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CHAPTER 6 : SERVICE MAINTENANCE

1. REVISION EXTECH ELECTRONICS CO LTD DATE 07 17 97 FILE 7420 75 Tech SERVICE MAINTENANCE 6 3 3 Model 7430 Schematic Block Diagram eont 7440 EE 7 06 CN1 FRONT 13 12 e gt 12 12 CNB gt REAR Se o ooo D EXTECH ELECTRONICS CO LTD DATE 075107 FILE 74300 6 3 4 Model 7430 with Built in Scanner Option 004 Schematic Block Diagram GND CNT2 16 CNB H con FRONT 2 RETURN 26 CN9 CN _____ H gt FRONT 2 CNI2 prest COH REAR 5 4 CKB 03 2 l RETURNS preser REAR IL CONT CN3 2 PASS TEST gt bC FAIL R
2. 7440 8 ech SERVICE MAINTENANCE 6 4 REPLACEMENT PARTS amp ACCESSORIES LIST Xx denotes version number of PC Board Y denotes version number of Transformers Part Number Qt Reference Description Designator 2PCB 7440 Axx 7440 Main Control Board 2PCB CHV 06 1 CHV 06 HV Control Board 1 2 03 03 Keypad Board 7402 2PCB CSU 105 1 CSU 105A Scanner Matrix Board for 7440 m ne 2PCB REC 17 1 REC 17 Rectifier Board 5 7410 LCD 2002 1 ___ LCD Display 20 x 2 Characters SW DIG R B L 1 Reset Switch Red SW D16 G B L tee Test Switch Green SW 2 10 1 ____ Power Switch 2P 10A 250V IC89C52 IC12 IC Microcontroller 8 bit 20Mhz 89C52 T 7420 T1 Y T 7410 T1 Y T 7440 T2 Y 1 T2 Output High Voltage Transformer for 7440 amp 7430 Input Transformer for 7420 Input Transformer for 7410 1 1 1 1 1 T 7440 T1 Y nh Input Transformer for 7440 amp 7430 Output High Voltage Transformer 7420 amp 7410 T 7420 T2 Y ACCESSORIES H3U 2 30 Rack Bracket 78 ccH SERVICE MAINTENANCE HB3U 2 3URackMountHande 1101 1 HiehVolasee TestLead 1100 1 1 Test Lead 1103 1 HiehCumentTestLead 1104 1 HiehCurrent Return Test Lead 7440 onlv 140 1 HiehVoltaee Cable
3. 600 O OFF Use the Numeric keys to enter the LO Limit setting in 1 step then press the ENTER key The program will store the LO Limit setting and advance to the Dwell Time parameter automatically Note If the LO Limit is set to 0 the LO Limit judgment is disabled 3 2 4 5 Dwell Time setting The display will show Dwell Time s Range 0 5 999 9 0 Constant Use the Numeric keys to enter the Dwell Time setting in 0 1 second step then press the ENTER key The analyzer will store the Dwell Time setting and advance to the Frequency selection parameter automatically CX MANUAL OPERATIONS Note If the Dwell Time is set to 0 the timer will continue to count to the maximum test time then reset to 0 and start over automatically The test will continue until RESET button is pressed or a failure occurs 3 2 4 6 Frequency Selection The display will show Frequency 60 Hz Frequency 50 Hz lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to select the Output Frequency then press v key to advance to Scanner Channel setting 3 2 4 7 Scanner Channel setting The display will show Scanner CH X Range 1 16 0 OFF If the Scanner is not installed it is not necessary to enter this parameter Press v key to advance to Offset parameter Use the Numeric keys to enter the scanner channel number then press the ENTE
4. Other Packaging If you do not have the original packaging materials please follow these guidelines 1 Wrap the instrument in a bubble pack or similar foam Enclose the same T ec ON H INTRODUCTION information as above 2 Use a strong double wall container that is made for shipping instrumentation 350 Ib test material is adequate 3 Use a layer of shock absorbing material 70 to 100 mm 3 to 4 inch thick around all sides of the instrument Protect the control panel with cardboard 4 Seal the container securely 5 Mark the container FRAGILE to insure proper handling 1 9 Field Installation Of Options There are no field installable options on this instrument ELECTRONICS Specifications Front amp Rear Panel Descriptions CHAPTER 2 SPECIFICATIONS FRONT amp REAR PANEL DESCRIPTIONS 2 1 FUNCTIONAL SPECIFICATIONS Model 7440 7430 7420 7410 INPUT Voltage 115 230 VAC 15 Single Phase User selection Fuse 6 3A Model 7440 30 20 5 0A Model 7410 DIELECTRIC WITHSTAND TEST MODE Output Rating 5 KV AC 40 mA Model 7440 30 30mA Model 7420 10 6 KV DC 10 mA Output Adjustment Range 0 5KV AC 0 6 KV DC Resolution volt step Accuracy t 1 of setting 5 volts Ramp HI DC 12mA peak maximum ON OFF selectable Charge LO DC Range 0 0 350 0 uA DC or Auto set HI Limit AC Range 0 00 40 00 mA Resolution 0 01 mA step Accuracy t 1 596 of setting 3 counts DC
5. Range 0 3500 uA 3000 9990 HA Resolution per step 0 per step Accuracy t 1 5 of setting 3 counts LO Limit AC Range 0 000 9 999 mA Resolution 0 001 mA step Accuracy t 1 596 of setting 3 counts 0 0 999 9 uA Resolution 0 1 n A step Accuracy 2 of setting 2 counts Arc Detection Range 9 most sensitive Failure Detector Audible and Visual ELECTRONICS Specifications Front amp Rear Panel Descriptions Voltage Display Range 0 00 6 00 KV Full Scale Resolution 10 volt step Accuracy 1 of reading 1 counts Current Display Auto Range AC Range 0 000 3 500 mA Resolution 0 001 mA step Accuracy 1 5 of reading 3 counts Range 3 00 mA 40 00 mA Resolution 0 01 mA step Accuracy 1 5 of reading 3 counts DC Range 0 0 350 0 300 3500 3000 9990 uA Resolution 0 1 nA 10 per step Accuracy 1 5 of reading 3 counts AC 0 2 000 mA or AUTO set 1 __ DC 0 200 pA or AUTO set DC Output Ripple lt 4 Ripple RMS at 6 KV DC 3 5 mA Resistive Load AC Output Wave Sine Wave Crest Factor gt 1 3 and lt 1 5 Form Output Frequency Range 60 or 50 Hz User Selection Accuracy 100 PPM Output Regulation 0 8 of setting 3 volts from no load to full load Dwell Timer Range 0 4 999 9 sec 0 Constant Resolution 0 1 sec increments Accuracy 0 1 0 05 sec Ramp Timer Range AC
6. Use the Numeric keys to enter the standard value of voltage unit V and then press the ENTER key to store the standard value of DC hipot voltage for calibration and the display will show DCW Voltage 6000V OK TEST to Calibrate QN 6 ech CALIBRATION 5 6 IR VOLTAGE CALIBRATION Press the v key the program will advance to the DC Voltage calibration of the IR test The display will show IR Voltage 1000V TEST to Calibrate Connect a DC standard voltage meter which can measure up to 1000V to the output connectors and then press the TEST button the program will automatically generate an output of about 1000VDC and the display will show IR Voltage V Enter Standard V out Use the Numeric keys to enter the standard value of DC voltage unit then press the ENTER key to store the standard value of IR test voltage for calibration and the display will show IR Voltage 1000V OK lt TEST gt to Calibrate 5 7 AC CURRENT 40 RANGE CALIBRATION Press the v key the program will advance to the AC 40mA range calibration of the ACW test The display will show AC 40mA 100 lt TEST gt to Calibrate Connect a resistor about in series with a AC standard Ammeter which can measure up to 10mA to the output leads The Ammeter should be connected to the return lead then press the TEST button the program will automatically generate an outpu
7. 223 25 22 20 1 2 5 4567 89 11 12114 ta 16 1 18 19 10 15 POWER SWITCH Rocker style switch RESET BUTTON Reset the system before you can proceed to the next test TEST BUTTON Press to start the test MEMORY KEY To select one of the 50 memories location STEP KEY To select one of the 8 steps within each memory LOCK KEY To select key lockout mode LOCAL PRINT KEY To change the operation of the instrument from Remote to the Local mode When Printer Port Card is installed press this key will output test data to a printer 8 AC W KEY To select AC Withstand Test 9 DC W KEY To select DC Withstand Test 10 INSULATION KEY To select Insulation Resistance Test 11 GROUND CHECK KEY To select Ground Check Test 12 UP DOWN ARROW KEYS To scroll the display through the function parameter menus 13 SETUP KEY To enter the setup menu and view or change the GPIB address display contrast alarm volume PLC remote settings or the stop on fail setting 14 EXIT KEY To exit any menu or to clear an unwanted entry in a parameter field 15 DATA ENTRY KEYS To input numeric parameters 16 ENTER REVIEW KEY To accept numeric data for parameter settings or to review up to 8 connected test results after a test has been completed 17 HIGH VOLTAGE OUTPUT JACK output use the high voltage test lead model 1101 18 RETURN OUTPUT JACK Use the Return test
8. 8 CHANNEL HIGH VOLTAGE OUTPUT JACK Scanner output For the connection of the high voltage test lead model 1109 to UUT Unit Under Test 9 CHASSIS GROUND EARTH TERMINAL This terminal should be connected to a good earth ground before operation 10 FUSE RECEPTACLE Please replace the fuse with correct rating 11 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord 12 RETURN OUTPUT JACK For the connection of the Return test lead model 1102 13 HIGH VOLTAGE OUTPUT JACK For the connection of the high voltage test lead model 1101 22 XT eccH ELECTRONICS Specifications Front amp Rear Panel Descriptions 2 3 4 REAR PANEL OF MODEL 7410 N CA N 1 HIGH VOLTAGE OUTPUT JACK For the connection of the high voltage test lead model 1101 2 RETURN OUTPUT JACK For the connection of the Return test lead model 1102 3 INPUT POWER SWITCH Line voltage selection for 110V or 230V operation 4 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord 5 FUSE RECEPTACLE Please replace the fuse with correct rating 6 CHASSIS GROUND EARTH TERMINAL This terminal should be connected to a good earth ground before operation THERMAL COOLING FAN Runs continuously to cool the instrument INTERFACE Standard interface is RS232 fa
9. 1 During the DC Withstand Voltage test when the values are being updated in real time during the Ramp cycle the display will show DCW Ramp XXX X s MXX X X XX KV XXXX uA 3 4 2 3 Dwell 3 4 2 3 1 During the DC Withstand Voltage test when the values are being updated in real time during the Dwell cycle the display will show DCW Dwell XXX X 8 MXX X X XX KV XX XX HA 3 4 2 3 2 If the Ramp time is very short and the program has not read the meter readings the display will show DCW Dwell XXX X s MXXX aen 3 4 2 4 Ramp Hi 3 4 2 4 1 If the Ramp HI function is enabled and the leakage current during the Ramp cycle exceeds 10mA then the display will show DCW Ramp HI XXX X s MXX X X XX KV gt 9999 uA 3 4 2 5 Charge LO 3 4 2 5 1 If the leakage current during the Ramp cycle falls below the Charge LO setting then the display will show DCW Charge LO XXX X s MXX X X XX KV XXX X uA 3 4 2 6 HI Limit 3 4 2 6 1 If the DUT current exceeds the HI Limit of DC Withstand Voltage test and the leakage current is within the metering range the display will show DCW HI Limit XXX X s MXX X X XX KV XXXX uA CX MANUAL OPERATIONS 3 4 2 6 2 If the DUT current exceeds the HI Limit of DC Withstand Voltage test and the leakage current is not within the metering range the display will show DCW HI Limit XXX X s MXX X X XX KV gt 9999 uA 3 4 2 7 Short 3 4 2 7 1 If the DUT current is well beyond the metering range of
10. 89 1113 14 19 16 17 10 12 POWER SWITCH Rocker style switch RESET BUTTON Reset the system before you can proceed to the next test TEST BUTTON Press to start the test MEMORY KEY To select one of the 50 memories location STEP KEY To select one of the 8 steps within each memory LOCK KEY To select key lockout mode LOCAL PRINT KEY To change the operation of the instrument from Remote to the Local mode When Printer Port Card is installed press this key will output test data to a printer AC W KEY To select AC Withstand Test DC W KEY To select DC Withstand Test INSULATION KEY To select Insulation Resistance Test UP DOWN ARROW KEYS To scroll the display through the function parameter menus SETUP KEY To enter the setup menu and view or change the GPIB address display contrast alarm volume PLC remote settings or the stop on fail setting EXIT KEY To exit any menu or to clear an unwanted entry in a parameter field DATA ENTRY KEYS To input numeric parameters ENTER REVIEW KEY To accept numeric data for parameter settings or to review up to 8 connected test results after a test has been completed HIGH VOLTAGE OUTPUT JACK HV output use the high voltage test lead model 1101 RETURN OUTPUT JACK Use the Return test lead model 1102 LCD DISPLAY The 2x20 character display BUS REMOTE LED To indicate the instrument is in the Remote Control mode LOCK LED To indicate the keys are locked the user will
11. Current setting in 10mA step XX XX mQ Ground Continuity Resistance 0 01 step Use the v arrow keys to progress through the test parameters menu The ue forward menu items are Current Voltage HI Limit LO Limit Dwell Time Frequency Scanner Set Offset Connect 40 CX MANUAL OPERATIONS 3 2 4 1 Output Current setting The display will show XX XX A Range 3 00 30 00 Use the Numeric keys to enter the Current setting then press the ENTER key The analyzer will store the Current setting in 0 01A step and advance to the Output Voltage parameter automatically 3 2 4 2 Output Voltage setting The display will show Voltage X XX V Range 3 00 8 00 Use the Numeric keys to enter the voltage setting then press the ENTER key The analyzer will store the Voltage setting in 0 01 volt step and advance to the HI Limit parameter automatically This setting controls the open circuit voltage and does not take effect when the current is being regulated at the Output Current setting 3 2 4 3 HI Limit Ground Resistance setting The display will show HI Limit XXX Range 0 600 Use the Numeric keys to enter the HI Limit setting in 1 step then press the ENTER key The analyzer will store the HI Limit setting and advance to the LO Limit parameter automatically 3 2 4 4 Low Limit Ground Resistance setting The display will show LO Limit XXX mQ Range 0
