time of Test Run ATUnitID Text 25 As tb VoltechATUnitID ATUni tID PartID Text 25 Part name FixtureID Text 25 Fixture name OperatorID Text 25 Operator name BatchID Text 25 Batch name TransformerSerialNo Text 25 Transformer serial number OverallResult Text 10 PASS FAIL RE RUN ABORTOverall test pass or fail result and Re Run result VOLTECH ATI USER MANUAL PAGE 4 25 AT SERIES SERVER Table tbl VoltechTestID Field For
74. C Operating Temperature 0 to 40 C Humidity 10 to 90 RH non condensing Mechanical Weight approx 5 5kg A 65mm Height of front edge B 434mm Full length C 147mm Rear height Width 387mm a B PAGE 8 34 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 4 EMC COMPLIANCE 8 4 1 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY Manufacturer s Name Voltech Instruments Ltd Manufacturer s Address 65 Milton Park Abingdon Oxon United Kingdom Declares that the product Product Name Transformer Tester Model Number ATi conforms to the following product specifications Safety BS EN 61010 1993 amendment A2 1995 EMC BS EN 55022 1995 Class A BS EN 50082 2 1995 Supplementary Information The product herewith complies with the requirements of the EMC Directives 89 336 EEC and 92 31 EEC and the Low Voltage Directive 73 23 EEC Signed on behalf of Voltech Instruments Ltd 293 Martin Whitley Quality Manager Abingdon United Kingdom April 25 2000 VOLTECH ATI USER MANUAL PAGE 8 35 SPECIFICATIONS 8 4 2 EMC PRECAUTIONS Conducted and Radiated Emissions The ATi complies with the limits of BS EN 55022 Class A Immunity The ATi may be susceptible to Fast Electrical Transients on the power line and Electrostatic Discharges which can disrupt the operation of the unit In the event of these circumstances return the ATi to normal operation by 1 Switching off the
75. C445 IM FHAS ELEM CFixture mode Settings Prg AUTO Ws AUTO Hz Mes 2 84 lU 1 The number of primary turns entered will be retained by the tester until the More softkey is selected i e if you exit LCR FIX and re enter or if you select TRL LL or C the value for Np remains the same 6 1 3 INSULATION RESISTANCE Insualtion resistance measurements involve applying a relatively high DC voltage to the part under test in order to measure a high value of resistance Because of the high voltages involved IR meaurements operate in a slightly different way to other tests There is a separate voltage setting menu and ON VOLTECH ATI USER MANUAL PAGE 6 13 FRONT PANEL MODES OFF contols are provided for maximum operator safety To measure insulation resistance select IR from either the LCR BNC or LCR FIX modes Insulation Resistance Foc Ma Mare 5 4 uU Un CFixture made Settings Fregi i88 U CAUTION The insulation resistance test can generate voltages of up to 500V DC Although the available energy of the source has been limited in accordance with EN61010 1 care should be taken to avoid accidental or unexpected electrical shocks For this reason the high voltage insulation resistance source must be turned on by pressing softkey 3 every time this screen is displayed When softkey 3 HV Off On is pressed the high voltage is applied to the chosen nodes On is sho
76. CTY For Help press F1 Top Left Continuity Winding Resistance LS Inductance Series Circ LP Inductance Parallel Cii QL Q Factor RLS Equivalent Series Resi RLP Equivalent Parallel Res LL Leakage Inductance LLO Leakage Inductance wi E Interwinding Capacitant TR Turns Ratio MAGI Magnetising Current voc Open Circuit Voltage IR Insulation Resistance High Pot dc High Pot ac ae Program List Low Terminal B Maximum Valu Inductance with Bias S LPB Inductance with Bias P WATT Wattage SURG Stress Test Surge TRIM Trimming Adjustment Output to User Port 73 000 Ohms A simplified view of the transformer schematic omitting the wiring to the nodes This is a passive window intended to be used as a memory aid it cannot be used to change the schematic If you need to alter the schematic at any time simply click on Schematic then Edit in the top level menu Bottom Left The Program Window Right PAGE 3 20 This is the list of tests that currently make up the test program Normally for a new program this window would initially be empty The display above shows the program of one resistance test created in the Quick Start Tutorial The Available Tests Window This is the list of tests that are available to be used in creating or modifying the test program From this display you may now create the test program suitable for your trans
77. D TIPS The following is a list of points that should be remembered when you are creating your test programs 1 PAGE 3 48 Create your schematic first When you are creating your test programs you should work in the following order a Initially create the schematic b Then set up the program options Finally create the list of tests that make up the program Note If you make any changes to the schematic after you have created the list of tests then some tests may be inadvertently deleted Examples where this may happen are deleting a winding or a terminal and renaming a terminal Use the recommended order for the tests in the program The actual tests used in the program are of course dependent upon the type of transformer to be tested and the number of parameters you have chosen to test However it is recommended that you generally do the tests in the following order a e Continuity To detect a transformer not correctly plugged into the test fixture and any open circuit windings Primary inductance To detect faulty core material and the wrong number of primary turns Turns ratios To detect any windings with the wrong number of turns VOLTECH ATI USER MANUAL PROGRAM EDITOR d Insulation resistance To detect poor interwinding isolation where safety is not an issue for example between two secondary windings e Safety tests such as hi pot Available only on the Volte
78. DUCTION 1 8 5 Test Fixtures When running the test program in production how do you connect your transformer with its own arrangement of terminals to the test nodes of the AT Series Tester The AT Series of transformer testers has been designed with its own test fixture system to answer just this question e Fixtures are constructed on a standard fixture board which fits into the top surface of the tester The fixture system uses Kelvin connections to give the best possible measurements when testing wound components The fixture system will accommodate different types of connectors suitable for both PCB mounting and flying lead transformers A single test fixture can be used for all transformers wound on the same bobbin Please see the fixtures section chapter 5 of this manual for more information VOLTECH ATI USER MANUAL PAGE 1 23 INTRODUCTION 1 8 6 Operating the AT Series Testers in Production Test The ATi is suitable for use in both manual and robotic production situations Manual Use Testing Smaller Batches of Different Transformers Operator 1 Chooses transformer part number from a list or swipes a barcode 2 Fits the fixture as prompted 3 Touches pad or presses footswitch Remote PC records all test data for statistical analysis using Run Stop Fail Busy Voltech server software signals for process control Good parts for further processes Parts to be test
79. E e eeeeen serene enean annnm n mss a sana nene 9 1 VOLTECH ATI USER MANUAL PAGE V 9 4 Warranty iu eee petit bea autre arise oH ree Beeren 9 5 9 2 Limitation of Warranty eoe etu 9 5 9 8 Service and GCalibralion dc e o Hr Rene 9 6 9 4 Obtaining Service and Applications Support seen 9 6 9 5 Firmware Upgrade Spisi atte s ta 9 7 TOINDE X oct ten era etek tes ae ese ieu nIiedIe 10 1 PAGE VI VOLTECH ATI USER MANUAL 1 INTRODUCTION Thank you for choosing to use this Voltech product If you experience any difficulty during installation or use of the ATi or are unsure of any of its features or abilities please do not hesitate to contact either your local supplier or a Voltech main service centre as listed inside the front cover VOLTECH ATI USER MANUAL PAGE 1 1 INTRODUCTION PAGE 1 2 VOLTECH ATI USER MANUAL INTRODUCTION Contents Introduction 1 1 How TO 5 1 5 1 2 GENERAL SAFETY INSTRUCTIONS eene nennen nennen nnn nennen nn nnn nnns 1 6 1 3 ATI AND AT 3600 eterne eterno cansebiedetesenessnancbecets yes 1 7 1 4 TESTS SUPPLIED 1 Ie eire rase Dr antera aane Ua or er saam Ursa Ede 1 8 1 4 1 Standard Program Tests sssssssssssseee eene 1 8 1 4 2
80. E 2 23 GETTING STARTED The following dialogue box will appear 1 Initially enter the terminal names Input A as the high terminal and B as the low terminal moving between the fill in boxes using the TAB key Click anywhere over the High and Low Terminal drop down boxes to see a list of the available terminals 2 Now enter the resistance limits This can be done in four ways 96 Click on this button to enter a nominal value with a percentage tolerance for example 66 with 10 tolerance gt lt Click on this button to enter minimum and maximum values for example 590 and 739 gt Click on this button to enter just a minimum value for example gt 590 Click on this button to enter just a maximum value for example 73Q In this example gt lt limits will be used The Ohm units button is selected by clicking with the mouse PAGE 2 24 VOLTECH ATI USER MANUAL GETTING STARTED Winding Resistance xj Integration C Shot Medium Long r Terminals High Terminal Low Terminal Resistance Limits C X gt lt Minimum 59 C mOhm Ohm C kOhm C MOhm Maximum 73 C mOhm hmi C kOhm MOhm m User Offset User Offset Enabled manm Measure Cancel 3 If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered in the units shown is then added to any results returned from the
81. FF Pass Beeper SHORT OFF Key Response CLICK BEEP Beeper Volume CHANGE Display Contrast CHANGE Display Background LIGHT DARK Clock E yyyy mmm dd hh mm Touch Pad Options L ANDR LORR LONLY RONLY OFF Pad Response CLICK BEEP OFF BNC Lead Calibration CHANGE AT Password CHANGE Program Store SERVER INTERNAL Five of the options require more than just pressing the third softkey VOLTECH ATI USER MANUAL PAGE 2 79 GETTING STARTED Beeper Volume Pressing the softkey Change brings up an additional display Beeper Volume Press T and 4 to adjust then ERIT Press the T and softkeys until the beeper makes the level of sound you require then press the EXIT softkey to return to the set up list Display Contrast The additional option display is very similar to the beeper volume display again with T and J softkeys which this time adjust the display contrast To change the display background select LIGHT or DARK LIGHT has been chosen as the default setting as this will provide the clearest display across a broad range of contrast settings and ambient temperature Clock There are five fields to set up Initially the cursor will be in the first field yyyy which is the year Type the number you require using the keyboard and press either the ENTER key 1 or the softkey to move to the next field For the second field mmm which is the month th
82. I USER MANUAL Where Used The turns ratio by inductance test is used on transformers that have poor coupling btween windings and where a turns ratio by voltage TR test may not produce the expected result For example transformers for electronic lighting ballasts are often deliberately wound to have relatively large values of leakage inductance During voltage TR testing some of the voltage will appear across the leakage inductance and alter the result The TRL test is not affected by leakage inductance and other parasitic components in this way Test Conditions To measure turns ratio by inductance two inductance measurements are made one on each winding The same voltage at the specified amplitude and frequency is applied to each winding in turn and the inductance of each is determined from the measured voltage and current using harmonic analysis The turns ratio is then calculated as the square root of the ratio of the inductances The inductance of a winding can often depend upon the flux density in the core windings Since the flux density will depend upon the signal energising the winding it is important that both windings are energized at the same level This will ensure that both inductances are measured along the same region of the B H curve of the core and give a true ratio Choosing Test Conditions The simplest method of setting the test conditions is to use the Measure button of the PC Editor software There
83. IFICATIONS SUMMARY AVAILABLE TESTS User Entered Test Data Measurement Range Test Signal Test Frequency ICATIONS 1 CTY Continuity 10kQ 10MQ n a n a DC Resistance DC Resistance 1 1000 1000 1 n a n a 0 296 Match Inductance Series LS Inductance Parallel lit Factor Dissipation 0 001 1000 ImV 5V 20Hz 3MHz Factor tan Equivalent Series Leakage LL 1 20 100mA 20Hz 3MHz Inductance Resistance Equivalent Parallel Resistance Leakage Inductance with Offset Interwinding Capacitance Capacitance CP s G Series Reactance Turns Ratio and Phasing VOLTECH ATI USER MANUAL 1nH IMH ImV 5V 20Hz 3MHz 1nH ImV 5V 20Hz 3MHz 1040 ImV 5V 20Hz 3MHz 1040 1OMQ ImV 5V 20Hz 3MHz 1 20 100mA 20Hz 3MHz 100fF ImF ImV 5V 20Hz 3MHz Capacit apacitance 100fF 1mF ImV 5V 20Hz 3MHz Parallel 100fF ImF ImV 5V 20Hz 3MHz 1mQ IMQ 5V 20Hz 3MHz 1 100k 100k 1 ImV 5V 20Hz 3MHz n a 0 0596 0 0596 0 596 0 596 0 05 0 05 0 1 0 1 0 1 0 1 0 1 0 2 0 1 PAGE 8 5 SPECIFICATIONS User Entered Test Data 1 Test Measurement Range Test Signal Test Frequency Turns Ratio b TRL T 30 1 1 30 ImV 5V 20Hz 3MHz 0 1 Inductance Low Voltage LVOC MA 100 5V 5V 20Hz 3MHz 0 196 pen Circuit
84. LCR BHC LCR FIK Self Test To access set up mode from the top level menu see above press the Set Up softkey to change to the following display VOLTECH ATI USER MANUAL PAGE 2 77 GETTING STARTED The two main functions of set up mode each have their own softkeys at this display Press the Groups softkey to download a group of test programs from the Server to the tester s internal memory or press the Set Up softkey to change any of the tester s set up options Pressing EXIT at this point will return the tester to the top level display 2 9 1 Set up Softkey Pressing the softkey Set Up at the Set Up mode display shown above will reveal SHORT Continuous Pass Beeper OFF Key Response CLICK Beeper Volume This display is the start of a list of options under the title Set Up To modify an option Press the cursor softkeys T and J which appear in context to scroll up and down the list so that the option you wish to modify is positioned on the third line For most options press the third softkey to cycle round the available settings for that option In the example of Pass Beeper this will be PAGE 2 78 VOLTECH ATI USER MANUAL GETTING STARTED Set Up Fail Beeper SHORT SHORT Key Response CLICK Beeper Wolume Display Contrast The full list of options is shown below Fail Beeper SHORT CONTINUOUS O
85. MANUAL GETTING STARTED Programs Programs Programs Results Results Results Before installing an expansion card ensure that the PC is switched off and that you follow all of the manufacturer s instructions All supporting software must also be installed before attempting to configure the Server application The same server program is used for all AT Series Testers excluding the discontinued AT3500 and AT1000 VOLTECH ATI USER MANUAL PAGE 2 15 GETTING STARTED PC COM Port Configuration Before proceeding any further check within the Windows Control Panel to ensure that the desired COM Port s are recognized by Windows Port Setup Ports Board DigiBoard Windows Virtual Base Virtual Char Type Port Port 170 Address IRQ Ready Pin disabled disabled COM4 disabled disabled OFF OFF COM5 disabled disabled OFF COMB disabled disabled OFF OFF COM7 disabled disabled OFF OFF COM8 disabled disabled OFF OFF COM9 disabled disabled OFF OFF OOAUpN Settings Windows Poit Port Options Windows COM Port cow3 8 Char Ready Flag Auto Enumerate Pin Virtual Enable Virtual Port for DOS Virtual Port WOAddess E mote B Device Contention Always Warn Never Warn O Idle in sec Example of setup for DIGIBOARD XE Server Software Set up When the installation of the S
86. MANUAL SPECIFICATIONS 8 3 INTERFACE DETAILS The following interfaces are available at the rear of the ATi Hee ee eee 3 FOR CONTINUED PROTECTION AGAINST RISK OF FIRE ia REPLACE THE FUSE ONLY WITH THE SAME TYPE AND Voltech AT cE LET RERAC PENG Voltech Instruments Inc N C USA INPUT 85 265V 47 MONZ 100VA_ Tek 919 461 1701 Emai salos votoch com Instruments Ltd Oxon UK aant L j SE aaien o CAUTION REFER TO USER MANUAL BEFORE INSTALLATION OR USE NO USER SERVICEABLE PARTS INSIDE DO NOT REMOVE COVERS THIS EQUIPMENT MUST BE EARTHED REMOTE From left to right Barcode Server Printer Auxiliary Editor Remote User Ground All these ports may be susceptible to damage from static discharge Switch off and observe anti static precautions when making connections 8 3 1 BARCODE PORT RS232 interface for barcode entry 9 pin female D type connector Baud rate 9600 Parity None Stop bits 1 VOLTECH ATI USER MANUAL PAGE 8 25 SPECIFICATIONS ri Serana Pm Semanan No connection No connection RX OV TX No connection No connection 5V No connection The recommended barcode reader for the AT Series Testers is the Smart Wand Barcode Reader from Hewlett Packard available from Farnell Electronic Components Hewlett Packard List No HBSW 8300 The HP Smart Wand reader connects directly to the barcode port no extra interfacing is required
87. MANUAL PAGE 6 3 FRONT PANEL MODES PAGE 6 4 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 1 LCR Basic FUNCTIONS As well as executing complete test sequences at high speed on multiple windings for production testing the ATi can make LCR and turns ratio type measurements on a component or single winding without using the PC based test program editor Measures L C R DC and AC Z 0 X Q D Turns Ratio Leakage Inductance and Insulation Resistance All parameters required to fully characterize a winding or component BNC to Kelvin clip leads provided for accurate 4 terminal measurements Quick and easy connection eliminates contact resistance errors Intuitive softkey control sets up measurements in a few key presses Ready to test in a few seconds Ideal for design and prototyping of wound components Rapid change of test and test conditions without programming Fully automatic or manual test voltage and frequency Automatic test conditions for quick accurate results or fully programmable almost infinite steps of voltage and frequency for complete control Inductance and AC resistance tests with bias Test windings designed to operate with a DC current bias Simultaneous large character display of two parameters and test conditions Easy to read no hidden factors or warnings VOLTECH ATI USER MANUAL PAGE 6 5 FRONT PANEL MODES From the top level display Programs LCR CBHC LCR FIs Set Up
88. NDITIONS 7 1 9 LSB LPB INDUCTANCE WITH BIAS SERIES AND PARALLEL CIRCUIT DC Bias Measure Test Test Basic Range Voltage Frequency Accuracy 1mA to 1A 1nH 1MH 1mVto5V 20Hz to 3MHz 0 05 AT Series Tester Inductance is the electrical parameter that is commonly used to check that a high frequency transformer has been constructed according to its design and that it will operate properly in use As well as operating with AC signals some transformers and chokes are designed to operate with a DC bias current flowing in a winding The inductance of a winding is determined by the number of turns and the construction and dimension of the core materials it may also vary with test conditions such as voltage and frequency Where Used The series and parallel inductance tests are used with DC bias when testing transformers with ferrite type cores that carry a significant DC bias current in normal operation Such transformers and chokes are common in switched mode power conversion circuits Faults in numbers of turns core material and core gapping may be determined using this test PAGE 7 38 VOLTECH ATI USER MANUAL For line frequency iron cored transformers where the inductance varies rapidly with voltage a magnetizing current test MAGI is recommended This test is only available on the AT3600 See also the LS and LP tests for testing transformers where a DC bias current is not required Test Conditions To measure inductance
89. Quality Factor is obtained Choosing the Test Signal For optimum accuracy and performance use the test conditions chosen for inductance in the previous section of this chapter The test conditions can also be determined automatically by the ATi according to this table Signal Specified voltage Specified current Auto Specified Specified Specified Note that a fixed signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 27 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Choose the integration period normally medium and enter the terminal to be measured Use the Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value PAGE 7 28 VOLTECH ATI USER MANUAL Typically Q is tested against a minimum value A typical ferrite cored transformer may have a Q gt 20 A specially designed low loss transformer may have a Q 2100 Because Q is a ratio of two impedances it has no units If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then add
90. R In the Delimiters section of this screen ensure that only the Comma option is checked Click on Next gt and proceed to step three Text Import Wizard Step 3 of 3 I2 x This screen lets you select each column and set r Column Data Format the Data Format ot General converts numeric values to numbers date C Text values to dates and all remaining values to text pw C Date C Do Not Import Column Skip Data Preview Cancel lt Back Check that the Column Data Format option is checked as General and click on finish PAGE 4 48 VOLTECH ATI USER MANUAL AT SERIES SERVER The results will now be displayed as shown below 6 Ele Edit View Insert Format Tools Data Window Hep i HE xl IAE e E sS E fart o 9 8 o A Al VOLTECH AT3600 RESULTS FILE p D fa VOLTECHIATS600 RESULTS FILE Server Program Version 2 04 J Communications Channel B AT3600 ID 0571 AT3600 Software Version 2 16 File name C6200697 atr 7 Test Date 20 Jun 1997 Part Fixture ID TEST 1 Operator Batch No Fixture Compensation GjResult Serial Time Pass Fail 001 R 002 LS Minimum Maximum Reading Minimum Maximum Reading 1 10 44 20 Pass 59 73 6 78E401 Pass 3 3 22E40 2 10 44 23 Pass 59 73 6 78E401 Pass 3 3 11E 0 3 10 44 24 Pass 59 73 amp 78E4
91. RR DR PR DR Dr De ci De ER rw eR 2 10 2 2 1 Switching On eA TE ta be a 2 10 2 2 2 Installing the PC Editor na 2 12 2 2 3 Installing the PC Server sse 2 14 2 3 QUICK START TUTORIAL c aare iora aa raap aei thin aade raadiis 2 19 2 9 1 IntFoOdUClian EAE i e EE 2 19 2 3 2 Drawing the Transformer Schematic senes 2 20 2 3 3 Creating the Test Program sss eene 2 22 2 3 4 Running the Program from the Editor esee 2 30 2 3 5 Server Quick Slart e dein E eo e ue e 2 33 2 3 6 Running a Program on the Tester seen 2 36 2 3 7 Storing Programs uoo si t a 2 45 QA SELF EST get 2 49 2 5 PRODUCTION MODE a a aa a a ea are ae aeaa haai ae Ehake Eaei 2 52 2 5 1 Production Mode With No Options Enabled sss 2 53 25 2 Eror Messagas uio o oe EE e Hes 2 56 2 5 3 Indications Displayed While Tests Are 2 58 2 9 4 Re measuring Fixture Compensation essen 2 60 2 5 5 Execute Mode With Options Enabled sss 2 61 2 6 STOP ON FAIL 2 69 2 T 2 71 2 8 FIXTURE COMPENSATION eren serene nennen annnm manas a saa a sa sanas nannan 2 73 VOLTECH ATI USER MANUAL PAGE
92. Schematic Program Tester Server Setup Help BEE I A connection from the core will appear on the screen You may now add a core to node connection 3 2 8 DELETING A CORE CONNECTION To delete a core connection 1 Select the core connection you wish to delete by left clicking on it with the mouse 2 Choose Delete Core Connection from the Schematic menu 3 The connection from the core will be removed from the schematic Note that ALL tests containing the deleted core will also be DELETED VOLTECH ATI USER MANUAL PAGE 3 11 PROGRAM EDITOR 3 2 9 ADDING A SCREEN CONNECTION To add a screen connection Choose Add Screen Connection from the Schematic menu Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Help Ode a 5 Lu Seems Minimize A connection from the screen will appear on the schematic You may now add a screen to node connection 3 2 10 DELETING A SCREEN CONNECTION To delete a screen connection 1 Select the connection you wish to delete by pointing at it with the 8 ouse prompt and pressing the left mouse button 2 Choose Delete Screen Connection from the Schematic menu The screen connection will be removed from the schematic Note that ALL tests containing the deleted screen will also be DELETED PAGE 3 12 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 3 CREATING THE TEST PROGRAM This section describes the procedures used when creatin
93. Series and parallel circuits 7 124 Server Hardware connections 2 14 Server Installation Getting Started 2 14 SERVER PORT sse 8 27 Service o iso OR 9 6 5 6 24 Signal tede 6 22 2 8 Specification summary 8 5 STATISTICS PAGE 10 2 BASIC STATISTICS 4 14 Stop on 2 69 Stop On Fail Editor 3 17 Switching 2 10 WANG p E Ee IDEE 7 30 3 7 5 3 8 TEST LIMITS EDITOR 3 27 TESTS 5 3 21 Tests and test conditions 7 4 DEINER RETENTO 2 71 nnns 7 112 TURNS RATIO esee 7 60 TURNS RATIO BY INDUCTANCE 7 68 Upgrades hene 9 7 5 8 31 VOLTAGE OPEN CIRCUIT 7 73 9 5 Weight iuo der 8 34 3 7 ATI USER MANUAL
94. TECH ATI USER MANUAL FRONT PANEL MODES 6 2 TESTS AVAILABLE IN THE LCR MODES The available combinations are More 1 4 Softkey 1 Ls Lp Cs Cp More 2 4 Softkey 1 Z R More 3 4 Softkey 1 Rdc IR More 4 4 LCR FIX only Softkey 1 TR TRL LL C Softkey 3 Q D Rs Q D Rp D Q Rs D Q Rp Softkey 3 6 Q D X Softkey 3 Off On Softkey 3 POL PHAS POL The active display combination is always shown in inverse video The results are always shown to 5 significant figures using normal engineering notation and normal symbols for the units of measurement VOLTECH ATI USER MANUAL PAGE 6 17 FRONT PANEL MODES The symbols used are Measurement Symbol Units Display Units DC Resistance Rdc Ohms Q DC Resistance Using High IR Ohms Q voltage Source AC Resistance Series Circuit Rs Ohms AC Resistance Parallel Circuit Rp Ohms Q Inductance Series Circuit Ls Henries H Inductance Parallel Circuit Lp Henries H Capacitance Series Circuit Cs Farads F Capacitance Parallel Circuit Cp Farads F Interwinding Capacitance C Farads F Quality Factor Q Dissipation Factor or tan D AC Impedance Magnitude of Z Ohms Q Complex Impedance Phase Angle of Impedance 0 Degrees AC Reactance Imaginary Part X Ohms jQ of Impedance Turns Ratio TR Turns Ratio by Inductance TRL Polarity POL Interwinding Phase PHAS Degrees Leakage Inductance LL Henries H P
95. TECH ATI USER MANUAL INTRODUCTION Limitations Requires the Server PC to be permanently connected This is to allow the tester uninterrupted access to the Server for the purposes of accessing programs and storing results Usually requires an additional PC which could be a portable to be attached locally to the auxiliary port of one of the testers when a new program needs to be developed and evaluated VOLTECH ATI USER MANUAL PAGE 1 21 INTRODUCTION Small Production Facility At the other extreme and possibly more suitable for a small production facility with a single AT series tester and limited or temporary access to a PC 1 Connect the AT to the PC running both Editor and Server software as shown above when developing the test programs 2 Download a group of programs from the Server to the AT where they will be held in the internal non volatile memory 3 Remove the PC and run all the production test programs from the AT internal memory Advantages Requires only occasional use of a PC which could be a portable to develop test programs and load them into the AT Test programs can be executed by the AT without the PC attached which may be of advantage if the working space is limited Limitations Suitable for small numbers of test programs e g 50 Test results cannot be archived to disk or analysed by other Windows based applications PAGE 1 22 VOLTECH ATI USER MANUAL INTRO
96. TR L2 C2 GBAL LBAL ILOS RLOS and Z Choosing Test Conditions On selecting TRIM Trimming Adjustment from the Available Tests Window the following dialogue box will be displayed Trimming Adjustment Ea Adjust the previous test on failure Cancel To program the test Select OK The test will then be displayed in the program window PAGE 7 112 VOLTECH ATI USER MANUAL 7 1 29 OUT CoNTROL EXTERNAL DEVICES The AT Series testers normally make all the necessary connections for testing automatically using a matrix of internal relays When for example an external component such as a resistor is required for testing then during the test sequence the resistor may be switched into or out of the test circuit using an OUT test A 12V DC power supply ensures that everything necessary to drive an external 12V DC relay is available Pin 5 Relay O Drive Output des 5 4 3 2 1 User Port l 9 8 7 6 o p User Relay Drive 0 o p User Relay Drive 1 2 o p User Relay Drive 2 7 o p User Relay Drive 3 3 o p User Relay Drive 4 8 o p User Relay Drive 5 5 4 amp 9 i p Do Not Use The OUT test is used to switch external relays at any point in a test sequence The user relays may in turn be used to switch in external components such as impedance matching resistors important for audio and telecommunications transformers or to connect windings in series for subsequent testing T
97. Tx 0 Failed Test Min Max Last Result FAILS Polarity PolFAILS 1CTY 10 000 kOhm 62277 mOhm 1 218 1 1640 mH 1 2360 mH 1 1847 mH 0 3TR 2 6460 2 7540 2 7084 1 0 The batch statistics window display is automatically shown once this feature is enabled For each AT connected to the Server the following information is displayed The type of AT and its serial number and the part name operator and batch PASS or FAIL for the last part tested the total tested so far and the serial number of the last part tested The number that have passed and failed and the AQL lt gt Acceptable Quality Level of the transformer The number of re tries that have been attempted the percentage of failures so far and the number of transformers that failed out of the last 10 tested For each test in the program the test limits the last result and the accumulated number of fails for each test Results may also be exported or printed using the normal options found under the file menu AQL AQL Acceptable Quality Level settings for production test are defined for each program using the Editor AQL is the level of test failures in a batch that are acceptable Exceeding the AQL is an indication that there is problem with VOLTECH ATI USER MANUAL PAGE 4 15 AT SERIES SERVER the quality of the production process or the quality of materials used AQL monitoring is an optional feature of the Voltech PC Server which displays live summary results fro
98. UAL PROGRAM EDITOR If you have chosen fixed voltage current or frequency conditions it may not be possible for the tester to make a measurement For example if the AC impedance of the winding under test is only 0 1Q at the specified frequency and you have specified a 5V test signal then the AT would have to supply 5V 0 10 50 Amps You will then see a warning similar to this Editor Windows Application 4 The signal level requested is not ideal Changing V or F will prevent this warning Would you like the tester to choose a signal level Check first that the winding is properly connected to the right nodes Choose Yes and the AT will choose suitable voltage conditions for you and enter them into the test dialogue Choose No and no conditions will be chosen See Chapter 7 Tests and test conditions for suitable values VOLTECH ATI USER MANUAL PAGE 3 37 PROGRAM EDITOR 3 4 3 RESTRICTIONS FOR AUTOMATICALLY OBTAINING TEST PARAMETERS As shown above the LS Winding Inductance Series Circuit test is one where both the test voltage or current and frequency may be obtained automatically by using the Measure button Alternatively you may wish to specify yourself either one or both of the parameters before using the Measure button In this case the tester will attempt to make use of the parameter s that you have specified and enter a value only for parameters that you have not specified
99. Voltage Open Circuit Most but usually not line frequency Checks windings have correct turns Insulation Resistance All Checks winding isolation checks where safety is not involved General Longitudinal Balance Audio amp telecom Checks common mode rejection ratio Longitudinal Balance VOLTECH ATI USER MANUAL Audio amp telecom Checks common mode rejection ratio PAGE 7 9 TESTS AND TEST CONDITIONS Test Description Tr nsformer Application Reason for Test ILOS Insertion Loss Audio amp telecom Checks Rower lost Within the transformer RESP Frequency Response Audio amp telecom Checks losses oera range of frequencies RLOS Return Loss Audio amp telecom Checks power returned by a transformer Z Impedance Audio amp telecom Checks impedance at a given frequency ZB Impedance with Bias Audio amp telecom Checks impedance at a given frequency ANGL Impedance Phase Angle Audio amp telecom Checks phase angle of complex impedance PHAS Interwinding Phase Angle Measuring amp signal Checks phase of voltage between windings Checks imaginary part of X Reactance Audio amp telecom the complex impedance at a given frequency Transformers with variable Adjusts transformer TRIM Trimming Adjustment Itri parameter to desired rimmable components value during test Performs external OUT Output to User Port Switching as part of the test program Chec
100. ady using COM Port 1 2 Setup the COM Port on the PC From the top level menu select Setup Communications x Setup gt Communications COM P enn In the dialogue box select the PC communications port that is connected to the transformer tester WARNING If the chosen COM port is reserved by another Windows application an error message will appear You should select another port 3 Fit the appropriate fixture to the tester VOLTECH ATI USER MANUAL PAGE 3 31 PROGRAM EDITOR 4 Have available both a sample transformer and possibly a shorting header if you wish to add tests to the program for which you will be applying short circuit compensation 3 4 2 EXAMPLE OF USING THE MEASURE BUTTON WITH THE LS TEST LS Winding Inductance Series Circuit is one of the tests where both the test voltage and frequency and the actual measurement may be obtained by using the Measure button The following example assumes that this is what you wish to do Initially select the LS test in the normal way by double clicking with the mouse in the Available Tests list In the LS test dialogue box Enter the terminal names in the normal way Select the integration you require if different from the default setting of Medium In the Test Parameters section leave both the Signal and the Frequency edit boxes blank The default units button for the Signal is mV With this setting the Editor will enter the test voltage chose
101. al Saue Press Local Save and the program that has been downloaded from the PC Editor will be saved in the tester s local program store Note that any programs previously stored in the tester will be lost All PC connections to the tester may now be removed PAGE 2 88 VOLTECH ATI USER MANUAL 3 PROGRAM EDITOR VOLTECH ATI USER MANUAL PAGE 3 1 PROGRAM EDITOR PAGE 3 2 VOLTECH ATI USER MANUAL PROGRAM EDITOR Contents Program Editor 3 1 CREATING A PROGRAM e eeeneenn enne nennen nnne nnn nn san nannte nn nnns 3 5 3 2 CREATING THE TRANSFORMER 3 6 3 2 1 ADDING A TRANSFORMER 3 7 3 2 2 CONNECTING THE WINDING TERMINALS 5 3 8 3 2 3 DELETING A WINDING esisi peri poer edP Ee Rove de adeo 3 8 3 2 4 RENAMING A 3 9 3 2 5 ADDING A TERMINAL TO AN EXISTING 3 10 3 2 6 DELETING A TERMINAL FROM AN EXISTING 3 11 3 2 7 3 11 3 2 8 DELETING A CORE CONNECTION essen nnne nnne nnne nnn