12. For ACW the controller send a 50 or 60 Hz sine wave to the amplifier for signal amplification T2 will step up the output voltage to 5 000 volts For DCW the controller sends a 600 Hz sine wave to the amplifier for signal amplification T2 will step up the output voltage to 6 000 volts and pass through rectifier to obtain DC high voltage output For IR it is the same principle as DCW But the output voltage is limited to 1000 volts For Ground Continuity the controller sends a 50 60 Hz sine wave to the amplifier After amplification the signal is directed to Current O P The output voltage and current are measured by the voltage and current sensors The measured values are fed back to the Controller via A D converters There are separate V amp A sensors for ARC Leakage and Overload The microprocessor controller will base on these information to make comparison with inputs data to make judgment deciding PASS and Fail conditions All these information are then display to the 20x2 LCD display 72 ech SERVICE MAINTENANCE 6 2 TROUBLESHOOTING Please note that the analyzer has one year warranty for manufacturing defects Extech will repair the analyzer free of charge Please return the analyzer to Extech office or the authorized local distributor The warranty is void if the analyzer is opened by unauthorized person THE ANALYZER SHOULD ONLY BE REPAIRED BY QUALIFIED ENGINEERS AND TECHNICIANS MAKING REPAIR WITHOUT PROPER TRA
13. INSTRUMENT MUST BE CONNECTED TO THE PROTECTIVE CONDUCTOR OF THE LINE MAINS POWER CORD THE MAIN PLUG SHALL ONLY BE INSERTED IN A SOCKET OUTLET RECEPTACLE PROVIDED WITH A PROTECTIVE GROUND EARTH CONTACT THIS PROTECTIVE GROUND EARTH MUST NOT BE DEFEATED BY THE USE OF AN EXTENSION CORD POWER CABLE WITHOUT A PROTECTIVE CONDUCTOR GROUNDING WARNING This instrument is shipped with a three wire power cable When this cable is connected to an appropriate AC power source this cable connects the chassis to earth ground 1 8 OPERATING STORAGE AND SHIPMENT ENVIRONMENT 1 8 1 Operating Environment This instrument may be operated in temperatures from 0 40 C and Relative humidity of 0 to 90 1 8 2 Storage Environment This instrument may be stored or shipped in environments with the following limits 40 to 55 C The instrument should also be protected against temperature extremes which may cause condensation within the instrument 1 8 3 Shipment Environment Original Packaging Please retain all original packaging materials that you originally received If you are returning your instrument to us for servicing please repackage the instrument in its original container Please enclose the instrument with all options accessories and test leads Indicate the nature of the problem or type of service needed Also please mark the container FRAGILE to insure proper handling
14. and connect the next transformer to be tested After that the cover is closed and the Fixture A is now on Standby condition It waits until the Fixture B has passed and then proceeds the testing automatically on the Fixture A again This process is repeated and very single piece of the transformer are guarantee tested When one of the tests has failed then system will lockout and will not continue testing until the system is reset Opt 727 JigA 8CH JigB 8CH Matrix Scanner Opt 728 JigA 4CH JigB 4CH Matrix Scanner MODEL7420 Opt 727 JigA 8CH JigB 8CH Matrix Scanner 1927Test fixture 1927 SIGNAL INPUT SIGNAL OUTPUT 57 LED SIGNALOUTPUT CX ccH MANUAL OPERATIONS 3 6 1 Signal input 9 Pin D type MODEL 7420 at Rear anel SIGNAL INPUT socket A control Pin 7 8 B control Pin 7 9 3 6 2 LED Signal Output 25 Pin D Type MODEL 7420 at Rear panel INTERFACE socket 1 A TEST Pin 2 Yellow 4 B TEST Pin 6 Yellow 2 A TEST Pin 3 Green 5 B TEST Pin 7 Green 3 A TEST Pin 4 Red 6 B TEST Pin 8 Red 7 GND Pin 25 58 CX RS232 amp GPIB INTERFACE CHAPTER 4 RS232 amp GPIB INTERFACE 4 1 BUS REMOTE INTERFACE RS232 GPIB This section provides information on the proper use and configuration of the RS232 and GPIB remote interface The command list are the same for both RS232 GPIB interface except SRQ function is unique to GPIB interface For 7440 and 7430 RS232 interface is sta
15. be unable to change any settings ARC LED To indicate Arc Detector detects an arcing condition This indicator will function even when the Arc Fail has been disabled 19 CXT ecl RONICS Specifications Front amp Rear Panel Descriptions 2 3 REAR PANEL LAYOUT 2 3 1 REAR PANEL OF MODEL 7440 1 SCANNER 1 CONNECTOR For connection of first External Scanner Model 7002 2 SCANNER 2 CONNECTOR For connection of second External Scanner Model 7002 3 REMOTE SIGNAL OUTPUT 9 Pin D subminiature male connector for remote control of TEST and RESET functions and program memory selection 1 2 or 3 4 REMOTE SIGNAL INPUT 9 Pin D subminiature female connector for monitoring PASS FAIL and PROCESSING signals relay output 5 INPUT POWER SWITCH Line voltage selection for 110V or 230V operation 6 INTERFACE Standard interface is RS232 factory installed For GPIB user order a GPIB card model 1117 and substitute the RS232 card 7 THERMAL COOLING FAN Runs continuously to cool the instrument 8 CHASSIS GROUND EARTH TERMINAL This terminal should be connected to a good earth ground before operation 9 FUSE RECEPTACLE Please replace the fuse with correct rating 10 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord 11 CURRENT OUTPUT JACK For the connection of the high current output lead used for the ground continuity test
16. charging current was lower then the setting the test cables may not be connected properly ALL 7400 series analyzer can set the Charge LO value manually or automatically To set the Charge LO value manually use the numeric keys to enter the Charge LO current setting and then press the ENTER key The analyzer will store the Charge LO setting and advance to the HI Limit parameter setting The setting range of Charge LO is from 0 0 to 350 0 uA in step Please be aware that the following procedure will activate WARNING high voltage on the output connector once the Test button is pressed To use Auto Set connect the test cables and or test fixture between the instrument and DUT Be sure that the test parameter of Output Voltage has been set to the values that will be used for the Final test If the scanner is to be used then the scanner channel must also be set and then press the TEST button The instrument will apply the voltage that has been entered for this memory step selection The analyzer will read the charging current of DUT and set the Charge LO current at approximately one half 1 2 of the reading The display will show Charge LO XXX X uA TEST to Auto Set Note The value showing on the display is the Charge LO setting and is not the reading of the charging current of the DUT Then press the key to advance to HI Limit parameter setting 3 2 3 3 HI Limit Current setting The display will show HI Li
17. damaged inspect the contents for visible damage such as dents scratches or broken meters If the instrument is damaged notify the carrier and the Extech Electronics customer support department immediately Please save the shipping carton and packing material for the carriers inspection Our customer support department will assist you in the repair or replacement of your instrument Please do not return your product without first notifying us and receiving an RMA return material authorization number 1 6 STANDARD ACCESSORIES The standard accessories should include the following items C ccH INTRODUCTION 1 Power Cable x 1 pc 2 Instruction Manual x 1 set 3 Fuse x 2 pcs 4 Test Leads x 1 set 7 Model 7410 amp Model 1101 x 1 Model 1102 x 1 7420 Model 7430 Model 1101 x 1 Model 1102 x1 Model 7440 Model 1101 x1 Model 1103 x1 Model 1104 x 1 1 7 PREPARATION FOR USE 1 7 1 Instrument Return Connection to DUT CAUTION The output power supplies of this instrument are referenced directly to earth ground Any conductor that completes a path between the high voltage and earth ground will form a completed circuit However the Return lead of instrument is not connected directly to earth ground to eliminate monitoring stray leakage currents that flow to earth ground The metering circuit monitors only leakage current flowing from the DUT through the Return test lead to the Return connector Therefore it is crucial that t
18. in double quotes If the Test Function has already been selected to ACW mode and you wish to set the ramp time of the ACW test across the IEEE bus at 10 seconds do the following send the string SD 10 00 This tells the instrument to set the AC Ramp Time at 10 00 seconds To set outputs 1 amp 2 of the scanner to High outputs 3 amp 4 to Low and outputs 4 8 to Off type in the following string after the ACW Test Function has been selected All ports not being specifically set will automatically be set to O open To read the 2 x 20 display first send the string then send the GPIB command to read 40 bytes The instrument will send 40 bytes one byte for each character on the display including spaces 4 1 2 3 Non Volatile Memory The instrument saves each parameter in non volatile memory when the parameter is changed The non volatile memory has a limited write cycle life therefore there is a special volatile memory location that is available for programmers who wish to send all parameters before executing each test Memory 50 step 8 is the memory location that will NOT write the parameter to non volatile memory Settings written to this location from GPIB mode will be lost when power is shut down Parameter changes to this location is unlimited and will not effect the life of the internal non volatile memory chip FOR MORE INFORMATION ON IEEE GPIB PLEASE CONTACT The Institute of Ele
19. is read by the controller 4 1 2 RS232 GPIB Interface Command List The following commands are used to toggle ON OFF functions or menu selection items No other values or parameters are needed to execute these commands However when using commands that are usable for a certain function only function specific the appropriate function select command FC FD FE or FF must be executed first to access the parameter for that function 59 i ELECTAONICS RS232 amp GPIB INTERFACE Command Function Function Specific FC ACW Function Select FD___ DCW Function Select f o O FE ____ IR Function Select 2 FF GND Function Select_ 7440 only FG ACW DCW Continuity 7430 Only x FH____ ACW DCW Continuity 7430 Only x FI ACW 60Hz 1 FJ ACW 50Hz FK____ ACW Arc FailOn x FL ACW Arc Fail Off FM____ DCW Arc FailOn _ DCW Arc Fail Of x FR jComectOff ES FailStopOn FT FailStopOfe FU GND Autooffset 4404 ACW Auto Offset X __ FY DCW 1 Enable Pass SRQ Disable Pass SRQ Enable Fail SRQ Disable Fail SRQ Enable Abort SRQ Disable Abort SRQ Enable Error Command SRQ x X gt gt lt gt gt The following S commands will set test parameters on the instrument that require numeric or al
20. maximum duty cycle is 70 at rated output Therefore it cannot be used continuously at 30mA output 4 ELECT MANUAL OPERATIONS 3 2 1 6 Frequency Selection The display will show Frequency 60 Hz Frequency 50 Hz lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to select the Output Frequency then press the v key to advance to Arc Sensitivity setting 3 2 1 7 Arc Sensitivity setting and Arc Fail selection The display will show Arc Sense X XX mA Range 2 00 20 00 mA Use the Numeric keys to enter the current sensitivity desired for Arc Sense setting in 0 01 mA step then press the ENTER key The program will store the Arc Sense setting and advance to the ARC Fail mode selection automatically The display will show Arc Fall 2 or Arc Fail OFF lt ENTER gt to Select lt ENTER gt to Select If the Arc Fail mode is set to the analyzer will indicate an arc failure when the arc current is over the setting The analyzer will stop the test immediately and the ARC indicator on the front panel will lit and alarm If the Arc Fail mode is set to OFF the analyzer will not indicate an arc failure when the arc current is over the setting The analyzer will not stop the test but the ARC indicator on the front panel will lit when arcing is present Use the ENTER key to select the Arc Fail mode then press the v key to advance the program to scanner channel set
21. on the output leads of about 30AAC and the display will show G Current A Enter Standard I out Use the Numeric keys to enter the standard value of current unit A and then press the ENTER key to store the standard value of AC Ground Continuity current and display will show Ground A 30A OK lt TEST gt to Calibrate 1 ELECTRONICS SERVICE MAINTENANCE CHAPTER 6 SERVICE MAINTENANCE 6 1 THEORY OF OPERATION 74XX SERIES BLOCK DIAGRAM AMPLIFIER POWER VP i bio v ml 71 AC DC uv mm 2 115 230V 3 3 SELECT CAO 5 e CURRENT O P DISPLAY LOW VOLTAGE POWER SUPPLY KEYBOARD SCAN INTERFACE uP CONTROLER V amp A SENSER GPIB PRINT REMOTE I O The 74XX series Safety Analyzers are microprocessor controlled instruments The external user interface to the microprocessor controller are display keyboard Remote I O GPIB and Scanner
22. on the rear panel GPIB INTERFACE FUNCTIONS TEEE 488 INTERFACE Complete handshake capability Talker Listener functions Service request capability No remote local capability No parallel poll capability No device clear capability No device trigger capability No controller capability 3 state driver CONTROLLABLE ITEMS Test Reset control Setting of test status parameters for test Display Reading Results Reading DATA CODES ASCII DELIMITER CR LF EOD 4 1 2 1 GPIB Address Each device on the GPIB IEEE 488 interface must have a unique address You can set the address of the 7440 or 7430 to any value between 0 and 30 The address is set to 8 when the instrument is shipped from the factory The address can only be set from the front panel The address is stored in non volatile memory and does not change when the power has been off or after a remote interface reset 4 1 2 2 Example of communicating over the IEEE bus To write commands over the IEEE bus you must enter the code that is specific to the software language you are using Then follow the example below To set the output voltage across the IEEE bus at 1240 volts do the following First select the ACW mode by sending the string then send the string SA 1240 63 RS232 amp GPIB INTERFACE This tells the instrument to set the AC voltage at 1240 volts A string is a list of ASCII characters octal or hex bytes or special symbols enclosed
23. separate from the functional settings The system settings are also global and are not specific to any memory location 3 3 1 PLC REMOTE SELECTION Press the Setup key and the display will show PLC Remote ON or PLC Remote OFF ENTER to Select ENTER to Select Use the ENTER key to select the mode PLC Remote Control If the Remote Control is set to ON the test function will be controlled by the Remote Control via the remote connectors located on the rear panel The 43 CX MANUAL OPERATIONS TEST button on the front panel is disabled but the RESET button is still enabled If the Remote Control is set to OFF the operation of the instrument will be controlled by the local TEST and RESET buttons on the front panel The remote Memory Program recall functions can be performed only when the PLC Remote is set In addition when the PLC remote is set to ON the remote TEST signal input is active while in the Bus Remote Mode After selecting PLC Remote mode press the SETUP key again If the GPIB Interface Card is installed on this analyzer the analyzer will advance to GPIB addressing setting If this instrument does not have the GPIB interface card installed the analyzer will advance to the contrast setting The instrument will store the selection of PLC Remote automatically 3 3 2 GPIB ADDRESS SETTING If the GPIB interface card is not installed on this instrument th
24. setting in 0 01 mA step then press the ENTER key The program will store the HI Limit setting and advance to the LO Limit parameter automatically 3 2 1 3 LO Limit Current setting The display will show LO Limit X XXX mA Range 0 000 9 999 Use the Numeric keys to enter the minimum leakage current allowed for LO Limit setting in 0 01 mA step then press the ENTER key The program will store the LO Limit setting and advance to the Ramp Time parameter automatically Note If the LO Limit is set to 0 the LO Limit judgment is disabled 3 2 1 4 Ramp Time setting The display will show Ramp Time XXX X s Range 0 1 999 9 Use the Numeric keys to enter the Ramp Up Time required in 0 1 sec step then press the ENTER key The analyzer will store the Ramp Time setting and advance to the Dwell Time setting automatically 3 2 1 5 Dwell Time setting The display will show Dwell Time s Range 0 3 999 9 0 Constant Use the Numeric keys to enter the Dwell Time required in 0 1 sec step then press the ENTER key The program will store the Dwell Time setting and advance to the Frequency selection parameter automatically If the Dwell Time is set to 0 the timer will continue to count to the maximum test time then reset to 0 and start over automatically The test will continue until a reset is executed or a failure occurs Note For model 7420 and 7410 the
25. single setting for both modes Press the MEMORY key the display will show Memory XX Range 1 50 To recall the memory use the Numeric Key to enter the Memory location number and then press the ENTER key The program will recall the test parameters stored in that location and return to the operation mode 27 ccH MANUAL OPERATIONS 3 1 2 STEP KEY Press the STEP key the display will show the test parameters of the functions selected for that step i e the parameters of AC Withstand Voltage DC Withstand Voltage Insulation Resistance or Ground Bond test Pressing the step key again will advance to the next step in sequence with step 1 following step 8 Note When the step is connected you will see an underbar character on the display just after the step number M25 1 The following display indicates that after running Memory 25 Step 1 the tester will continue to run Memory 25 Step 2 ACW Set XXX X s M25 1 X XX KV XX XX mA 3 1 3 LOCK KEY Press the LOCK key If the Password is Enabled the display will show Range 0 9999 Enter the password and then press the ENTER key The program will switch the Key Lock function from LOCK to UNLOCK or UNLOCK to mode and advance the program to Operation mode automatically If the instrument is in the Lock mode the LOCK indicator on the front panel will lit If the wrong password is entered the program will give a
26. test and the ground continuity resistance is beyond the metering range the display will show GND HI Limit XXX X s 0 00A gt 600 mQ 3 4 4 4 LO Limit 3 4 4 4 1 If the DUT resistance falls below the LO Limit of the Ground Bond test the display will show GND LO Limit XXX X s XX XXA XXX mQ 3 4 4 5 Pass 3 4 4 5 1 When the DUT passed the Ground Bond test when the test process is complete the display will show GND Pass XXX X s MXX X XX XXA XXX mQ 3 5 REMOTE I O Two 9 pin D type connectors are mounted on the rear panel which provide REMOTE INPUT OUTPUT control and information These connectors mate 54 MANUAL OPERATIONS with standard 9 pin D subminiature connector provided by the user For best performance a shielded cable should be used To avoid ground loops the shield should not be grounded at both ends of the cable Suggested AMP part numbers for interconnecting to the Remote I O are shown below 205204 4 PLUG SHELL WITH GROUND INDENTS 205203 3 RECEPTACLE SHELL 745254 7 CRIMP SNAP IN PIN CONTACT for plug 745253 7 CRIMP SNAP IN SOCKET CONTACT for receptacle 745171 1 SHIELDED CABLE CLAMP for either plug or receptacle 747784 3 JACKSCREW SET 2 Remote Interface Rear Panel SIGNAL OUT SIGNAL IN FAIL PASS ESSING 3 5 1 Signal Outputs on Remote I O The rear panel connector provides output signals to remotely mon
27. test cables are connected properly at the beginning of a test A capacitive DUT will draw charging current on the DC Withstand Voltage test when the Output is activated If the charging current was lower then the setting the test cables may not be connected properly ALL 7400 series analyzer can set the Charge LO value manually or automatically To set the Charge LO value manually use the numeric keys to enter the Charge LO current setting and then press the ENTER key he analyzer will store the Charge LO setting and advance to the Ramp HI parameter The setting range of Charge LO is from 0 0 to 350 0 uA in 0 1 pA step Please be aware that the following procedure will activate WARNING high voltage on the output connector once the Test button is pressed To use Auto Set connect the test cables and or test fixture between the instrument and DUT Be sure that the test parameter of Output Voltage and Ramp Time have been set to the values that will be used for the Final test If the scanner is to be used then the scanner channel must also be set and then press the TEST button The instrument will apply the voltage that has been entered for this memory step selection 34 CX MANUAL OPERATIONS The analyzer will read the charging current of DUT and set the Charge LO current at approximately one half 1 2 of the reading The display will show Charge LO XXX X uA lt TEST gt to Auto Set Note The value showing on the display is t
28. when in Lock Mode If the MR Lock is selected OFF the Memory selection Menu will be enabled when in Lock Mode Different memories can be recalled but the test parameters or steps can not be changed The MR Lock default is preset to ON at the factory 65 eclt ELECTRONICS CALIBRATION 5 4 ACW VOLTAGE CALIBRATION Press the v key the program will advance to the AC Voltage calibration of the ACW test The display will show ACW Voltage 5000V lt TEST gt to Calibrate Connect an AC standard voltage meter which can measure up to 5000 to the output connectors and then press the TEST button the program will automatically generate an output of about 5000V AC and the display will show HI Voltage V Enter Standard V out Use the Numeric keys to enter the standard value of voltage unit V and then press the ENTER key to store the standard value of AC hipot voltage for calibration and display will show ACW Voltage 5000V OK lt TEST gt to Calibrate 5 5 DCW VOLTAGE CALIBRATION Press the v key the program will advance to the DC Voltage calibration of the DCW test The display will show DCW Voltage 6000V lt TEST gt to Calibrate Connect a DC standard voltage meter which can measure up to 6000V to the output connectors and then press the TEST button the program will automatically generate an output of about 6000VDC and the display will show HI Voltage V Enter Standard V out
29. wish to offset the leakage current of the test leads and fixture you may skip this function by pressing the v key The analyzer will advance to the Step Connection setting automatically You may use the Numeric keys to enter the offset value of the leakage current or press Test button for the analyzer to make a measurement and saved the measured value as an offset 3 2 1 10 Step Connection setting The display will show Connect ON Or Connect OFF lt ENTER gt to Select lt ENTER gt to Select If Connect is set to the next step in the sequence will be executed If Connect is set to OFF the test sequence will stop at this step Use the ENTER key to select the Step Connection mode then press v key The display will return to AC Output Voltage Setting which is similar to 2 1 1 showing the value of the voltage keyed earlier This is the end of parameter setting for AC Withstand Test Use the or v key to scroll the display to check for setting error When a error is found just simply enter the correct setting and process Press the EXIT key to exit from the setting mode to operation mode Now the analyzer is ready to perform AC Withstand Voltage Test to the DUT Note If Step 8 is set to ON the test process will be connected to the first step of the next Memory 32 C 4 ELECT MANUAL OPERATIONS 3 2 2 DC W KEY Press the DCW key will enter the setting mode o
30. 0 1 999 9 sec DC 0 1 999 9 sec Resolution 0 1 sec increments Accuracy 0 1 0 05 sec INSULATION RESISTANCE TEST MODE Output Voltage Range 100 1000 Volts DC Resolution 1 volt step Accuracy 1 of setting 3 volts 10 ELECTRONICS Specifications Front amp Rear Panel Descriptions Voltage Display Range 0 1000 V Resolution volt step Accuracy t 1 of reading 3 counts Resistance Display Range 9999 MO 4 Digit Auto Ranging Accuracy 2 of reading 2 counts at test voltage 500 1000V and 1 1000 t 8 of reading 2 counts at test voltage 500 1000V and 1000 9999 MQ 8 of reading 2 counts at test voltage 100 500V and 1 1000 MQ Charge LO Range 0 000 3 500 or Auto Set Delay Timer Range 0 5 999 9 sec 0 Constant Resolution 0 1 sec step Accuracy t 0 1 0 05 sec Ground Check Current DC 0 1A 0 01A fixed Model 7430 only 10 3010 fixed GROUND CONTINUITY TEST MODE Model 7440 only Output Voltage Range 3 00 8 00 Volts AC Open Circuit Resolution 0 01 volt step Limit Accuracy t 1 96 of Setting 0 03V Condition Output Frequency Range 60 or 50 Hz User Selection D ems mn _ Output Current Range 3 00 30 00 Amps AC 0 01 Amp step Resolution 0 01 Amp step Accuracy t 1 of Setting 0 03 Current Display Range 0 00 35 00 Amps Resolution 0 01 Amp step Accuracy t 1 of Reading 0 03 Resista
31. AC CURRENT 3 5mA RANGE 68 5 9 DC CURRENT 10 mA RANGE 68 5 10 DC CURRENT 35004A RANGE 22 69 5 11 DC CURRENT 350 RANGE 2202 69 5 12 IR RESISTANCE XXX XMO RANGE 70 5 13 IR RESISTANCE RANGE 70 5 14 GROUND CONTINUITY AC VOLTAGE CALIBRAITON Model 7440 only ie eave t e eaaet eu 70 5 15 GROUND CONTINUITY AC CURRENT CALIBRATION Model 7440 Only a e Eie doe E Ree ET ERE HET ten 71 SERVICE MAINTENANCE pp 72 THEORY OF OPERATION ete erp bed E IS Y 72 6 2 TROUBLESHOOTING 2 tetti irme does Sanaa en 73 6 3 SCHEMATIC BLOCK 75 6 4 REPLACEMENT PARTS amp ACCESSORIES 1157 78 6 5 SPARE PART KIT FOR 7400 8 83 ii C T ec HON H INTRODUCTION CHAPTER 1 INTRODUCTION 1 1 SAFETY PRECAUTIONS 1 1 1 General This product and its related documentation must be reviewed for familiarization with safety markings and instructions bef
32. CK Scanner output For the connection of the high voltage test lead model 1109 to UUT Unit Under Test 9 CHASSIS GROUND EARTH TERMINAL This terminal should be connected to a good earth ground before operation 10 FUSE RECEPTACLE Please replace the fuse with correct rating 11 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord 12 RETURN OUTPUT JACK For the connection of the Return test lead model 1102 13 HIGH VOLTAGE OUTPUT JACK For the connection of the high voltage test lead model 1101 21 OXT eul Specifications Front amp Rear Panel Descriptions 2 3 3 REAR PANEL OF MODEL 7420 u 4 1 SCANNER 1 CONNECTOR For connection of first External Scanner Model 7002 2 SCANNER 2 CONNECTOR For connection of second External Scanner Model 7002 3 REMOTE SIGNAL OUTPUT 9 Pin D subminiature male connector for remote control of TEST and RESET functions and program memory selection 1 2 or 3 4 REMOTE SIGNAL INPUT 9 Pin D subminiature female connector for monitoring PASS FAIL and PROCESSING signals relay output 5 INPUT POWER SWITCH Line voltage selection for 110V or 230V operation 6 INTERFACE Standard interface is RS232 factory installed For GPIB user order a GPIB card model 1117 and substitute the RS232 card 7 THERMAL COOLING FAN Runs continuously to cool the instrument 8