102. als it may also vary with test conditions such as voltage and frequency See the LS and LP tests Windings consisting of the same number of turns and wound on the same core should have the same inductance value Where Used The inductance match test as opposed to an ordinary inductance measurement LS or LP is used on power conversion audio and telecommunications transformers where it is important that the inductance of different pairs of windings is controlled and matched to a specified ratio The absolute value of the inductances may be of less importance to the performance of the transformer than the match between two inductances Test Conditions To measure inductance match the tester makes two series inductance PAGE 7 42 VOLTECH ATI USER MANUAL measurements see the LS test and compares the two results Limits for the match of the two measured inductances may be set in terms of the ratio between them e g 1 1 5 By adding further inductance match tests to the program any number of inductances can be tested for match Choosing Test Conditions For optimum accuracy and performance use the test conditions shown in the inductance section of this chapter for each of the two windings The frequency will be common to both windings being tested for match The test conditions can also be determined automatically by the ATi according to this table Signa Specified voltage Specified current Auto Auto Specified Specif
103. an also be determined automatically by the ATi according to this table Specified voltage Specified current Auto ELE Specified Specified Specified Note that a fixed signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 31 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Choose the integration period normally Medium and enter the terminals to be measured Use the Editor s Measure button together with a sample part if you are unsure of the nominal value Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only Amaximum value only PAGE 7 32 VOLTECH ATI USER MANUAL Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Typically D is tested against a maximum value A typical film dielectric capacitor may have a D 0 01 Because D is a ratio of two impedances it has no units If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 33 TESTS AND TEST CONDITIONS 7 1 8 RLS RLP AC RESISTANCE SERIES AND PARALLEL CIRCUIT Measurement Test Test Basic Range Voltage Frequency Accuracy 10uQ to 10MQ 1mV to 5V 20Hz to 3MHz 0 059
104. ansformers where it is important that the capacitance between different pairs of windings is controlled and matched Mismatched capacitances may couple unwanted noise signals from one winding to another or ground The test will determine if one winding has been placed incorrectly or if the wrong thickness of insulation has been used VOLTECH ATI USER MANUAL PAGE 7 57 TESTS AND TEST CONDITIONS Test Conditions To measure capacitance match the tester makes two capacitance measurements see the C test and compares the two results Limits for the match of the two measured capacitances may be set in terms of the ratio between them e g 1 1 5 By adding further capacitance match tests to the program any number of inter winding capacitances can be tested for match The AT Series Testers use a parallel equivalent circuit for capacitance match measurements Programming the Test Using the PC Test Editor Capacitance Choose the integration period normally Medium PAGE 7 58 VOLTECH ATI USER MANUAL To enter the capacitor terminals into the Editor C2 test dialogue box add the terminals for the first capacitor X into the High and Low areas For example if the capacitance is between terminals A and B add A to the High Terminals X Used area and B to the Low Terminals X Used area Then click on the Terminals Y button and add the High and Low terminals for the second
105. anually apply a good short circuit to the transformer and run a normal LS test The best short circuit will be a length of tinned copper wired as short as possible securely soldered directly across the secondary connections If the result of this LS test is significantly different to the LL test without the manual sort circuit but under the same test conditions then use an LLO leakage inductance with offset test with an appropriate offset for production testing For example LL 550 nH LS 500 nH perfect short circuit same conditions Use an LLO test with 50nH offset Choosing the Test Signal Choose a suitable test current and frequency based on the expected value of the leakage inductance using the following table PAGE 7 46 VOLTECH ATI USER MANUAL Pr ferred Test Signal Leakage ductance Range Fr quency Current 300kHz 100kHz 30kHz 10kHz 1kHz 100Hz 100Hz 50Hz deve ae debo The test conditions can also be determined automatically by the ATi according to this table Specified voltage Specified current Auto Auto ERAN Specified Specified Specified Auto Note that a fixed signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 47 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Leakage Inductance xi Test Parameters Integration Signal o C uA C Shot Medium Frequency o Hz kHz C MHz C Long m Primary Terminals
106. ar frequency those measurements will be stored and need not be repeated again VOLTECH ATI USER MANUAL PAGE 6 29 FRONT PANEL MODES To compensate for the effect of stray inductance the ATi must make a measurement with a short circuit in place of the winding s under test This is called short circuit compensation The short circuit should be made of a piece of copper wire that is as short as possible If you are making measurements using a fixture plate it is usually convenient to make a part up with short circuits in place of the windings on a sample bobbin without cores LLL 1 1 1 1 Transformer Shorting bobbin for compensation To compensate for the effect of stray capacitance the ATi must make a measurement with no winding s in place This is called open circuit compensation The DC resistance test Rdc uses short circuit compenstion only the other LCZ measurement require both Once L C or Z is compensated this compensation is stored and applied to any L C or Z measurement as long as the measurement conditions and nodes are not changed Compensation values are unique to the voltage and frequency test conditions and thus you must re compensate if any of these values are changed The display will always show comp req when valid compensation measurements are not available PAGE 6 30 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 4 1 PERFORMING COMPENSATION To perform compensati
107. are two other methods of inputting the test parameters one is to set the primary voltage and frequency and let the editor set the secondary voltage and the second is to set both voltages manually VOLTECH ATI USER MANUAL PAGE 7 69 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Turns Ratio from Inductance Using the Measure Button to Set Test Parameters Select the integration period you require enter the primary and secondary terminals then click on the Measure button as explained in the Editor section of this manual The Editor will then enter the test signal and show the measured turns ratio Set percentage limits on this ratio and click OK you may select a polarity test before clicking OK Using the Auto Button to Set Secondary Voltage To do this you must know the primary inductance Select the test voltage and frequency for the primary from the table below and enter them in the TRL dialogue box Enter the turns ratio then press the Auto button next to the secondary voltage parameter the tester will automatically select the appropriate test voltage for the secondary winding when the program is running PAGE 7 70 VOLTECH ATI USER MANUAL Setting the Primary and Secondary Parameters Manually To do this you will need to know the inductance of the primary and secondary windings The optimum test conditions are chosen for an inductance value that is between the primary and
108. as the largest number of turns However if by doing this the expected voltage on the winding with the smallest number of turns falls below 1mV then the test voltage should be increased This may also require an increase in the test frequency so that the current taken by the driven winding does not become too large but in general this frequency increase should be kept as small as possible to avoid problems caused by stray capacitance at high frequencies Where Matching in Groups Is Important In some transformer designs the turns ratio between a primary winding and a secondary winding is not as important as the ratio between different primaries or different secondaries To make the most accurate measurements in such cases apply the test signal to the primary winding and measure the turns ratio from primary to one of the secondaries Then leaving the primary energized as above measure the turns ratio between the secondaries Next energize a secondary winding possibly at a different voltage and or frequency depending on its inductance and measure the turns ratio between the various primaries VOLTECH ATI USER MANUAL PAGE 7 63 TESTS AND TEST CONDITIONS In this way windings that should be matched are treated equally during the test PAGE 7 64 VOLTECH ATI USER MANUAL Choosing Test Limits The limits may be entered as 1 Anominal value together with a percentage tolerance 96 Enter the nominal Primary to Secondary ra
109. as the winding that requires the additional terminal Upon clicking the left mouse button a form fill in dialogue box will appear on the screen with prompts to insert the terminal names of the new winding Voltech Test Program Editor New Part e x Part Schematic Program Tester Server Setup Help Gjem 5 Schematic 3 Name the terminals of the second winding giving one terminal the same name as a terminal of the previous winding 4 Press ENTER or click on OK The dialogue box will be removed and the schematic will show the two windings joined at the common terminal as Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Help BEE ew PAGE 3 10 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 2 6 DELETING A TERMINAL FROM AN EXISTING WINDING To remove a terminal from a transformer winding 1 Select the terminal which you would like to be removed by using the mouse pointer and clicking the left mouse button once 2 Choose Delete Winding from the Schematic menu on the menu bar The bottom terminal of the winding will be removed from the screen together with any connections to that terminal that are present Note that ALL tests containing the deleted terminals will also be DELETED 3 2 7 ADDING A CORE CONNECTION To add a core connection Choose Add Core Connection from the Schematic menu zs Voltech Test Program Editor New Part Part
110. available for local use The parts will be stored in non volatile RAM No programs are lost after power down The following dialogue is used to configure groups and may be located under the Setup menu in the Server Edit group BATCH1 x Parts in current directory Parts in group Directories OK i c at3600 server TRA ES TR1 Cancel Help Network TR5 TR2 TR3 Drives P amp c ms dos 5 bd lt lt Remove From Group Double clicking on any part in the left hand list will add it to the right hand grouped list When you have completed editing a group you will see it added to the available group list To transfer the group to the tester it must be requested by the tester See Chapter 2 of the manual for details IMPORTANT The group function does not store a new copy of each part when a group is defined Only reference is made to the part being in a group DO NOT delete a part after including it in a group other wise the part will be lost and the group rendered invalid PAGE 4 10 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 3 TEST RESULTS HANDLING 4 3 1 RECEIVING TEST RESULTS By default the AT Series Tester does not automatically send test results back to the Server Results will only be sent back for test programs that have been set up with the Send Results to Server option enabled The Server receives test results from the tester via the same serial connection used for transferring test
111. available functions for controlling an attached instrument via the server This is to allow basic instrument control in applications where the AT is being used entirely remotely The functions available allow a program to be loaded into an AT and give the ability to run and stop it Variant LoadProgramToAT LPCSTR ComPort LPCSTR ProgName PROGRAM DOES NOT EXIST Program is not in the Server s program folder INVALID PROGRAM Program fails AT test program validation LOADING Returned when command is first sent to server and every subsequent time it is sent until loading finishes LOADED The program has been successfully loaded this will continue to be returned and the program will not load until either StopAT is called or the server receives results on that COM port Variant RunProgramInAT LPCSTR ComPort NO PROGRAM The AT has no program to run SENT Returned when the program has started to run and every subsequent time the function is called until the server receives results DONE The program has finished running results will be available If the function is called after it has returned this value it will cause the program to be run again Variant StopAT LPCSTR ComPort STOPPED The AT must stop whatever test it is running PAGE 4 40 VOLTECH ATI USER MANUAL AT SERIES SERVER Example of On line Analysis This section contains a simple example to illustrate how you may use OLE to transfer the mea
112. ay line indicating Pass Fail or Stop as appropriate VOLTECH ATI USER MANUAL PAGE 2 65 GETTING STARTED Enter the new serial number Last 1 Last transformer PA Ss Delete Abort Shift If the next serial number to be used simply follows on in sequence after the previous one then press the Last 1 softkey or the touch pads This will enter the next serial number automatically and return the display to the RUN FINISH selection Note Last 1 will be displayed only if the serial number is of the form xxxAnnnn Where xxx is a field containing any characters A is a non numeric character and nnnn is a field of all numeric characters Both xxx and nnnn can be of any length provided that the total serial number is no more than 20 characters When nnnn is all 9 s for example 99 the next number will show nnnn as all 0 s for example 00 the characters xxxA will not be changed Alternatively if the next serial number does not follow from the previous one in sequence you may use the keypad or the barcode reader to type in a new number After typing the new number press the ENTER key the ENTER softkey or the footswitch to return to the RUN FINISH display PAGE 2 66 VOLTECH ATI USER MANUAL GETTING STARTED Again cursor softkeys lt lt appear in context and may be used with the Delete softkey to correct mistakes Note Pressing the Abort
113. be performed one after the other The order in which S C and O C compensation is performed is unimportant VOLTECH ATI USER MANUAL PAGE 2 73 GETTING STARTED CFor 5 C COMP connect all used terminals together For O C COMP use an empti fixture S D Comp Comp Ho Comp For S C compensation first make up a transformer bobbin with shorting links in place of the windings To make a shorting bobbin solder short pieces of wire across the relevant pins or all of the pins a spare blank bobbin or complete transformer O 3 O 000 09 e e eo Put the short circuit bobbin into the fixture and Transformer Shorting Bobbin for S C compensation Press softkey 1 S C COMP to begin short circuit compensation Remove the short circuit bobbin but leave the fixture in place and Press softkey 2 O C COMP to begin open circuit compensation PAGE 2 74 VOLTECH ATI USER MANUAL GETTING STARTED Press softkey 4 NO COMP to abort compensation and begin running the program Once you have chosen either S C compensation or O C compensation the ATi will make very accurate measurements of the stray components A typical S C compensation measurement might take 10 seconds or more during which time you will see a progress bar on the display Compensating fixture Following one compensation and assuming you have performed S C first you will be prompted to perform the oth
114. button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits mOhm Ohm etc when entering absolute values as limits Test limits should be set as close as possible to detect assembly faults If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester PAGE 7 102 VOLTECH ATI USER MANUAL 7 1 25 X REACTANCE Measurement Test Test Basic Range Voltage Frequency Accuracy 1mQ to 1MQ 1mV to 5V 20Hz to 3MHz 0 296 AT Series Impedance Z Tester The impedance of a transformer is usually complex that is it consists of real resistive and inductive or capacitive imaginary parts The total impedance at a specified frequency is the vector sum of these parts Z R jX Where R and X are the real and imaginary parts of the total impedance Where Used The X test checks the reactance or imaginary part of the complex impedance of audio and telecommunications transformers that are to be used with transmission lines of specified impedance The test helps to ensure that the transforme
115. can be purchased at any time and are available on disk or by e mail so that your ATi can be upgraded in a few minutes with the aid of the Voltech Editor software running on a PC The tests available at the time of printing are listed in the next section of this chapter Check with your Voltech supplier or on the Voltech website at www voltech com for the up to date list Iron Core Transformers For iron core transformers operating at 50 60 400 Hz Voltech recommends the use of a magnetizing current test rather than inductance This test is available only on the Voltech AT3600 Hi Pot or Flash Testing Transformers are often used to provide safety isolation between the AC line and the user Where this is the case very high voltages 2000 to 5000VAC must be used to test this isolation The Voltech AT3600 incorporates this test as well as all of those available for the ATi and more Self Resonant Frequency Practical inductive components are not perfect inductors they have stray resistances and capacitances associated with them For certain components especially those with a low inductance value the impedance of the stray capacitance can become significant when compared to that of the inductance 1 X 2IIfL Ac AC At a sufficiently high frequency the capacitive impedance can dominate making a measurement of the inductance impossible Under these VOLTECH ATI USER MANUAL PAGE 7 7 TESTS AND TEST CONDITIONS circumstanc
116. capacitance Choosing Test Conditions For optimum accuracy and performance choose test conditions based on the nominal value of capacitance as listed in the previous capacitance section The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency Use the Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions See also the notes relating to choosing tests conditions for capacitance in the previous section Choosing Test Limits The test limits are entered as a and percentage around a nominal ratio Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 59 TESTS AND TEST CONDITIONS 7 1 15 TR TURNS RATIO AND PHASING Measurement Test Test Basic Range Voltage Frequency Accuracy 1 100 000 100 000 1 1mV to 5V 20Hz to 3MHz 0 196 AT Series AT Secondary Tester measurements In phase Anti phase Applying an AC voltage to the primary of the transformer will produce an AC voltage in the secondary Turns ratio describes the voltage ratio of the measure
117. ch AT3600 Hi Pot must be used to detect poor interwinding isolation where safety is an issue For example from a primary winding to a secondary winding on a mains isolation transformer For iron cored transformers operating at the 50 or 60Hz line frequency where normal operation extends to the point of core saturation magnetizing current and open circuit voltage measurement are normally the preferred tests These tests are available only on the Voltech AT3600 3 Usetest limits that are as wide as possible For example if you are testing the turns ratio between windings where the actual number of turns on one of the windings is only 10 specify limits of 5 which is equivalent to half a turn 4 Make use of the Measure button For many tests the dialogue box for the test contains a button labeled Measure If when you are creating your test program you have a tester connected to your PC fitted with the appropriate test fixture containing a specimen transformer clicking on the Measure button will signal the tester to measure the actual parameter of the test The result will be returned to the PC and the Editor will insert it as the nominal value in the limits section of the test dialogue box This is often the best way to find the value for some of the parameters which you may wish to test but which do not appear on the actual transformer design documents 5 Finally download and run the program from the Editor an
118. connections Clips supplied with BNC leads Kelvin pins VOLTECH ATI USER MANUAL PAGE 5 23 FIXTURES PAGE 5 24 VOLTECH ATI USER MANUAL 6 FRONT PANEL MODES VOLTECH ATI USER MANUAL PAGE 6 1 FRONT PANEL MODES PAGE 6 2 VOLTECH ATI USER MANUAL FRONT PANEL MODES Contents Front panel Modes 6 1 LCR MODE BASIC FUNCTIONS eene nennen nnne 6 5 61 1 LCR BNC Mode eite d edd tie edades 6 7 6 12 ECRAFIX Modes soon 6 11 6 1 3 Insulation Resistance m 6 13 6 2 TESTS AVAILABLE IN THE LCR 5 6 17 6 3 6 19 6 351 ECR BNC Mer i iii ettet t te ted 6 19 6 3 2 EGRYFEIX Menus REC 6 20 6 3 3 L CR Mode Settings n de m 6 21 6 4 COMPENSATION pecu EDEN 6 29 6 4 1 Performing Compensation esses eiie 6 31 6 4 2 Compensation Fail oie 6 33 6 5 LCR MODE ERROR MESSAGES eene nnnm tnmen 6 35 6 6 PROGRAM MODE 0 treni cere ei ieedensess 6 39 6 6 1 Creating a New Test 8 6 40 6 6 2 Setting Up Test Program Options sse 6 44 6 6 3 Running a Test Program sss nnne nnne 6 47 6 6 4 Password Prolection i o e DH e 6 48 VOLTECH ATI USER
119. curacy is 10 of the requested value VOLTECH ATI USER MANUAL PAGE 8 7 SPECIFICATIONS 8 2 ACCURACY SPECIFICATIONS AVAILABLE TESTS 8 2 1 R TEST The accuracy is based on the test conditions chosen to measure the winding resistance and is given as Ar AptActAytA Where Ar is the total accuracy AR is the basic relative accuracy Ac is the calibration accuracy Ay is the correction for voltage level Ar is the correction for current level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 2 Ay 0 03 0 01 Vy A 0 03 0 01 I1 Where Vu is the measured voltage V Im is the measured current A PAGE 8 8 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 2 LS LP LSB LPB RLS RLP AND X TESTS The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test and is given as AT Where Ar An Ac Av Ao As AR Ac 4 1 AQ AB is the total accuracy 96 is the basic relative accuracy 96 is the calibration accuracy 96 is the correction for voltage level 96 is the correction for current level 96 is the correction for Q factor 96 is the correction for Bias 96 The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 0896 0 00001 x Fm 0
120. d make sure the results are what you expect before you use it in production VOLTECH ATI USER MANUAL PAGE 3 49 PROGRAM EDITOR PAGE 3 50 VOLTECH ATI USER MANUAL 4 AT SERIES SERVER VOLTECH ATI USER MANUAL PAGE 4 1 AT SERIES SERVER PAGE 4 2 VOLTECH ATI USER MANUAL AT SERIES SERVER Contents AT Series Server 4 1 INTRODUCTION ciere rte r o Enna nun un yR EN nana nk un yu SERE NOn CR DN a a Cn n CR Dx 4 5 4 2 TEST PROGRAM HANDLING eere enne nenne nennen nnn nn nn nn ennnen nennen nenene nnna 4 6 4 2 1 Storing Test Programs sss seen nnne 4 6 4 2 2 Viewing a Test POQTAIN cc cccccecsececsensenensesneneneneeesesanensenedeensesesenseueesenees 4 7 4 2 3 Saving a New Copy of a Part nnne 4 8 4 2 4 Deleting a Test Program sessi sees essetis nnn nnne nnn 4 9 4 2 5 Grouping Test Programs eene inneren nnns 4 10 4 3 TEST RESULTS 4 11 4 3 1 Receiving Test Hesults ose e ertt 4 11 4 3 2 Result Display and Analysis essen 4 13 4 3 3 Simple On line Monitoring eese nnns 4 13 4 3 4 Batch Statistics On line Analysis sese 4 14 4 3 5 On line Analysis via a 856 4 17 4 3 6 Database Tables
121. d the COM port is correctly configured in the Server software At this point the tester should still be powered on the display should still show a last transformer message produced when the test program was run from the Editor It will be similar to the following Fart number Eun TUTORIAL Settings Total 1 Failed 8 Results Last transformer A 5 Finish Before running any new test program return the tester to the top level menu by pressing the Finish softkey PAGE 2 36 VOLTECH ATI USER MANUAL GETTING STARTED Use the following sequence of key presses to ensure that the AT is configured to use the Server as the source for test programs 1 From the top level menu choose Set Up to change to the following display 2 Press the softkey Set Up and at the following display Fail Beeper SHORT Continuous Pass Beeper OFF Key Response CLICK Beeper Volume 3 Press the softkey until the third line shows the words Program Store VOLTECH ATI USER MANUAL PAGE 2 37 GETTING STARTED Set Up HT Password Program Store INTERNAL 4 If as shown above the origin is INTERNAL then press the softkey Server so that the third line reads as follows Set Up HT Password Program Store SERVER 5 Press the softkey EXIT to return to the Set Up display and then press the EXIT softkey again to return to the top level display PAGE 2 38 VOLTECH ATI USER
122. d voltages from one winding and another The secondary voltage may be in phase with the primary voltage or it may be anti phase depending on the winding and the termination of the windings Where Used The turns ratio test is used to confirm that windings have the correct ratio of turns between them and that the phasing of the windings is correct This test is the preferred test for signal pulse and switched mode power transformers where the normal operating conditions require only small excursions of the B H curve never extending beyond the linear region See also the test TRL turns ratio by inductance PAGE 7 60 VOLTECH ATI USER MANUAL Test Conditions To measure turns ratio the test signal is applied to one winding called the energized winding The voltages across two other windings one of which may be the energized winding are measured The turns ratio is then measured by dividing one measured voltage by the other and making a compensation for the effects of winding resistance It is recommended that you choose the winding with the highest number of turns as the one to be energized A possible exception to this rule is when you wish to measure the ratio between two windings that should be accurately matched at 1 1 In this case it may be better to energize a third winding with a lower number of turns to ensure that any measurement errors apply equally to the two windings under test Choosing Test Conditions The recommen
123. ded test conditions depend on the inductance of the energized winding they are given in the table below assuming that the energized winding is the one with the highest number of turns Induc ance of the Prefer ed Test Signal Energ zed Winding Frequen y Voltage 300kHz 100kHz 30kHz 10kHz 1kHz 100Hz 100Hz 50Hz 50Hz 50Hz 20Hz m 3 5 5 zi E 3 3 VOLTECH ATI USER MANUAL PAGE 7 61 TESTS AND TEST CONDITIONS The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency Programming the Test Using the PC Test Editor Turns Ratio Choose the integration period normally Medium Energized Terminals The terminals where the test signal will be applied This is normally the winding with the greatest number of turns PAGE 7 62 VOLTECH ATI USER MANUAL Primary Terminals High and Low The zero phase reference terminals which are often the same as the energized terminals Secondary Terminals High and Low The turns ratio and polarity measurement will be made between the primary and secondary terminals Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Notes The signal is applied to the primary winding or the winding that h
124. dialogue box select the PC COM port that is connected to the tester WARNING If the chosen COM port is reserved by another Windows application an error message will appear You should select another port 4 Fit the appropriate fixture to the tester and plug in the specimen transformer Voltech Test Program Editor Part TUTORIAL File Part Schematic Program MESOS Server Setup Help You are now ready to Dias Download Program download and run your test Upload Program program A Compensate Fixture B Run Program 4 From the top level menu Download FINIS bar select Tester Download Program VOLTECH ATI USER MANUAL PAGE 3 39 PROGRAM EDITOR The Editor will now download the test program to the tester After a few seconds you should see a message to say that the download was successful 5 Again from the top level menu bar select Tester Run Program The test program will now begin execution When it is finished you will see a dialogue box containing the results of the test Test Results x 1 R 777 17 Ohm PASS 0000 2 15 1 9372 H PASS 0000 RUN TIME 399 msec Refun Test From the results you should be able to see any tests where there may be problems Return to the Program Editor to make the necessary changes then download the program again and run the corrected version Continue in this way until you are satisfied that the program is correct before archiving it
125. ding used for inductance and Q as the reference winding The test TRL Turns Ratio by Inductance can provide improved measurement accuracy in cases where the coupling between windings is poor C Interwinding Capacitance A capacitance test between windings can check for insulation thickness between them and for their correct placement along the length of the bobbin This can be important not just for confirming the insulation but to check that unwanted signal noise are not unexpectedly coupled in the final application Check the main primary to secondary capacitance and between secondaries where insulation is important LL Leakage Inductance The leakage inductance is a measure of how good the magnetic coupling between windings is A higher than expected leakage inductance can indicate inaccurately aligned core halves or poor layering of the windings Check between the primary and the secondaries The ATi automatically creates short circuits across the secondary windings that you specify for this test IR Insulation Resistance An insulation resistance test applies a high voltage up to 500V DC between windings to check that they are no defects in the insulation Check wherever windings are supposed to be insulated from one another PAGE 7 6 VOLTECH ATI USER MANUAL More Tests A comprehensive suite of more than 20 different tests is available for the ATi and new tests are constantly being developed Additional tests
126. e tester WARNING If the chosen COM port is reserved by another Windows application an error message will appear You should select another port VOLTECH ATI USER MANUAL PAGE 2 13 GETTING STARTED 2 2 3 Installing the PC Server Check that your PC satisfies the following hardware requirements PC processor 486 or better Memory 4MB minimum Hard disk space 3MB minimum Note 3MB does not include disk space required for storing programs or test results Operating system Windows 95 or later CD ROM drive x2 minimum speed To install the Server software follow the same basic instructions as for the Editor The Server is often installed on a different PC to that which will be used for the Editor depending on your production needs A Server PC needs to be permanently connected to the ATi only if you wish to store test results or use a central program store rather than the ATi s own memory Server Hardware Connections In some applications you may wish to position the Server PC some distance away from the tester which will require a cable longer than the one supplied The AT Series Server port connector details are shown in Chapter 8 to enable you to make up a cable of the length you require To use more than one or two AT Series Testers with the same Server host PC an intelligent COM port expansion card will be required The server application supports the DIGIBOARD XE eight channel device PAGE 2 14 VOLTECH ATI USER
127. e MS Windows environment provides a system of transferring data between active applications in real time known as Object Link Embedding OLE OLE2 is the latest version of the transfer standard and is fully supported by the Server application Embedded data links allow test results received by the server to automatically pass into a second application which may be your own custom software or a spreadsheet such as Microsoft Excel Server OLE commands also allow you to load and execute test programs OLE is the analysis and control method preferred by users who wish to operate the AT under software control OLE is already configured ready to go within the Server application Your client application will need to be setup to request data from the Server Refer to your own application handbook for details of OLE setup IMPORTANT Attempting to make more than ten data requests per second may result in data loss or corruption NOTES The automation object is called Server Results The exposed OLE automation methods are GetVariantResult LPCSTR ComPort short TestNumber Where LPCSTR ComPort is a pointer to a string ComPort ComPort COM9 the port connected to the AT Series Tester that gives the required result TestNumber Integer number for test within program VOLTECH ATI USER MANUAL PAGE 4 35 AT SERIES SERVER The number returned is a float representing the value of the result measured or a zero if no resu
128. e PC Test Editor Longitudinal Balance EN The voltage and frequency are usually determined by the final application of the part under test Select the integration period that is normally Medium Enter the required terminal names Terminals X the energized winding VOLTECH ATI USER MANUAL PAGE 7 87 TESTS AND TEST CONDITIONS Terminals X the measured voltage VOUT1 Terminals Y the energized terminals for creating a common mode voltage Terminals Y the measured voltage VOUT2 Note that the PC Editor s Measure button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester PAGE 7 88 VOLTECH ATI USER MANUAL 7 1 21 RESP FREQUENCY RESPONSE Measurement Test Test Basic Range Voltage Frequency Accuracy 100dB to 100dB 1mV to 20Hz to 3MHz 1 0dB AT Series Tester Where Used The frequency response test RESP may be used to check that the variation in power loss of a telecommunications or audio transformer over a specified
129. e a Pass result After pressing the Continue softkey the remaining tests in the program will be executed and at the end of the measurement the component will be classed as a Fail Pressing the Re Run softkey will re start the test sequence from the beginning VOLTECH ATI USER MANUAL PAGE 2 71 GETTING STARTED Note After making the necessary adjustments you must press Re Run to enable the component to be recorded as a Pass If further adjustment is necessary you may re run from the start as many times as you like Unless the option Send Retry Results to Server is enabled there will be no data sent back to the Server until the measurements for all tests in the program have been completed PAGE 2 72 All transformers are capable of generating voltages much higher than the test voltage When making adjustments take care not to touch any transformer terminals the transformer body or any exposed metal on the test fixture Ideally make sure that you use a trimming tool with a well insulated handle When applying a test signal to a winding always be mindful of the turns ratio of the transformer that you are testing Very high voltages can be generated on the other windings of the transformer if these voltages exceed 250V the tester may be permanently damaged VOLTECH ATI USER MANUAL GETTING STARTED 2 8 FIXTURE COMPENSATION The AT s fixture compensation eliminates errors due to stray