33. Continuity 4004 JOFF O 7 oo S S Phy i Sume 0000000000000000 F ema Im 24 C cult ELECTRONICS Specifications Front amp Rear Panel Descriptions Defaults continue Function Parameter Value Vonge lv HHimt lmo LOlimt Om Dwl 08 O Frquncy 60 ________ Scammer 0 O Ofst Conc PLC Remote Address GPIB only Stop Calibration Password rn S 2 4 2 Step 1 Unpacking Unpack the instrument from its special shipping container Be sure to save all packaging materials in case you need to return it to the factory for service Check the accessories supplied against the packing list inside the box If there is any discrepancy please contact Extech or its authorized distributor Step 2 Setup Locate a suitable testing area and be sure you have read all safety instructions for the operation of the instrument and suggestions on the test area set up in the Safety section Locate a three prong grounded outlet Be sure the outlet has been tested for proper wiring before connecting the instrument to it Step 3 Check Input Power CAUTION Check to be sure the correct input line voltage has been selected on the rear panel Either 115 volts AC or 230 volts AC Connect the power input plug into its s
34. DC Withstand Voltage test the instrument assumes that the failure is due to a short circuit the display will show DCW Short XXX X 8 KV gt 9999 uA 3 4 2 8 Breakdown 4 2 8 1 If the DUT current is well beyond the metering range of DC Withstand Voltage test and an Arcing condition beyond the Arc Sense limit is indicated the display will show DCW Breakdown XXX X 8 MXX X gt 9999 LA 3 4 2 9 LO Limit 3 4 2 9 1 If the DUT current falls below the LO Limit of DC Withstand Voltage test and the leakage current is within the metering range the display will show DCW LO Limit XXX X s MXX X X XX KV XXX X uA 3 4 2 10 Arc Fail 3 4 2 10 1 If the DC current within the metering range of the DC Withstand Voltage test and an Arcing current exceeds the Arc Sense limit and the Arc functions is set to ON then an Arc failure has occurred and the display will show DCW Arc Fail XXX X 8 MXX X X XXKV XX X uA 3 4 2 11 Pass 3 4 2 11 1 When the DUT passed the DC Withstand Voltage test when the test process is complete the display will show DCW Pass XXX Xs MXX X XXXX LA 51 CX MANUAL OPERATIONS 3 4 3 INSULATION RESISTANCE TEST 3 4 3 1 Abort 3 4 3 1 1 If the test in process is Aborted with the RESET button or remote control the display will show IR Abort XXX X s MXX X XXX V XXXX MO 3 4 3 1 2 If the test in process is Aborted with the RESET button or remote control before
35. ESET DSP 06 ad D _____ gt 50 105 1 ONT8 ONT HV6 EXTECH ELECTRONICS CO LTD 07 3197 FILE 7430 80 76 CXT ccH 6 3 5 Model 7440 Schematic Block Diagram l RESET 3 PASS TEST 3 FAIL RESET o gt DSP 06 CNT AMP 270 SERVICE MAINTENANCE CN9 ont 3 06 CN13 12 CN1 Hv FRONT BAT CN3 gt REAR OR EXTECH ELECTRONICS CO LTD REVISION C DATE 07 31 97 FILE NAME 7440C CURRENT o CSU 105 EXTECH ELECTRONICS LTD 77 07 31 97 FILE
36. INING COULD POSSIBLY CAUSE BODILY INJURY OR DEATH Turn on Power LCD is not lit 1 Check input AC voltage setting 115V 230VAC 2 Check and make sure proper fuse is used Analyzer is working but no 1 Check 7440 crystal for 7 372 Mhz oscillation LCD display a If no signal output check IC20 or XTAL b If there is signal output check IC12 2 Check 7440 TP27 for 5VDC a If no 5 VDC check IC46 D22 or D23 3 Check the cable connecting CN8 on 7440 to LCD CNI 4 LCD display board faulty Front Panel Keys inactive 1 LOCK LED is lit Keyboard Lock function activated Press LOCK key and enter password to unlock 2 Check the cable connecting CN9 on PCB7440 to CKB 03 CNI 3 Check PCB 7440 IC13 and IC 24 Display shows 0 00 KVAC 1 Check 7440 12 for sine wave output a if no output check IC21 IC41 IC36 and IC33 b if there is output possible PCB AMP 270 faulty 2 Check AMP 270 voltage if no output check REC 17 BRI BR2 b if there is output check AMP 270 for output i has no output check Q1 Q18 R1 R26 ii TP1 has output T2 may be faulty iii If T2 has output check R2 on 06 73 ech SERVICE MAINTENANCE 3 Check IC18 Pin 9 for voltage output If no output check IC18 IC21 IC2 IC17 4 If CSU 105 has no HV output check High Voltage Relay RY Display shows OFL 1 Check PCB 7440 TP13 If the wav
37. L CAUTION INPUTS THIS COULD RESULT IN DAMAGE TO THE CONTROL CIRCUITRY 56 CX Poult MANUAL OPERATIONS MEMORY ONE Momentarily connecting terminal 7 to 8 signals the instrument to immediately begin the test program that is stored in memory one MEMORY TWO Momentarily connecting terminal 7 to 9 signals the instrument to immediately begin the test program that is stored in memory two MEMORY THREE Momentarily connecting terminal 7 to terminals 8 and 9 signals the instrument to immediately begin the test program that is stored in memory three 3 6 Jig A B Testing System for 7410 7412 7420 7430 7440 Jig A B Testing System is Due to high demand from the transformer manufacturer an automatic test system with safer high testing speed and accuracy is designed especially to increase the productivity in the production This method of testing has considered the user safety purpose with safety covers included on the Jig A B Testing System A transformer is connected to one of the fixture and is known as Fixture A The system will start testing as soon as the safety cover is closed Another fixture known as Fixture B is use to connect the other transformer Upon closing the cover of this Fixture B it is now on Standby condition and waits until the Fixture A has passed the test and then it will proceed testing automatically on this transformer of Fixture B In the meanwhile the cover of Fixture A is opened to remove the tested transformer
38. OLOHLL 3 2 3 7 Step Connection setting The display will show Connect ON Or Connect OFF lt ENTER gt to Select lt ENTER gt to Select If Connect is set to the next step in the sequence will be executed If Connect is set to OFF the test sequence will stop at this step Use the ENTER key to select the Step Connection mode then press v key to advance the analyzer to the beginning display of Voltage setting which is shown in 2 3 1 66 A0 This is the end of parameter setting for IR Test Use the or v key to scroll the display to check for setting error When a error is found just simply enter the correct setting and process Press the EXIT key to exit from the setting mode to operation mode Now the analyzer is ready to perform IR Test to the DUT Use the ENTER key to select the Step Connection mode then press the or v key to advance the program to another test parameter or press the EXIT key to exit from the setting mode to the operation mode If Step 8 is set to ON the test process will be connected to the first step of the next Memory 3 2 4 GROUNDING KEY Model 7440 only Press the GROUNDING key and the display will show GND Set XXX Xs MXX X XX XX A XXX mO Note X the numeric GND Set Ground Bond test setting screen XXX Xs Dwell Time setting in 0 1 second step MXX Memory Program number 1 50 Test Step number 1 8 XX XX A AC Output
39. OPERATION AND SERVICE MANUAL MODEL 7440 7430 7420 7410 Electrical Safety Compliance Analyzer AC DC HIPOT WITH INSULATION RESISTANCE TESTER GROUND BOND CONTINUITY TESTER AND RS 232 INTERFACE SERIAL NUMBER Extech Electronics Ltd Co 2001 M O d 5 4F NO 252 Nan Yang Street Shih Chih City 7 4 X X Taipei Hsien Taiwan R O C E 2 Ge 4 5 TABLE OF CONTENTS INTRODUCTION 1 13 SAFETY PRECAUTIONS E i E A Ry ee YER 1 12 TEST SLATION rei Ducha exer Re 2 13 TEST OPERATOR use eR EU E 2 14 TEST RE ra ESE EE Sa 4 1 5 UNPACKING AND 4 4 16 STANDARD 5 8 4 1 7 et edere eR eene P HE EE I E 5 1 8 OPERATING STORAGE AND SHIPMENT ENVIRONMBENT enn 6 1 9 Field Installation Of SPECIFICATIONS FRONT amp REAR PANEL DESCRIPTIONS 8 2 1 FUNCTIONAL 68 2 8 22 FRONT PANEL ciescinasstansgerceta
40. R key The analyzer will store the scanner channel number and advance to the Offset parameter automatically The Scanner Status LED will lit according to the channel selected When more than 8 channels of grounding test are required an external scanner is used the channel status are shown on the external scanner Note To operate from the front panel output connectors with the Scanner option installed the Scanner Channel must be set to 0 to receive accurate readings 3 2 4 8 Offset setting The display will show Offset XXX TEST to Auto Set This instrument can set the mQ offset value by Manual Offset and Auto Offset For Manual Offset use the Numeric keys to enter the mQ Offset value in 1mQ step and then press the ENTER key The analyzer will store the mQ Offset setting and advance to the Connect setting The range of Offset is from 0 to 200 For Auto Offset setup the test parameter of Output Voltage Current and Frequency and connect the test cables and or test fixture to the instrument first Then short circuit the ends of the test cables If the scanner is being used the scanner channel has to be set Then press the TEST button The program will activate the test current and frequency that has been set for this memory step The display will show Offset XXX TEST to Auto Set CX MANUAL OPERATIONS The display will show the measured Offset value and the program wil
41. Scanner Linkto 1106 1 Current Cable Scanner Link to 7440 1107 1 Current Return Cable Scanner Link 1108 o o Til m Return Cable Scanner Link to 7430 1109 1 Hieh Voltage Cable Scanner Link to UUT 11 Remote TEST RESET Controller 111 1 Scan Bus Cable 1112 1 __ HipotIR TestCable Fixture for 7430 ______ 1 HipotIR TestCable Fixture for 7440 ______ 1114 1 RemoteGTestPrope 1145 1 __ o 1 __ d RS232mtefae 1117 1 GPIB Interface Card 6 5 SPARE PART KIT FOR 7400 SERIES Recommended spare part kit for 7440 and 7430 is listed below Please contact Extech customer support for price enquiry Part Number Qty Reference Description Designator 2PCB 7440 Axx 7440 Main Control Board 2PCB CHV 06 CHV 06 HV Control Board AXx 2PCB CKB 03 1 03 Keypad Board 2 03 03 Analog Meter Board 1148 14 RY 3392 1 High Voltage Relay 79 4 lech SERVICE MAINTENANCE Customer Support Department Tel 886 2 6943030 x 202 Fax 886 2 6945563 email maint202 extech com tw website www extech com tw KKK KK KK KK K 80
42. W 1000VDC standard resistor to the output connectors then press the TEST button the program will automatically calibrate the XXXX MQ range of IR test and the display will show XXXXMO STD 50MQ OK lt TEST gt to Calibrate 5 14 GROUND CONTINUITY AC VOLTAGE CALIBRAITON Model 7440 only Press the v key the program will advance to the AC Voltage calibration of the Ground continuity test The display will show Ground V 7V lt TEST gt to Calibrate Connect a AC standard voltage meter which can measure up to to the High current and Return output leads then press the TEST button the program will automatically generate an output of about 7VAC and the display n 2 G Voltage V Enter Standard V out 0 CX CALIBRATION Use the Numeric keys to enter the standard value of voltage unit V and then press the ENTER key to store the standard value of AC Ground Continuity voltage and display will show Ground V 7V OK lt TEST gt to Calibrate 5 15 GROUND CONTINUITY AC CURRENT CALIBRATION Model 7440 Only Press the v key the program will advance to the AC Current calibration of the Ground continuity test The display will show Ground A 30A lt TEST gt to Calibrate Connect a AC standard Ammeter which can measure up to 30AAC to the High current and Return output leads then press the TEST button the program will automatically generate an output
43. X mA 3 4 1 2 2 During the AC Withstand Voltage test when the values are being updated in real time during the ramp cycle the display will show ACW Ramp XXX X s MXX X X XX KV XX XX mA 47 CX MANUAL OPERATIONS 3 4 1 3 Dwell 3 4 1 3 1 During the AC Withstand Voltage test when the values are being updated in real time during the dwell cycle the display will show ACW Dwell XXX X s X XX KV XX XX mA 3 4 1 3 2 If the ramp time is very short and the program has not read the meter readings the display will show ACW Dwell XXX X 8 MXX X KV 3 4 1 4 HI Limit 3 4 1 4 1 If the DUT current exceeds the HI Limit of AC Withstand Voltage test and the leakage current is within the metering range the display will show ACW HI Limit XXX X 8 MXX X X XX KV XX XX mA 3 4 1 4 2 If the DUT current exceeds the HI Limit of AC Withstand Voltage test and the leakage current is not within the metering range the display will show ACW HI Limit XXX X 8 MXX X X XX KV gt 40 mA 3 4 1 5 Short 3 4 1 5 1 If the DUT current is well beyond the metering range of AC Withstand Voltage test the instrument assumes that the failure is due to a short circuit the display will show ACW Short XXX X s KV gt 40 mA 3 4 1 6 Breakdown 3 4 1 6 1 If the DUT current is well beyond the metering range of AC Withstand Voltage test and an Arcing condition beyond the Arc Sense limit is indicated the disp
44. ain or press the SETUP key to forward to the Fail Stop selection The program will store the Volume setting automatically 3 3 5 FAIL TO STOP CONTINUE SELECTION The display will show Fail Stop or Fail Stop OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to select the mode of Fail Stop This function is used when multiple steps have been connected If the Fail Stop mode is set ON the test process will stop at the step that fails or at the end of test process When there are unfinished steps to be completed pressing the TEST button will continue the test process at the next step Pressing the RESET button and then the TEST button will start the test process from the first step After the selection of Fail Stop mode press the SETUP key to advance to the beginning of the menu PLC Remote or press the EXIT key to exit from the Fail Stop selection to the operation mode The Program will store the selection of Fail Stop automatically If the Fail Stop is set to OFF the analyzer instrument will continue to complete the entire test process even if there were failed steps during the test The display will show the results of each step at the end of test process as follows i Memory Progra 45 ccH MANUAL OPERATIONS The pass or fail status is indicated by the letter F Fail or P Pass The Pass Fail status of the fir
45. akage current desired in 0 1 step then press the ENTER key The analyzer will store the LO Limit setting and advance to the Ramp Time parameter automatically If the LO Limit is set to 0 the LO Limit is disabled XT ecH ELECTRONICS MANUAL OPERATIONS 3 2 2 4 Ramp Time setting The display will show Ramp Time XXX X s Range 0 4 999 9 Use the Numeric keys to enter the time desired for the voltage to ramp up from 0 to the required voltage then press the ENTER key The analyzer will store the Ramp Time setting and advance to the Dwell Time parameter automatically 3 2 2 5 Dwell Time setting The display will show Dwell Time XXX Xs Range 0 5 999 9 0 Constant Use the Numeric keys to enter the time you wish to hold the voltage after the required voltage is reached then press the ENTER key The analyzer will store the Dwell Time setting and advance to the Charge LO parameter automatically If the Dwell Time is set to 0 the timer will continue to count to the maximum test time then reset to O and start over automatically The test will continue until a reset is executed or a failure occurs Note For model 7420 and 7410 the maximum duty cycle is 70 at rated output Therefore it is not advisable to use 0 at 10 mA output 3 2 2 6 Charge LO The display will show Charge LO XXX X uA lt TEST gt to Auto Set The Charge LO function is used to check if the
46. atacsaceagasaesbeaadsnesad te 14 2 3 REAR PANER LAYOUT meant 20 24 QUICK START tem PARU e EE LARA E RAM N GEEA 24 MANUAL OPERATIONS P Pu PE UE RUE 27 3 PROGRAM KEYS iecit reperi e ru DH ei e ARE Rae sie day 27 32 KEYS 29 33 PARAMETER KEY35 ede vba ve b Petras nues ede die 43 34 DISPLAYED MESSAGES dotem RES E PE 47 3 REMOTE RI BIN EIN 54 3 6 hg A B Tes ng SyStem io p aet RO A I VRHENRMEER ER ER dci Sake 57 RS232 amp GPIB INTERFACE 59 41 BUS REMOTE INTERFACE 5232 2 59 CALIBRATION C e E 65 5 1 ENTER THE CALIBRATION MODE 65 5 2 PASSWORD SETTING binges emere e AE 65 5 3 MEMORY LOCK SELECTION certe RR e er e Pine 65 54 ACW VOLTAGE CALIBRATION csper irria teaa EAEI SNEER m emn emen 66 5 5 DCW VOLTAGE 0 00001 66 5 6 IR VOLTAGE 00 67 57 AC CURRENT 40mA RANGE 67 5 8
47. ctory installed For GPIB user order a GPIB card model 1117 and substitute the RS232 card 9 REMOTE SIGNAL INPUT 9 Pin D subminiature female connector for monitoring PASS FAIL and PROCESSING signals relay output 10 REMOTE SIGNAL OUTPUT 9 Pin D subminiature male connector for remote control of TEST and RESET functions and program memory selection 1 2 or 3 11 SCANNER 2 CONNECTOR For connection of second External Scanner Model 7002 12 SCANNER 1 CONNECTOR For connection of first External Scanner Model 7002 gei 23 Specifications Front amp Rear Panel Descriptions 2 4 QUICK START This quick start guide assumes the operator has some familiarity with automated testing and desires to use the default settings on the instrument The default settings shown will remain in memory unless you choose to override them with your own test program The instrument default settings that appear in memories 1 40 are as follows 2 4 1 DEFAULTS ACW HHLimt 0 LO Limit 0 000mA _______ RampTime 0 jDwelTim ________ Frequency 607 02 JAmSene 5 O _______ Arc Fail Scanner _________ 0000000000000000 Connect OFF Continuity 7430 only OFF 2 Limit 3500pA LOLmi OWA RampTime pf Dwell Time 1480 _______ OPPO CmmgeLO A 1 _______ Are Rail OFF ______ 0000000000000000 X Comet OF
48. ctrical and Electronic Engineers Inc 345 East 47th Street New York NY 10017 1 212 705 7018 Communications Society of IEEE Internet http www ieee org 64 ELECTRONICS CALIBRATION CHAPTER 5 CALIBRATION See APPENDIX A for information on instrument needed for calibration 5 1 ENTER THE CALIBRATION MODE Press the O and 1 keys simultaneously and then turn the input power switch on The program will automatically enter to the calibration mode and the display screen will show Calibration Mode v Forward Backward Use the v Forward and Backward keys to move through the calibration menu The following instructions follow the sequential Forward scrolling through the menu 5 2 PASSWORD SETTING Press the key the program will advance to the Password setting mode The display will show Password 0 or Password XXXX Range 0 9999 Range 0 9999 The Password can be any four 4 digit number If the Password is set to 0 the keyboard lock out will be selected by the LOCK key on the front panel without a Password The Password default is preset to 0 at the factory 5 3 MEMORY LOCK SELECTION Press the v key the program will advance to the Memory Lock selection mode The display will show MR Lock ON or MR Lock OFF ENTER to Select lt ENTER gt to Select If the MR Lock is selected the Memory selection Menu will be disabled
49. ecifications Front amp Rear Panel Descriptions ELECTAOHICS Model 7430 EIA 3Ux 500 mm D 22 0 Kg Model 7420 EIA 3Ux 500 mm D 18 0 Kg EIA 3Ux 300 mm D 11 5 Kg Model 7410 Operating 0 40 C 0 90 RH Temperature RH Product specifications are subject to change without notice 13 CXT ec RONICS Specifications Front amp Rear Panel Descriptions 2 2 FRONT PANEL LAYOUT 2 2 1 FRONT PANEL OF MODEL 7440 SS 10 11 12 13 14 15 16 17 18 19 20 21 25 22 26 24 23 21 20 ENT ELH ELECTRONICS 7440 ELECTRICAL SAFETY COMPLIANCE ANALYZER 1 2 5 4567 89111 1214 15 15 17 18 19 10 13 POWER SWITCH Rocker style switch RESET BUTTON Reset the system before you can proceed to the next test TEST BUTTON Press to start the test MEMORY KEY To select one of the 50 memories location STEP KEY To select one of the 8 steps within each memory LOCK KEY To select key lockout mode LOCAL PRINT KEY To change the operation of the instrument from Remote to the Local mode When Printer Port Card is installed press this key will output test data to a printer AC W KEY To select AC Withstand Test DC W KEY To select DC Withstand Test INSULATION KEY To select Insulation Resistance Test GROUNDING KEY To select Ground Continuity Test UP DOWN ARROW KEYS To scroll the display through the function pa
50. ector will flash If the device under test passes the test then you will hear a brief BEEP to let you know the item was successfully tested and it PASSED In the case of device under test fails the test the instrument will display the test results on the LCD display and it will remain until the next test is initiated Depressing the RESET button will prepare the instrument for the next test but will not clear the display until the next test is started or another reset is executed Step 6 Result The result of the test is displayed in 2x20 LCD Please refer to Chapter 3 for explanation of message 26 ELECTRONICS MANUAL OPERATIONS CHAPTER 3 MANUAL OPERATIONS 3 1 PROGRAM KEYS 3 1 1 MEMORY KEY Each memory location contains 8 steps which can be connected sequentially to the next consecutive step Only one function can be selected for each step The following memory map illustrates the separate locations for each function Stpl 2 ____ Step8 Select one ACW ACW ACW function only for DCW DCW DCW each step IR IR IR G Continuity G Continuity G Continuity Memory 2 Select one ACW ACW ACW function only for DCW DCW DCW each step IR IR IR G Continuity G Continuity G Continuity Memory 50 Note On model 7430 7420 and 7410 disregard the location for G Continuity parameters For model 7430 the Continuity Check parameter is stored within the ACW and DCW functions as a
51. eform is not correct check IC28 29 Inaccurate Display of Current 1 Perform calibration 2 IC 36 on PCB 7440 faulty TEST Check IC34 IC35 IC38 IC39 48 1 49 Voltage Display different Set 1 Perform calibration value 2 Check IC 36 on PCB 7440 No sound from Buzzer 1 If TP3 PCB 7440 is LO 71 faulty If TP3 is HI check IC3 PASS FAIL not lighted 1 On PCB 7440 Pin 11 amp 12 on IC10 is LO Check LED If they are HI check IC10 74 C X I ecl ELECTRONICS 6 3 SCHEMATIC BLOCK DIAGRAM 6 3 1 Model 7410 SERVICE MAINTENANCE J1 J2 4 SHORT o 150 s gt HERR FRONT HV gt REAR EXTECH ELECTRONICS LTD 6 3 2 Model 7420 s DRAWBY DATE 07 17 97 FILE 7410 LCD 16 a A CN1 26 g 2 i TEST CKB 03 RESET 5 PASS TEST 2 FAIL RESET 9 nv 10 CNZ gt FRONT ES o 3 REAR MN
52. f DC Withstanding Voltage test and the display will show DCW Set XXX Xs X XX XXXXX nA Note X Numeric DCW Set DC Withstand Voltage test Setting screen XXX Xs Dwell Time setting in 0 1 sec MXX Memory Program number 1 50 X Test Step number 1 8 X XX KV DC Output Voltage setting in 0 01 KV XXXX uA DC High Limit current setting Use the v arrow keys to progress through the test parameters menu The v key will advance forward and key will advance backward The sequential forward menu items are Voltage HI Limit LO Limit Ramp Time Dwell Time Charge LO Ramp HI Arc Sense Arc Fail Scanner Set Offset Connect 3 2 2 1 DC Output Voltage setting The display will show Voltage Range 0 6000 Use the Numeric keys to enter the DC withstand voltage desired in 1 volt step then press the ENTER key The analyzer will store the voltage setting and advance to the HI Limit parameter automatically 3 2 2 2 HI Limit Current setting The display will show HI Limit XXX uA Range 0 9999 Use the Numeric keys to enter the upper limit of leakage current in 1 step then press the ENTER key The analyzer will store the HI Limit setting and advance to the Low Limit parameter automatically 3 2 2 3 LO Limit Current setting The display will show LO Limit XXX X pA Range 0 000 9 999 Use the Numeric keys to enter the minimum le
53. he Charge LO setting and is not the reading of the charging current of the DUT Then press the v key to advance to Ramp Hi test parameter 3 2 2 7 Ramp HI The display will show or Ramp HI OFF lt ENTER gt to Select lt gt to Select Use the ENTER key to select the Ramp HI mode then press the v key to advance to Arc Sense parameter setting The Ramp HI function is active during the Ramp Up period only Ramp HI will allow current higher than the normal HI Limit current setting of the DC Withstand Voltage test to avoid false failure due to charging current 3 2 2 8 Arc Sensitivity setting and Arc Fail selection The display will show Arc Sense X XX mA Range 2 00 20 00 Use the Numeric keys to enter the desired Arc Sense sensitivity setting in 0 01 mA step then press the ENTER key The analyzer will store the Arc Sense setting and advance to the ARC Fail mode selection automatically The display will show Arc or Arc Fail OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to select the Arc Fail mode then press the v key to advance to Scanner Channel setting If the Arc Fail mode is set to the program will indicate an arc failure when the arc current is over the setting The analyzer will shut down the test immediately and the ARC indicator on the front panel will lit If the Arc Fail mode is set to OFF t
54. he DUT does not make direct contact with earth ground or the metering circuit and leakage fail detectors will be Bypassed If the DUT grounding can not be avoided please consult the factory for information regarding reconfiguring the instrument for Grounded Return When the instrument Return in grounded internal and external stray leakage will be monitored due to currents that flow from High Voltage to earth grounded such as from HV to the chassis of the instrument This current can not be avoided and will cause errors when trying to monitor very low leakage currents in the microamp range 1 7 2 Power Requirements and Line Voltage Selection This instrument requires a power source of either 115 volts AC 15 or 230 volts AC 15 47 63 Hz single phase Please check the rear panel to be sure the proper switch setting is selected for your line voltage requirements before turning your instrument on In addition please be sure the correct fuse is selected and installed while the instrument is in the off position CAUTION Do not switch the line voltage selector switch located on the rear panel while the instrument is on or operating This may cause internal damage and represents a safety risk to the operator echt INTRODUCTION Fuse The fuse used is 6 3A slow blow fuse for Model 7440 7430 7420 and 5 0A for 7410 Power Cable BEFORE CONNECTING POWER TO THIS INSTRUMENT THE PROTECTIVE GROUND EARTH TERMINALS OF THIS
55. he analyzer will not indicate an arc failure when the arc current is over the setting The analyzer will not stop testing but the ARC indicator on the front panel will lit only when arcing is present 3 2 2 9 Scanner Channel setting The display will show Scanner Set CH 1 16 XXXXXXXXXXXXXXXX Note X H O or L 35 CX T ccH MANUAL OPERATIONS If the Scanner is not installed you may skip this step by pressing the v key Use the Numeric keys to enter the status of High Open or Low for each scanner channel then press the ENTER key The analyzer will store the Scanner Channel status and advance to the Offset setting automatically The table below is the cross reference of the numeric keys which are used for the Scanner channel setting Channel Status H High Connected to High Voltage Output 1 L Low 0 Connected to Return O Open Not connected to High Voltage or Return The Channel setting will start from Channel 1 on the left end and stop at Channel 16 on the right end The analyzer will set any unassigned channel s to OPEN after pressing the ENTER key and advance to Offset parameter setting The Scanner Status LED will lit according to the channel selected When more than 8 channels of DC Withstand test are required an external scanner is used the channel status are shown on the external scanner For example you wish to set Channel and 5 to High and Channel 3 6 and 7 to Low you will