130. e atten s teet us 8 8 8 2 2 LS LP LSB LPB RLS RLP and X 8 9 8 2 3 LE and LEO Tests a ipee ed Pies 8 10 6 2 4 C GS and CP TES E ten nes b c D 8 11 92 5 Ql and D Tests ot oor lo db b 8 12 8 2 6 TR Test dene aloes 8 13 627 EVOC Test iso ute PIDE SERES 8 14 82 8 TRE Test tee p o em d e eie 8 15 92 9 IR Testis ceo Ue eu ole d 8 16 82 10 12 G2 and R2 Tests s e iei Soe eee ee 8 17 82 1T GBAL Testi dob EE 8 18 8 2 12 LBAL ILOS and RESP Tests 8 19 8 2 13 RLOS Test ssi e osea ure in ee 8 20 82 14 Zand ole i 8 21 8 245 ANGLE TS 0 ete der f e etg eet 8 22 8 2 16 PHAS Test seda dee et p ertet 8 23 8 2 17 ESBX and EPBX Tests oss c e dun EO ee ee 8 24 8 3 INTERFACE DETAIL Sa ma Leere tiere tet e cusa cueva ran rindi 8 25 8 3 1 Barcode Port ico ida ea de pr i 8 25 8 3 2 Se ver Ports iu o v RU HEP 8 27 8 3 3 AuxIllary POrt bach ee 8 27 8 3 4 PrintercPOIL ie ead E EH RETRO rd 8 28 6 3 5 R mole Port 5 ete etaed teta 8 29 823 6 USB Port aui in ipae ied es up vs Pp eal 8 31 8 3 7 Environmental Conditions esses 8 34 VOLTECH ATI USER MANUAL PAGE 8 3 SPECIFICATIONS 8 4 EMC COMPLIANCE 8 4 1 Declaration of Conformity 8 4 2 EMC Precautions PAGE 8 4 VOLTECH ATI USER MANUAL SPECIF 8 1 SPEC
131. e from Voltech In addition complete ready to use fixturing solutions are also available from Voltech s fixturing partners Visit our website www voltech com for the latest information VOLTECH ATI USER MANUAL PAGE 5 5 FIXTURES 5 2 DESCRIPTION The Voltech AT Series fixture system allows you freedom and flexibility when considering your fixturing needs All fixtures are mounted on fixture boards which are available as a blank fixture plate and also as fixture kit which contains parts to help you The following basic building blocks are available A Fixture Plate Designed for mounting existing fixtures to an AT Series Tester Comprises Base plate including contacts with cover Test piece interface plate B Custom Fixture Kit A kit of parts for constructing your own fixtures Interconnecting wire test probes or clips and a drilling template will also be required Comprises Base plate including contacts with cover Test piece interface plate Probe housing box Bezel Guides 12 off PAGE 5 6 VOLTECH ATI USER MANUAL FIXTURES C 40 Socket Fixture A fixture board fitted with 40 4mm sockets 20 red power and 20 black sense The sockets are wired to the 40 contacts which align with the tester s 40 nodes This complete fixture may be used for convenient wiring to existing fixtures or as a means of connecting flying leads and clips for use in developing test programs or t
132. e in series with the winding This impedance is known as the leakage inductance Low leakage inductance implies good coupling high leakage inductance poor coupling Leakage inductance is important in many transformer designs such as switching power supply power transformers and electronic lighting ballasts The test is used to ensure that the windings and core have been positioned correctly VOLTECH ATI USER MANUAL PAGE 7 45 TESTS AND TEST CONDITIONS Test Conditions Leakage inductance is tested by measuring the inductance of a primary winding when one or more secondary windings are shorted out See also the LS test Typically the impedance to be measured is very small so a constant current AC test signal is used to provide stable accurate results over a broad range of values The tester applies the short circuit automatically without using any external switches or components By measuring and analysing the small voltage present across the short circuit the tester compensates for the impedance of the wiring and other connections in the shorted path The error due to the small short circuit impedance can often be ignored This is the term Asc quoted in the accuracy specifications When measuring on certain components and particularly where the leakage inductance is below 1H it may not be possible for the AT to properly compensate for all parasitic effects To confirm the accuracy of the LL test during program development m
133. e is used Note that the fixture name does not have to be the same as the program part name This makes it possible to have one fixture common to a number of transformers which may for example have the same arrangement of pins but have different windings requiring different test programs External AC Source This option is applicable to the AT3600 only When you have selected all the required options click on the OK button to return to the Top Level menu Stop on Fail With this function enabled the tester will stop program execution whenever a fail is detected rather than carrying out all the tests in the test program and reporting the passes and fails at the end This enables the user to quickly identify a faulty transformer and replace it with another before all the tests have been carried out thus speeding up the test process When a fail is encountered the tester will display a warning screen and stop the program The display will inform the user of a test failure and indicate which limits have been exceeded VOLTECH ATI USER MANUAL PAGE 3 17 PROGRAM EDITOR An example of this display for an inductance test is shown below TUTORIAL FAIL at test 4 LS Continue 1 1847mH Vertical bar Represents Box Represents the user the value measured programmable limits for the test From this display after you have pressed the CONTINUE softkey the tester will execute the remaining tests in the
134. e nnns 3 11 3 2 9 ADDING A SCREEN 3 12 3 2 10 DELETING 3 12 3 3 CREATING THE TEST PROGRAM eene nennen nnn nnn nnn nnn 3 13 3 3 1 SETTING THE 3 14 3 3 2 ADDING TESTS vi Lt ag ge rater edet attend 3 21 3 3 3 INSERTING TESTS 3 eet need beta 3 22 3 3 4 MODIFYING TESTS iiit pe tree ore RR Eee eh 3 24 3 3 5 DELETING TESTS x iiie Hee a ae 3 25 3 3 6 TEST DARAMETERS 2 3 e qe E tired 3 26 3 3 7 TEST LIMITS e iie eO Ea 3 27 3 4 USING THE MEASURE BUTTON ecce ee eene enne enn n nn annnm u nnus 3 31 3 4 1 HARDWARE CONNECTIONS FOR USING THE MEASURE BUTTON 3 31 3 4 2 EXAMPLE OF USING THE MEASURE BUTTON WITH THE LS TEST 3 32 3 4 3 RESTRICTIONS FOR AUTOMATICALLY OBTAINING TEST PARAMETERS 3 38 3 4 4 VERIFYING YOUR PROGRAM s eeeseseeie nensem nannten nnne 3 39 3 5 ERROR oir du intro vea ate 3 42 VOLTECH ATI USER MANUAL PAGE 3 3 PROGRAM EDITOR 3 5 1 FRONT PANEL ERROR CODES essentiam 3 43 3 5 2 EDITOR ERROR id rp de poe t e tete 3 43 3 6 FIXTURE COMPENSATION SEE ALSO SECTION 2 8 3 46
135. e result number requested can be read as invalid Including this test in the loop will trap out this error Instead of using the GetVariantResult function itself to determine if new data is available the NewDataAvailable function can be used This function is recommended for use when more than one item of data is to be read after new data is available For example the NewDataAvailable function can be read in the do loop until it returns true after which any other OLE function can be called to gather their return values knowing that all the data will be valid Using the NewDataAvailable function also means that checking for INVALID RESULT NUMBER and NO RESULT return values is no longer necessary 4 3 9 OFF LINE ANALYSIS If you have no requirement for real time analysis but are interested in post test analysis of test results off line data analysis should be adopted An example of this would be to view the results file created the previous day As described in section one of this chapter the batch result file is stored in a text based Comma Separated Variable format CSV A spreadsheet is an ideal environment to analyze and manage your test data Almost all spreadsheet applications are able to import a CSV file Once imported test results may be graphed calculated edited and printed like any other data Using a package such as Microsoft Excel macros may be setup to sort and extract the appropriate result sections calculate and compile
136. e softkeys change to give the names of each month Press the appropriate softkey to select which month PAGE 2 80 VOLTECH ATI USER MANUAL GETTING STARTED The remaining fields dd hh and mm day hour and minute are changed in the same way as the year using the number pad BNC Lead Calibration For optimum measurement accuracy in LCR mode using the BNC leads calibration factors are stored within the ATi This calibration is set at the factory for the BNC leads supplied with the ATi and it is not normally necessary to adjust this calibration If the leads are replaced by others or modified in any way then the leads should be re calibrated To calibrate the leads press the softkey Change when BNC lead calibration is selected BHC Lead Calibration Continue BHC calibration requires a FORE resistor 7 250R Note that you will need a nominal 750 Ohm resistor later in the process A typical 680 ohm 1 4 watt resistor will be sufficient The exact value of the resistor is not important to this process but you must use exactly the same resistor whenever it is required during this process The BNC calibration process consists of six measurements an open circuit short circuit and 750 ohm measurement across nodes 13 and 15 on the fixture and then the same measurements made using the BNC leads VOLTECH ATI USER MANUAL PAGE 2 81 GETTING STARTED e Press Continue short together nodes 13 and 15 on the
137. e the faulty unit free of charge for a unit returned to an authorized service center Shipment from the customer address will be the responsibility of the customer e Voltech reserve the right to waive this benefit in any event where it is clear upon inspection that the cause of the failure is due to customer misuse 9 Voltech will be the sole arbiter in this circumstance e Voltech will pay all return shipment charges from the Voltech service center to the customer e Voltech will recalibrate the customer unit before dispatch A certificate of calibration will be issued as a matter of course 9 2 LIMITATION OF WARRANTY The foregoing warranty shall not apply to defects resulting from unauthorized modification or misuse or operation outside specification of instrument No other warranty is expressed or implied While every care has been taken in compiling the information in this publication Voltech Instruments cannot accept legal liability for any inaccuracies contained herein Voltech Instruments has an intensive program of design and development which may well alter product specification and reserve the right to alter specification without notice and whenever necessary VOLTECH ATI USER MANUAL PAGE 9 5 WARRANTY AND SERVICE to ensure optimum performance from its product range Because software is inherently complex and may not be completely free of errors you are advised to verify your work In no event will Voltech be liable
138. e the first message box defined in the code Microsoft Excel Press the RUN soft key on the AT Click on the OK button When you have pressed the RUN softkey and the first result has been read the message box will disappear and you will then see the first result entered into cell F3 of the spreadsheet Continue pressing the RUN softkey until the second message box is seen Microsoft Excel Done Click on the OK button to finish running the code 4 3 8 ADDITIONAL NOTES FOR THE ABOVE EXAMPLE If there appear to be any problems while the code is running press the escape key This will halt the execution and bring up a dialog box to allow you to either exit from the code execution or to debug your code for example by single stepping through it VOLTECH ATI USER MANUAL PAGE 4 43 AT SERIES SERVER Once the results have been placed into cells in the spreadsheet standard Excel functions may be used to perform further analysis on the data or to present the data in different ways As an example you may wish to use the Excel Chart Wizard to produce a graph of the results Alternatively you may wish to add further code to the example shown above as another way of extending the functionality For guidance of what may be possible please refer to the Microsoft Excel user manuals In the code example shown above it is worth noting the following points vntResult 1 To 99 is declared as a variant type because the Ge
139. ed before finishing Touch pads or foot switch to start the test Failed parts for rejection or rework Low cost fixture plates e Quick connections to the transformer under test e Rapid change of fixture for different transformer types PAGE 1 24 VOLTECH ATI USER MANUAL INTRODUCTION Robotic Automatic Handling Use In robotic situations the tester s remote port provides the digital inputs and outputs for connecting into your system Remote PC records all test data Run Stop Fail Busy for statistical analysis using signals for process Voltech server software control Good parts for further processes Parts to be tested before finishing Failed parts for rejection or rework Again the tester may be connected to a Server PC or used stand alone as described above VOLTECH ATI USER MANUAL PAGE 1 25 INTRODUCTION 1 9 How DOES THE ATi TESTER RUN A TEST It is not necessary to understand how the tester works in order to install program or operate it successfully This section is provided for your information only Source 1 Relay Matr Up to 5V rms c ay Matrix DC and 20Hz to 3MHz Source 2 Up to 1A constant current Source 3 Up to 500V dc for IR Processors Keyboard Display and Interfaces Measurement Circuits The ATi consists of the following 7 basic functional blocks Relay Switching Matrix The relay switching matrix is used to connect the selected test source and
140. ed the results will have no meaning but you have now successfully installed the ATi and the Voltech AT Editor software The results window will give you the options to 1 2 Print the test results Re run the test program 3 Close the window Closing the window will return you to the top level menu PAGE 2 32 VOLTECH ATI USER MANUAL GETTING STARTED 2 3 5 Server Quick Start Transferring the Program to the Server The Voltech Server software is supplied with every AT Series Tester The use of the Server software is required for handling and storage of test results and is recommended for handling large numbers of different test programs Having created saved and tested the program TUTORIAL using the Editor you are now in a position to run it again on your AT Series Tester but this time using the Server The procedure for transferring the program to the Server archive will depend on where you have installed the Editor and Server programs Editor and Server on Separate PC s In many situations the Editor and Server can be installed on separate PC s as shown in the illustration earlier In this situation the AT is used to perform the transfer Before proceeding further make sure that all the following have been set up e The interface cable between the tester s auxiliary port and the selected COM Port on the Editor PC is correctly fitted and that the COM Port is correctly configured in the Editor software see the Edito
141. ed to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 29 TESTS AND TEST CONDITIONS 7 1 7 D DISSIPATION FACTOR OR TANS Measurement Test Test Basic Range Voltage Frequency Accuracy 0 001 to 1000 1mV to 5V 20Hz to 3MHz 0 596 SEE ALSO THE CAPACITOR TESTING SECTION OF THIS CHAPTER AT Series Tester The parameter D is most often used as a measurement of the losses in a capacitor It is analogous to Q for a transformer winding For this equivalent circuit the Dissipation Factor D is defined as D Rs _ where o 2 1 aCs For a given capacitance the lower the equivalent series resistance the lower is the value of the dissipation factor or tan i e the better the capacitor Where Used The dissipation factor test would normally be used for capacitors of all types A D factor test will help to determine that the capacitor has been manufactured correctly PAGE 7 30 VOLTECH ATI USER MANUAL Test Conditions To measure Dissipation Factor the tester applies an AC voltage across the selected winding and measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain a complex impedance from which the Dissipation Factor is obtained Choosing the Test Signal For optimum accuracy and performance use the test conditions chosen for capacitance in a later section of this chapter The test conditions c
142. ement ne doit tre confi e qu un personnel qualifi ayant lu et compris le pr sent manuel d utilisation Dans le doute s adresser au fournisseur GEFAHR VON ELEKTRISCHEM SCHOCK Nur entsprechend ausgebildetes Personal ist berechtigt diese Ausr stung nach dem Lesen und Verst ndnis dieses Anwendungshandbuches zu installieren Falls Sie Zweifel haben sollten wenden Sie sich bitte an Ihren Lieferanten RISCHIO DI SCARICHE ELETTRICHE Solo personale qualificato pu installare questo strumento dopo la lettura e la comprensione di questo manuale Se esistono dubbi consultate il vostro rivenditore VOLTECH ATI USER MANUAL PAGE III Contents T INTRODUCTION ees lecce cea p er st oz ec cs cu Reet 1 1 1 1 How to Use this Manual eene 1 5 1 2 General Safety Instructions eese eene nnne 1 6 T G ATE and ATO600 oid die ep nde ua eh 1 7 1 4 Tests S pplied doe E ee a m e Cee 1 8 1 5 ATi Features Summary iii i RE 1 11 1 6 Typical Production Installation esee nnns 1 12 1 7 Using the ATi for Design and Evaluation eene 1 14 1 G OVerVieW 1 15 1 9 How Does the ATi Tester Run a 7 1 26 2 Getting Started eere tere iemeirrr 2 1 2T o E e Ee tote teg 2 5 2 2 Installation tae do Lb pete ei 2 10 2 3 Quick Start Tutorial ento 2 19 24
143. energylost Real part of impedance Rs tan Energy stored Imaginary part of impedance X Where is the angle between the total complex impedance Z and the imaginary axis VOLTECH ATI USER MANUAL PAGE 7 125 TESTS AND TEST CONDITIONS ESR Equivalent Series Resistance This is also a measure of the losses in the capacitor The ESR is the equivalent AC resistance of the series equivalent circuit To measure ESR choose the test RLS in the PC editor or select Rs SERIES circuit from the front panel LCR mode Use the test conditions determined for the C test ESR is a measure of equivalent AC resistance at a specified frequency and will be different to the expected DC resistance of contacts and leads Compensation For most capacitors and especially film and ceramic types the dissipation factor will be very low typically 0 01 The errors due to connections and lead impedances can thus be very significant For the best accuracy always use 4 terminal connections and perform compensation before recording measurements PAGE 7 126 VOLTECH ATI USER MANUAL 8 SPECIFICATIONS VOLTECH ATI USER MANUAL PAGE 8 1 SPECIFICATIONS PAGE 8 2 VOLTECH ATI USER MANUAL SPECIFICATIONS Contents Specifications 8 1 SPECIFICATIONS SUMMARY AVAILABLE 5 8 5 8 2 ACCURACY SPECIFICATIONS AVAILABLE 5 8 8 8 2 TH TeSlu ue ed eem
144. er Directories OK TRI c at3600 server Cancel TR2 Delete TR3 TR4 He TR5 Help Network Drives v c ms dos amp When you have selected the correct part to open click on the OK button You will now be able to view the text listing of the test program chosen Part TUTORIAL File 081545 ox Definition 01 Part TUTORIAL Fixture TUTORIAL Schematic 1 LL LR LR NND n 10 8 Header VOLTECH ATI USER MANUAL PAGE 4 7 AT SERIES SERVER 4 2 3 SAVING A NEW COPY OF A PART Using the SAVE AS function under the PART menu you are able to save a new copy of the same test program under a new part name e Open the part required and select SAVE AS e Enter the new part name and select the appropriate file path e Click on the OK button A new copy of the test program will now be saved with the new part name as specified Save Part Part Number Directories Tre c at3600 server Cancel a CA S at3600 server Help Network ug Drives amp c ms dos 5 IMPORTANT When using the SAVE AS function you must be aware that it is not a RENAME function The previous copy of the test program with the original part name will remain in your program directory Note that if you are attempting to save a new part under the same name as an already existing part a message box will appear asking you if you wan
145. er Offset provides this additional feature See also the notes under test conditions above Choose test limits as close as possible to the nominal value in order to detect faults It is common practice to specify a maximum limit only VOLTECH ATI USER MANUAL PAGE 7 49 TESTS AND TEST CONDITIONS 7 1 12 C INTERWINDING CAPACITANCE TEST PARALLEL CIRCUIT Measurement Test Test Basic Range Voltage Frequency Accuracy 100fF to 1mF 1mV to 5V 20Hz to 3MHz 0 196 SEE ALSO THE CS AND CP TESTS AND THE CAPACITOR TESTING AT Series Tester SECTION OF THIS CHAPTER Capacitance occurs in transformers due to the physical proximity of and electrostatic coupling between different turns of wire In general the capacitance is distributed between different layers within a winding and between the outside layer of one winding and the inside layer of the next Although the capacitance is distributed across windings it is usually represented by a simple equivalent circuit showing a single capacitance from one winding to the next Where Used An interwinding capacitance test can be used to check for correct winding position and to check for the correct insulation thickness between windings where isolation between primary and secondary windings is important The test can be used to check for capacitance between windings where for example too large a capacitance may couple unwanted noise signals between power and control circuits PAGE 7
146. er compensation O C compensation in this case Remove the S C bobbin but leave the fixture in place before performing an O C comp You do not have to perform both types of compensation but it is always recommended VOLTECH ATI USER MANUAL PAGE 2 75 GETTING STARTED SC compensation FAIL SC Comp CFor SC COMP connect all used terminals together Ho S7C Comp Should either S C or O C compensation display a FAIL as shown above check 9 The short circuit connections for S C compensation That there are no erroneous short circuits on the fixture 9 That the fixture is properly seated and locked down into the fixture bay Then retry the compensation 9 That for each node that is used the fixture short circuits power and sense together when there is no test piece in place One compensation has been successfully completed the compensation values are stored within the AT until a new program is loaded the tester is switched off or compensation is re run Test programs can be run without fixture compensation being performed but this may affect the accuracy of the results depending upon the type of transformer being tested and the fixture design PAGE 2 76 VOLTECH ATI USER MANUAL GETTING STARTED 2 9 SET UP MODE Set up mode has two main functions To change the tester s set up options including setting up for Server operation and to download a group of programs from the Server PC to the tester s internal memory
147. eriod normally Medium and enter the terminals to be measured Do use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be 96 A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only PAGE 7 40 VOLTECH ATI USER MANUAL Use Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits nH mH etc when entering absolute values as limits Test limits should be set as close as possible to detect assembly faults A transformer made with a pair of gapped ferrite cores can often be tested to a tolerance of 2 For un gapped cores the tolerance may have to be as much as 20 because of the core manufacturer s tolerance If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 41 TESTS AND TEST CONDITIONS 7 1 10 L2 INDUCTANCE MATCH Measurement Test Test Basic Range Voltage Frequency Accuracy 1 10000 to 10000 1 1mV to 5V 20Hz to 3MHz 0 196 AT Series AT Secondary Tester measurements The inductance of a winding is determined by the number of turns and the construction and dimension of the core materi
148. erver has been completed you will see the Server icon in the program group Voltech Software Double click with the left mouse button on the Server icon to start the program Before you can use the Server the PC communication channels must be assigned for each tester connected PAGE 2 16 VOLTECH ATI USER MANUAL GETTING STARTED When the Server is executed for the first time the following dialogue will be displayed r Voltech Tester Type COM Port AT x Open COM4 Add gt lt Remove Do not display this dialogue at Startup Close A check box Do not display this dialogue at Startup exists to prevent it from being displayed each time the Server application is launched When this option is activated this dialogue box can be accessed via the Setup Communications menu To assign a particular AT Series Tester to a COM port 1 Select the communication port to which your tester is connected from the COM PORT selection box 2 Click on the ADD button to append your connection to the current connection list 3 To remove a current connection select it from the list and then click on the REMOVE button IMPORTANT You must have at least one AT Series Tester connection to use the program transfer or results storage functions of the Server application VOLTECH ATI USER MANUAL PAGE 2 17 GETTING STARTED The final stage of setting up the server involves specify
149. es any measurement instrument may report negative inductance values and measurement errors Should these symptoms be observed reduce the test frequency to avoid problems The frequency at which the inductive impedance equals the capacitive impedance X is known as the self resonant frequency SRF of the component At this point the phase angle of the impedance which can be measured using the ANGL test is zero At test conditions where the frequency is low enough for problems with capacitive impedance to be negligible the phase angle will be positive and close to 90 degrees Therefore an ANGL test can be used during program development to confirm if measurement problems are due to the chosen test frequency approaching the SRF of the part under test If the angle is significantly less than 90 degrees consider reducing the test frequency Note that stray fixture capacitance will add to the capacitance of the component and reduce the SRF Performing compensation will remove the effect of stray fixture capacitance on the measurement of capacitance but cannot remove its effect on SRF PAGE 7 8 VOLTECH ATI USER MANUAL Tests Currently Available Tr nsformer Application Reason for Test Checks properly installed CTY Continuity All fixture and part Checks properly installed R DC Resistance All fixture and part correct wire used and integrity of terminations R2 DC Resistance Match SMPS audi
150. es with a 2 15uF capacitor Entering the impedance in terms of R and X allows even more complex networks to be used for the RLOS test Remember that X the imaginary impedance is the impedance at the specified test frequency PAGE 7 98 VOLTECH ATI USER MANUAL Xe 1 2 Note that the PC Editor s Measure button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt Aminimum value only lt Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 99 TESTS AND TEST CONDITIONS 7 1 24 Z ZB IMPEDANCE IMPEDANCE WITH BIAS Measurement Test Test Basic Range Voltage Frequency Accuracy 1mQ to 1MQ 1mV to 5V 20Hz to 3MHz 0 296 RM AT Series Impedance Z Tester The impedance of a transformer is usually complex that is it consists of real resistive and inductive or capacitive imaginary parts The total impedance at a specified frequency is the vector sum of these parts Z V R x Where R and X are the real and imaginary parts of the total impedance The impedance test checks the i
151. est Other measurement circuit Measured V Program V There are circumstances when the ATi cannot maintain the measured voltage to be equal to the program voltage For example if the AC impedance of the winding under test is only 0 10 at the specified frequency and you have specified a 5V test signal then the AT yould have to supply 5V 0 10 50 Amps and this is not possible Under these circumstances the ATi display of both program and measured voltages will clearly show the difference PAGE 6 36 VOLTECH ATI USER MANUAL FRONT PANEL MODES 1 089 3mH 2 5656 CFixture made Frint Pegi 3 Ws 58 Hz More Tests Mes 218m 386m Sh Hz There may also be circumstances where the ATi cannot stabilize sufficiently to make a repeatable measurement in which case the measurement will be 0 and the bottom line of the display will show Overload adjust V or f If you see either of the above error messages either decrease the test voltage or increase the test frequency until an acceptable condition is reached You could of course choose AUTO values of voltage and current In either case the ATi will not sustain any damage even if it is left permanently in the overload condition If you are using a value of DC bias current other than 0 you may also see the message Overload reduce bias VOLTECH ATI USER MANUAL PAGE 6 37 FRONT PANEL MODES in which case you should reduce the bias level until a result is dis
152. esting small quantities D Fixture Clamp The hand clamp is supplied with 7 height blocks and fixings VOLTECH ATI USER MANUAL PAGE 5 7 FIXTURES 5 2 1 BASIC FIXTURE PLATE The Fixture Plate may be used to mount existing test fixtures onto an AT Series Tester or to create test fixtures for flying lead parts where spring probes are not required Fixture Plate Components 1 Base Plate Already fitted with 20 pairs of contacts the base plate fits into the top of the tester and makes electrical connection to the tester s 20 pairs of test nodes The base plate has moulded indents and guides to ease the fitting and wiring of larger test sockets and posts for flying leads 2 Cover Plate This mounting plate allows convenient attachment of various sockets and connectors Please note that this plate is only 1mm in thickness and is therefore not suited for probe or Kelvin pin mounting Refer to the Custom Fixture Kit for this purpose PAGE 5 8 VOLTECH ATI USER MANUAL FIXTURES 5 2 2 CUSTOM FIXTURE KIT The Custom Fixture Kit enables many types of transformers and other wound components to be quickly and securely connected to an AT Series tester for fast and accurate testing The system can accommodate transformer sizes of up to 63 5mm 2 5 and with suitable probes parts with surface mounting pin blade or flying lead connections can be connected The fixture system is supplied as detailed in the comprehe
153. fe fixtures using the guidelines given in the fixturing section of this manual e Beware of testing parts with high turns ratios such that a small applied test signal can generate an unsafe high voltage e Beware of energy stored with the capacitance or inductance of the part being tested when handling the part after test PAGE 1 6 VOLTECH ATI USER MANUAL INTRODUCTION 1 3 ATI AND AT3600 The ATi is one of a family of automatic testers from Voltech that share the same fixture construction and PC Editor and Server software ATi s and AT3600 s can share the same Server application simultaneously recalling test programs and recording test results AT 3600 ATi ATi 20 way switching matrix Y PC test editor and results server Y Test fixture system Y Small signal tests e g inductance capacitance turns Y Y Telecom tests e g return loss longiti Jinal balance Y Y Insulation resistance 500V 7000V Hi pot AC 5500V Hi pot DC 7000V Surge testing 5000V Magnetizing current and open circuit Itage 270V Watts Stress Watts v Leakage current VOLTECH ATI USER MANUAL PAGE 1 7 INTRODUCTION 1 4 TESTS SUPPLIED At the time of printing the following tests are available for the ATi 1 4 1 Standard Program Tests CTY Continuity R DC resistance RLS AC resistance series circuit RLP AC resistance parallel circuit LS Inductance series circui
154. fixture and press Continue again to make the first measurement which is a short circuit compensation e Next remove the short but ensure that the power and sense terminals are short circuited together on nodes 13 and 15 Press Continue to run a short circuit compensation e Next connect the nominal 750 Ohm resistor between node 13 and 15 and press Continue BHC Lead Calibration Measuring 756R resistor on the fixture EN h 3 9 h Next the process is repeated using the BNC leads e Ashort circuit compensation on the BNC leads e An open circuit compensation on the BNC leads e Ameasurement of the 750 Ohm resistor using the BNC leads At the end of the process press continue to save the new calibration factors or press Abort to discard them and return to the previously stored calibration You may press the Abort softkey at any time to stop the process and discard changes PAGE 2 82 VOLTECH ATI USER MANUAL GETTING STARTED BHC Lead Calibration Continue BHC calibration successful Press to save neu calibration factors HE p AT Password Pressing the Change softkey brings up the following display Confirmation Enter the neu AT Password Delete Abort Shift Enter the new AT password via the instrument keypad using the Shift softkey to activate letter entry if necessary Press Enter to confirm the new password Resetti
155. former by adding tests to the program from the VOLTECH ATI USER MANUAL PROGRAM EDITOR Available Tests list The following sections describe how to do this Winding Resistance Valtech 3 3 2 ADDING TESTS A test program is a list of tests chosen from the Available Tests list To create a new program you simply add tests to the list To add a test use the mouse to select the test you require from the Available Tests list and double click on that test with the left button This will open the dialogue box particular to that test You simply fill in all the fields of the dialogue box and then click on the OK button The test will be added at the end of the Program As an example if you wish to add another R Winding Resistance to the program Double click on the R Winding Resistance test in Available Test list VOLTECH ATI USER MANUAL PAGE 3 21 PROGRAM EDITOR Fill in the fields of the dialogue box Click on the OK button You will now see this test added to the Program Program List Maximize Winding Resistance Integration Medium High Terminal Low Terminal B LS Minimum Value 59 000 Ohms Maximum Value 73 000 Ohms Low Terminal D Maximum Value For Help press F1 3 3 3 INSERTING TESTS Normally if you are creating a new test program you would add the tests in the correct order of execution as described in the previous section You would also use this procedure
156. frequency range is less than specified limits Measurement Conditions The RESP test consists of a number of Insertion Loss ILOS tests repeated at different frequencies The resistors shown are fitted to the test fixture and should be switched out of circuit when making other measurements such as resistance and inductance This can be done by fitting relays to the fixture and switching them at appropriate points in the test program using OUT tests The first ILOS test is made at a reference frequency that is usually near the middle of the band of frequencies of interest The result of this test is the OdB reference level Further ILOS tests are then carried out at user selected frequencies and the results referred to the reference dB level VOLTECH ATI USER MANUAL PAGE 7 89 TESTS AND TEST CONDITIONS 0B QE c SS 5dB 10dB Insertion Loss Frequency The result of a RESP test is a single value chosen as follows If all the referred ILOS results are at or inside the specified limits the result of a RESP test is the referred ILOS result that is closest to the limit If any of the referred ILOS results are outside the specified limits the RESP result is the referred ILOS result that is furthest away from the limit Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test PAGE 7 90 VOLTECH ATI USER MANUAL Programming the Test Using the PC Test Editor F
157. g the Auxiliary port Editor software Pull down menus in the Editor allow you to download the program to the tester so that it may be run for the purposes of evaluation and modification 1 8 2 Storing Programs and Results The Server The Editor software previously described allows you to create and evaluate each individual test program It is not intended to manage the large numbers of test programs that may be required on a daily basis once they are in production use This is the function of a second PC program supplied with your ATi called the Server Usually the Server would be installed on a PC with access to a large disk that could be attached to the PC itself or connected via a network The Server and disk would then be used for any of the following purposes To provide the master archive for test programs To archive test results To interface to an SPC package To remotely control the tester The tester has a separate server port on its rear panel for connecting to the PC VOLTECH ATI USER MANUAL PAGE 1 17 INTRODUCTION 1 8 3 Transferring Programs between Editor and Server Within your test environment there are several possible ways in which the Server and Editor may be installed and used depending on how many separate PC s are available Programs The standard installation uses separate PC s for the Editor and Server Transferring a new test program from the Editor to the Serve
158. g the test program with the AT Series Editor By the end of this section you will be able to Set up the program options Add a test to the program Insert a test in the program Modify an existing test in the program Delete a test Use the measure button to create test parameters Verify the program including fixture compensation VOLTECH ATI USER MANUAL PAGE 3 13 PROGRAM EDITOR 3 3 1 SETTING THE PROGRAM OPTIONS Overview After you have created the program schematic and before starting to insert any tests in the program you should set up which program options you would like to use From the top level menu bar select Program Options Yoltech Test Program Editor New Part Program Options You will then see the following dialogue box Configure Transformer Tester m m Bee PAGE 3 14 VOLTECH ATI USER MANUAL PROGRAM EDITOR You may now set up any of the following options by simply clicking with the left button of the mouse Results Printing Printed reports may be obtained from the printer port of the tester as follows There will be no results printed out during the test execution Failures Only Full Reporting Operator Numbering Batch Numbering Serial Numbering Send Results to Server Send Retry Results to Server Stop on Fail VOLTECH ATI USER MANUAL The results of the tests producing a fail result will be printed The results for all the tests in the pr
159. gif Sten VOLT luci 0 00000255 INDUCTANCE Temporary UCL 0 00000255 Mean 0 00000253 LCL 0 00000252 mR 2 Just Suen 4 EN a p E y AAA d Nat v VT Vt Macr UCL Target ae ee ae Se a ea ee ee Te a en ee ee eee 1 4 55 649 B string filled in bmp SAAT Server AT on C amp B cHARTrunner S CHARTrunner I 11 07 Inductance Trend Analysis ECH ATI USER MANUAL PAGE 4 27 AT SERIES SERVER HARTrunner Inductance Fit Edit View Help RESISTANCE Er r1 T amp amp Basic Statistics zl 8 8 50 Data points B B poin al Maximum 0 031 Mean 0 02395237 R Minimum 0 048 AN Sigma i 0002903942 24 S N Skewness 0 20929300 Kurtosis 0 17929887 i Coeff Of Variation 12 27195590 6 Dpm 1000000 nol i Subgroup Statistics mR 2 l Avg Range 0 00256057 54 i j i Avg Sigma 0 00181059 Estimated Sigma 0 00227001 i H Capability Indexes 1 i Cp 0 00001468 k Cpk 3 51684307 zl Cr 68100 19539731 a4 d Chi square e 5 724 f i 2 degreesof freedom 4 i N Normal distribution zi l Confidence Level 90 Fits the curve Resistance Distribution Analysis CHARTrunner Overall PassFail File Edit View Help Count Percent
160. hat are being used AQL monitoring is an optional feature of the Voltech PC Server which displays live summary results from multiple AT testers When the AQL set here is reached or exceeded the Server will display a warning Both types of AQL limits may be used at the same time Reaching any one limit will cause a warning to be displayed on the Server For further details see the AT Server section of this manual AQL No of Parts AQL 96 of Parts Fixture ID PAGE 3 16 This is the number of failures in the batch at which a warning will be displayed on the Server This is most often used when the batch size is always similar or zero very small numbers of defects are expected This is the percentage level of failures at which a warning will be displayed on the Server Note that this AQL is only applied after sufficient parts have been tested to make the percentage meaningful When setting AQL of Parts to be 1 for example a warning will only be displayed after 100 1 100 parts have been tested Finally you should enter a fixture name The Fixture ID can be up to 20 characters long You may use any of the characters that appear on the tester s keyboard A Z upper case only 0123456789 and space VOLTECH ATI USER MANUAL PROGRAM EDITOR When the test program is run on the AT Series Tester the operator will be prompted to fit the fixture with this name This will help to make sure that the correct fixtur
161. he ATi may be rendered inoperable and require Service at a service center For optimum performance and reliability always upgrade the boot code when prompted If there is a risk that power or communications may be disrupted you may choose not to upgrade the boot code at this time but you should do so at the earliest opportunity The ATi will continue to function without new boot code PAGE 9 8 ATI USER MANUAL 10 INDEX Applications Support 9 6 AQL euet aee Barcode Input 6 68 Beeper Volume BNC connectors BNC Lead Calibration 2 81 calibration system 9 9 7 50 CAPACITANCE 7 57 Capacitor measurements 7 126 Clock setting 2 79 COM Port configuration Editor 2 13 COM port configuration Server 2 16 COMP feq eerte 6 7 Compensation 2 73 3 46 compensation editor measure 3 33 Compensation LCR mode 6 29 CONTINUITY 7 12 CORE CONNECTION 3 11 DATABASE 5 4 24 Display Background 2 79 Dis
162. he correction for current level 96 The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below c 0 0896 0 000000146 x Fy Ay 0 0896 0 000003 V4 A 0 08 0 0000003 11 0 03 x Ip Im Where Fm is the measurement frequency Hz Vm is the measured voltage V Iu is the measured current A is the bias current A VOLTECH ATI USER MANUAL PAGE 8 21 SPECIFICATIONS 8 2 15 ANGL TEST The accuracy is given as Ar AptActAytA Where Ar is the total accuracy Ar is the basic relative accuracy Ac is the calibration accuracy Ay is the correction for voltage level is the correction for current level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below 0 03 0 0000005 x Ay 0 03 0 000003 V A 0 03 0 0000003 0 03 x Ip Iu Where Fm is the measurement frequency Hz Vm is the measured voltage V Iu is the measured current A is the bias current A PAGE 8 22 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 2 16 PHAS TEST The accuracy is given as Ar AptActAytaAy Where Ar is the total accuracy Ar is the basic relative accuracy Ac is the calibration accuracy Av is the correction for voltage level AN is the correction for turns ratio 7 The value of Ag is given in the
163. he default user name Admin with no password may be adequate Consult your database administrator if you need a specific user name and password PAGE 4 20 VOLTECH ATI USER MANUAL AT SERIES SERVER When you click on Test Connection you should see something similar to Microsoft Data Link i Tx Next click on OK of the Test connection succeeded dialogue and select the Advanced tab VOLTECH ATI USER MANUAL PAGE 4 21 AT SERIES SERVER po Data Link Properties Check that the Access permissions for the database are as required Share Deny None is the default and is usually the most suitable setting PAGE 4 22 VOLTECH ATI USER MANUAL AT SERIES SERVER Under the All tab all of the individual settings can be reviewed and adjusted if necessary Ls Data Link Properties x Provider Connection Advanced All These are the initialization properties for this type of data To edita value select a property then choose Edit Value below Name Value Data Source C Program Files Voltech Ins Extended Properties SCOUNTRY 0 CP 1252 LAN Jet OLEDB Database Password Jet OLEDB Global Partial Bulk Ops 2 Jet OLEDB Registry Path Jet OLEDB System database Locale Identifier 1033 Mode Share Deny None Password Persist Security Info False UserID Admin Click on OK to complete the setting of the data link properties A typical AT Server advanced database results dialogue would be Database Result
164. he fixture PAGE 7 94 VOLTECH ATI USER MANUAL Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt Aminimum value only Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 95 TESTS AND TEST CONDITIONS 7 1 23 RLOS RETURN Loss Measurement Test Test Basic Voltage Frequenc Accurac Range g q y y 100dB to 100dB 1mV to 5V 20Hz to 3MHz 0 296 5 AT Series Impedance Z Tester The return loss is a measure of the impedance mismatch between the transformer and a transmission line If the impedances are not the same some signal power is reflected or returned to the transmission line instead of being coupled through the transformer Where Used The return loss test is used to check the impedance of audio and telecommunications transformers that are to be used with transmission lines of specified impedance The test helps to ensure that the transformer has been assembled properly using the correct core and winding materials Test Conditions The load resistor RL is connected to the transformer under test as shown This may be done automatically using
165. he measurement can be compensated for any scaling on the fixture For example where the fixture transformer is not 1 1 Note that the Editor s Measure button CANNOT be used to determine the test voltage VOLTECH ATI USER MANUAL PAGE 7 83 TESTS AND TEST CONDITIONS Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only lt Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value PAGE 7 84 VOLTECH ATI USER MANUAL 7 1 20 LBAL LONGITUDINAL BALANCE Measurement Test Test Basic Range Voltage Frequency Accuracy 0 dB to 100 dB 1mV to 5V 20Hz to 3MHz 0 5dB Longitudinal balance is a measure of the common mode rejection ratio CMRR of a transformer That is the ability of the transformer to reject unwanted noise signals that are common to both input terminals with respect to a common point An ideal transformer would have infinite CMRR Vout1 0 In practice differences in symmetry of transformer construction mean that input common mode signals appear as unwanted output voltages See also the GBAL test Where Used The longitudinal balance test is used to confirm the CMRR of audio and telecommunications transformers that are designed to be connected to a balanced line The test ensures that the transformer will reject common mode no
166. he test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt Aminimum value only lt Amaximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits mOhm Ohm etc when entering absolute values as limits Normally it is important to set a maximum limit as closely to the nominal value as possible to ensure that the correct wire has been used Typically a limit of 5 or 20mQ whichever is greater is set The minimum value is not usually so critical It can be set to any value that ensures that there is no solder splash causing a short circuit between pins Typically 20 VOLTECH ATI USER MANUAL PAGE 7 15 TESTS AND TEST CONDITIONS 7 1 4 R2 DC RESISTANCE MATCH Measurement Test Test Basic Range Voltage Frequency Accuracy 1 1000 to 1000 1 N a N a 0 296 Po ane N AT Series NE AT Secondary m urement Tester Xo mss ds b a Where Used The DC resistance match test as opposed to an ordinary DC resistance measurement R is used on audio and telecommunications transformers where it is important that the resistance of different pairs of windings is controlled and matched to a specified ratio The absolute value of the resistances may be of less importance to the performance of the transformer than the match between two resistances
167. he user port is situated at the rear of the ATi VOLTECH ATI USER MANUAL PAGE 7 113 TESTS AND TEST CONDITIONS See also the tests for audio and telecommunications transformers LBAL GBAL ILOS RLOS and Z Most types of power and many signal transformers will be tested using the tester s internal relay matrix to perform switching and an OUT test is not required for these Test Options The OUT test is programmed into a test sequence like any other test The OUT test programmes any of the six available relay drives in any pattern desired The drives stay in the programmed state until another OUT test is performed or a new part is tested The relay drives controlled by the OUT test are designed for switching external user supplied relays only and should NOT be connected directly to the tester s test nodes Choosing Test Options Each of the relay driver outputs can be set to on or off closed or open respectively as shown Output to User Port Lx Relay Settings Relay 0 On C Off Relay 1 On Off Relay 2 On 5 Off Relay 3 C On 5 Off Relay 4 C Off Relay 5 C On Off Once the settings are correct click on OK to accept them PAGE 7 114 VOLTECH ATI USER MANUAL Note The relay drivers are only set as and when the tester encounters an OUT test The settings given will remain in place until another OUT test is encountered Therefore if the settings are required for one part of the test program only two OUT
168. heck is a very quick test to determine if the transformer has been inserted correctly into the fixture Used with the Stop on Fail feature of the ATi the transformer can be re seated without wasting test time or recording a FAIL R Resistance Check the DC resistance of every winding to ensure that the correct diameter wire has been used and that it is finished or terminated properly A poor solder joint may not show as an out of tolerance inductance but could lead to a reduced service life for the transformer LS Inductance Series Circuit As described above an inductance measurement will confirm that the correct number of turns has been wound and that the correct cores have been properly assembled The test is usually performed on one winding only If there is no obvious primary winding use the winding with the greatest number of turns for the best accuracy and stability Q Quality Factor Q is the ratio between the imaginary inductive and real AC resistive parts of the winding s complex impedance Measuring the expected Q figure gives further indication that the correct wire turns and cores have been used Q is usually measured once only on the primary TR Turns Ratio and Phasing Turns ratio checks the correct number of turns has been wound in the right direction or phase Turns ratio should be performed on every winding with the VOLTECH ATI USER MANUAL PAGE 7 5 TESTS AND TEST CONDITIONS win
169. i Shown on the back of the instrument PAGE 9 6 ATI USER MANUAL WARRANTY AND SERVICE e The firmware revision level of the ATi Shown on the ATi s front panel during power on e The software revision levels of the PC Editor and Server software that you are using 9 5 FIRMWARE UPGRADES The firmware of the ATi controls how tests are carried out which tests are available and how the interfaces including the front panel function New versions of the firmware are made available periodically and electronic copies are available free of charge To maximize the performance and longevity of your ATi you should install these upgrades as they become available Contact your local supplier or see the Voltech website at www voltech com for details Upgrade firmware is distributed in a file with the extension ABS Upgrade firmware is available at the Voltech website or from your supplier and can be downloaded into any ATi If you have purchased new tests you will be supplied with a file called ATIxxxx ABS that contains the tests you have requested as well as the latest version of firmware An ATIxxxx ABS file can only be used with the serial number xxxx of the tester that it is registered to Save the file to a local or network directory normally C Program Files WVoltech Instruments Voltech AT Editor You may also be supplied with a file called BOOTATi ABS You must save this file in the same directory To upgrade locate
170. icence for use must be obtained from your Voltech supplier All results formats can be saved simultaneously VOLTECH ATI USER MANUAL PAGE 4 17 AT SERIES SERVER Click on Advanced to set up your database connection Database Results Advanced x Connection String Connection Type OK Cancel To connect to your database the Server software uses a connection string that contains amongst other things the name of a provider the name and location of the database and a valid database user name and password if required You may need to consult with the database or network administrator to obtain this information If a connection has already been established you will see the connection string in the window inside this dialogue If you wish to remove an existing connection string click on Clear Connection PAGE 4 18 VOLTECH ATI USER MANUAL AT SERIES SERVER To establish a new connection click on Connection Type Ls Data Link Properties x Provider Connection Advanced All Select the data you want to connect to OLE DB Provider s Microsoft Jet 3 51 OLE DB PI E Microsoft Jet 4 0 OLE DB Provider Microsoft OLE DB Provider for Internet Publishing Microsoft OLE DB Provider for ODBC Drivers Microsoft OLE DB Provider for OLAP Services Microsoft OLE DB Provider for Oracle Microsoft OLE DB Provider for SQL Server Microsoft OLE DB Simple Provider MS Remote MSDataShape The Data Link Proper
171. idge can be determined and the tester is then programmed to deliver the same test conditions across the inductance the results will then agree See also the comments below on differences caused by the choice of equivalent circuit d Equivalent Circuit Inductance is always measured as part of a complex impedance the result being expressed in terms of either a series or parallel equivalent circuit Note that for any given winding the inductance values for the two circuits are not necessarily the same This should be born in mind when specifying the test limits Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values Aminimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits nH mH etc when entering absolute values as limits PAGE 7 24 VOLTECH ATI USER MANUAL Test limits should be set as close as possible to detect assembly faults A transformer made with a pair of gapped ferrite cores can often be tested to a tolerance of 2 For un gapped cores the tolerance may have to be as much as 20 because of the core s manufacturing tolerance If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered in the units shown is then added to any results re
172. ied Specified Auto Note that a fixed signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 43 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Inductance Match Choose the integration period normally Medium and enter the terminals to be measured Terminals X High and Low Winding 1 Terminals Y High and Low Winding 2 Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing the Test Limits The test limits are a nominal value together with and percentage limits Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Test limits should be set as close as possible to detect assembly faults If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester PAGE 7 44 VOLTECH ATI USER MANUAL 7 1 11 LL LLO LEAKAGE INDUCTANCE AND LEAKAGE INDUCTANCE WITH OFFSET Measurement Test Current Test Basic Range Frequency Accuracy 1nH to 1kH 20pA to 100mA 20Hz to 3MHz 0 196 LLO Offset Range 1H to 1H in 1nH steps Leakage L AT Series AT Secondary Tester measurement Due to imperfections in the coupling between windings a short circuited transformer acts as if there is inductive impedanc
173. ility and accuracy choose Long integration Compensation Compensation is described in detail in the next section VOLTECH ATI USER MANUAL PAGE 6 27 FRONT PANEL MODES Print Press the Print softkey in the settings menu and the measurement information displayed will be output to the printer port of the ATi Measurements can be recorded on any standard printer with a conventional PC type parallel centronics input The output is formatted using standard codes so that a simple 40 column ticket printer may be used DATE 30 JAN 02 14 55 26 LS 27 138uH Q 16 785 BNC comp req Prg AUTO V 123Hz Mes 1000mV 1 33mA 123Hz PAGE 6 28 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 4 COMPENSATION Measurements on the ATi can be compensated for the effects of stray connection capacitance and inductance that are always present The effect of the strays upon the measurement will vary significantly with the part being tested but for optimum accuracy Voltech recommends that all reference measurements should be made after compensation Program V Measured V xX Winding under test The ATi is fully compensated at the factory for a broad range of frequencies and compensation is often not required when using the LCR modes If compensation is required one of the following measurements will be displayed BNC comp req Fixture comp req Once compensation measurements have been carried out at a particul
174. imary but because of the physical errors already described these limits may be too severe for a normal good part This is why a combination of inductance and turns ratio tests are normally used to confirm the correct assembly of transformers The polarity test may be selected as ve ve or no test To measure the exact interwinding phase angle use the PHAS test Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 67 TESTS AND TEST CONDITIONS 7 1 16 TRL TURNS RATIO BY INDUCTANCE Measurement Test Test Basic Range Voltage Frequency Accuracy 1 100 100 1 1mV to 5V 20Hz to 3MHz 0 1 AT Series AT Secondary Tester measurements The correct ratio of the number of turns on one winding to the number of turns on another winding is important for the proper operation of any transformer The turns ratio is often determined by calculating the ratio of the voltages produced across the windings the TR test but it can also be determined from a measurement of the two winding inductances The inductance of a winding is proportional to the number of turns Squared L N and the turns ratio can thus be calculated as the square root of the inductance ratio PAGE 7 68 VOLTECH AT
175. imits The test limits can be Anominal value together with and percentage limits gt lt Minimum and maximum values VOLTECH ATI USER MANUAL PAGE 7 53 TESTS AND TEST CONDITIONS gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits pF nF etc when entering absolute values as limits Test limits should be set as close as possible to the nominal value in order to detect faults A typical tolerance would be 20 If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester PAGE 7 54 VOLTECH ATI USER MANUAL 7 1 13 CS AND CP CAPACITANCE TEST SERIES AND PARALLEL CIRCUIT Measurement Test Test Basic Range Voltage Frequency Accuracy 100fF to 1mF 1mV to 5V 20Hz to 3MHz 0 196 SEE ALSO THE C TEST AND THE CAPACITOR TESTING SECTION OF AT Series Tester THIS CHAPTER The CS and CP tests can be used to measure the capacitance of a wide range of components up to 1 milli farad Test Conditions To measure capacitance the tester applies an AC voltage across the designated terminals It then measures the voltage and the resulting current Dividing the voltage by the current gives the complex impedance from which the capacitance is extracted using harmonic ana
176. inductance capacitance or resistance measurements made and is given as Ap Where Ar is the total accuracy 96 Ax is the accuracy of the X measurement 96 Av is the accuracy of the Y measurement 96 Refer to the accuracy specifications for the LS C and R tests to determine the accuracy of the X and Y measurements VOLTECH ATI USER MANUAL PAGE 8 17 SPECIFICATIONS 8 2 11 GBAL TEST The accuracy is based on the test conditions chosen to measure the longitudinal balance of the transformer under test and is given as Ap Ap 0 87 ActAyytAyy Where Ar An Ac Avx Avy is the total accuracy dB is the basic relative accuracy dB is the correction for calibration is the correction for the X measurement voltage level is the correction for the Y measurement voltage level The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 1 0 000000196 x Fy Ayy O00 EAT Vix Ayy 0 001 PAV anal Vuy Where Fm Vix AVcuny is the measurement frequency Hz is the measured voltage for the X measurement V is the measured voltage for the Ymeasurement V is the error due to the common mode voltage in the X measurement is the error due to the common mode voltage in the Y measurement The error due to the common mode voltage in the measurement AVcmnx and AVcmny is given as AVoun Where Vomn PAGE 8
177. ing the file location paths MAT Server File Setup View Help Communications Directories Groups Password Results Select directories used when looking For and saving programs and results The directory set up dialogue will prompt you with the current directory Change these settings if you wish to nominate your own program and results storage directories Set Default Directories Program Directory c ATSB00 SERVER Results Directory CAPROGRAM FILESSVOLTECH Cancel The setting of program path directories may be altered at any time The directory set up dialogue may be found under the SETUP section of the menu bar IMPORTANT If you change the factory default settings remember that the Server will only look in the directories specified for test programs or results PAGE 2 18 VOLTECH ATI USER MANUAL GETTING STARTED 2 3 Quick START TUTORIAL 2 3 1 Introduction After you have installed your ATi and its associated Editor and Server PC software packages as described in the previous section you may wish to follow through this tutorial before trying to create any programs for actual use The purpose of this tutorial is to familiarize you with the process of creating a schematic and a test program using the editor Creating a Schematic of a 2 Winding 4 Terminal Sample Transformer This tutorial describes a method of setting up the tester to test a two winding transformer with the f
178. is very easy to use However it is a complex instrument which can be installed and operated in many ways In order to maximize the benefits that the ATi can bring to your test environment please study the following section carefully 1 6 TvPICAL PRODUCTION INSTALLATION Editor PC used only when creating Server PC for handling detailed or editing test programs results and large numbers of test programs Untested transformers Tested transformers ES gt Fail Manual or robotic operation Barcode input e Run pad or footswitch to initiate operation Simple PASS FAIL operation by an unskilled operator Results Direct printing from the ATi printer port Results archiving to disk using the Server application Results for analysis can be easily exported to other Windows applications PAGE 1 12 VOLTECH ATI USER MANUAL INTRODUCTION Test Program Creation e Simple easy to use Windows based Editor for creating test programs Chapter 3 Requires no software programming skills or expertise Test conditions may be entered manually or chosen automatically by measuring a sample transformer Program Archive Management Windows based Server software for easy management of all test programs See chapter 4 Optionally programs may be resident in the tester for stand alone operation VOLTECH ATI USER MANUAL PAGE 1 13 INTRODUCTION 1 7 USING THE ATI FOR DESIGN AND EVALUATION e Tests
179. ise signals as required in use Faults in the placement of windings or core may be detected using this test VOLTECH ATI USER MANUAL PAGE 7 85 TESTS AND TEST CONDITIONS Test Conditions The source and load resistors RS and RL are connected to the transformer this may be done automatically using the tester s OUT test Then two measurements are performed using the circuits above which the tester automatically configures First the test voltage Vin is applied as a common mode signal and the output voltage Vout1 is recorded and then the same Vin is applied as a normal input voltage and the output Vout2 is recorded Longitudinal balance is calculated as the ratio LBAL 20 log Vout2 Vout1 A D AN R AN S Visi Ri Vout Rs v B E V P AN AN Vino Vour2 CH SE in red aca Few A 8 5 Temmas as c D E PAGE 7 86 VOLTECH ATI USER MANUAL Choosing Test Conditions The source and load resistors are not shown on the Editor schematic They are switched in circuit using an OUT test that must be inserted in the program before the GBAL test The relay patterns associated with inserting and removing fixture resistors have deliberately not been included in the GBAL test dialogue for two reasons a it would make the dialogue too complicated and b it is not always necessary e g in the case of a fixture where the resistors are permanently fitted in circuit Programming the Test Using th
180. ity Factor Q Dissipation Factor or tan D AC impedance magnitude of omplex impedance Z Ohms Q Phase angle of impedance 0 Degrees AC reactance imaginary part gt f impedance X Ohms Q Turns ratio by voltage TR Turns ratio by inductance TRL Leakage inductance LL Henries H Interwinding capacitance C Farads VOLTECH ATI USER MANUAL PAGE 1 9 INTRODUCTION To determine which options were installed on your tester during manufacture check the list attached to the calibration certificate shipped with your ATi PAGE 1 10 VOLTECH ATI USER MANUAL 1 5 ATI FEATURES SUMMARY INTRODUCTION The ATi tester is a fast accurate and versatile automatic LCR meter FAST Typically more than 10 DIFFERENT tests per second 20 way switch matrix Automatically switches from making measurements on one winding of a transformer to another winding Measures across different windings e No need to manually change connections Fast execution of a sequence of different tests on multiple windings of a transformer ACCURATE 0 05 basic Inductance from Any frequency from Any voltage from AC constant current source DC bias up to VERSATILE Easy to use High speed production tester Laboratory grade LCR meter 1nH to 1MH 20Hz to 3MHz 1 to 5V 20 to 100mA 1A Upgrades and new tests installed from disk VOLTECH ATI USER MANUAL PAGE 1 11 INTRODUCTION The ATi
181. k kk Sk kc ko ko kc KKK KK OLE Demo Sub Procedure to demonstrate linking AT results into an Excel spreadsheet in real time using OLE The procedure will read the third test in the program and put the result into a cell on the third row of the spreadsheet The procedure will do this for a total of 3 program runs and then exit Sub OLE Demo Dim objServerResult As Object Dim vntResult 1 To 99 As Variant Set objServerResult CreateObject Server Results nTest 3 nNumRuns sComPort 3 COM2 Dummy read to clear any previous result vntResult nTest objServerResult GetVariantResult sComPort nTest MsgBox Press the RUN softkey on the AT For nRun 1 To nNumRuns Get the results Do vntResult nTest objServerResult GetVariantResult sComPort nTest Loop Until vntResult nTest lt gt NO RESULT And _ vntResult nTest lt gt INVALID RESULT NUMBER Cells 3 5 nRun vntResult nTest Put result in spreadsheet Next nRun MsgBox Done End Sub PAGE 4 42 VOLTECH ATI USER MANUAL AT SERIES SERVER When you have finished typing the code return to the Sheet 1 of the spreadsheet To run the code again from the Excel top level menu bar select Tools Macro At the dialog box select the name of the macro OLE_Demo and click on the RUN button The code will now start to run and after a few seconds you will se
182. keying in the numbers you require or by using the Measure button Clearly you would type in the test parameters if for example they have been specified by the designer of the transformer If you are not sure what values to PAGE 3 26 VOLTECH ATI USER MANUAL PROGRAM EDITOR use some guidance is given in chapter 7 Tests amp Test Conditions later in this manual If you are using the Measure button to enter limit values as described in the section later in this chapter you may also at the same time have the AT Series Tester enter the recommended test parameter values To do this in the case of the LS test you simply leave the Signal and Frequency edit boxes empty at the time you click on the Measure button If you choose either the mV or V unit button before clicking the Measure button the test signal determined by the tester will be entered as a voltage alternatively if you choose the mA units button before clicking the Measure button the test signal determined by the tester will be entered as a current Note that not all tests allow the test parameters to be chosen by the tester The programming details for each test in section 7 Tests and Test Conditions of this chapter specify which tests allow the Measure button to enter the test parameter values 3 3 7 TEST LIMITS In the Quick Start Tutorial chapter 2 it was stated that for the R Winding Resistance test the limits could be entered in four different wa
183. ks number of turns Wound components that right grade of correctly Inductance with External usually carry a significant assembled core LSBX Bias Series Circuit DC Bias current in normal material where bias operation current is greater than LSB test can handle Checks number of turns Wound components that right grade of correctly Inductance with External usually carry a significant assembled core LPBX Bias Parallel Circuit DC Bias current in normal material where bias operation current is greater than LPB test can handle Checks impedance at a given frequency while ZBX Impedance wil Exetel Audio amp Telecom applying a greater bias Bias current than is possible with ZB test Check www voltech com for the latest list of available tests Each test is described in detail in the following pages together with programming guidance for use with the Voltech PC Editor PAGE 7 10 VOLTECH ATI USER MANUAL These tests require the use of one or more Voltech DC1000 Precision DC Bias Current Sources Contact your Voltech sales office for details VOLTECH ATI USER MANUAL PAGE 7 11 TESTS AND TEST CONDITIONS 7 1 2 CTY CONTINUITY Measurement Range 10kQ to 10MQ Where Used The continuity test should be placed as the first test in the program to check that a transformer has been inserted correctly into the test fixture The test checks that every winding has a resistance less than a user specified limi
184. l secondary terminals Low Note that the Editor s Measure button CANNOT be used to determine the test voltage Choosing Test Limits Although the tester is capable of measuring insulation resistance values greater than 1GQ there is no need to specify so high a value to check that windings are isolated In many cases specifying a lower value will speed up the execution of the test A value of 100MQ is generally suitable for most applications Where higher voltage safety testing is required see the Hi Pot tests that are available with the Voltech AT3600 If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 79 TESTS AND TEST CONDITIONS 7 1 19 GBAL GENERAL LONGITUDINAL BALANCE Measurement Test Test Basic Range Voltage Frequency Accuracy 0 dB to 100 dB 1mV to5V 20Hz to 3MHz 0 5dB AT Series Tester IEEE 455 Fixture Transformer Fixture Transformer FCC 68 310 Longitudinal balance is a measure of the common mode rejection ratio CMRR of a transformer That is the ability of the transformer to reject unwanted noise signals that are common to both input terminals with respect to a common point An ideal transformer would have infinite CMRR Vout1 0 In practice differences in symmetry of transformer construction mean that input common mode signals appear as
185. lease see the chapter Tests and Test Conditions for a detailed description of each of these measurements and their application PAGE 6 18 VOLTECH ATI USER MANUAL 6 3 LCR MENUS See the previous section for details of the tests that are available FRONT PANEL MODES The following flow diagrams describe the menu structure for LCR BNC and LCR FIX modes 6 3 1 LCR BNC MENU VOLTECH ATI USER MANUAL LCR BNC LCR FIX More 1 3 Execute H D Rs More 2 3 ES Program Settings QD More 3 3 Settings Self Test EXIT Settings EXIT EXIT Y Signal Enter f gt Fix Integration Enter V Auto Compensate Enter I Delete Print Enter IBias Enter Cancel Shift Short IBias XBias EM Long Delete Enter Cancel Cancel OK Short One A11 Open One All OK PAGE 6 19 FRONT PANEL MODES 6 3 2 LCR FIX MENU LCR BNC ceno M up cs cp Execute More 1 4 Program H D Rs More 2 4 Settings QD More