56. he first test executed 22 Read the 2 x 20 display results of the second test executed Read the 2 x 20 display results of the third test executed 24 Read the 2 x 20 display results of the fourth test executed 5 Step Buffer 5 40 Read the 2 x 20 display results of the fifth test executed 26 Step Buffer 6 40 Read the 2 x 20 display results of the sixth test executed Step Buffer 7 Read the 2 x 20 display results of the seventh test executed Step Buffer 8 Read the 2 x 20 display results of 28 UNE the eighth test executed 2A Ground Bond Offset 2C 2K Read the Ground Offset Setting B DCW Charge LO Read the DCW Charge LO Setting S PO gt ew modemas peaetve e IR Charge LO Read the IR Charge LO Setting NN 01 hex Reset ON Status 00 hex Reset OFF Read the 2 x 20 display in real time or after the test If an error occurs when the command is sent the instrument will send an ASCII code 15h after the read command is sent 40 40 5 5 5 1 40 62 ELECTRONICS RS232 amp GPIB INTERFACE 4 1 2 GPIB INTERFACE FUNCTIONS The capability of a device connected to the bus is specified by its interface functions These functions provide the means for a device to receive process and send messages over the bus The interface functions are listed in the chart below functions may be controlled over the bus except input voltage which is Selectable
57. ill advance to the setting and reading of DC 320uA range calibration of the DCW test The display will show DC 350 IMQ lt TEST gt to Calibrate Connect a resistor about 1MQ 0 25W in series with a DC standard Ammeter which can measure up to Connect the Ammeter to the return leads then press the TEST button the program will automatically generate an output of about 300V 300uA and the display will show Current Enter Standard I out Use the Numeric keys to enter the standard value of current unit uA and then press the ENTER key to store the standard value of DC 350 range and the display will show DC 350 IMQ OK lt TEST gt to Calibrate ON 9 eclt ELECTRONICS CALIBRATION 5 12 IR RESISTANCE XXX XMQ RANGE CALIBRAITON Press the v key the program will advance to the XXX XMQ range calibration of the IR test The display will show XXX XMO STD 50MO lt TEST gt to Calibrate Connect 50MQ 0 25W 1000VDC standard resistor to the output connectors then press the TEST button the program will automatically calibrate the XXX X MQ range of IR test and the display will show XXX XMQ STD 50MQ OK lt TEST gt to Calibrate 5 13 IR RESISTANCE RANGE CALIBRATION Press the v key the program will advance to the XXXXMQ range calibration of the IR test The display will show XXXXMQ STD lt TEST gt to Calibrate Connect 50MQ 0 25
58. int the information on the display when DUT fails the test No information will be printed when the DUT passes the test After Print Mode setting press SETUP key will enter Print Code Number Setting mode 46 CX MANUAL OPERATIONS 3 3 8 PRINT NUMBER PrintNO 0 Range 0 9999 The Print NO will start from 0 when the tester is turned On The number will increase by 1 when TEST button is pressed until 9999 and loop back to 0 The user can set the starting Print NO by entering the number in this mode Enter the starting Print NO and press ENTER key When the tester is turned OFF the Print NO will be reset to 0 When the SETUP key is pressed the display will loop back to 3 3 1 PLC REMOTE SELECTION or press EXIT to exit parameter setting mode 3 4 DISPLAYED MESSAGES 3 4 1 AC WITHSTAND VOLTAGE TEST 3 4 1 1 Abort 3 4 1 1 1 If the test in process is Aborted with the RESET button or remote control the display will show ACW Abort XXX X s XX XX mA 3 4 1 1 2 If the test in process is Aborted with the RESET button or remote control before the meter readings are taken the display will show ACW Abort XXX X s or ACW Abort XXX X s mA MXX X 3 4 1 2 Ramp 3 4 1 2 1 At the beginning of AC Withstand Voltage test when the voltage begins to ramp but before the meter readings are taken the display will show ACW Ramp XXX X s MXX
59. is setup program will not appear on the setup menu The display will show Address XX Range 0 30 Use the Numeric keys to enter the GPIB Address then press the ENTER key and the display will show the current address immediately Press the SETUP key to advance to the Contrast setting The program will store the address setting automatically 3 3 3 LCD CONTRAST SETTING The display will show Contrast X Range 1 9 9 High Use the Numeric keys to enter the LCD Contrast level then press the ENTER key The analyzer will change the LCD Contrast immediately when the ENTER key is pressed so the setting can be viewed Change the LCD Contrast again or press the SETUP key to advance to the Volume setting The program will store the Contrast setting automatically The LCD Contrast level is from 1 9 for Level 1 is the lowest contrast and level 9 is the highest contrast 44 ELECTAONICS MANUAL OPERATIONS 3 3 4 Audible Alarm Volume setting The display will show Volume X Range 0 9 9 High The Audible Alarm Volume level is from 0 9 for level 0 is used to disable the Audible Alarm level 1 is the lowest volume and level 9 is the loudest Use the Numeric keys to enter the Audible Alarm level then press the ENTER key The analyzer will provide a sample sound for checking immediately when the ENTER key is pressed Change the Volume ag
60. istor about 100KQ 10W in series with DC standard Ammeter which can measure up to 10 The Ammeter should be connected to the return lead then press the TEST button the program will automatically generate an output of about 1000V 10mA and the display will show Current mA Enter Standard I out Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of DC 10mA range the display will show DC 10 100 OK lt TEST gt to Calibrate 8 Tech CALIBRATION 5 10 DC CURRENT 3500uA RANGE CALIBRATION Press the v key the program will advance to the DC 3500 range calibration of DCW test The display will show DC 3500 100 lt TEST gt to Calibrate Connect a resistor about in series with a DC standard Ammeter which can measure up to The Ammeter should be connected to the return lead then press the TEST button the program will automatically generate an output of about 300 3000 and the display will show Current Enter Standard I out Use the Numeric keys to enter the standard value of current unit uA and then press the ENTER key to store the standard value of DC 3500u A range and the display will show DC 3500 100 OK lt TEST gt to Calibrate 5 11 DC CURRENT 350uA RANGE CALIBRATION Press the v key the program w
61. itor PASS FAIL and PROCESSING conditions These signals are provided by three normally open internal relays that switch on to indicate the current condition of the tester These are normally open free contacts and will not provide any voltage or current The ratings of the contacts are 250 VAC 0 5 The signal outputs are provided on the 9 pin female type D connector Below is a listing that indicates what conditions activate each pin When a terminal becomes active the relay closes thereby allowing the external voltage to operate an external device Pins 1 and 2 provide the PASS signal 55 ccH MANUAL OPERATIONS Pins 3 and 4 provide the FAIL signal Pins 5 and 6 provide the PROCESSING signal Pins 7 8 and 9 are blank The following describes how the relays operate for each test condition PROCESSING The relay contact closes the connection between pin 5 and pin 6 while the analyzer is performing a test The connection is opened at the end of the test PASS The relay contact closes the connection between pin 1 and pin 2 after detecting that the item under test passed all tests The connection is opened when the next test is initiated or the reset function is activated FAIL The relay contact closes the connection between pin 3 and pin 4 after detecting that the item under test failed any test The connection is opened when the next test is initiated or the reset function activated 3 5 2 Signal I
62. key to exit from the setting mode to operation mode Now the analyzer is ready to perform DC Withstand Voltage Test to the DUT Note If Step 8 is set to ON the test process will be connected to the first step of the next Memory 3 2 3 INSULATION KEY Press the INSULATION key and the display will show Set XXX Xs MXX X V XXXXX MO Note X the numeric Set Insulation Resistance test setting screen XXX Xs Delay Time setting in 0 1 sec step MXX Memory Program number 1 50 X Test Step number 1 8 XXXX V DC Output Voltage XXXX MQ Low Limit of Insulation Resistance Use the v arrow keys to progress through the test parameters menu The forward menu items are Voltage Charge LO HI Limit LO Limit Delay Time Scanner Set Connect 3 2 3 1 Output Voltage setting The display will show Voltage XXXX V Range 100 1000 Use the Numeric keys to enter the desired voltage setting in 1 volt step then press the ENTER key The analyzer will store the voltage setting and advance to the Charge LO parameter automatically 37 4 MANUAL OPERATIONS 3 2 3 2 Charge LO The display will show Charge LO X XXX uA lt TEST gt to Auto Set The Charge LO function is used to check if the test cables are connected properly at the beginning of a test A capacitive DUT will draw charging current on the DC Withstand Voltage test when the Output is activated If the
63. l use this value for the Offset setting Each step has its own individual Offset value and must be set separately This allows the user to compensate for different lead lengths when using a scanner or external fixturing for Ground Continuity testing Then press v key to advance to Step Connect setting 3 2 4 9 Step Connection setting The display will show Connect ON or Connect OFF ENTER to Select lt ENTER gt to Select If Connect is set to the next step in the sequence will be executed If Connect is set to OFF the test sequence will stop at this step Use the ENTER key to select the Step Connection mode then press v key to advance the analyzer to the beginning display of Current setting which is shown in 2 4 1 This is the end of parameter setting for GROUND CONTINUITY Test Use the v key to scroll the display to check for setting error When a error is found just simply enter the correct setting and process Press the EXIT key to exit from the setting mode to operation mode Now the analyzer is ready to perform GROUND CONTINUITY Test to the DUT 3 3 PARAMETER KEYS Use the SETUP key to progress through the menu of System Parameters Successive key presses will advance the menu forward The sequential forward menu items are PLC Remote Address Contrast Volume Fail Stop The setting of system parameters affect the operating conditions of the instrument and are
64. lay will show ACW Breakdown XXX X 8 MXX X X XXKV gt 40 mA 48 CX MANUAL OPERATIONS 3 4 1 7 LO limit 3 4 1 7 1 If the DUT current falls below the LO Limit of AC Withstand Voltage test the display will show ACW LO limit XXX X s MXX X X XX KV XX XX mA 3 4 1 8 Arc Fail 3 4 1 8 1 If the DUT current is within the metering range of the AC Withstand Voltage test and an Arcing current exceeds the Arc Sense limit and the Arc function is set to ON then an Arc failure has occurred and the display will show ACW Arc Fail XXX Xs MXX X X XX KV XX XX mA 3 4 1 9 Pass 3 4 1 9 1 When the DUT passed the AC Withstand Voltage test when the test process is complete the display will show ACW Pass XXX Xs MXX X X XX KV XX XX mA 3 4 2 DC WITHSTAND VOLTAGE TEST 3 4 2 1 Abort 3 4 2 1 1 If the test in process is Aborted with the RESET button or remote control the display will show DCW Abort XXX X s XXXX uA 3 4 2 1 2 If the test in process is Aborted with the RESET button or remote control before the meter readings are taken the display will show DCW Abort XXX X s or DCW Abort XXX X s MXX X KV MXX X X XXKV 3 4 2 2 Ramp 3 4 2 2 1 At the beginning of DC Withstand Voltage test when the voltage begins to ramp but before the meter readings are taken the display will show 49 CX MANUAL OPERATIONS DCW Ramp XXX X s 3 4 2 2
65. lead model 1102 19 GROUND CHECK OUTPUT JACK Use the Return test model 1102 20 ANALOG METER To indicate the High Voltage at the output jack 17 APS SSS 21 SCANNER STATUS LED s These LED s indicate the status of the 8 H V channel 16 Tec Specifications Front amp Rear Panel Descriptions LCD DISPLAY The 2x20 character display 3 BUS REMOTE LED To indicate the instrument is the Remote Control mode 24 LOCK LED To indicate the keys are locked the user will be unable to change any settings 25 ARC LED To indicate Arc Detector detects an arcing condition This indicator will function even when the Arc Fail has been disabled 17 CXT eul Specifications Front amp Rear Panel Descriptions 2 2 3 FRONT PANEL OF MODEL 7420 Wy 1 5 4567 89 14 TS 16 17 TO 12 POWER SWITCH Rocker style switch RESET BUTTON Reset the system before you can proceed to the next test TEST BUTTON Press to start the test MEMORY KEY To select one of the 50 memories location STEP KEY To select one of the 8 steps within each memory LOCK KEY To select key lockout mode LOCAL PRINT KEY To change the operation of the instrument from Remote to the Local mode When Printer Port Card is installed press this key will output test data to a printer 8 AC W KEY To select AC Withstand Test 9 DC W KEY To select DC Withs