186. ll be seen TUTOR TAL FAIL at test 4 LS Continue SL 1 1 184rmH This display shows Part name number Failing test number and test mnemonic Graphical qualification of the failure showing the value measured with respect to the range of legal values where Box Represents the legal limits for the test Vertical bar Represents the value measured Replaced by an arrowhead to represent higher or lower when the measured value is significantly outside of the legal range See notes below Value measured with appropriate units VOLTECH ATI USER MANUAL PAGE 2 69 GETTING STARTED Note The third line showing the graphical comparison of the measured value and test limits has a logarithmic scale The measured value may be represented by either a vertical bar as shown when it lies within the range that can be displayed on the LCD or by an arrowhead or gt at the end of the horizontal bar when it lies outside the range that can be displayed on the LCD Pressing the Abort softkey stops the program and allows the operator to discard the failing component at the earliest opportunity to minimize test times The abort is also reported to the Server when the program option Send retry results to server is enabled and printed out when a results printing option is Set After pressing the Continue softkey the remaining tests in the program will be executed Stop on Fail will remain active and any
187. ll provide a storage system for archiving both the test programs and the test results In this chapter you will learn e Howto install the tester e How to set up the Editor and Server software e How to create and run a simple test program VOLTECH ATI USER MANUAL PAGE 2 5 GETTING STARTED 2 1 1 Package Contents The following items are supplied in the packing case along with this manual e ATi transformer tester e Power cord e ABNC to Kelvin clip lead four color coded BNC s to two clips e An LCR fixture with four Kelvin leads attached e Q9 pin D 9 pin D F F cable e 9 pin D 25 pin D F F cable 25 pin D 25 pin D F F cable e CD ROM inside the cover of this manual which contains the Editor and Server installation files and other important information Calibration certificate Product registration information Please report any missing items to your Voltech supplier Returning your product registration card will ensure that you continue to receive the latest product and application information PAGE 2 6 VOLTECH ATI USER MANUAL GETTING STARTED 2 1 2 The ATi Front Panel Liquid Crystal Display LCD RUN Indicator Softkeys PASS Indicator FAIL Indicator BNC connectors The front panel of the ATi is mounted towards of the rear of the fixture bay to allow easy access for loading transformers and to avoid accidental damage to the display and keys The main features are as fo
188. llows LCD Display The brightly lit graphics display is used both to display test results and to provide prompts for data entry within the menu structure RUN Indicator The RUN indicator is a yellow LED This is illuminated when the tester is busy for example when running a test program PASS Indicator The PASS indicator is a green LED This is illuminated after running a test program when the result is Pass FAIL Indicator The FAIL indicator is a red LED This is illuminated after running a test program when the result is Fail VOLTECH ATI USER MANUAL PAGE 2 7 GETTING STARTED Beeper A programmable beeper is built into the ATi to give an audible indication of PASS or FAIL as desired Logic level signals representing the RUN PASS FAIL and BEEP actions are available on the REMOTE port at the back of the ATi for use with automatic handling equipment and external indicators Keypad The keypad allows you to enter text data such as the part number i e test program name of the transformer to be tested Softkeys The six softkeys adjacent to the LCD are provided for functions that vary with different aspects of the tester s operation The function for each softkey at any given time is shown in the text boxes at the right hand side of the LCD PAGE 2 8 VOLTECH ATI USER MANUAL GETTING STARTED 2 1 3 Other Data Inputs To give you the greatest ergonomic flexibility methods other than the keyboard can be used to
189. lt was available This call returns a result on success or a failure string INVALID COM PORT no valid COM port found COM PORT IS NOT OPEN COM port requested not connected to an AT Series Tester INVALID RESULT NUMBER the requested result number is out of range NO RESULT no updated result data available Further Voltech Server OLE functions are described below They use the same format and failure strings as GetVariant Result Only function specific responses and return values are shown NewDataAvailable LPCSTR ComPort Returns TRUE or FALSE Boolean 1 or 0 as variant depending on whether new data is available If this function returns true it means that new data can be read back via the OLE If false then no new data has come in since the last read GetPartID LPCSTR ComPort Returns the part name on success or a failure string NO PART ID no valid part name found GetFixturelD LPCSTR ComPort This call returns the fixture name on success or a failure string NO FIXTURE ID no valid fixture name found GetOperatorlD LPCSTR ComPort This call returns the operator name on success or a failure string NO OPERATOR ID no valid operator name found PAGE 4 36 VOLTECH ATI USER MANUAL AT SERIES SERVER GetBatchID LPCSTR ComPort This call returns the batch number on success or a failure string NO BATCH ID no valid batch number found GetFirmwarelD LPCSTR ComPort This call returns the firm
190. lues Enter a nominal value and then the limits as negative and positive values gt lt Enter minimum and maximum values Enter just a minimum value Enter just a maximum value 5 Select OK The test specification will then be displayed in the program window VOLTECH ATI USER MANUAL PAGE 7 117 TESTS AND TEST CONDITIONS 7 1 31 LPBX INDUCTANCE WITH EXTERNAL BIAS PARALLEL CIRCUIT DC Bias Measure Test Test Basic Range Voltage Frequency Accuracy 0 1A to 1nH 1MH 1mV to 5V 20Hz to 3MHz 0 2 Q gt 10 250A This test requires the use of one or more Voltech DC1000 Precision DC Bias Current Sources Contact your Voltech sales office for details The inductance of a transformer winding while an external bias current is flowing through it may be tested using series or parallel equivalent circuit models Initially the DC bias current is set up and allowed to stabilize An AC voltage is applied across the selected winding the voltage across and current through the winding are then measured using harmonic analysis The measured voltage is divided by the current to obtain a complex impedance and the inductance is calculated On selecting LPBX Inductance with External Bias Parallel Circuit from the Available Tests window a dialogue box will be displayed Inductance with External Bias Parallel Circuit Test Parameters Integration Signal f mv CV C m Short Frequency C Hz kHz C MHz Medium Bias Current f
191. lvin blades 4mm sockets ATE pin types Rotary point Castellated Point Cup Crown 5 4 FIXTURE PARTS AVAILABLE FROM VOLTECH A number of components parts and kits are available from your Voltech supplier to help you assemble your own fixtures MORE INFORMATION A comprehensive guide to the construction of your own custom fixtures is supplied with each custom fixture plate kit A copy of the guide is also available on the ATi CD ROM in Adobe PDF format Please contact your Voltech supplier for more information or visit our website at www voltech com for details VOLTECH ATI USER MANUAL PAGE 5 13 FIXTURES pe Example probe box drilled for multiple RM bobbin types M Series Kelvin Fixture PAGE 5 14 VOLTECH ATI USER MANUAL FIXTURES 5 4 1 FIXTURE PLATE VOLTECH PART NUMBER 91 184 Designed for mounting existing fixtures to an AT series tester the fixture plate comprises Item 1 Base plate including contact pins with cover Item 2 Test piece interface plate Fittings and fasteners for above VOLTECH ATI USER MANUAL PAGE 5 15 FIXTURES 5 4 2 CUSTOM FIXTURE KIT VOLTECH PART NUMBER 91 185 A kit of parts for constructing your own fixtures Interconnecting wire test probes or clips and a drilling template will also be required The custom fixture kit comprises Item 1 Base plate including contact pins with cover Item 2 Test piece interface plate Item 3 Probe housing box Item 4 Bezel Item
192. lyses Choosing the Test Signal Recommended test conditions for different values of capacitance are the same as for the C test VOLTECH ATI USER MANUAL PAGE 7 55 TESTS AND TEST CONDITIONS Test Conditions for Capacitance Measurement The test conditions can also be determined automatically by the ATi according to this table Voltage Specified Auto Auto Specified Specified Auto Note that a fixed voltage signal cannot be used with an Auto frequency CS and CP are currently only available on the Ati s front panel LCR mode Contact your local supplier or check the Voltech website at www voltech com for up to date information PAGE 7 56 VOLTECH ATI USER MANUAL 7 1 14 C2 CAPACITANCE MATCH Measurement Test Test Basic Range Voltage Frequency Accuracy 1 1000 to 1000 1 1mV to 5V 20Hz to 3MHz 0 2 AT Series Tester Capacitance occurs in transformers due to the physical proximity of and electrostatic coupling between different turns of wire In general the capacitance is distributed between different layers within a winding and between the outside layer of one winding and the inside layer of the next Although the capacitance is distributed it is usually represented by a simple equivalent circuit showing a single capacitance from one winding to the next Where Used The capacitance match test as opposed to an ordinary capacitance measurement C is used on power conversion audio and telecommunications tr
193. m multiple AT testers When the AQL level set here is reached or exceeded the Server will display a warning AQL No of Parts is the number of failures in the batch at which a warning will be displayed on the Server This is most often used when the batch size is always similar or zero very small numbers of defects are expected AQL 96 of Parts is the percentage level of failures at which a warning will be displayed on the Server Note that this AQL is only applied after sufficient parts have been tested to make the percentage meaningful When setting AQL 96 of Parts to be 1 for example a warning will only be displayed after 100 1 100 parts have been tested Both types of limit may be used at the same time Reaching any one limit will cause a warning to be displayed on the Server When an AQL level is reached or exceeded the Server will display a warning Wat oncom2 ATi Part Name Operator 1135 PART NUMBER ATServer xl AT on COM2 Transformer Serial No AQL Exceeded Last Part Fail A PASS 5 FAIL 1 AQL 1 RE TRIES 0 FAIL 16 667 Last 10 Tx 1 Failed Test Min Max Last Result FAILS Polarity PolFAILS 1 CTY 10 000 kOhm 2 0238 GOhm 1 218 1 1640 mH 1 2350 mH 1 1801 mH 0 3 TR 2 6460 2 7540 73 441 1 0 Click on OK to acknowledge the warning You will be given the option to disable the warning for further parts in the batch Normally you would select No to leave the AQL checking active for the
194. m the tester they will be displayed in the monitoring window before passing to the batch result file The most recent result for each channel will be visible in the window An open result window may be minimised at any time and subsequently maximized using the icons indicated Minimize Maximize AT3600 Server AT3090 on COME Ele Setup View Window 1 R 67 826 Ohm PASS 0000 4 2 IS 3 3237 H PASS 0000 3 TE 1 0007 PASS 0000 VOLTECH ATI USER MANUAL PAGE 4 13 AT SERIES SERVER 4 3 4 BATCH STATISTICS ON LINE ANALYSIS Setting Up Batch Statistics From the Set up menu select Results to see the following dialogue Results Setup x Standard Results Saving CSV Display Basic Statistics Database Results Saving Advanced Cancel Select Display Basic Statistics to save results to a database For this feature to operate a licence for use must first be obtained from your Voltech supplier All results formats can be saved simultaneously Basic statistics displays on line a summary of the results for the current batch of transformers that is being tested on every AT connected to the Server Results for previous batches can also be opened and the statistics displayed and printed PAGE 4 14 VOLTECH ATI USER MANUAL AT SERIES SERVER Part Name Operator 1135 PART NUMBER Transformer Serial No Last Part Pass Tested 37 PASS 36 FAL 1 AQL AQL Disabled RE TRIES 0 FAIL 2 703 Last 10
195. mal printer or similar There are no options fro printing from the LCR modes PAGE 8 28 VOLTECH ATI USER MANUAL SPECIFICATIONS 8 3 5 REMOTE PORT TTL compatible interface for operation with various peripherals including foot switch remote controller and monitor output 15 pin female D type connector Pin Sanat name Pin o p BEEP 9 DO NOT USE OV 10 IPASS Binl 12V 11 i ISTOP FAIL BinStrb 12 i IRUN DO NOT USE 13 OV OV 14 45V BUSY BinO 15 NOT USED DO NOT USE 1 2 3 4 5 6 7 8 Signals with a name starting with are active Lo IRUN Input Pin 12 The RUN input is an active Lo input with an internal pull up resistor In the execution of programs it is equivalent to pressing the RUN key on the front panel To use this with a footswitch wire the switch between this input and OV VOLTECH ATI USER MANUAL PAGE 8 29 SPECIFICATIONS ISTOP Input Pin 11 The STOP input is an active Lo input with an internal pull up resistor The active going edge of this input halts all Tester activity turning off all signal Sources To use this with an emergency stop switch wire the switch between this input and OV Fail Busy and Pass Outputs Pins 4 7 and 10 The status outputs are standard 5 Volt logic signals In the standard set up the three status outputs are active Lo signals which duplicate the three LED s on the front panel Busy Pass and Fail They could for example be connected as statu
196. mat Notes TestID Text 25 Index ID TestMnemonic Text 10 Individual test mnemonic TestUnits Text 10 Individual test units CheckType Text 5 NONE MIN MAX DIFF POLType of test limits see MinLimit Number Single Minimum limit for test see MaxLimit Number Single Maximum limit for test see Notes CheckType NONE CheckType MIN CheckType MAX CheckType DIFF CheckType POL If there are no Min or Max limits MinLimit 0 and MaxLimit 0 If there is a Min limit only MaxLimit 0 If there is a Max limit only MinLimit 0 If there is a Min and Max limit Polarity test If Positive Polarity test MinLimit 0 and MaxLimit 1 If Negative Polarity test MinLimit 1 and MaxLimit 0 PAGE 4 26 VOLTECH ATI USER MANUAL AT SERIES SERVER Charting and Analysis Using SPC SQC Software Once an AT Server to database connection has been made it is possible to connect third party analysis software to the same database for live on line or offline data analysis The example reports presented here were created using PQ Systems ChartRunner but many other charting and analysis programs are available Voltech does not recommend one package more than any other You should choose to use the one that best meets your needs 2 CHARTrunner Inductance File Edit View Help 0 00000270 0 00000265 0 00000260 0 00000250 0 00000245 0 00000240 0 00000235 0 00000230
197. mpedance of audio and telecommunications transformers that are to be used with transmission lines of specified impedance The test helps to ensure that the transformer has been assembled properly using the correct core and winding materials Test Conditions The test may be made on the part alone or with a load resistor RL attached to the secondary to simulate the load impedance of the transformer when it is used in its final application The optional load resistor RL is connected to the transformer under test as shown This may be done automatically using the tester s OUT test PAGE 7 100 VOLTECH ATI USER MANUAL To measure Z the tester applies the specified voltage and for impedance with bias the specified DC bias current By measuring both the applied AC voltage and the resulting AC current the total impedance is calculated Z is the magnitude of the complex impedance Z v R X Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test Programming the Test Using the PC Test Editor Winding Impedance 9 9 Pie e Loose Mewe Cance VOLTECH ATI USER MANUAL PAGE 7 101 9 o d p K TESTS AND TEST CONDITIONS Choose the integration period normally Medium and enter the High and Low Terminal names For the impedance with bias test you may also select a DC bias current Note that the Editor s Measure
198. n absolute terms use a limit of 1 2 turn less than the number of turns you want to detect In this case set a limit of 0 pri and 7 sec This will result in equivalent limits of 19 and 21 Ideal for detecting errors of one turn or more What happens if set absolute limits for both primary and secondary windings If you want to detect up to a ten turn error on the primary and one turn on the secondary in the above example set 917 pri and 12 sec The tester uses the equivalent ratio limits 21 95 and 18 05 Setting both limits WIDENS the limit to allow for an error of ten turns on the primary SIMULTANEOUSLY with one turn on the secondary l e to allow 190 11 17 27 and 210 9 23 33 Notice that these limits will NOT detect just a one turn error on the secondary because you have now chosen limits to allow for errors on both primary and secondary resulting in a broader tolerance on the absolute ratio VOLTECH ATI USER MANUAL How do set limits that will detect a one turn error on either the primary or the secondary To do this you must set limits that will detect the smallest possible error This will be due to the one turn error being on the winding with the largest number of turns In the above example then set absolute limits of turn pri and 0 turn sec Remember to use the n rule The equivalent limits used by the tester will be 20 05 and 19 95 This will certainly detect a one turn error in the pr
199. n by the tester changing as appropriate to the V button if the signal is large Alternatively if you wish the test signal to be determined as a current click on the mA units button Finally in the lower section of the dialogue box select the desired limits type PAGE 3 32 VOLTECH ATI USER MANUAL PROGRAM EDITOR At this point the dialogue box should be as follows Winding Inductance Series Circuit x m Test Parameters Integration Signal 0 fm C Shot Medium Frequency 0 f Hz C kHz C MHz C Long m Terminals High Terminal Low Terminal fa fe m Inductance Limits CX gt lt Minimum fO Cni mH CH C lt Maximum C nH mH CH User Offset User Offset Enabled Gk Measure Cancel Now using the mouse click on the Measure button Because the LS test is one where compensation can be applied you will then see the following message Measure without Fixture Compensation C Compensate Fixture Disable Compensation If compensation is disabled it can be enabled again by selecting preferences from the setup menu Disable Compensation will stop this dialogue being displayed for subsequent presses of the Measure button for this program only Disable Compensation does not stop you being offered the opportunity to compensate the fixture for all tests when the complete program is downloaded to
200. n download and run mode They are shown at the end of each test result Only the first four digit error code is displayed when using the Editor VOLTECH ATI USER MANUAL PAGE 3 43 PROGRAM EDITOR File TELECOM1 atp Voltech Test Progra Part Schematic Program Test Dig a 5 v Avenable Tests Interwinding Phase Insertion Loss Return Loss Ohm Ohn dB dB dB 74 405 mdB 0 0000 103 62 Ohm 131 46 Ohm 21 998 H xternal Source 1 0044 ce 22 349 u ternal Source Eraarar List 7 28 sec n Off Off oft Winding Impedance Test Voltage 1 0000 V Test Frequency 1 0000 kHz Integration Medium High Terminal A Low Terminal B For Help press F1 NUM 7 A S Dlinbox Micr 5 R Microsoft w 28 Part TE BRESA 1314 If you look at the test results screen shown above you will see that test 4 LBAL contains a status error code of 0010 This error code indicates that The measurement had not settled in time Although this test passed it indicates that a problem existed during the test sequence In this particular example the fault was due to a poor connection to the core of the transformer The following table gives the error codes that can appear when using the run facility in the Editor or when viewing on line results with the Server These error codes can give specific help in modifying the test program depending on
201. n error code during transformer testing to assist in diagnosing whether incorrect test parameters have been used or poor connections have caused the fault During normal component or transformer testing and or while running self test voltage and current signals are constantly being generated stabilized measured and dissipated Should a problem occur during one of these four stages a unique error code is produced and displayed by the AT Series tester The error code consists of a DSP digital signal processor status error code and a reason for DSP status error code The DSP status error code is a four digit number that indicates that something has gone wrong Each error code translates into an effect a short description of the fault such as a current or voltage overload that can help the operator diagnose the cause of the problem The DSP status error code is seen on self test failures and on the Editors results screen The reason for DSP status error code is a one or two digit number displayed in parentheses that explains the reason for the four digit DSP status error code These reason for DSP status error code translates into why a status error was displayed This again can help the operator diagnose the cause of the problem The reason for DSP status error code is only seen on self test failures For the operator the DSP status error codes can assist in determining if the fault is due to a poor fixture or an incorrectly seated pa
202. nd the downloaded group programs available to you locally on the tester Local programs Hew program PROGRAM 1 Delete TUTOR TAL Results Analysis You may wish to use another application for further analysis of test results sent back to the Server Close down the Server so that you may have full access to the results file The results will be stored in the directory chosen for results when the Server was installed earlier in a file with a name similar to C2311096 ATR where C2311096 is a coded version of the date and ATR is the file extension used by the AT Server for results files As an example use the procedure outlined in section 4 of this manual to import the results into an Excel spreadsheet PAGE 2 48 VOLTECH ATI USER MANUAL GETTING STARTED 2 4 SELF TEST Self test is a sequence of checks made by the tester to ensure the unit is functioning correctly Self test checks that all of the relays in the 20 way matrix are opening and closing properly and checks that all the test signal sources and measuring circuits are working properly and within their calibration limits Once the tester has warmed up for an hour you may run self test at any time by pressing the SELF TEST softkey in the top level menu Remove any test fixture Continue and BHC connections then press the soft key COHTIHUE Before commencing self test please ensure that there is nothing touching any of the test nodes on the
203. ndary capacitance of a transformer by taking all primary terminals High and all secondary terminals Low PAGE 7 52 VOLTECH ATI USER MANUAL When choosing the test conditions the following potential problems should be considered a Current Levels For larger capacitance particularly at higher frequencies the current flowing during the measurement can be very high and similarly the measured current could also be very small for small capacitance at lower frequencies and voltages Where possible you should use the recommended test signal levels in the table above to ensure that the currents which flow can be measured accurately b Non linear Capacitance Normally non linearities in the stray capacitance of transformers are not a problem and therefore capacitance is measured with as large a voltage as possible c Equivalent Circuit As with inductance capacitance is actually measured as a complex impedance and therefore the result can be expressed in terms of either a series or a parallel equivalent circuit See the Series and Parallel Circuits and Capacitor Measurements sections at the end of this chapter The tester always uses a parallel equivalent circuit for inter winding capacitance measurements Series and parallel capacitance tests CS and CP are also available Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test L
204. nding isolation First set up the program options From the top level menu bar select PAGE 2 22 Program gt Options The following dialogue box will appear Configure Transformer Tester p Results Printing Operator Numbering Off Batch Numbering Serial Numbering C Failures Only Send Results to Server Send Retry Results to Server C Full Reporting I Stop on Fail Date and Time on Reports AGL of Parts AQLZofPars Fisture ID External AC Source None X Cancel VOLTECH ATI USER MANUAL GETTING STARTED By clicking with the mouse enable the following option Send Results to Server In the Fixture ID box enter the name UNIVERSAL Click on OK or press Return to accept and close the dialogue box You can now move on to create the program 1 From the top level Program menu select Edit The screen will now be made up of three Windows Top left The schematic window showing the two windings Right The available tests window listing all the tests available on your tester If the tester is connected any tests not available will be greyed out Lower left The program window displaying the tests programmed so far Lal Far Help press FT T NOM By double clicking the left mouse button select R Winding Resistance from the Available Tests window VOLTECH ATI USER MANUAL PAG
205. nductance with External Bias Parallel Circuit 7 118 7 1 32 ZBX Impedance with External Bias seen 7 120 7 2 SERIES AND PARALLEL CIRCUITS eene 7 123 7 3 CAPACITOR MEASUREMENTS e ee eene nana nana annnm nna 7 125 VOLTECH ATI USER MANUAL PAGE 7 3 TESTS AND TEST CONDITIONS 7 1 INTRODUCTION Tests and Test Conditions This chapter provides guidance for the use of each of the tests currently available for the ATi For the latest information please check the Voltech web site at www voltech com 7 1 1 CHOOSING TESTS FOR A TRANSFORMER In order for a completed transformer to function properly in its intended application it should be constructed in accordance with the designer s specification The test specification or ATi test program calls for various electrical parameters to be measured such that the transformer construction is verified For example a measurement of inductance will help to confirm that the correct number of turns has been used with the correct grade of core material and that the cores have been assembled correctly with the right air gap To fully verify the transformer construction however a complete series of tests should be carried out PAGE 7 4 VOLTECH ATI USER MANUAL Recommended Tests EXAMPLE Switched mode DC DC converter ferrite power transformer CTY Continuity A continuity c
206. ng Tester Set Up Options Please note that pressing the decimal point on the instrument keypad VOLTECH ATI USER MANUAL PAGE 2 83 GETTING STARTED during boot up at the general information screen will reset all tester options to the factory defaults including screen contrast screen background and beep volume excluding the real time clock The factory default settings are Option Default Setting FAIL Beeper OFF PASS Beeper OFF Key Response CLICK Beeper Volume 6 Display Contrast 8 Display Background LIGHT Touch Pad Option L ANDR Pad Response CLICK Program Store INTERNAL 2 9 2 Groups Softkey When the tester is set up to use the INTERNAL program store and after you have entered the part name it will search for that name in the programs that are stored in its own non volatile RAM To store these programs you must use either the group download or tester download features described here Group Download Using the Server Before attempting to download a group of programs ensure that the Server software is running on its PC that the lead is connected from the tester s Server port to the Server PC and that the COM port is correctly set up in the Server Also ensure that the group you wish to use has been created within the Server From the Server top level menu select Setup Groups etc as explained in chapter 4 PAGE 2 84 VOLTECH ATI USER MANUAL
207. ng measured by the ATi This does not apply to Ibias the DC bias current Press Enter to accept the value that you have entered Press Auto to have the ATi automatically choose a voltage or frequency Remember that the combination of AUTO f and a fixed voltage is not allowed Press Cancel at any time to discard any changes that you have made and to return to the previous screen The Shift key is used to enter the multipliers k x1 000 or M x 1 000 000 Ibias is always entered and displayed in mA There are no multipliers for Ibias To enter 10 5 kHz for example Either press 1 0 5 0 ENTER f or press 1 0 5 SHIFT 5 ENTER f PAGE 6 24 VOLTECH ATI USER MANUAL FRONT PANEL MODES Enter value Fix Pri Hz Ab Auto Sec AUTO Y AUTO Hz mAb Delete 18 5 Enter 151 amp 3yH Cancel 1 35mH When the Shift key softkey 6 is pressed it is shown in reverse video Press 5 with the Shift key in reverse to enter the multiplier k x1 000 Press 6 with the Shift key in reverse to enter the mulitiplier M x1 000 000 Press softkey 4 Delete to correct mistakes The value is changed when you press the Enter softkey Pressing Cancel will return you to the previous screen VOLTECH ATI USER MANUAL PAGE 6 25 FRONT PANEL MODES Signal settings Enter f
208. nsive user guide to fixture construction The kit is designed such that fixtures can be quickly assembled using a basic vertical drill and simple hand tools Fixture Kit Components 1 Base Plate Already fitted with 20 pairs of contacts the base plate fits into the top of the tester and makes electrical connection to the tester s 20 pairs of test nodes VOLTECH ATI USER MANUAL PAGE 5 9 FIXTURES The base plate has moulded indents and guides to ease the fitting and wiring of larger test sockets and posts for flying leads 2 Probe Housing Box This 9mm thick plate is designed especially to hold a wide range of ATE probes and Kelvin pins 3 Clamp An optional hand clamp holds the test piece against the test probes The clamp is adjustable in height and in spring pressure Voltech Part No 91 187 4 Guides 12 adjustable guides are supplied to locate the test piece in the fixture quickly and accurately 5 Drilling Tools 5 different pitches of template are available for marking and drilling the holes for test probes or Kelvin pins To enable the probe housing box and the test piece interface plate be drilled to the accuracy required drilling templates are available in the following grid pitches 1 27mm 2 00mm 2 50mm 2 54mm and 3 81mm Pack of 5 1 of each pitch drilling templates Voltech Part No 50 307 PAGE 5 10 VOLTECH ATI USER MANUAL FIXTURES 5 2 3 40 SOCKET FIXTURE Red Terminal Power Black Terminal
209. nt to the polarity test PAGE 7 108 VOLTECH ATI USER MANUAL incorporated into the TR Turns Ratio test that can only determine ve or ve polarity Test Conditions The AT Series Tester applies the specified AC voltage to one winding and measures the voltage produced across two windings one of which may be the energized winding The phase angle between the voltages is determined using harmonic analysis Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test Programming the Test Using the PC Test Editor Interwinding Phase Voltech VOLTECH ATI USER MANUAL PAGE 7 109 TESTS AND TEST CONDITIONS Choose the integration period normally Medium Energized Terminals The terminals where the test signal will be applied This is normally the winding with the greatest number of turns Primary Terminals High and Low The zero phase reference terminals that are often the same as the energized terminals Secondary Terminals High and Low The inter winding phase angle measurement will be the angle between the primary and secondary terminals High and Low Terminal names Note that the PC Editor s Measure button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and limits of up to 90 and 90 deg gt lt Minimum and maximum values
210. o amp telecom Checks matching between windings Inductance LS Series Circuit Checks primary turns right Inductance grade of correctly LP Parallel Circuit assembled core material QL Quality Factor Most but not usually line D Dissipation Factor tan frequency Checks right grade of RLS Equivalent Series correctly assembled core Resistance material and for shorted RLP Equivalent Parallel turns Resistance LSB with Bias Transformers that carry a Checks number of turns Current Series Circuit duct ith Bi significant DC bias current right grade of correctly LPB DC as in normal operation assembled core material Current Parallel Circuit L2 Inductance Match SMPS audio amp telecom Checks matching between Leakage Inductance SMPS electronic ballasts windings Checks windings have been installed in the correct position relative to the core Interwinding Capacitance Parallel Circuit High frequency isolating Checks winding positioning and insulation thickness between windings Capacitance Series Circuit Testing capacitors Capacitance Parallel Circuit Testing capacitors Capacitance Match SMPS audio amp telecom Checks correct winding position on bobbin Turns Ratio and Phasing Turns Ratio by Inductance Most but usually not line frequency Checks windings have correct turns and polarity Checks windings have correct turns Low
211. odified data in the Program window PAGE 3 24 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 3 5 DELETING TESTS To delete a test from the Program with the Editor software is very simple 1 In the Program list window click with the left mouse button to highlight the test you wish to delete NOTE Take care to correctly select the test to be deleted as the Editor software will permanently delete the test 2 From the top level menu bar select Program gt Delete Test zs Voltech Test Program Editor Part 40235 File Q Pat Schematic Maier Tester Server Setup He Options Edit Tc Edit Test Insert Test D 3 Confirm your selection by clicking Yes in the following dialogue box AT Series Editor Software x You will now see that the test has been removed from the list in the Program window VOLTECH ATI USER MANUAL PAGE 3 25 PROGRAM EDITOR 3 3 6 TEST PARAMETERS Some tests such as the R Winding Resistance test as used in the quick start tutorial chapter 2 are relatively simple to program because you do not have to set up any test conditions This is not the normal case The LS Winding Inductance series circuit test is more typical requiring the test parameters Signal and Frequency to be specified Winding Inductance Series Circuit Voltech For many tests including the LS test you may enter the Test Parameters in two ways either by simply
212. oftware can automatically select appropriate control limits from the data This is the default and recommended setting EX CHARTrunner Inductance 0 0000026 0 0000025 0 000024 incre PAGE 4 32 VOLTECH ATI USER MANUAL AT SERIES SERVER Under the Control Chart tab display options including axis scaling can be altered CHARTrunner Inductance BERRERLLL x n Iv v Iv a Iv SGT Other options including chart titles and size can be altered by selecting the Titles and Misc tabs Click on OK when finished Double click on the chart definition to display the chart Please refer to the help system of the analysis software you are using for further advice and information on chart types connectivity options and statistical analysis in general VOLTECH ATI USER MANUAL PAGE 4 33 AT SERIES SERVER Free trial versions of ChartRunner are available from PQSystems at www pqsystems com or any of their regional offices United States PQ Systems Inc Corporate Headquarters Toll free 1 800 777 3020 Phone 937 885 2255 E mail sales pqsystems com Europe PQ Systems Europe Ltd Phone 44 1704 871465 E mail sales pqsys demon co uk Asia Pacific PQ Systems Pty Ltd Tel Australia 03 9770 1960 E mail sales pqsystems com au PAGE 4 34 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 3 7 ON LINE ANALYSIS VIA OLE Th