66. mit XXXX MO Range 0 9999 0 OFF Use the Numeric keys to enter the desired HI Limit setting in step then press the ENTER key The analyzer will store the HI Limit setting and advance to the LO Limit parameter automatically Enter 0 if no judgment is required CX MANUAL OPERATIONS 3 2 3 4 LO Limit Current setting The display will show LO Limit XXXX MQ Range 1 9999 Use the Numeric keys to enter the LO Limit setting in step then press the ENTER key The analyzer will store the LO Limit setting and advance to the Delay Time setting automatically 3 2 3 5 Delay Time setting The display will show Delay Time s Range 0 5 999 9 0 Constant Use the Numeric keys to enter the Delay Time setting in 0 1 second step then press the ENTER key The analyzer will store the Delay Time setting and advance to the Scanner Channel setting automatically Note Delay Time sets the time when should the analyzer compare measured readings to the HI Limit and LO limit settings This delay allows charging current to stabilize before a test judgment is made The capacitance of the DUT will dictate what delay setting is required to perform an accurate IR measurement If the Delay Time is set to 0 the analyzer will continue until the RESET button is pressed The display will show the measured readings during the test The timer will count the total
67. model 1103 This lead is only used for the ground continuity test 12 RETURN OUTPUT JACK For the connection of the Return test lead model 1104 This jack will carry high current for the Ground Continuity test 13 HIGH VOLTAGE OUTPUT JACK For the connection of the high voltage test lead model 1101 14 8 CHANNEL HIGH VOLTAGE OUTPUT JACK Scanner output For the connection of the high voltage test lead model 1109 to UUT Unit Under Test 15 8 CHANNEL GROUND CONTINUITY TERMINALS Scanner output For the connection of Ground wire to UUT 20 CXT ecl RONICS Specifications Front amp Rear Panel Descriptions 2 3 2 REAR PANEL OF MODEL 7430 1 SCANNER 1 CONNECTOR For connection of first External Scanner Model 7002 2 SCANNER 2 CONNECTOR For connection of second External Scanner Model 7002 3 REMOTE SIGNAL OUTPUT 9 Pin D subminiature male connector for remote control of TEST and RESET functions and program memory selection 1 2 or 3 4 REMOTE SIGNAL INPUT 9 D subminiature female connector for monitoring PASS FAIL and PROCESSING signals relay output 5 INPUT POWER SWITCH Line voltage selection for 110V or 230V operation 6 INTERFACE Standard interface is RS232 factory installed For GPIB user order a GPIB card model 1117 and substitute the RS232 card 7 THERMAL COOLING FAN Runs continuously to cool the instrument 8 8 CHANNEL HIGH VOLTAGE OUTPUT JA
68. nce Display Range 0 600 mQ Resolution mQ step Accuracy t 1 of Reading 1 mQ 11 ELECTAONICS Specifications Front amp Rear Panel Descriptions HI Limit Range 0 600 mA for 3 10 0 150 for 3 30 A Resolution 1 mQ step Accuracy 1 of Setting 1 10 30 t 1 of Setting 2 mQ 3 10A LO Limit Range 0 600 mQ for 3 10A 0 150 for 3 30 A Resolution 1 mQ step Accuracy t 1 of Setting 1 10 30 t 1 of Setting 2 mQ 3 10A Dwell Timer Range 0 5 999 9 sec 0 Constant Resolution 0 1 sec step Accuracy 0 1 0 05 sec Milliohm Offset Max Offset 200 mQ Capability Resolution 1 step Accuracy t 1 of Setting 1 GENERAL SPECIFICATIONS PLC Remote Input Test Reset Recall memory 1 2 3 Control Output Pass Fail Test in Process Memory Allows storage of up to 50 groups different test programs and 8 step each memory Security User definable 4 Digit password lockout capability to avoid unauthorized access to test set up program LCD Contrast 9 ranges set by the numeric keys on the front panel Setting Buzzer Volume 10 ranges set by the numeric key on the front panel Setting Calibration Software and adjustments are made through front panel Two Port Maximum including the built in scanner Scanner High Voltage x 8 Ports 7440A and 7430 Dimension weight 12 Sp
69. ndard RS232 or GPIB interface capability are available for all 7400 series analyzers as option 4 1 1 RS232 INTERFACE 4 1 1 1 Introduction The RS232 cabling should be configured as follows for a 9 pin serial port interface PC Bus Controller RD 2 2 RD SIG 5 5 SIG GND GND The COM port should have the following configuration 9600 baud 8 data bits 1 stop bit no parity This interface does not support XON XOFF protocol or any hardware handshaking The controller should be configured to ignore the handshaking lines DTR pin 4 DSR pin 6 CTS pin 8 and RTS pin 9 If the port can not be configured through software to ignore the lines then the handshake lines should be jumpered together in two different sets Pins 4 and 6 jumpered together and pins 7 and 8 jumpered together at the controller end of the cable When sending command over the RS232 bus the 7400 series analyzers will echo a response string identical to the string that was sent if the transfer was recognized and accepted by the instrument This allows for software handshaking to monitor and control data flow If there is an error with the command string that is sent the instrument will respond with 15h or the ASCII control code When requesting data from the instrument it automatically send the data to the controller input buffer The controller input buffer will accumulate data being sent from the instrument including the echo response string until it
70. nputs of Remote I O and Memory Programs The Signal Input remote connector enables remote operation of the TEST and RESET functions or allows the operator to select one of three pre programmed tests When the remote function is ON the TEST switch on the front panel will be disabled to prevent a test from being activated through the test switch A normally open momentary switch can then be wired across pins 3 and 5 to allow remote operation of the TEST function normally open momentary switch can also be wired across pins 2 and 5 which allows remote operation of the RESET function For safety reason the front panel RESET switch remains active even when a remote RESET switch is connected so that high voltage can be shut down from either location The 7400 series analyzers also allow access to three MEMORY PROGRAMS through the remote control connector This gives the user the capability to quickly change parameters and initiate a test remotely The 7400 series analyzers basically operates in a PLC mode by responding to simple switch or relay contact closures The built in memory programs of the instrument are used to accomplish this Three internal memory programs can be accessed by connecting terminals 7 8 and 9 in different combinations ACTIVATING MEMORY PROGRAM FUNCTIONS THROUGH THE REMOTE CONNECTOR SELECTS THE PROGRAM AND STARTS THE TEST WHICH IS PREPROGRAMMED INTO THAT MEMORY DO NOT CONNECT VOLTAGE OR CURRENT TO THE SIGNA
71. ocket on the rear panel of the instrument Connect the male end of the plug to the outlet receptacle Please be sure that the safety ground on the power line cord is not defeated and that you are connecting to a grounded power source 25 CX ELECTAQNICS Specifications Front amp Rear Panel Descriptions Step 4 Power Up Turn on the POWER switch located on the lower left hand side of the front panel All LEDs on the Front Panel will be lit for visual inspection Connect the appropriate test leads to the device under test DUT or test fixture Then connect the Return Lead first black to the test fixture or item followed by the High Voltage Output lead red Note The Return Lead of this instrument is not connected directly to Earth Ground The DUT must not contact Earth Ground directly Step 5 Test DO NOT TOUCH THE DEVICE UNDER TEST ONCE THE TEST HAS BEEN STARTED Press the GREEN test button on the front panel once The instrument will begin the automated test sequence using the defaults If a failure occurs you will HEAR an audible alarm Press the RED button marked RESET to stop the alarm This will silence the alarm and reset the instrument ready for the next test This RESET button may also be used as a safety button to quickly ABORT a test and cut off the HIGH VOLTAGE When HIGH VOLTAGE is present the RED arrow indicator located in the lower right side of the front panel near the high voltage conn
72. ore operation This product is a Safety Class I instrument provided with a protective earth terminal Before applying power please verify that the instrument is set to the correct line voltage 110V or 220V and the correct fuse is installed 1 1 2 Safety Symbols INSTRUCTION MANUAL SYMBOL PLEASE REFER TO THE INSTRUCTION MANUAL FOR SPECIFIC WARNING OR CAUTION INFORMATION TO AVOID PERSONAL INJURY OR DAMAGE TO THE PRODUCT AN INDICATES HAZARDOUS VOLTAGES MAY BE PRESENT CHASSIS GROUND SYMBOL CALLS ATTENTION TO A PROCEDURE PRACTICE OR CONDITION THAT COULD POSSIBLY CAUSE BODILY INJURY OR DEATH WARNING CALLS ATTENTION TO A PROCEDURE PRACTICE OR CAUTION CONDITION THAT COULD POSSIBLY CAUSE DAMAGE TO EQUIPMENT OR PERMANENT LOSS OF DATA WARNING A Hipot tester produces voltages and currents which can cause harmful or fatal cult ELECTRONICS INTRODUCTION electric shock To prevent accidental injury or death these safety procedures must be strictly observed when handling and using the test instrument 3 Service And Maintenance User Service To prevent electric shock do not remove the instrument cover There are no user serviceable parts inside Routine maintenance or cleaning of internal parts is not necessary Any external cleaning should be done with a clean dry or slightly damp cloth Avoid the use of cleaning agents or chemicals to prevent any foreign liquid from entering the cabinet through ventilation holes o
73. phanumeric input To execute these commands the appropriate function must first be selected with the above Function Select command FC FD FE or FF to have access to the parameter menu 0 5000 60 RS232 amp GPIB INTERFACE SB HI Limit 0 00 40 00 mA SE Dwell Time 0 0 3 999 9 5 SE ArcSense 1910 SG Scanner H Hi L Low O Open pre Pe lema DCW SP ArcSense 1 6 224 up to 16 channels IR S X S Scanner H Hi L Low O Open up to 16 channels SY 300 3000 IAA Sz oa vv S mim oo m EB 2 mo 3 995 SY 57 50 51 52 53 54 Dwell Time 05 99 45 53 Same e Chame 4 ote 0 30 o 5 General Operation alue Memory Select 50 Step Select 1 8 8 61 ELECTRONICS RS232 amp GPIB INTERFACE When the Controller sends a correct S or F command the analyzer will echo back the identical command string if a GPIB read command is sent after the command string If an error occurs when the command is sent the instrument will send an ASCII code 15h after the read command is sent The following functions will read data from the instrument when executed For every command written a corresponding read command of the appropriate byte length shown below must be executed to retrieve the data from the instrument Function 21 Step Buffer 1 40 Read the 2 x 20 display results of t
74. press 17 7 0 1 7 0 0 and the display will show HOLOHLL 3 2 2 10 Offset setting The display will show WARNING Please be aware that the following procedure will activate WARNING high voltage on the output connector once the Test button is pressed Offset X X uA lt Test gt to Auto Set If you do not wish to offset the leakage current of the test leads and fixture you may skip this function by pressing the v key The analyzer will advance to the Step Connection setting automatically You may use the Numeric keys to enter the offset value of the leakage current or press Test button for the analyzer to make a measurement and saved the measured value as an offset 3 2 2 11 Step Connection setting The display will show Connect ON or Connect OFF lt ENTER gt to Select lt ENTER gt to Select 4 MANUAL OPERATIONS If Connect is set to the next step in the sequence will be executed If Connect is set to OFF the test sequence will stop at this step Use the ENTER key to select the Step Connection mode then press v key to advance the analyzer to the beginning display of Voltage setting which is shown in 2 2 1 This is the end of parameter setting for DC Withstand Test Use the or v key to scroll the display to check for setting error When a error is found just simply enter the correct setting and process Press the EXIT
75. r damaging controls and switches also some chemicals may damage plastic parts or lettering Any replacement cables and high voltage components should be acquired directly from Extech Electronics Co or its distributor EXTECH ELECTRONICS CO LTD PHONE 886 2 26943030 4F NO 5 LANE 194 HUAN HO FAX 886 2 26945563 STREET E MAIL extech ms1 hinet net SHIH CHIH TAIPEI HSIEN TAIWAN R O C User Modifications Unauthorized user modifications will void your warranty Extech Electronics will not be responsible for any injuries sustained due to unauthorized equipment modifications or use of parts not specified by Extech Electronics Instruments returned to Extech Electronics with unsafe modifications will be returned to their original operating condition at your expense 1 2 TEST STATION 1 2 1 Location Select an area away from the main stream of activity which employees do not walk through in performing their normal duties If this is not practical because of production line flow then the area should be roped off and marked for HIGH VOLTAGE TESTING No employees other than the test operators should be allowed inside If benches are placed back to back be especially careful about the use of the bench opposite the test station Signs should be posted DANGER HIGH VOLTAGE TEST IN PROGRESS UNAUTHORIZED PERSONNEL KEEP AWAY 1 2 2 Power Dielectric Voltage Withstand Test Equipment must be connected to a good ground Be cer