213. ogram will be printed out for each transformer tested During program execution the operator will be prompted to enter his or her identity code All results will then be tagged with this code During program execution the operator will be prompted to enter a batch number which will be attached to the test results During program execution the operator will be prompted to enter a serial number for each transformer The number will then be attached to the results for the next transformer tested Select this option if you wish to have the tester send all the measurement results back to the Server PC for archive or analysis Enable this function if you wish the Server to contain the results from the additional measurements associated with re running a program for example after execution has been halted by the STOP ON FAIL program option Select this option to give the fastest test throughput During program execution only transformers that produce a pass result will be fully tested failures will be rejected at the earliest opportunity PAGE 3 15 PROGRAM EDITOR Date and Time on Reports Select this option to have the reports date and time tagged AQL Acceptable Quality Level Settings for production test are defined here AQL is the level of test failures in a batch that are acceptable Exceeding the AQL is an indication that there is a problem with the quality of the production process or the quality of materials t
214. ollowing specification aE Resistance of winding AB 59 to 73Q Resistance of winding CD 59 to 73Q Inductance of winding AB gt 3H Before proceeding ensure that the tester is connected to the Editor PC as described in earlier in this chapter VOLTECH ATI USER MANUAL PAGE 2 19 GETTING STARTED 2 3 2 Drawing the Transformer Schematic At the PC double click on the editor icon to start the PC Editor The first thing to do is to draw a schematic of the transformer to be tested 1 Using the left mouse button click on Schematic on the top Level menu bar and select Add Winding from the menu Voltech Test Program Editor New Part Program Tester Server Setup Help Add Screen Connection Delete Screen Connection You will now see a winding with two terminals floating below the mouse pointer 2 Place the winding on the left hand side of the screen and press the left mouse button 3 Adialogue box will ask you to name the terminals of the winding the cursor will be in the box for Terminal 1 Type the name of the Terminal 1 e g A Press TAB to move to the Terminal 2 box and type the name of the second terminal e g B in that box Then click OK or press Enter PAGE 2 20 VOLTECH ATI USER MANUAL GETTING STARTED 4 Repeat steps 1 3 to create a second winding This time place the winding on the right hand side of the screen a mirror image of the first winding and use diffe
215. on press softkey 3 Compensate in either the LCR BNC or LCR FIX settings menus You will see Compensation Short One All Open One All Full compensation required for 123 Hz If you have chosen a frequency that has not already been compensated that frequency will be displayed as above The One short or open frequency compensation options will be available if you have chosen any fixed frequency Choosing One sets up the ATi to perform compensation measurements at the chosen frequency only and is the preferred choice Choosing All will set up the tester to re compensate at all frequencies and this can take up to two minutes or more and is not normally necessary All is the only available choice if the ATi is set up with an Auto frequency To perform short circuit compensation for stray inductance and resistance first short circuit together all the nodes in this case clip the alligator clips of the BNC leads together and press softkey 1 Short and select One or All VOLTECH ATI USER MANUAL PAGE 6 31 FRONT PANEL MODES To perform open circuit compensation for stray capacitance remove all parts under test but leave the BNC leads or test fixture in place and press softkey 2 Open and select One or All For optimum accuracy place any leads or other connectors that can move in a position as close as possible to that which will be used when making measurements Compensation To perform sho
216. on the Editor schematic They are switched in circuit using an OUT test that must be inserted in the program before the GBAL test The relay patterns associated with inserting and removing fixture resistors have deliberately not been included in the GBAL test dialogue for two reasons a it would make the dialogue too complicated and b it is not always necessary e g in the case of a fixture where the resistors are permanently fitted in circuit PAGE 7 82 VOLTECH ATI USER MANUAL Programming the Test Using the PC Test Editor General Longitudinal Balance p Test Parameters Integration Voltage ev Short Medium Frequency 0 G Hz CkHz CMHz C Long r Terminals X r Terminals Y Energised Measured Energised Measured Hi Hi Lo Lo Optional 2nd Optional 2nd Energised Hi Energised Hi Longitudinal Balance X Y Limits Caj C Minimum 0 dB Maximum dB Compensation for Test Fixture Scaling 0 dB OK Measure Cancel The voltage and frequency are usually determined by the final application of the part under test Select the integration period which is normally Medium Enter the required terminal names Terminals X the energized winding Terminals X the measured voltage VOUT 1 Terminals Y the energized winding normally the same as the Terminals X energized winding Terminals Y the measured voltage VOUT2 T
217. on the bobbin The quality of the insulation can be assessed by applying a DC voltage across the insulation and measuring the resistance The voltage applied is usually greater than the voltage that the insulation will see in normal use Where Used An Insulation Resistance check is recommended as good practice for most transformers to check the integrity of the insulation between separate windings or between a windings or between a winding and a screen Test Conditions VOLTECH ATI USER MANUAL PAGE 7 77 TESTS AND TEST CONDITIONS To measure insulation resistance the tester applies a DC voltage between two groups of windings with the windings in each group being shorted together Each group may contain as many windings as you wish The voltage and current are measured dividing the voltage by the current gives the insulation resistance Choosing Test Conditions The voltage should normally be set to just greater than twice the peak working voltage of the winding Programming the Test Using the PC Test Editor Insulation Resistance E cv Choose the integration period normally Medium and enter the terminals to be measured More than one terminal can be High and more than one PAGE 7 78 VOLTECH ATI USER MANUAL terminal can be Low This is to allow testing for example of the complete primary to secondary insulation resistance of a transformer by taking all primary terminals High and al
218. or Part TUTORIAL File the test program to the Part Schematic Program Server Setup Help tester After a few seconds MAE DOOR Ri ra Upload Program you should see a message A Compensate Fixture to say that the download was Bun Program o successful Download Firmware If you see a message indicating that the download has failed check your cable COM Port connections and try again If the download continues to fail reboot your PC and try again The front panel of the AT will now display SAWE PROGRAM Continue Saving this program to the local store will overwrite an existing program group Local Save 2 This allows the program to be stored on the AT by pressing the softkey next to Local Save See section 2 3 4 for a description of running the program on the transformer tester VOLTECH ATI USER MANUAL PAGE 2 31 GETTING STARTED 3 For now run the program from the editor software and ignore the AT display Again from the top level menu bar select Tester Run Program The test program will now begin execution When it is finished you will see a dialogue box containing the results of the test If the transformer had been connected up as in the schematic to nodes 7 8 9 and 10 then the results might be Test Results Lx 65 571 Ohm 2 R 65 358 Ohm LS 3 7752 H 4 TR 1 0151 PASS 0000 PASS 0000 PASS 0000 RUN TIME 977 msec Re Run Test If no transformer is fitt
219. ot gt 4 SS rr c rw wr cnr Insert a new test above the currently selected test NUM In this example a Turns Ratio test will be inserted before the Inductance test 3 in the Program You will now see the dialogue box for the test you wish to insert 4 Enter the appropriate test data in the fields of the dialogue box and click on OK VOLTECH ATI USER MANUAL PAGE 3 23 PROGRAM EDITOR You will now see the new test inserted into the program Winding Resistance Integration Medium High Terminal C Low Terminal D Minimum Value 180 00 m hms Maximum Value 200 00 m hms Minimum Error 01 00 Maximum Error 01 00 Inductance Series Circuit Test Voltage 1 0000 V Test Frequency 50 000 Hz Integration Medium High Terminal A Low Terminal B Minimum Value 3 0000 H 3 3 4 MODIFYING TESTS As part of creating a new test program you would normally experiment by running it with a sample batch of transformers At this point you may find that some tests need to be modified a typical example being that you need to change the test limits With the Editor software modifying a test is very simple 1 In the Program list window double click with the left mouse button on the test you wish to modify This will re open the dialogue box for that particular test Make any changes you require to the test data in the fields of the dialogue box and click on OK You will now see the test with the m
220. ou may move the cursor focus between the fill in boxes by using the TAB key or by pointing and clicking with the mouse 5 When both terminals have been named you should press ENTER on the keyboard or click on OK with the mouse in the dialogue box 6 To make a winding with more than two terminals see Adding a terminal to an Existing Winding later in this chapter NOTE Terminal names may be between 1 and 6 characters in length and may contain any upper case letter or AT Series keyboard character excluding SPACE VOLTECH ATI USER MANUAL PAGE 3 7 PROGRAM EDITOR 3 2 2 CONNECTING THE WINDING TERMINALS TO NODES To connect the winding terminals to test nodes 1 Select a terminal to connect with the RIGHT mouse button Keeping the right button pressed drag the wire to the selected test node When the mouse pointer is over the test node release the mouse button A OO N The connection may also be made in reverse by first selecting the test node and then connecting it to the winding terminal To change a connection simply use the right button to pick it up and move it to either another test node or to another transformer terminal To delete a connection again use the right mouse button to pick up the connection but this time release it when it is not over either a node or a terminal 3 2 3 DELETING A WINDING To delete a winding 1 Select a winding by pointing at it with the mouse pointer and clicking the left mouse bu
221. play Contrast 2 79 DISSIPATION 7 30 EMC Compliance 8 35 3 42 7 127 Execute Mode 2 52 FAIL Indicator 2 7 Fixture Compensation 2 73 Fixture Parts from Voltech 5 13 Fixtures Description 5 6 Footswitch uuuuss 2 9 FREQUENCY RESPONSE 7 89 8 Hints and Tips VOLTECH ATI USER MANUAL INDUCTANCE 7 19 7 38 7 117 7 119 INDUCTANCE MATCH eee 7 42 INSERTION 055 7 93 8 8 1 2 10 Installing the PC Editor Gettng Started ess 2 12 INSULATION RESISTANCE 7 77 Integration eee 6 27 Interface Details 8 25 Inter Winding Phase Angle 7 109 IR LCR SETTINGS 6 13 Iron core transformers 7 7 Kelvin Connections 5 18 Keypad a 2 8 LCD Display 2 7 LCR 6 7 LGR FIM iem 6 11 LCR Menu MON Us 2 o et eR Ro 6 19 LCR Mode Basic Functions
222. played If you make a mistake choosing test parameters the ATi will sound a short beep and return to the previous screen condition Examples are attempting to enter AUTO frequency when a fixed voltage has already been entered or entering a value outside the specification of the ATi such as 10MHz for test frequency PAGE 6 38 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 6 PRoGRAM MODE As well as using the AT Editor software to create test programs for the ATi programs for your ATi tester may be created directly from the instrument s front panel From the top level menu choose softkey 1 Programs Programs LCR BHC LCR FIKI Set Up Self Test The resulting programs screen displays a list of programs available in the local or Server program store depending upon the general program store set up of the tester which you may choose to a run at this time by pressing the Run softkey b change the set up of by choosing Set Up or c delete from the program store by choosing Delete Or you may choose to create a new test program directly from the front panel VOLTECH ATI USER MANUAL PAGE 6 39 FRONT PANEL MODES Local programs Heu program PROGRAM 1 Delete 6 6 1 CREATING A NEW TEST PROGRAM In order to create a new test program select New program using the arrow softkey and choose Set up softkey 2 Local programs Hew program PROGRAM 1 The
223. power 2 Waiting for 5 seconds 3 Switching on again Observe anti static precautions when making connections to the interfaces on the rear panel of the instrument PAGE 8 36 VOLTECH ATI USER MANUAL 9 WARRANTY AND SERVICE VOLTECH ATI USER MANUAL PAGE 9 1 WARRANTY AND SERVICE PAGE 9 2 ATI USER MANUAL WARRANTY AND SERVICE Contents Warranty and Service 9 5 9 2 LIMITATION OF WARRANTY eese nennen nn nnnm nnn nnns antra sn annann nnn 9 5 9 3 SERVICE AND CALIBRATION seen e nenne nennen nnn ennnen nenna ennnen annann nna 9 6 9 4 OBTAINING SERVICE AND APPLICATIONS SUPPORT 9 6 9 5 FIRMWARE UPGRADES eene eene enne nennen nnn nnne nnn nn inan nnns nnn n anna 9 7 VOLTECH ATI USER MANUAL PAGE 9 3 WARRANTY AND SERVICE PAGE 9 4 ATI USER MANUAL WARRANTY AND SERVICE 9 1 WARRANTY The Voltech ATi is warranted against defects in materials and workmanship for a period of twelve 12 months from the date of shipment OR ten million 10 000 000 wound component tests whichever occurs first The electrical switching relays are warranted against defects in materials and workmanship for a period of twenty four 24 months OR ten million 10 000 000 transformer tests whichever occurs first In the event of failure of a customer unit during this period Voltech will e AtVoltech s discretion repair or replac
224. program and the transformer will be recorded as a fail If any further tests fail then there will be another display similar to the one above for each failing test If you simply wish to throw away the failing transformer at the earliest opportunity then press the ABORT softkey to terminate this program run and return to the RUN FINISH display from where you can start the program again for the next transformer in the batch Alternatively you may use the RE RUN softkey if for example the failure is due to the fact that the transformer is not correctly inserted in the test fixture In this case program execution starts again and the transformer will receive a pass if the only fault was that it had been wrongly inserted at the first attempt PAGE 3 18 VOLTECH ATI USER MANUAL PROGRAM EDITOR After you have pressed the RE RUN softkey the tester will then be executing a retry When results are sent to the Server unless you have enabled the program option Send Retry Results to Server then no result will be sent to the Server Results File except those for the final execution run i e the one that produces the pass or fail front panel display If you wish to see the measured results from each retry in your Server Results File then you should enable the program option Send Retry Results to Server when the program is created in the Editor This option could provide data for example which allows you to improve your produc
225. programs to the tester Results handling is a separate function of the Server program and is not part of program transfer Where more than one tester is connected to your server PC the one Server program handles all the transformer tester results as well as acting as the central Server All results sent by one tester s channel during one day are collected together and formed into one large file This file is known as the batch results file One batch results file will be generated per open channel per day Batch files are stored under the specified results directory see chapter 2 section 2 2 6 The DOS filename of the batch results file is generated as follows c lt n gt lt dd gt lt mm gt lt yy gt atr Where n channel number dd day number mm month number yy year number example c1250297 atr Channel 1 25 02 1997 atr is the reserved file extension used by the Server to indicate a stored test result file What follows is an example of the first part of a batch result file as viewed in a standard text editor Note the DOS file name c6200697 atr and the part name TUTORIAL are both listed within the file VOLTECH ATI USER MANUAL PAGE 4 11 AT SERIES SERVER VOLTECH ATi RESULTS FILE Server Program Version 2 37 Communication Channel 6 YATE IDs ATi Software Version 2 46 File name C6200500 atr Test Date 20 May 2000 Part Tutorial Fixture ID Universal Operator Ba
226. r archive can be done in any of three ways Via the tester Directly from PC to PC via a floppy disk Via a network connection between the PC s using Save As in the editor to transfer the program to the directory used by the Server for programs PAGE 1 18 VOLTECH ATI USER MANUAL INTRODUCTION With both Server and Editor installed on the same PC transferring a new test program from the Editor to the Server archive can be done in either of two ways Via the tester if the auxiliary port connection is made Directly from the Editor using save as to the directory used by the Server for programs Auxiliary port connected using the Editor Server port VOLTECH ATI USER MANUAL PAGE 1 19 INTRODUCTION 1 8 4 Executing Programs Large Production Facility The standard installation in a large production facility could use several testers together with a Server PC for test program and results archive Programs Programs Programs Results Results Results Advantages Convenient storage and management of large numbers of test programs e g 21000 Easy storage and management of test results Importing results into other Windows applications for analysis The Server PC can be located away from the test area for example in a supervisor s office allowing results analysis to be performed where it is required Up to eight AT series testers may be connected to each Server PC PAGE 1 20 VOL
227. r capacitive impedance Rp is the stray parallel resistance Rs is the stray series resistance VOLTECH ATI USER MANUAL PAGE 7 123 TESTS AND TEST CONDITIONS For an INDUCTIVE IMPEDANCE Rs represents the copper losses in the wire and Rp represents the in phase core losses X oL is usually much lower than Rp so Rp is insignificant Choose the SERIES equivalent circuit If the inductance is large gt 1 Henry and or the series resistance Rs is very small the parallel equivalent circuit is sometimes used For a CAPACITIVE IMPEDANCE X is usually much higher than Rp making Rp very significant Choose the PARALLEL equivalent circuit If the capacitance is large small impedance then Rp will be insignificant and the series equivalent circuit can be chosen PAGE 7 124 VOLTECH ATI USER MANUAL 7 3 CAPACITOR MEASUREMENTS The ATi and its front panel LCR mode are ideal for making precise measurements on capacitors Capacitance Farads To measure the capacitance use the C test in the PC editor or simply select C on the top line of the LCR mode The measurement conditions can be fully automatic or user programmed following the guidelines given earlier in this chapter Measurements are usually made using the parallel equivalent circuit see the preceding section D Dissipation Factor or tand D can be selected as a second line parameter of the LCR mode D is a measure of the losses in a capacitor and is defined to be D
228. r has been assembled properly using the correct core and winding materials Test Conditions The test may be made on the part alone or with a load resistor RL attached to the secondary to simulate the load impedance of the transformer when it is used in its final application The optional load resistor RL is connected to the VOLTECH ATI USER MANUAL PAGE 7 103 TESTS AND TEST CONDITIONS transformer under test as shown This may be done automatically using the tester s OUT test To measure X the tester applies the specified voltage and by measures both the applied voltage and the resulting current Using harmonic analysis the measured voltage is divided by the current to obtain a complex impedance from which X the imaginary part of the impedance is obtained Inductive Capacitive X is the imaginary part of the complex impedance Z R jx Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test The X test is only available on the ATi s front panel LCR mode PAGE 7 104 VOLTECH ATI USER MANUAL 7 1 26 ANGL PHASE ANGLE OF IMPEDANCE Measurement Test Test Basic Range Voltage Frequency Accuracy inductive 90 AT Series Tester resistive 90 capacitive 360 to 360 1mV to 5V 20Hz to 3MHz 0 055 The impedance of a winding is usually complex as it consists of real resistive and inductive or capacitive imaginary parts The phase
229. r lost by a transformer relative to the maximum theoretical power that the transformer could transmit to a given load Core and winding resistance losses mean that some power is always consumed by a transformer reducing the power available to the load from the theoretical maximum Where Used The insertion loss test is used to check the power loss of audio and telecommunications transformers The test helps to ensure that the transformer has been assembled properly using the correct core and winding materials Test Conditions The source and load resistors RS and RL are connected to the transformer under test as shown This may be done automatically using the testers OUT test VOLTECH ATI USER MANUAL PAGE 7 93 TESTS AND TEST CONDITIONS The tester applies the specified voltage Vin and the voltage Vout is measured The ratio of actual to theoretical power loss is calculated using the formula ILOS 101og o Vin2 RL 4 Vout2 RS Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test Programming the Test Using the PC Test Editor Insertion Loss Note that the PC Editor s Measure button CANNOT be used to determine the test voltage Select the integration period that is normally Medium Enter the Input and Output terminal names Remember to enter the values of Rs Source Resistance and RI Load resistance as used on t
230. r quick start earlier e The interface cable between the tester s server port and the selected COM port on the Server PC is correctly fitted and that the COM Port is correctly configured in the Server software see earlier e Both the Editor and the Server software packages are running e The tester is still powered on as described above VOLTECH ATI USER MANUAL PAGE 2 33 GETTING STARTED To transfer the program from s Voltech Test Program Editor Pa Pat Schematic Program Tester Dis e ep N 7 TUTORIAL File QK13 Setup Help the top level menu bar select ad Program Server Download Program The Editor will now download the test program to the Server using the AT After a few seconds you should see a message to say that the Download was successful If you see a message indicating that the download has failed check your cable COM Port connections and try again If the download continues to fail reboot both PC s and try again Editor and Server Both on a Single PC If the Server and Editor are installed on the same PC the easiest way to transfer the test program to the Server is to use the Save As menu in the Editor From the top level menu bar select Part gt Save As Voltech Test Program Editor Part TUTORIAL File QF201003 atp Schematic Program Tester Server Setup Help New Ctrl N Open Ctr O Save CtrleS Print Ctrl P Print Preview Print Header Prin
231. ratio should be 1 1 One turn in error would produce a ratio error of 1096 or 10 i e 11 10 or 10 11 and therefore limits of 5 and 5 would be suitable to detect the error PAGE 7 72 VOLTECH ATI USER MANUAL 7 1 17 LVOC Low VOLTAGE OPEN CIRCUIT Measurement Test Test Basic Range Voltage Frequency Accuracy 100 to 1mV to 5V 20Hz to 3MHz 0 196 AT Series AT Secondary Tester measurements In phase Anti phase Applying an AC voltage to the primary of the transformer will produce an AC voltage in the secondary Low Voltage Open Circuit measures the open circuit voltage produced when the specified test signal is applied The secondary voltage may be in phase with the primary voltage or it may be anti phase depending on the winding and the termination of the windings Where Used The low voltage open circuit test is used to confirm that windings have the correct ratio of turns between them and that the phasing of the windings is correct This test is used for signal pulse and switched mode power transformers where the normal operating conditions require only small excursions of the B H curve never extending beyond the linear region On the AT3600 only a high voltage open circuit test is available for testing line VOLTECH ATI USER MANUAL PAGE 7 73 TESTS AND TEST CONDITIONS frequency transformers at their operating point up to 270V 1kHz and 2A See also the test TR turns ratio Test Conditions To
232. read and understood Important information that explains a general principle or refers to other sections of the manual The contents of this manual are believed to be accurate at the time of printing Voltech reserves the right however to change the operation or specification of the ATi without notice No liability is accepted for the inappropriate negligent or incorrect set up of the ATi by the user by either manual or automated means VOLTECH ATI USER MANUAL PAGE 1 5 INTRODUCTION 1 2 GENERAL SAFETY INSTRUCTIONS WARNING The ATi must be connected to a safety ground earth Only insert the power lead into a socket with a protective ground contact Ensure that the power lead is in good condition and free from damage before use Replace the fuse only with the same type and rating as indicated on the rear of the ATi Refer servicing only to qualified personnel who understand the danger of shock hazards WARNING The ATi wound component tester can generate voltages of up to 500V during insulation resistance testing Although the available energy of the source has been limited in accordance with EN61010 1 and can be considered safe care should be taken to avoid accidental or unexpected electrical shocks e Ensure operators are aware of the potential shock hazard e Ensure operators are trained to avoid making contact with the part being tested or any exposed parts of the fixture during an IR test e Construct sa
233. red ID Code wcasuP DXB4UJ AMPWUX Key Code Your software is registered If you wish to transfer the software license 1 Install the software on another computer 2 Enter the new ID Code from the new software installation in the Transfer ID Code box below 3 Enter the Transfer Key Code generated into the Key Code box of the new software installation This operation will disable this copy of the software Transfer ID Code Transfer Key Code e Install the software on the new destination PC e Take the ID code displayed in the new installation and enter it into the Transfer ID Code section of the dialogue of the licensed software as above on the old installation e Take the Transfer Key Code that will be displayed in the dialogue above of the old installation and enter this as the Key Code on the new PC e The software will now be licensed on the new PC and disabled on the old Please do not hesitate to contact your Voltech supplier if you have any problems with this procedure PAGE 4 52 VOLTECH ATI USER MANUAL 5 FIXTURES VOLTECH ATI USER MANUAL PAGE 5 1 FIXTURES PAGE 5 2 VOLTECH ATI USER MANUAL FIXTURES Contents Fixtures L5 BR INTRODUCTION aer E 5 5 5 2 DESCRIPTION e 5 6 5 2 1 Basic Fixture Plate a dae Ret 5 8 5 2 2 Custom Fixture Kit ui e ate ea em ete RR asus 5 9 5 2 3 40 Socket Fixture ui relie ER ERR AR 5 11 5 3 FIXTURE SYSTEM SPECIFICATION
234. rements of impedance Each of the ATi s 20 measurement nodes including the BNC connectors consists of two terminals Power and Sense to allow complete 4 terminal testing Why use Kelvin connections Consider measuring a perfect 1 000 ohm resistor to check that it is within its 196 tolerance at dc In a standard 2 terminal measurement there are TWO sources of error The resistance of the connecting leads The resistance of the contact between the connection and the lead of the resistor the resistance of the leads is fixed and can be compensated for Let s assume it is 2mQ for good quality leads Rc the connection or contact resistance is a variable and cannot be compensated for Rc will vary with the cleanliness of the leads and connector the pressure applied and the contact surface area all of which can be difficult to control Let s assume Rc varies from a few mQ to tens of mQ but is typically 5 mQ PAGE 5 18 VOLTECH ATI USER MANUAL FIXTURES V 100mV R 1 000 2 wire measurement circuit The measurement system applies 100 0mV dc to the leads measures the current flowing and divides V by I to obtain R the dc resistance R V I In this case the total resistance of the circuit is 2 5 1000 5 2 1014 l 100 1014 98 62mA 2 wire R V I 100 98 62 1 014 Q 2 wire R 1 014Q This shows that the resistor is 1 496 and out of tolerance when it is really
235. rent terminal names e g C and D The screen should then look like this as Voltech Test Program Editor New Part BEI ES Part Schematic Program Tester Server Setup Help A Cs EE Gn CR ae 8 Now you must connect the windings to the test nodes of the tester Place the mouse pointer over terminal A press and hold the right mouse button Continue holding this mouse button down and drag the mouse pointer to test node 9 Release the button A wire will now connect terminal A to test node 9 Repeat this procedure to connect the other three terminals B C and D to nodes 7 10 and 8 The screen should now look like this Voltech Test Program Editor New Part Per Schematic Program Tester Server Setup Help A e rou NE M RIGHT MOUSE CLICK TO DRAG CONNECTIONS For Help press NUM You have now created a schematic layout of a four terminal transformer VOLTECH ATI USER MANUAL PAGE 2 21 GETTING STARTED 2 3 3 Creating the Test Program After creating the transformer schematic you may now create an example program containing the following four tests Resistance of winding AB 59 to 73 Resistance of winding CD 59 to 73Q Inductance of winding AB gt 3H Turns ratio AB to CD 1 1 2 It is probable that the actual program used to test such a transformer in production would be the same four tests plus an additional insulation resistance test to check for winding to wi
236. requency Response Voltech e Enter the voltage and frequency parameters of the reference test signal e Select the integration time required Normally Medium e Enter the names of the Hi and Lo input terminals e Enter the names of the Hi and Lo output terminals e Add test frequencies as required by entering the frequency and clicking add There are normally at least 2 additional test frequencies one at either end of the frequency band of interest Additional mid band test frequencies can be entered to ensure that the transformer response is flat throughout the band e Set the frequency response limits VOLTECH ATI USER MANUAL PAGE 7 91 TESTS AND TEST CONDITIONS e Select OK The test specification will then be displayed in the program window Note that although resistors should be fitted to the fixture there is no need to enter their values here since the RESP test result is the difference between two ratios based on the same resistor values The resistor values cancel out in the calculation If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester PAGE 7 92 VOLTECH ATI USER MANUAL 7 1 22 ILOS INSERTION Loss Measurement Test Test Basic Range Voltage Frequency Accuracy 100dB to 100dB 1mV to 5V 20Hz to 3MHz 0 5dB AT Series Tester The insertion loss is a measure of the powe
237. rminals do not permit the use of four wires all the way to the body of the component under test In such cases separate power and sense leads are used up to the base of the terminal and the length of common lead from the junction of the power and sense leads through the terminal and the component lead to the body of the component should be kept to a minimum The common lead length is shown as AA and BB in the diagram below V 100mV ps Semi Kelvin Connection VOLTECH ATI USER MANUAL PAGE 5 21 FIXTURES The AT Series testers provide all the connections required to take advantage of Kelvin measurements A test node may be considered to be a pair of connections consisting of one power and one sense terminal The following diagram indicates how to identify the node terminal function mura a rum ra amem Power Sense POWER terminals are all on the outside of the fixture area SENSE terminals are all on the inside of the fixture area The BNC to clip leads supplied with your ATi provide true 4 terminal Kelvin connections IMPORTANT Kelvin four terminal connections are generally advised to be used in all test fixtures they are essential for transformers whose winding resistance s are less then 10 VOLTECH ATI USER MANUAL PAGE 5 22 FIXTURES When Kelvin connections are not possible because of space limitations use a semi Kelvin connection Below are two examples of Kelvin
238. rminals for each test 4 Select mouse click the button the type of limits you require and enter the values gt lt lt Enter a nominal value and then the limits as negative and positive values Enter minimum and maximum values Enter just a minimum value Enter just a maximum value 5 Select OK The test specification will then be displayed in the program window VOLTECH ATI USER MANUAL PAGE 7 119 TESTS AND TEST CONDITIONS 7 1 32 ZBX IMPEDANCE WITH EXTERNAL BIAS DC Bias Measurement Test Test Basic Range Voltage Frequency Accuracy 0 1A to 250A 1mQ to 1MQ imV to 20Hz to 0 2 5V 3MHz This test requires the use of one or more Voltech DC1000 Precision DC Bias Current Sources Contact your Voltech sales office for details The Winding Impedance with External Bias test measures the impedance of a selected winding while applying a DC current from the DC1000 through the winding An AC voltage is also applied across the winding from the AT This test can be used with inductors to measure the change in impedance with a bias current On selecting ZBX Impedance with External Bias from the available tests window the following dialog box is displayed PAGE 7 120 VOLTECH ATI USER MANUAL mpedance with External Bias rim To program the test 1 Enterthe value of a voltage or current for the signal and the required frequency of the test Also enter the bias current yo
239. rom the AT Server port to the Server PC has a broken wire or is not plugged in correctly COM port The COM port has not been set up in the Server application Server not running Either the Server PC is not powered on or the Server application is not running PAGE 2 56 VOLTECH ATI USER MANUAL GETTING STARTED If the Server software and connection to the Server PC are working correctly the following error screen may appear Error TEST1 not found in Server program directory Continue Cause The directory set up in the Server application as the location of test programs does not contain a test program file with the requested name Local Program Store Error Error FART not found in program group in AT internal memory Continue VOLTECH ATI USER MANUAL PAGE 2 57 GETTING STARTED Cause The requested part number is not resident in the group of programs that have been downloaded into the AT At all the above displays pressing the Continue softkey will take you back to the top level display 2 5 3 Indications Displayed While Tests Are Running Fart number TUTORIAL Executing test 1 Where 1 represents the position of the test within the test program The operator may terminate the measurements at any time by pressing the Stop softkey Alternatively you may use the STOP input signal on the tester s remote port which may be connected for example to an emergency stop
240. rt or it could prompt an investigation into the appropriate test parameters being used For the more serious faults the user can contact their local Voltech technical support group and by explaining the application along with the DSP status error code can speed up and help the technical support engineer investigate the cause of the fault PAGE 3 42 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 5 1 FRONT PANEL ERROR CODES When a fault is detected the first DSP error code seen is a four digit hexadecimal number called the DSP status error code the second is a one or a two digit hexadecimal number in parentheses called the reason for DSP status error code This one or two digit code is only displayed with self test failures Status error codes can be seen after a self test failure To view the error code at the FAIL display press the Details softkey The following display will show the two status error codes the first four digits being the DSP status error code and the second single or two digit number in parentheses being the reason for DSP status error code Important Note Should self test fail for any reason contact Voltech technical support immediately providing the following information e Serial number of the instrument e Status error codes the four digit number and the one or two digit number in parentheses on the display 3 5 2 EDITOR ERROR CODES Status error codes are also shown when using the Editor software i
241. rt circuit compensation at 123 Hz short the leads together and press the start button Press softkey 5 Start begin the compensation process Press softkey 6 OK to use any compensation measurements that have just been made and return to the previous LCR screen During short or open circuit compensation the ATi is making very accurate measurements of the small stray or parasitic components Remember that the power amp sense terminal of each node must be connected together The PAGE 6 32 VOLTECH ATI USER MANUAL FRONT PANEL MODES measurement may take up to 2 minutes during which you will see the following display Compensation Compensating short circuit Press softkey 5 CANCEL at any time to cancel or stop the compensation measurement and you will be returned to the previous screen Once both short and open circuit compensation have been performed succesfully the words comp req will be removed from the compensation screen and from the main LCR or Rdc IR measurement screen See Section 6 1 2 for node s when performing LCR FIX mode compensation 6 4 2 COMPENSATION FAIL Should any compensation measurement fail this is most likely because either the short circuit S C COMP or the open circuit O C COMP were not connected properly VOLTECH ATI USER MANUAL PAGE 6 33 FRONT PANEL MODES Compensation Short One All pen Ore A11 Short circui
242. s Choosing Test Limits The test limits are the specific resistances for both X and Y terminals together with and percentage limits Use the PC Editor s Measure button together with a sample part if you are unsure of the resistance values PAGE 7 18 VOLTECH ATI USER MANUAL 7 1 5 LS LP INDUCTANCE SERIES AND PARALLEL EQUIVALENT CIRCUIT Range Test voltage Test frequency Basic accuracy 1nH to 1MH 1mV to 5V 20Hz to 3MHz 0 0596 AT Series Tester Inductance is the electrical parameter that is commonly used to check that a high frequency transformer has been constructed according to its design and that it will operate properly in use The inductance of a winding is determined by the number of turns and the construction and dimensions of the core materials it may also vary with test conditions such as voltage and frequency The series and parallel inductance tests are used when testing signal pulse switched mode and similar transformers with ferrite type cores where the inductance remains the same from small signals up to the operating conditions Faults in numbers of turns core material and core gapping may be determined using this test For line frequency iron cored transformers where the inductance varies rapidly with voltage a magnetizing current test MAGI is recommended The MAGI test is only available on the Voltech AT3600 VOLTECH ATI USER MANUAL PAGE 7 19 TESTS AND TEST CONDITIONS Tes
243. s Advanced x Connection String Provider Microsoft Jet OLEDB 3 51 Persist Security Info False User ID Admin Data Source C Program Files Voltech Instruments Voltech AT Server Sample Access Database mdb Mode Share Deny None Extended Properties COUNTRY 0 CP 1252 LANGID 0x0409 Jet OLEDB System database Jet OLEDB Registry Path Jet OLEDB Database Password Jet OLEDB Global Partial Bulk Ops 2 z Clear Connection OK Cancel Click on OK to return to the results dialogue At this point the AT Server will automatically create the required database tables if they do not already exist VOLTECH ATI USER MANUAL PAGE 4 23 AT SERIES SERVER Ensure that Database Results Saving is checked and click on OK Whenever a results window is open the results will now be stored in the selected database 4 3 6 DATABASE TABLES The server software automatically creates the following tables in the selected database if they do not already exist and stores data within the tables using the structure defined here The tables store all the information that is available concerning the results including time date limits operator etc in a very compact and efficient structure Note that new data is not necessarily appended to the end of a table it may appear anywhere within Table tbIVoltechA TUnitID Field Format Notes ATUnitID Text 25 Index ID UnitType Text 10 AT3600 AT1600
244. s Schematic Editor allows you to recreate the configuration of the transformer on the fixture as a schematic diagram on the screen Once the way in which the AT s nodes are connected to the transformer pins has been entered into this schematic you can create test programs without having to refer to the tester s node numbers This section describes how to create a transformer schematic using the AT Series Schematic editor How to e Create or add a transformer winding e Connect the winding terminals to test nodes e Delete a winding e Rename a terminal Adda terminal e Delete a terminal e Add a core connection e Delete a core connection e Adda screen connection e Delete a screen connection PAGE 3 6 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 2 1 ADDING A TRANSFORMER WINDING To add a transformer winding onto the screen 1 Select Add Winding from the Schematic menu on the menu bar 2 Place the winding on the screen A selected winding will now be displayed attached to the mouse pointer on the screen You must decide which half of the screen to place the winding On crossing the mid point of the screen the winding is mirrored to face the nearest test nodes Click the left mouse button to place the winding 3 Name the winding terminals 2 When the winding is placed a dialogue box appears prompting you to name both of the winding s two terminals Enter Terminal Names L Terminal 1 Terminal 2 Conco 4 Y
245. s are required on any topic they can be found in later chapters of this manual VOLTECH ATI USER MANUAL PAGE 1 15 INTRODUCTION 1 8 1 Creating Programs The Editor The test program is simply the list of tests that you wish to apply to your transformer Individual transformers will each have their own program but as an example a typical program for a three winding switch mode power supply transformer could be as follows Program W2 Resistance w1 Resistance w2 w1 Resistance W3 Inductance w1 Turns Ratio W1 to W2 w3 Turns Ratio W2 to W3 Insulation Resistance W1 to W2 W3 Part Number SMPSE42 A The Test Program Editor supplied with your tester allows you to create such a program without software programming skills Each test required for the program is selected from a list of available tests by clicking with the mouse The test details such as the transformer terminals test conditions and pass fail limits are then entered into a form fill dialogue box Winding Resistance x Integration C Short Medium Long Terminals High Terminal Low Terminal Resistance Limits CX Minimum fo mOhm Ohm C kOhm C MOhm C C Maximum jo mOhm Ohm kOhm C MOhm Measure Cancel PAGE 1 16 VOLTECH ATI USER MANUAL INTRODUCTION Normally the Editor is used with the auxiliary port of the tester connected to a spare COM port on the PC PC runnin
246. s inputs to a robot controller or a bin selector Beep Output Pin 1 This is an active Hi output that copies the internal beeper It is configured in the test program header 1kQ see the Test Editor section of this manual All the outputs pins 1 4 7 and 10 are fitted with 1kQ protection resistors and therefore they cannot directly drive external high current loads such as indicators or bin select relays Minimum input resistance of devices connected to these outputs to be 10kQ DO NOT USE Pins 5 8 and 9 These pins are intended for use with Voltech approved accessories and must be left unconnected DANGER Pin 8 may have voltages of up to 500V present during normal operation of the ATi PAGE 8 30 VOLTECH ATI USER MANUAL SPECIFICATIONS 12V pin 3 Total maximum current Remote port pin 3 User port pin 5 100mA 45V pin 14 Maximum current 800mA 8 3 6 USER PORT The port contains six open collector relay drive outputs and two HC MOS compatible inputs The relay drives are switched on and off by certain optional tests e g the OUT test inserted into your test program This will enable you for example to switch a dummy load on to the secondary winding of the transformer under test so that subsequent tests are performed on the loaded transformer The user port connections must always be fully isolated from the test nodes A coil to contact isolation of 1000V is recommended for the relay Load
247. s limited in the table to 5 0mA maximum In addition the problem of self resonant frequency listed under the primary inductance test also applies when measuring leakage inductance so always use the lower of the available band of frequencies Use the Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value Remember to click on the units of limits nH mH etc when entering absolute values as limits Note that more than one secondary can be short circuited at the same time by adding more of the available terminals to the used section of the dialogue If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester Normally a user offset would not be required However for small values of leakage inductance lt 1uH when there are a number of additional low terminals it is not always possible during fixture compensation for the tester to remove all of the parasitic errors of the test fixture In this case the user offset may be required to fully remove the errors The Us
248. s the operator to edit test programs that are stored in the AT Server or the AT s local program store save new or modified programs or delete test programs directly from the front panel To help protect existing test programs and their set up two AT passwords may be created a Server password and a local password The Server password helps protect programs stored on the AT Server whereas the local AT password protects the local program store When a password has been set up the instrument will force the operator to enter the correct password before a program can be saved or deleted The AT Server password must be set up from within the Server software go to Setup Password PAGE 6 48 VOLTECH ATI USER MANUAL FRONT PANEL MODES Setting the Internal AT Password As well as from within the Editor software see chapter 3 the internal local AT password may be set up directly from the main set up menu of the ATi From the top level instrument menu choose Set Up At the set up screen choose Softkey 2 Set Up Use the down arrow key to scroll to the AT Password option and press Change Set Up BHC Lead Calibration AT Password Program Store IHTERHRL If no password has been set the ATi will immediately prompt for a new password to be entered via the instrument keypad Confirmation Enter the neu AT Password VOLTECH ATI USER MANUAL PAGE 6 49 FRONT PANEL MODES If a password has already been
249. se of the database results storage feature for up to 30 days from registration Please see below BEFORE requesting your trial code Software Registration x Software Un Registered ID Code BX21HE LXSLBJ BPH703 Key Code To use licensed features of this software please contact your Voltech Supplier with the ID Code shown above to request a Key Code which you should enter above Transfer ID Code Transfer Key Code PAGE 4 50 VOLTECH ATI USER MANUAL AT SERIES SERVER To register the software e Look at the registration details found under Registration from the Help menu This dialogue will display an ID Code that is unique to that PC installation e Contact your Voltech supplier with the exact ID Code and you will be issued with a Key Code provided that the appropriate payment has been received A 30 day trial key code may be supplied FREE OF CHARGE e Open the Registration dialogue as above and enter the Key Code The software is now fully operational e The Key Code is not time related and may be entered at any time after you have sent the ID Code to Voltech VOLTECH ATI USER MANUAL PAGE 4 51 AT SERIES SERVER 4 4 2 TRANSFERRING THE LICENSE TO ANOTHER PC If you wish to use the software on another PC you must transfer the license as described below BEFORE losing access to the existing installation To transfer the license Software Registration Xj Software Registe
250. sed without PC Editor or Server software To operate the tester in this way the origin of the tester s programs must be set to the local program store On the tester at the Program mode display under the softkey SET UP change the Origin to LOCAL This is described in section Getting Started Working Without a Server Storing a SINGLE Program A single program may Voltech Test Program Editor Part TUTORIAL File be stored in the AT Pat Schematic Program Server Setup Help using the PC Editor Djek Once a program has oad Program Upload Program Compensate Fixture gt been entered using the ee ell Editor and downloaded to the tester the tester will display VOLTECH ATI USER MANUAL PAGE 2 45 GETTING STARTED SAVE PROGRAM Continue Saving this program to the local store will overwrite an existing program group Local Save Press Local Save and the program that has been downloaded from the PC editor will be saved in the tester s local program store Note that any programs previously stored in the tester will be lost All PC connections to the tester may now be removed To run the program at any time return the tester to the top level display press Programs at the top level display choose the program from the list of programs and press the Run key and continue as before Storing Groups of Programs Inside the ATi U
251. set the existing password must be entered at the screen below before a new internal password can be set Confirmation Enter the old HT Password Delete Abort Shift The internal AT password protection may be removed by setting the password to a blank password i e not enter any characters Note The AT s local password is set as blank by default PAGE 6 50 VOLTECH ATI USER MANUAL 7 TESTS AND TEST CONDITIONS VOLTECH ATI USER MANUAL PAGE 7 1 TESTS AND TEST CONDITIONS Contents Tests and Test Conditions TA INTRODUCTION mm 7 4 7 1 1 Choosing Tests for a Transformer sss nennen 7 4 TAB TY Gontinully t e e ep e eu d e e 7 12 FAB R DGC Resistance iie ert 7 13 7 1 4 R2 DC Resistance Match sse 7 16 7 1 5 LS LP Inductance Series and Parallel Equivalent Circuit 7 19 7 1 6 QL Quality Factor esses siis seen nnn innen A 7 26 7 1 7 D Dissipation Factor or Tan sssssssssses eene 7 30 7 1 8 RLS RLP AC Resistance Series and Parallel Circuit 7 34 7 1 9 LSB LPB Inductance with Bias Series and Parallel Circuit 7 38 ZA 10 02 Inauctance Malch uie ed nite 7 42 7 1 11 LL LLO Leakage Inductance and Leakage Inductance with Offset 7 45 7 1 12 C Interwinding Capacitance Test Parallel Circuit 7 50
252. sing the PC Server Rather than dealing simply with individual programs the AT Server allows you to create groups of programs which may be downloaded to the AT tester and then used individually from within the local tester facilities Having executed programs from the Server as it is connected to the tester you may want to download a group of programs to the tester so the tester can be used in a stand alone situation To do this use the Server software to create a named group of programs Ensure that the Server is still running and connected to the tester as described above PAGE 2 46 VOLTECH ATI USER MANUAL GETTING STARTED On the tester at the top level display choose Set Up Then at the Set up display press the Groups softkey followed by the List softkey to obtain a list of program groups available for download Enter the group name Select the group to be downloaded to the tester and press Enter If the group download is completed successfully you will see the following display Group successfully dounloaded Continue VOLTECH ATI USER MANUAL PAGE 2 47 GETTING STARTED At this point unless you wish to archive measured results on the Server the Server connection may be removed Return to the tester s top level display by pressing the Continue softkey change the set up of the tester to use the internal program store instead of the Server press the Programs softkey and you will fi
253. softkey will also take you back to the RUN FINISH display but with no serial number entered This would be the correct action if the next softkey you wish to press is FINISH Subsequently pressing RUN would merely return you to the Enter the serial number display Re inputting the Options When options are enabled the RUN FINISH display allows access to additional softkeys that enable you to change the batch number or operator name without having to re enter the test program name You may access those additional softkeys via the Settings softkey from the RUN FINISH display Fart number Eun FROGRAM 1 Settings Total 1 Failed Results Last transformer P A 5 Finish To change the batch number press Settings and the following display will be revealed Choose the New Batch softkey to enter a new batch number at this time or to change the operator name press the Operator softkey VOLTECH ATI USER MANUAL PAGE 2 67 GETTING STARTED PAGE 2 68 Fart number FROGRAM 1 Total 1 Failed Last tranzformer Compensate Operator Hew Batch VOLTECH ATI USER MANUAL GETTING STARTED 2 6 STOP ON FAIL Stop on Fail is another program option that is either enabled or disabled when the program is created see chapter 3 When enabled it will cause the measurements to be terminated after each test that has produced a Fail result A display similar to the following wi
254. st conditions chosen for inductance in the previous section of this chapter The test conditions can also be determined automatically by the ATi according to this table Signal Specified voltage Specified current Auto Auto Specified Specified Specified Auto Note that a fixed signal cannot be used with an Auto frequency VOLTECH ATI USER MANUAL PAGE 7 35 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Equivalent Series Resistance Choose the integration period normally Medium and enter the terminals to be measured Use the PC Editor s Measure button together with a sample part if you are unsure of how to choose the test conditions Choosing Test Limits The test limits can be 96 A nominal value together with and percentage limits gt lt Minimum and maximum values gt A minimum value only lt A maximum value only Use the PC Editor s Measure button together with a sample part if you are unsure of the nominal value PAGE 7 36 VOLTECH ATI USER MANUAL Remember to click on the units of limits mOhm Ohm etc when entering absolute values as limits Test limits should be set as close as possible to detect assembly faults If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 37 TESTS AND TEST CO
255. subsequent test that also fails will produce a similar display At the end of the measurement the component will be classed as a Fail Pressing the Re Run softkey will re start the test sequence from the beginning You would normally press Re Run if the failure were caused by the component being incorrectly inserted into the fixture Unless the option Send retry results to server is enabled at this point there will be no data sent back to the Server Therefore after you have corrected the mistake following the re run good transformers will be reported as Pass PAGE 2 70 VOLTECH ATI USER MANUAL GETTING STARTED 2 7 TRIM If the TRIM test is included in a program the behavior in production mode is similar to the Stop on Fail option described above If the test before the TRIM test produces a Pass result then the program proceeds directly to the next test after the TRIM test If the test before the TRIM test produces a Fail result then the front panel display will be similar to the following TUTOR TAL TRIM at test 59 LS Continue H___ 1 1 1842mH The main difference between this and the Stop on fail display is that the reading on the fourth line will be continuously updated allowing adjustments to be made to bring the test result within limits Pressing the Abort softkey again stops the program and allows the operator to throw away a transformer that cannot be adjusted to giv
256. sured results into a spreadsheet as they happen in real time The spreadsheet used in the example is Microsoft Excel 97 and the module of code illustrated is written in the Visual Basic supplied with the spreadsheet Before attempting to create the spreadsheet set up the AT and server e Use the editor to create a program containing 5 tests where test number 3 measures a winding resistance e Ensure that the program option Send Results to Server is set to On e Transfer the program to the directory being used by the server for storing programs e Ensure that the server program is running and that the COM Port to be used has been enabled e Connect the AT to the server PC and use the PROGRAM SET UP menu to set the origin to SERVER e Atthe AT Top Level menu press the EXECUTE softkey and type in the name of the program e Run the program and check that the correct results are displayed in the on line monitoring window Leave the Server program running and on the same PC start Microsoft Excel 97 A new empty spreadsheet will be created From the Excel top level menu bar select Tools Macro Macros Enter the name OLE Demo and then create Excel will then bring up a module sheet labelled Module 1 Type the following code into this module sheet VOLTECH ATI USER MANUAL PAGE 4 41 AT SERIES SERVER Vk ck ck ck ck kk Ck Ck Sk KK KKK KKK KK KKK KKK KKK KKK ck kk ck kk kk ck kk ck kk ck kk S
257. suring inductance may be summarized below Select Nodes Select Type Set up Source Relay Switching Of Source Frequency v Ramp up Source Voltage Change Source Measure V amp Voltage Harmonic Analysis Signal Level Correct Y Compare With Calculate Ramp down Test Limits ES Inductance Source Voltage For other tests the sequence may be more complicated Notes All the relay switching is completed before the test source is energized This will ensure that there can be no arcing and prolong the life of the relays In contrast to some LCR bridges the AT Series testers trim the test source to give the user programmed test conditions This will guarantee that the same test conditions are applied to all transformers that use the same test program At the end of the test the source is safely ramped down so that the relay switching for any subsequent test will always occur with the source removed PAGE 1 28 VOLTECH ATI USER MANUAL 2 Getting Started VOLTECH ATI USER MANUAL PAGE 2 1 GETTING STARTED PAGE 2 2 VOLTECH ATI USER MANUAL GETTING STARTED Contents Getting Started 2 1 INTROD CTION sd sxc ecce ene ce NR nie 2 5 2 f 1 Package Contents ui a hd d i P ade 2 6 2 1 2 The ATi Front Panel eode er 2 7 2 43 Other Data Inputs e eidem tit eet ades 2 9 2 2 INSTAEEATION 2 22 cereo ener Reine sensu raa ei aeoa Re epe ys WR
258. t LP Inductance parallel circuit LSB Inductance series circuit with bias LPB Inductance parallel circuit with bias C Interwinding capacitance QL Quality factor D Dissipation factor tan Magnitude of complex impedance ZB Complex impedance with bias ANGL Angle of complex impedance TR Turns ratio and phase or by voltage IR Insulation resistance 1 4 2 Optional Program Tests LL Leakage inductance LLO Leakage inductance with user offset R2 DC resistance match L2 Inductance match C2 Capacitance match TRL Turns ratio by inductance PHAS Interwinding phase GBAL General longitudinal balance LBAL Longitudinal balance PAGE 1 8 VOLTECH ATI USER MANUAL INTRODUCTION Optional program tests continued ILOS Insertion loss RLOS Return loss LVOC Low voltage open circuit RESP Frequency response TRIM Trim adjustable part OUT User port relay control LSBX Inductance series circuit with external bias LPBX Inductance parallel circuit with external bias 1 4 3 ATi LCR Mode Functions Measurement Symbol Display Units DC resistance Rdc Ohms DC resistance using high voltage source IR Ohms Q AC resistance series circuit R Ohms AC resistance parallel circuit R Ohms Inductance series circuit L Henries H Inductance parallel circuit L Henries H Capacitance series circuit CS Farads F Capacitance parallel circuit CP Farads F Qual
259. t with the same limit being applied to all windings The continuity test will be quicker to execute than a series of resistance tests applied to each winding Used together with the Stop on Fail option CTY will allow you to re insert a transformer into the fixture without recording a FAIL or wasting further test time CTY is a production oriented test and is not available in the ATi s front panel LCR meter mode Programming the Test Using the PC Test Editor Continuity x Test Parameter Max Continuity Resistance fio kOhm C MOhm a value of 10 kOhm is optimum for speed Cancel Choosing the Test Limit When specifying the test limit remember that the same limit is applied to each winding so you must choose a value higher than the resistance of the biggest winding For most transformers where the winding resistances are less than 1kQ a test limit of 10kQ should be used as this will give the quickest test execution PAGE 7 12 VOLTECH ATI USER MANUAL 7 1 3 R DC RESISTANCE Measurement Range Basic Accuracy 0 to 10MQ 0 196 AT Series Tester R1 represents the resistance of the copper wire used to wind the transformer When current flows in the winding the resistance causes losses in the winding PR losses which cause undesirable heating within the transformer In addition the winding resistance causes a voltage drop in the winding when current flows causing the output
260. t Conditions To measure inductance the tester applies an AC voltage across the selected windings and measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain the complex impedance from which the inductance is extracted Generally it is not necessary to measure the inductance at the normal operating conditions of the transformer which could involve for example hundreds of volts This is because the core material can normally be assumed to behave linearly in the operating region and the inductance measured at a low level represents the inductance that will appear in use Also it can usually be assumed that the inductance value does not vary significantly with frequency Therefore although high frequencies are available with the tester measurement frequencies above a few hundred kilohertz should be used with caution This is because the errors caused by the stray inductance and capacitance of your fixture may become much more significant at these frequencies Compensation can be used to eliminate these errors Choosing the Test Signal Wherever possible the table below should be used for all inductance tests The inductance range should be chosen based on minimum value of inductance expected PAGE 7 20 VOLTECH ATI USER MANUAL Prefe red Test Signal Frequ Voltage Inc uctance Range 300KHz 100KHz 30KHz 10KHz 1KHz 100Hz 100Hz
261. t Enabled check box has the same function as before but in units of inductance Click on the OK button Again the test and its parameters will appear in the Program window 7 Finally by double clicking the left mouse button select TR Turns Ratio from the Available Tests window At the dialogue box enter the data required for the turns ratio test Voltage 1V Frequency 50Hz Integration Leave as the default Medium The AT measures the turns ratio between primary and secondary windings and allows the possibility of applying the test voltage to a third energized winding For this example the primary and energized windings are the same Energized high terminal A Energized low terminal B Primary high terminal A Primary low terminal B Secondary high terminal C Secondary low terminal D Using the default type of limits enter Primary Secondary 1 1 Neg 296 Pos 296 VOLTECH ATI USER MANUAL PAGE 2 27 GETTING STARTED Turns Ratio Click on the OK button Again the test and its parameters will appear in the Program window PAGE 2 28 VOLTECH ATI USER MANUAL GETTING STARTED The lower left window should now contain the complete program The scroll bars in this window enable you to view each test in the program in turn to check that it is correct The Editor will not allow a program to be run in the AT unless it has previously been saved From the top level men
262. t Setup Exit PAGE 2 34 VOLTECH ATI USER MANUAL GETTING STARTED At the dialogue box type in the part name TUTORIAL Save Part as before and change Part Number Directories ok the directory to the SEIS g me one selected for pee E program storage Network e g D C AT3600 SERVER d oe when the Server was installed Click on the OK button to close the dialogue box and save the test program in the Server program directory The next section of the tutorial demonstrates running the program on the AT from the archive on the server Before proceeding to that section if the Server and Editor are using the same COM Port on the single PC re allocate the COM Port from the Editor to the Server e Close down the Editor by clicking on e Part Exit in the top level menu e Start the Server by double clicking on its Windows icon e Configure the COM port as shown earlier 9 Remove the cable between the AT auxiliary port and the PC COM port 9 Connect the cable between the AT Server port and the PC COM port VOLTECH ATI USER MANUAL PAGE 2 35 GETTING STARTED 2 3 6 Running a Program on the Tester Having stored the program in the Server archive it is now possible to run the program on any AT that is connected to the Server Before proceeding further make sure that the Server is running with the interface cable correctly fitted between the tester s server port and the selected Server PC COM port an
263. t comp FAIL OC compensation is required for 123 Hz Check the connection either short or open circuit and repeat the compensation measurement In the unlikely event that compensation continues to fail you can use the ATi without compensation comp req will be shown on the display while contacting your Voltech supplier for applications assistance PAGE 6 34 VOLTECH ATI USER MANUAL FRONT PANEL MODES 6 5 LCR MODE ERROR MESSAGES The ATi is a precision measuring instrument with fully programmable test sources The ATi will whenever possible ensure that the programmed voltage frequency and DC bias current are present AT THE TERMINALS OF THE PART UNDER TEST This is done by measuring the voltage and current at the terminals of the part and if necessary trimming the test source to establish exactly the required conditions at the part This means that the ATi will automatically compensate for lead resistance and if 4 wire Kelvin connections are used the contact resistance between connector and the part under test Program V Measured V winding under test ATi basic measurement circuit Measured V Program V This is very different to commonly used LCR bridges which have a nominal impedance in their output to provide short circuit protection for the test signal generator VOLTECH ATI USER MANUAL PAGE 6 35 FRONT PANEL MODES Program V Measured V X se Winding under t
264. t to replace the existing part If a Server password has been set you will have to enter the correct authorization password in the Save As authorization dialog box see below PAGE 4 8 VOLTECH ATI USER MANUAL AT SERIES SERVER Enter authorisation password Cancel 4 2 4 DELETING A TEST PROGRAM If you need to remove a part from the Server program directory a button has been provided within the PART OPEN dialogue Select the part to be deleted and press the DELETE button You will then be prompted to enter the password as defined when installing the Server software to allow the part to be deleted The program will then be removed from the Server directory Open Part Part Number Directories TRS c at3600 server Cancel TR1 a C cA TR2 C3 at3600 Delete TR3 C3 server TR4 Help Network Drives c ms dos_6 IMPORTANT Once a part has been deleted it may not be recovered Before deleting a part it is advisable to open and view to ensure you are deleting the correct test program VOLTECH ATI USER MANUAL PAGE 4 9 AT SERIES SERVER 4 2 5 GROUPING TEST PROGRAMS Programs that are used on the transformer tester at similar times may be grouped for convenience For example a number of transformers all based on the same bobbin may be tested at the same time When a program group has been defined it may be downloaded to the tester Each of the parts within the group will then be
265. t value giving the minimum limit for the test TestNumber NO LIMIT This test has no minimum limit GetMaxLimit LPCSTR ComPort short TestNumber Float value giving the maximum limit for the test TestNumber NO LIMIT This test has no maximum limit GetTestStatus LPCSTR ComPort short TestNumber Returns four digit hex string HHP giving the test status as seen on Editor results screen GetTestMnemonic LPCSTR ComPort short TestNumber Returns the test mnemonic as a string i e LBAL PAGE 4 38 VOLTECH ATI USER MANUAL AT SERIES SERVER GetTestUnits LPCSTR ComPort short TestNumber Returns the test units as a string i e Ohm GetCompensationStatus LPCSTR ComPort NO COMPENSATION STATUS No status received yet No Fixture Compensation Program has not been compensated Fixture Compensation successful Compensation all OK Fixture Compensation fail ExtraString Compensation has failed GetUnitType LPCSTR ComPort Returns AT3600 AT1600 or ATi depending on the type of instrument connected to the ComPort GetResult LPCSTR ComPort short TestNumber The number returned is a float representing the value of the result measured or a zero if no result was available This function is included for compatibility with older versions of the Voltech AT Server It is not recommended for new applications VOLTECH ATI USER MANUAL PAGE 4 39 AT SERIES SERVER This section shows
266. tVariantResult method can return either a numerical value corresponding to a valid result or a string corresponding to an error message The line Set objServerResult CreateObject Server Results creates the server Results automation object within Visual Basic When trying to read the result with Do vntResult nTest objServerResult GetVariantResult sComPort nTest Loop Until vntResult nTest lt gt NO RESULT And _ vntResult nTest INVALID RESULT NUMBER two tests for No Result and Invalid Result Number are included The GetVariant method will normally read back No Result until a measurement has occurred The next time it is executed after a new result has been sent to the server GetVariant will read back the actual result value The act of doing this will set a flag in the Server to say that the data has been read so that any further executions of the GetVariant statement before another result has been transferred to the server will then return the No Result reply Although the test number is fixed 73 in this example the Invalid Result Number test is also included This is because the GetVariant method can be PAGE 4 44 VOLTECH ATI USER MANUAL AT SERIES SERVER activated at exactly the same time as the results are being transferred from the AT to the server Depending on the speed and other parameters of your PC there may be a small time during the transfer when th
267. tabase ready format for easy off line analysis e OLE 2 support allowing real time analysis of your production test system Test programs may be stored on floppy disk for back up or inter site transfer Installation and set up of the Server program is explained in chapter 2 VOLTECH ATI USER MANUAL PAGE 4 5 AT SERIES SERVER 4 2 TEST PROGRAM HANDLING 4 2 1 STORING TEST PROGRAMS After a test program has been created using the Editor application it will be ready for use with your AT Series Tester The diagram below shows a potential connection scheme for use with a single tester and two PCs Before program requests or uploads may be completed the tester must be configured for Server mode See chapter 2 Network connection or both installed on the same local PC Editor You may copy program files directly into the program directory used by the server application IMPORTANT When a program file is copied to the Server and a file with the same name is already resident within the Server the incoming file will replace the previous file PAGE 4 6 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 2 2 VIEWING A TEST PROGRAM Each test program has a part name To view a particular test program you will need to know its part name Select FILE PART and then OPEN from the menu bar You may select the part to open from the list displayed or change the path and drive to search for other parts Open Part Part Numb
268. table in section 8 1 of this chapter The values of the other factors are given below Ac 0 000005 x Fy Ay 0 002 1 Vp TR Vp Ay 0 05 1 Vp Vp TR I Where is the measurement frequency Hz Vp is the measured voltage across the primary winding V TR is the turns ratio between the primary and secondary windings VOLTECH ATI USER MANUAL PAGE 8 23 SPECIFICATIONS 8 2 17 LSBX AND LPBX TESTS The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test and is given as AT AC Ay AJ 4 AQ 7 AB Where Ar is the total accuracy 96 An is the basic relative accuracy 96 Ac is the calibration accuracy 96 Av is the correction for voltage level 96 is the correction for current level 96 Ao is the correction for Q factor 96 is the correction for Bias 96 The value of Ag is given in the table in section 8 1 of this chapter The values of the other factors are given below Ac 0 0896 0 00001 x Fm 0 08 0 001 Vu A 0 08 0 000196 Im 0 03 x Ig Im Aq 0 08 2 LS LP LSP LPS and X Aq 0 08 2 x Qm RLS and RLP Ag error from DC1000 Specification refer to DC1000 user manual Where Fm is the measurement frequency Hz Vm is the measured voltage V Iu is the measured current A is the bias current A Qu is the Q factor of the measured impedance PAGE 8 24 VOLTECH ATI USER
269. tch No Fixture Compensation Result Serial Time Pass Fail ww 001 R 002 ww ny ww no mw 7 Minimum Maximum Reading M mM Minimum Maximum R 1 10 44 20 Pass 59 73 6 776850E 01 Pass 3 3 2 10244223 Pass 59 73 6 776832E 01 Pags 3 3 3 10 44 24 Pass 59 73 6 776363E 01 4 3 10 44 26 Pass 59 73 6 777967E 01 Pass 3 3 5 75 10 44 27 Pase t 59 73 6 777842E 01 Passi 3 3 6 10 44 29 Pass 59 73 6 778374E 01 Pass 3 3 223899E 00 110549E 00 125640E 00 135034E 00 185198E 00 152627E 00 And so forth for each result until a change of batch or part If a result window is closed the connection to the transformer tester will be lost A warning before connections are removed is issued p p p p p p PAGE 4 12 VOLTECH ATI USER MANUAL AT SERIES SERVER 4 3 2 RESULT DISPLAY AND ANALYSIS Three approaches have been provided to allow observation of your test result data e Simple on line monitoring e Batch statistics on line analysis e On Line analysis e Off Line analysis 4 3 3 SIMPLE ON LINE MONITORING Each time a COM to AT Series Tester connection is opened using the Setup gt Communication menu an accompanying result monitoring window will be created One result monitoring window will be present for each open channel When results are sent fro
270. ter TUTORIAL as the program name and under Fix ID enter UNIVERSAL as your fixture ID To enter those names scroll to the appropriate line use the Delete softkey to delete the default description of PART 1 and then use the instrument keypad to enter your own description Program options Mame TUTORIAL Fix ID UNIVERSAL_ Results printing Off Delete Operator numbering OFF Batch numbering OFF Note that on this screen the shift key is not available for character entry On the program options screen the buttons on the instrument keypad will consecutively scroll you through both numbers and letters Once the character that you want to enter appears in inverse on the LCD pause briefly and the chosen letter or number will be entered To choose other program options such as sending test results to the Server highlight the appropriate line on the program option display and choose On or Off For example to automatically send test program results to the AT Server scroll to Send results to Server Off and choose softkey 3 On VOLTECH ATI USER MANUAL PAGE 6 45 FRONT PANEL MODES Program options Serial numbering OFF Send retry to Server Stop on fail off Date Time on Reports Once you have completed the program options set up press OK to return to the program test selection screen and OK again to confirm your set up Note that if a password has been set the AT requests the password to be
271. terlock port AT3600 only A hi pot trip interrupt has terminated the test a flashover has occurred or the current has exceeded the AT s current capabilities can occur on HPAC HPDC and IR AT3600 only A STOP interrupt has terminated the test from the STOP flag of the remote port An 8kV interrupt has terminated the test voltage gt 8kV AT3600 only An over temperature interrupt has terminated the test unit has become too hot AT3600 only An auxiliary trip interrupt has terminated the test this can be created by an attached device to the peripherals port VOLTECH ATI USER MANUAL PAGE 3 45 PROGRAM EDITOR 3 6 FIXTURE COMPENSATION SEE ALSO SECTION 2 8 Often when measuring small values of resistance inductance or capacitance the effects of the fixture can add significant errors to the results To allow you to make more accurate measurements the AT Series Testers have built in firmware to compensate for the fixture parasitics If fixture compensation is required follow steps 1 2 and 4 of the procedure in described earlier in this chapter so that the tester is connected and the program is downloaded Then from the top level menu bar select Tester Compensate Fixture Most programs will contain at least one test where fixture compensation can be applied In this case you will then see one or two messages AT Series Editor Software Ke Ci Short Circuit Fixture Compensation will be applied
272. tester s Server port to the Server PC has a broken wire or is not plugged in correctly COM port The COM port has not been set up in the Server application Server not running Either the Server PC is not powered on or the Server application is not running Errar GROUP HAME not found in Server program directory Continue Possible Cause The directory set up in the Server application as the location of test programs does not contain a group with the requested name At all the above displays pressing the Continue softkey will take you back to the top level display Press Continue to return to the top level display Your program group has now been loaded into the tester s internal store and the Server PC may be VOLTECH ATI USER MANUAL PAGE 2 87 GETTING STARTED disconnected These programs will be stored during power off and will only be overwritten by another group download Tester Download Using The Editor 55 Voltech Test Program Editor Part TUTORIAL File Pat Schematic Program IESG Server Setup Help be stored in the AT BEREAN load Program using the Editor PC Upload Program Compensate Fixture Bun Program A single program may Download Firmware Once a program has been entered using the Editor and downloaded to the tester the tester will display SALE PROGRAM Continue Saving this program to the local store will overwrite an existing program group Loc
273. tests will be required the first to turn the appropriate relay drivers on and the second to turn them back off See the Specification for details of the relay driver configuration VOLTECH ATI USER MANUAL PAGE 7 115 TESTS AND TEST CONDITIONS 7 1 30 LSBX INDUCTANCE WITH EXTERNAL BIAS SERIES CIRCUIT DC Bias Measure Test Test Basic Range Voltage Frequency Accuracy 0 1A to 1nH 1MH 1mV to 5V 20Hzto 3MHz 0 2 Q gt 10 250A This test requires the use of one or more Voltech DC1000 Precision DC Bias Current Sources Contact your Voltech sales office for details The inductance of a transformer winding while an external bias current is flowing through it may be tested using series or parallel equivalent circuit models Initially the DC bias current is set up and allowed to stabilize An AC voltage is applied across the selected winding the voltage across and current through the winding is then measured using harmonic analysis The measured voltage is divided by the current to obtain a complex impedance and the inductance is calculated On selecting LSBX Inductance with External Bias Series Circuit from the Available Tests window a dialogue box will be displayed Inductance with External Bias Series Circuit Test Parameters Integration Signal 100 Cm CV Cm C Short Frequency 100 Hz 5 kHz MHz Medium Bias Current 5 A C Long Terminals High Terminal Low Terminal E E Inductance Limits
274. the ABS file and double click on it Then select Voltech Test Program Editor New Part Tester gt Download Firmware Part Schematic Program Server Setup Help El R Download Program Upload Program Compensate Fixture as Run Program Download Firmware VOLTECH ATI USER MANUAL PAGE 9 7 WARRANTY AND SERVICE The firmware upgrade will now commence and the Editor screen will show a series of dialogue boxes to identify each stage in the process The download should take approximately 30 minutes In the unlikely event that the Editor display shows an ERROR dialogue box before the download is complete try repeating the entire procedure Should the error persist contact your Voltech distributor At the end of the download the tester will reset itself You may then carry on using your tester as normal with the benefits offered by the new firmware being available immediately If you were supplied with a BOOTATi ABS file the Editor will now check the boot code version already inside the AT If the boot code requires upgrading the Editor will prompt you with a warning that communications must not be disrupted during the 12 minutes that it takes to upgrade the boot code WARNING You must NOT switch off the AT or interrupt the communications during the 12 minutes required for this part of the upgrade If the power is removed from the ATi or the communications disrupted in any way during this process t
275. the ATi later VOLTECH ATI USER MANUAL PAGE 3 33 PROGRAM EDITOR Click on OK with Measure without Fixture Compensation selected if you do not wish to perform compensation This is normal if the value of inductance is high If you click on OK with Compensate Fixture selected then there will be additional messages depending on whether the test requires short or open circuit compensation or both see section 2 8 Compensation In this case the LS test requires both short circuit and open circuit compensation The following dialogue box will be shown first AT Series Editor Software xi i Short Circuit Fixture Compensation will be applied to this program Fit a short circuit link in place of each winding Yes No Fit the required short circuit header and click on OK The Editor will now command the tester to perform the Fixture Compensation for the required test in this case LS The tester will then store the zero value and subtract it from the next result returned for the test If the short circuit links are not correctly fitted you may see an error message which allows you to try again or to cancel the compensation You will then be prompted to perform open circuit compensation AT Series Editor Software Be x G Open Circuit Fixture Compensation will be applied to this program Remove any transformer on the fixture and ensure the fixture is empty Yes No P
276. the tester s OUT test The tester applies the specified voltage and using harmonic analysis measures the combined impedance of the transformer and load resistor PAGE 7 96 VOLTECH ATI USER MANUAL The return loss is calculated using the formula RLOS 20logio Zo Zul Zo Zu Where Z is a complex impedance in the form Z R jX Or 2 2117 Ro Rm X Xm r 20logi0 Ro Rm X X4 Where is the resistive portion of the reference impedance Rm is the resistive portion of the measured device s impedance is the reactive portion of the reference impedance Xm s the reactive portion of the measured device s impedance Choosing Test Conditions The voltage and frequency are usually determined by the final application of the part under test 1000Hz is typical for the mid band of audio telecommunications circuits VOLTECH ATI USER MANUAL PAGE 7 97 TESTS AND TEST CONDITIONS Programming the Test Using the PC Test Editor Return Loss Voltech Choose the integration period normally Medium and enter the High and Low Terminal names The reference impedance values are the nominal values of the transmission line to which the transformer will be connected in its final application This is a complex impedance Z R jX where R is the real part of the impedance and X is the imaginary part A typical impedance might be 600 Q resistive only or 6009 in seri
277. the tests used The error code is a 16 bit binary code which is shown in hexadecimal notation in the table below The error codes indicate one single bit of the 16 bit code and therefore one or more errors could occur at the same time which will be shown as a full 4 digit hexadecimal code For example if a voltage over range PAGE 3 44 VOLTECH ATI USER MANUAL PROGRAM EDITOR xxx1 and a current over range xxx2 have occurred at the same time during test then the error code is 0003 i e both bits 0 and 1 set in the 16 bit binary error code If a test has failed due to an interrupt then an additional code is attached to bits 12 15 of the error code as the table details further Hex Code Axx 1 Error Test passed with no errors Voltage over range occurred Current over range occurred Ramp up process has been aborted too much load The test parameters could not be trimmed to required value incorrect test parameters for the load An error occurred after ramp down current did not decay away in time Current limit fail hi pot tests only test current exceeded pre programmed limit AT3600 only Voltage present Vpres did not go away in time something on the fixture is staying charged AT3600 only The test has failed due to an interrupt see table below Where reason for interrupt fail The safety interlock interrupt has terminated the test a break has occurred from the safety in
278. ties dialogue is a standard one that is supplied by Windows You should choose the provider that will provide the connection to the type of database that you are using Several different types of provider are installed along with the Server software others may be available if you have a database application installed on the same PC as the Server If the provider you need is not available and the database is installed on another PC ask the database administrator for the database client tools for the Server PC VOLTECH ATI USER MANUAL PAGE 4 19 AT SERIES SERVER Typical provider types are Database Provider Microsoft Access 97 Microsoft Access 2000 Oracle SQL Server Microsoft Jet 3 51 Microsoft Jet 4 0 Microsoft OLE DB Provider for Oracle Microsoft OLE DB Provider for SQL Server In addition it is possible to connect to ODBC compliant databases including Microsoft Access using the Microsoft OLE DB Provider for ODBC Drivers Click on Next when you have chosen the correct provider Provider Connection Advanced All Specify the following to connectto Access data 1 Select or enter a database name yi 2 Enter information to log on to the database Username Admin Blankpassword Allow saving password Test Connection Select the database name that you will be using by clicking on Select If you wish to create a new database for AT Server results do so now using your database program T
279. tio together with the limits as positive and negative percentage values 2 absolute number of turns When limits are set as an absolute number of turns the tester converts these limits to the type in the following way PriLimit Sec Limit x 100 Pri Turns Sec Turns You can see the exact result of this conversion by clicking on limits in the Editor dialogue once the absolute limits have bee entered For example take a typical Switched Mode Power Supply transformer with windings in the ratio of 200 10 Typically a prior measurement of inductance will have confirmed the correct number of primary turns have been fitted with the correct cores Setting absolute limits of 0 on the primary and 1 on the secondary will result in limits of Nominal Ratio 200 10 20 Ratio 1 sec turn 18 18 Ratio 1 sec turn 22 22 Limits calculated by tester 0 200 1 10 x 100 10 The equivalent ratio limits used by tester are Upper limit 22 Lower Limit 18 VOLTECH ATI USER MANUAL PAGE 7 65 TESTS AND TEST CONDITIONS PAGE 7 66 Which equates to the actual ratios with a one turn error on the secondary In general the voltages obtained during any voltage turns ratio test will not equate exactly to the theoretical calculation of Np Ns because for example of the relative positions of the windings with respect to each other and the core General Rule When setting turns ratio limits i
280. tion process and yield Notes 1 The third line showing the graphical comparison of the measured value and user programmable limits has a logarithmic scale The measured value may be represented by either a vertical bar as shown when it lies within the range that can be displayed on the LCD or by an arrowhead or gt at the end of the horizontal bar when it lies outside the range that can be displayed on the LCD 2 Should the tester be returning results to a PC running the Editor software then the Editor software will freeze when this screen is displayed until the appropriate softkey Re run Continue or Abort is pressed Program Edit After you have created the program schematic and selected the program options you may then start creating the actual program of tests To edit the test program you must first switch to the Program Editor From the Top Level menu bar select Program gt Edit Voltech 2s Voltech Test Program Editor New Part 2s Voltech Test Program Editor New Part Editor New Part Part T ers iris ester Server e 68 1 Options InSentaest Delete Nest Se VOLTECH ATI USER MANUAL PAGE 3 19 PROGRAM EDITOR You will now see a display with three separate windows 2s Voltech Test Program Editor New Part Part Schematic Program Tester Server Setup Help Efe a 5 3 1 5 Schematic Maximize Available Tests Minimize
281. to this program Fit a short circuit link in place of each winding Yes No At this point you should ensure that the appropriate fixture has been placed on the tester and a short circuit bobbin fitted For the following open circuit compensation remember to remove the short circuit bobbin After you have clicked on the OK button at either of the messages the tester will be commanded to make the compensation measurements for your test program PAGE 3 46 VOLTECH ATI USER MANUAL PROGRAM EDITOR If errors are encountered such as a shorting link is not fitted the editor will display the appropriate warning message and allow you either to try again or to cancel the compensation When the compensation measurements have been successfully completed the compensation values for each test in the program will be stored inside the tester Any subsequent measurements started as described above by clicking on Tester Run Program will return compensated results to the Editor If you are not sure whether to compensate or not simply try it If any of the results change significantly then it should be done REMEMBER Whenever you make changes to the program the compensation results in the tester will no longer be valid Make sure to compensate again each time you download a test program to an AT Series Tester whether the program has changed or not VOLTECH ATI USER MANUAL PAGE 3 47 PROGRAM EDITOR 3 7 PROGRAMMING HINTS AN
282. tton once A selected winding will be indicated by a box surrounding the winding 2 Choose Delete Winding from the Schematic menu The selection will be removed from the screen Note that ALL tests containing the deleted terminals will also be DELETED PAGE 3 8 VOLTECH ATI USER MANUAL PROGRAM EDITOR 3 2 4 RENAMING A TERMINAL To rename a terminal either 1 Select the winding containing the terminal to rename by using the mouse pointer and clicking the left mouse button 2 Choose Rename Terminals from the Schematic menu OR use the mouse pointer and double click on the chosen winding 77 A fill in dialogue box will appear Each fill in box will contain the current names of the winding terminals You may change a name by 1 Selecting the appropriate terminal box with the mouse or by moving between the boxes with the TAB key on the keyboard and then typing the new name 2 Pressing ENTER or clicking the mouse pointer on OK The dialogue box will be removed and the corrections will be displayed on the screen Note that ALL tests containing the renamed terminals will be DELETED VOLTECH ATI USER MANUAL PAGE 3 9 PROGRAM EDITOR 3 2 5 ADDING A TERMINAL TO AN EXISTING WINDING To add a terminal to a transformer winding 1 Select Add Winding from the Schematic menu on the menu bar to create a second two terminal winding 2 Now place the new winding on the same side of the schematic
283. turned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 25 TESTS AND TEST CONDITIONS 7 1 6 QL QUALITY FACTOR Measurement Test Test Basic Range Voltage Frequency Accuracy 0 001 to 1000 1mV To 5V 20Hz To 3MHz 0 596 AT Series Tester When a transformer is energized the changing magnetic field in the core causes two types of losses hysteresis losses and eddy current losses The total of these losses can be represented on the equivalent circuit of a transformer by a resistance associated with the inductance of the winding For this equivalent circuit the Quality Factor Q is defined as Q Ls where 2nf Rs For a given inductance the lower the equivalent series resistance the higher is the value of Q i e the better the coil Where Used The Q factor test would normally be used for signal pulse and switched mode power transformers where the normal operating conditions require only small excursions of the B H curve never extending beyond the linear region PAGE 7 26 VOLTECH ATI USER MANUAL A Q Factor test will help to determine that the correct wires and cores have been correctly assembled for the part under test Test Conditions To measure Quality Factor the tester applies an AC voltage across the selected winding and measures the voltage across and the current through the winding Using harmonic analysis the measured voltage is divided by the current to obtain a complex impedance from which the
284. u bar select Part Save As VOLTECH ATI USER MANUAL PAGE 2 29 GETTING STARTED Yoltech Test Program Editor New Schematic Program Tester Serv New Ctrl N Open Ctrl O Schematic Save Ctrl S Print Ctrl P p Print Preview Print Header Print Setup Exit Save Part At the dialogue box Ran Numar er TUTORIAL c at3600 editor type in ETENIM g eme 5 editor Help TUTORIAL Network as the part name Drives amp c ms dos 6 x Click on the OK button to close the dialogue box and save the test program in the Editor default directory 2 9 4 Running the Program from the Editor The following section describes how to run a test program from the Editor To do this you must first create a program which includes only the test options installed in your tester Having created both the transformer schematic and the test program the program is now ready to run on your tester under the control of the Editor PAGE 2 30 VOLTECH ATI USER MANUAL GETTING STARTED Before proceeding further make sure that the interface cable between the tester s Auxiliary Port and the selected PC COM port is correctly fitted and that the COM Port is correctly configured in the editor see page 2 14 Ensure that the tester has been switched on To run the program 1 From the top level menu bar select Tester Download Program The Editor will now download s Voltech Test Program Edit
285. u would like to apply Please note that the Measure button may be used here For information refer to the Test Program Editor of your AT manual 2 Selectthe integration time required Medium is the default setting Long will give more stable readings for tighter limits at the expense of time and Short will test at the maximum speed but may give slightly noisier readings 3 Enterthe terminal names between which the impedance is to be measured 4 Setthe impedance limits Enter a nominal value and then the limits as negative and positive values VOLTECH ATI USER MANUAL PAGE 7 121 TESTS AND TEST CONDITIONS gt lt Enter minimum and maximum values gt Enter just a minimum value lt Enter just a maximum value 5 Select OK The test specification will then be displayed in the program window PAGE 7 122 VOLTECH ATI USER MANUAL 7 2 SERIES AND PARALLEL CIRCUITS The ATi can make measurements of many parameters such as Inductance L Capacitance C and AC resistance R using both the parallel and equivalent circuits The measurements for the series or parallel equivalent circuits will not necessarily be the same and care should be taken when choosing which equivalent circuit to use when testing Any practical inductor or capacitor will not be perfect and will have associated stray parallel and series resistance in its equivalent circuit X Rs Rp Where X is the purely imaginary inductive o
286. uery m How to treat the columns Column name Data type Treat as Display name TestNo Long OC Comp Text SC Comp Text Load Comp Text Result Double Measurement TestStatus Text bal View Data Save as default Refresh Columns Validate Chart Data Clear all OK Cancel Select the table of the database that holds the data that you want to chart You may also select a query that has been written in the database or write a Custom Query PAGE 4 30 VOLTECH ATI USER MANUAL AT SERIES SERVER In this case the database table tblVoltechresults has been chosen and the column Result flagged as a measurement To do this click on the Treat 85 column of the Result row and select Measurement from the drop down list Next click on Filtering and filter the data for TestNo 2 Filter for selecting rows from data table Select data where the date time in THIS column Is Between and Iv Inclusive AND S SS v Additional Conditions See WHERE clause Additional Conditions Help Clear all This selects only the results for test number 2 of the AT test program which is an inductance test VOLTECH ATI USER MANUAL PAGE 4 31 AT SERIES SERVER Next click on the Limits tab and enter appropriate specification limits that will appear on the chart The ChartRunner s
287. unwanted output voltages See also the LBAL test Where Used The general longitudinal balance test as opposed to the standard longitudinal balance test LBAL is used to confirm the longitudinal balance or CMRR of PAGE 7 80 VOLTECH ATI USER MANUAL audio and telecommunications transformers to the standards IEEE455 and FCC 68 310 and wherever similar connection methods are specified Test Conditions The source and load resistors RS and RL and the measuring transformer are connected to the transformer under test as shown This may be done automatically using the tester s OUT test The voltages Vout1 and Vout2 are measured whilst Vin is held constant The ratio of these two voltages reflects the transformer under test s ability to reject common mode voltages General Longitudinal balance is calculated as the ratio GBAL 20 log Vout2 Vout1 IEEE 455 Method Used in Canada Europe and ROW Fixture Transformer Energized Vin Measured Vout a Oe Terminals X A B C A C wem ae s VOLTECH ATI USER MANUAL PAGE 7 81 TESTS AND TEST CONDITIONS FCC 68 310 Method Used in USA Fixture Transformer Y b Energized Vin Measured Vout porc rmi to el ae ST eS RECANA termina Choosing Test Conditions The source and load resistors and the fixture transformer for the IEEE and FCC methods are assumed to be on the fixture but are not shown
288. ure button CANNOT be used to determine the test voltage Choosing Test Limits The test limits can be A nominal value together with and limits of up to 90 and 0 deg gt lt Minimum and maximum values Use the PC editor s Measure button together with a sample part if you are unsure of the nominal value Test limits should be set as close as possible to detect assembly faults If the User Offset Enabled check box is checked a value can be entered into the edit box The value entered is then added to any results returned from the AT tester VOLTECH ATI USER MANUAL PAGE 7 107 TESTS AND TEST CONDITIONS 7 1 27 PHAS INTERWINDING PHASE ANGLE Measurement Test Test Basic Range Voltage Frequency Accuracy 360 to 4360 1mV to 5V 20Hz to 3MHz 0 059 AT Series Tester Po SIE Re When the AC voltage across one winding is compared to the voltage across another they may be different in amplitude and phase Where the turns ratio or open circuit voltage tests measure the amplitude of the voltages the PHAS test measures the phase difference between the two voltage waveforms Where Used The interwinding phase angle test is most often used on measuring and other signal transformers where the phase displacement of signals is important to the operation of the complete circuit or product The test determines the angle measured in degrees between the voltage signals across two different windings This is differe
289. ware version number on success or a failure string NO FIRMWARE ID no valid firmware version found GetUnitID LPCSTR ComPort This call returns the tester serial number on success or a failure string NO UNIT ID no valid AT serial number found GetTransformerSerialNo LPCSTR ComPort This call returns the transformer serial number on success or a failure string NO SERIAL NO no valid transformer serial number found GetResultsFilename LPCSTR ComPort This call returns the results file filename on success or a failure string NO RESULTS FILE no valid filename found No results yet GetResultPolarity LPCSTR ComPort short TestNumber NO POLARITY Test has no polarity result VT Polarity is positive Polarity is negative GetPolarityPass LPCSTR ComPort short TestNumber NO POLARITY Test number has no polarity result PASS Polarity result has passed FAIL Polarity result has failed VOLTECH ATI USER MANUAL PAGE 4 37 AT SERIES SERVER GetTestPass LPCSTR ComPort short TestNumber PASS Test result has passed FAIL Test result has failed GetOverallPass LPCSTR ComPort PASS All tests have passed FAIL One or more tests have failed GetNumberOfTests LPCSTR ComPort Returns a short integer variant type giving the number of tests in the program Use for possible determination of the maximum value for TestNumber in other functions GetMinLimit LPCSTR ComPort short TestNumber Floa
290. wn in reverse video and both the program and measured voltages are shown at the bottom of the display Press softkey 3 HV Off On to switch off the high voltage when handling or connecting the part under test Press softkey 6 EXIT to return to the main LCR sreen PAGE 6 14 VOLTECH ATI USER MANUAL FRONT PANEL MODES Settings for the voltage integration can be changed by pressing softkey 4 Settings A Print option is included in this menu Insulation Resistance IR Woltage Integration CFixture modes Prg 168 uU More Tests m 4 2 T ct ae Press softkey 1 IR Voltage IE voltage settings IR 4 8888 at And then press Enter V to adjust the IR Voltage VOLTECH ATI USER MANUAL PAGE 6 15 FRONT PANEL MODES Enter value Delete 123 Enter E EE Cancel at Enter the required test voltage using the 12 key numeric keypad Press softkey 1 ENTER to accept the value that you have typed Press softkey 5 CANCEL to discard changes and return to the previous menu Press softkey 4 DELETE to correct mistakes Insulation resistance set ups cannot be stored in memory but the voltage and used nodes are automatically stored and recalled the next time that IR is selected The Integration Print and More Tests settings are common to all LCR measurements and are described later in this chapter PAGE 6 16 VOL
291. www voltech com ATI USER MANUAL Voltech Instruments Inc Voltech Instruments Ltd 11637 Kelly Road 148 6 Street Suite 306 Harwell International Business Centre Fort Myers FL 33908 U S A Didcot Oxon OX11 ORA U K Tel 239 437 0494 Tel 44 0 1235 834555 Fax 239 437 3841 Fax 44 0 1235 835016 sales voltech com sales voltech co uk VOLTECH ATI USER MANUAL PAGE Voltech Instruments is committed to a policy of continuous product development Hence product specification and the information given in this manual are subject to change without notice No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without prior written permission of Voltech Instruments Voltech Instruments 2002 2005 All rights reserved The Voltech ATi is protected by the following patents USA US 5500598 UK 2261957B Europe 0621953B Microsoft Windows and the Windows logo are either registered trademarks or trademarks of Microsoft Corporation in the United States and or other countries Voltech Part Number 98 067 Issue 8 October 2005 PAGE Il VOLTECH ATI USER MANUAL gt bbb DANGER OF ELECTRIC SHOCK Only qualified personnel should install this equipment after reading and understanding this user manual If in doubt consult your supplier RISQUE D ELECTROCUTION L installation de cet quip
292. ys The R test is not unique in this respect In fact most tests have several ways in which the limits may be entered allowing you greater flexibility in configuring each test to match your production testing requirements The four types of limits for the R Winding Resistance test are The limits are entered as positive and negative percentages about a nominal value gt lt The limits are entered as minimum and maximum values gt Thereis only a minimum limit lt There is only a maximum limit VOLTECH ATI USER MANUAL PAGE 3 27 PROGRAM EDITOR The corresponding dialogue boxes are as follows Winding Resistance Voltech limits Winding Resistance L math ok Mew Cance Voltech Minimum and maximum limits gt lt PAGE 3 28 VOLTECH ATI USER MANUAL PROGRAM EDITOR Winding Resistance P Voltech Voltech Maximum limit only lt VOLTECH ATI USER MANUAL PAGE 3 29 PROGRAM EDITOR Many of the tests available for the AT Series have all four limit types There are obviously some tests where it is not sensible to have four limits types IR insulation resistance being a clear example where only a minimum limit is applicable as the perfect insulation between windings has no upper limit to its resistance To choose which type of limit you wish to use simply use the mouse to click on one of the buttons 96 gt lt gt or After you have

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