76. rameter menus SETUP KEY To enter the setup menu and view or change the GPIB address display contrast alarm volume PLC remote settings or the stop on fail setting EXIT KEY To exit any menu or to clear an unwanted entry in a parameter field DATA ENTRY KEYS To input numeric parameters ENTER REVIEW KEY To accept numeric data for parameter settings or to review up to 8 connected test results after a test has been completed HIGH VOLTAGE OUTPUT JACK HV output use the high voltage test lead model 1101 RETURN OUTPUT JACK Use the Return test lead model 1104 This jack carries high current CURRENT OUTPUT JACK Use the high current output lead model 1103 ANALOG METER To indicate the High Voltage at the output jack 17 SCANNER STATUS LED s These LED s indicate the status of the 8 Ground continuity 14 T Specifications Front amp Rear Panel Descriptions 23 24 25 26 SCANNER STATUS LED s These LED s indicate the status of the 8 HV channels LCD DISPLAY The 2x20 character display BUS REMOTE LED To indicate the instrument is in the Remote Control mode LOCK LED To indicate the keys are locked the user will be unable to change any settings ARC LED To indicate Arc Detector detects an arcing condition This indicator will function even when the Arc Fail has been disabled 15 CXT ech Specifications Front amp Rear Panel Descriptions 2 2 2 FRONT PANEL OF MODEL 7430
77. s This instrument should not be operated by personnel with heart ailments or by personnel wearing devices such as pacemakers 1 4 TEST PROCEDURES NEVER PERFORM A HIPOT TEST ON ENERGIZED CIRCUITRY OR EQUIPMENT If the instrument has an external safety ground connection be sure that this is connected Then Connect the return lead first for any test regardless of whether the item under test is a sample of insulating material tested with electrodes a component tested with the high voltage test lead or a cord connected device with a two or three prong plug Plug in the high voltage test lead only when it is being used Handle its clip only by the insulator never touch the clip directly Be certain that the operator has control over any remote test switches connected to the Hipot Double check the return and high voltage connections to be certain that they are proper and secure CAUTION On Models 7440 and 7430 the return lead of the instrument is not grounded earthed This allows for the monitoring of very low leakage levels of current It is therefore important that the device under test is never grounded earthed or the current meter will essentially be bypassed and you will get incorrect current meter readings 1 5 UNPACKING AND INSPECTION Your instrument was shipped in a custom foam insulated container that complies with ASTM D4169 92a Assurance Level II Distribution Cycle 13 Performance Test Sequence If the shipping carton is
78. s not absolutely necessary for the test should be removed from the test bench and put away It should be clear to both the operator and to any observers which product is being tested and which ones are waiting to be tested or have already been tested Do not perform Hipot tests in a combustible atmosphere or in any area where combustible materials are present 1 3 TEST OPERATOR 1 3 1 Qualifications This instrument generates voltages and currents which can cause harmful or fatal electric shock and must only be operated by a skilled worker trained in its use The operator should understand the electrical fundamentals of voltage current and resistance They should recognize that the test instrument is a variable high voltage power supply with the return circuit directly connected to earth ground and therefore current from the high voltage output will flow through any available ground path 1 3 2 Safety Procedures Operators should be thoroughly trained to follow these and all other applicable safety rules and procedures before they begin a test Defeating any safety system should be treated as a serious offense and should result in severe penalties such as ccH INTRODUCTION removal from the Hipot testing job Allowing unauthorized personnel in the area during a test should also be dealt with as a serious offense 1 3 3 Dress Operators should not wear jewelry which could accidentally complete a circuit 1 3 4 Medical Restriction
79. setup the Test Parameters make sure that the analyzer is in the Unlock mode then follow this procedures to setup the Test Parameters 3 2 1 AC W KEY Press the ACW key will enter the setting mode of AC Withstanding Voltage test and the display will show ACW Set XXX X 8 MXX X X XX KV XX XX mA Note X Numeric ACW Set AC Withstand Voltage test setting screen XXX Xs Dwell Time setting in 0 1 sec MXX Memory Program number 1 50 Test Step number 1 8 X XX KV AC Output Voltage setting in 0 01 KV XX XX mA AC High Limit current setting in 0 01 mA Use the or v arrow keys to progress through the test parameters menu The v key will advance forward and key will advance backward The sequential forward menu items are Voltage HI Limit LO Limit Ramp Time Dwell Time Frequency Arc Sense Arc Fail Scanner Set Offset Connect 3 2 1 1 AC Output Voltage setting Press v key and advance to the display below Voltage Range 0 5000 29 CX ccH MANUAL OPERATIONS Use the Numeric keys to enter the AC voltage desired in 1 Volt step then press the ENTER key to confirm The analyzer will store the voltage setting and advance to the High Limit parameter automatically 3 2 1 2 HI Limit Current setting The display will show HI Limit XX XX mA Range 0 00 40 00 Use the Numeric keys to enter the maximum leakage current allowed for HI Limit
80. st memory Program will show on the left end and the second one will be on the right The pass fail status of the first 16 steps can be displayed A maximum of 16 steps will be saved If more than 16 steps are executed in sequence Results from those steps greater than 16 cannot be retrieved from memory Press ENTER REVIEW key to review the test result of each step up to maximum of 8 steps 3 3 6 AUTO PRINTER SETTING After the setting of Fail Stop press SETUP key will enter AUTO Print setting AUTO Print Or AUTO Print OFF lt ENTER gt to Select lt ENTER gt to Select Use Enter key to set AUTO Print mode to ON If AUTO Print ON The printer will print a Print Number and the result of every Step when the TEST key is pressed The Print Number will be incremented by 1 every time the 5 key is pressed This will keep track of the number of DUT tested If AUTO Print 2 OFF printing will be manual After the testing is completed the user can print the information of the display by pressing EXIT PRINT key 3 3 7 PRINT MODE SETTING After AUTO Print mode press SETUP will enter Print Mode Setting Print Mode ALL Or Print Mode Fail ENTER to Select lt ENTER gt to Select Use ENTER key to select ALL or Fail Print Mode ALL will print the information on the display after every step regardless of DUT passes or fails the test Print Mod Fail will only pr
81. t of about 1000V 10mA and the display will show Current mA Enter Standard I out Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of 40mA range for calibration and the display will show AC 40mA 100 OK lt TEST gt to Calibrate ON 7 ech CALIBRATION 5 8 AC CURRENT 3 5mA RANGE CALIBRATION Press the v key the program will advance to the AC 3 5mA range calibration of the ACW test The display will show AC 3 5mA 100 lt TEST gt to Calibrate Connect a resistor about in series with a AC standard Ammeter which can measure up to 3mA to the output leads The Ammeter should be connected to the return lead then press the TEST button the program will automatically generate an output on the output connectors about 300V 3mA and B un gt e un 2 o Current Enter Standard I out Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of AC 3 5mA range of the hipot test and the display will show AC 3 5mA 100K OK lt TEST gt to Calibrate 5 9 DC CURRENT 10 mA RANGE CALIBRATION Press the key the program will advance to the DC 10mA range calibration of the DCW test The display will show DC 10mA 100 lt TEST gt to Calibrate Connect a res
82. tain that the power wiring to the test bench is properly polarized and that the proper low resistance bonding to ground is in place 4 ccH INTRODUCTION Power to the test station should be arranged so that it can be shut off by one prominently marked switch located at the entrance to the test area In the event of an emergency anyone can cut off the power before entering the test area to offer assistance 1 2 3 Work Area Perform the tests on a non conducting table or workbench if possible If you cannot avoid using a conductive surface be certain that it is securely grounded to a good earth ground and insulate the high voltage connection from the grounded surface There should not be any metal in the work area between the operator and the location where products being tested will be positioned Any other metal in the work area should be connected to a good ground never left floating Position the tester so the operator does not have to reach over the product under test to activate or adjust the tester If the product or component being tested is small it may be possible to construct guards or an enclosure made of a non conducting material such as clear acrylic such that the item being tested is within the guards or enclosure during the test and fit them with switches so that the tester will not operate unless the guards are in place or the enclosure closed Keep the area clean and uncluttered All test equipment and test lead
83. tand Test 10 INSULATION KEY To select Insulation Resistance Test 11 UP DOWN ARROW KEYS To scroll the display through the function parameter menus 12 SETUP KEY To enter the setup menu and view or change the GPIB address display contrast alarm volume PLC remote settings or the stop on fail setting 13 EXIT KEY To exit any menu or to clear an unwanted entry in a parameter field 14 DATA ENTRY KEYS To input numeric parameters 15 ENTER REVIEW KEY To accept numeric data for parameter settings or to review up to 8 connected test results after a test has been completed 16 HIGH VOLTAGE OUTPUT JACK output use the high voltage test lead model 1101 17 RETURN OUTPUT JACK Use the Return test lead model 1102 18 SCANNER STATUS LED s These LED s indicate the status of the 8 channel 19 LCD DISPLAY The 2x20 character display 20 BUS REMOTE LED To indicate the instrument is in the Remote Control mode 21 LOCK LED To indicate the keys are locked the user will be unable to change any settings 22 ARC LED To indicate Arc Detector detects an arcing condition This indicator will function even when the Arc Fail has been disabled IIIA e m 18 CXT echt Specifications Front amp Rear Panel Descriptions 2 2 4 FRONT PANEL OF MODEL 7410 SASS 10 12 13 14 15 16 17 18 19 20 21 Wes 1 2 5 4567
84. test time and then will reset to 0 if RESET button is pressed again and the analyzer is ready for the next test 3 2 3 6 Scanner Channel setting The display will show Scanner Set CH 1 16 XXXXXXXXXXXXXXXX Note X 2H OorL If the Scanner is not installed you may skip this step by pressing the v key Use the Numeric keys to enter the status of High Open or Low for each scanner channel then press the ENTER key The analyzer will store the Scanner Channel status and advance to the Connecting setting automatically The table below is the cross reference of the numeric keys which are used for the Scanner channel setting Channel Status H High 1 Connected to High Voltage Output L Low 0 ConnetedtoRetum _ O Open Not connected to High Voltage or Return The Channel setting will start from Channel 1 on the left end and stop at Channel 16 on the 39 4 MANUAL OPERATIONS right end The analyzer will set any unassigned channel s to OPEN after pressing the ENTER key and advance to Offset parameter setting The Scanner Status LED will lit according to the channel selected When more than 8 channels of IR testing are required an external scanner is used the channel status are shown on the external scanner For example you wish to set Channel and 5 to High and Channel 3 6 and 7 to Low you will press 17 7 0 1 7 0 0 and the display will show H
85. the meter readings are taken the display will show IR Abort XXX X 8 or IR Abort XXX X 8 3 4 3 2 Delay 3 4 3 2 1 At the beginning of Insulation Resistance test when the voltage begins to ramp but before the meter readings are taken the display will show IR Delay XXX X s MXX X V 3 4 3 2 2 During the Insulation Resistance test when the values being updated real time during the Delay cycle the display will show IR Delay XXX X s 3 4 3 3 Charge LO 3 4 3 3 1 If the leakage current during the Ramp cycle falls below the Charge LO setting then the display will show IR Charge LO XXX X s MXX X 3 4 3 4 HI Limit 3 4 3 4 1 If the DUT current exceeds the HI Limit of Insulation Resistance test and the resistance is within the metering range the display will show HI Limit XXX X 8 MXX X XXXX V XXXX MO 3 4 3 4 2 If the DUT current exceeds the HI Limit of Insulation Resistance test and the resistance is not within the metering range the display will show 52 CX MANUAL OPERATIONS HI Limit XXX X 8 MXX X XXXXV gt 9999 3 4 3 5 LO Limit 3 4 3 5 1 If the DUT current falls below the LO Limit of Insulation Resistance test and the resistance is within the metering range the display will show IR LO Limit XXX X 8 MXX X XXXXV XXXX MO 4 3 5 2 If the DUT current falls belo
86. ting display 3 2 1 8 Scanner Channel setting The display will show Scanner Set CH 1 16 XXXXXXXXXXXXXXXX Note X 2H OorL If the Scanner is not installed you may skip this step by pressing the v key Use the Numeric keys to enter the status of High Open or Low for each scanner channel then press the ENTER key The analyzer will store the Scanner Channel status and advance to the Offset setting automatically The table below is the cross reference of the numeric keys which are used for the Scanner channel setting Channel Status H High 1 Connected to High Voltage Output L Low 0 ConnetedtoRetum O Open Not connected to High Voltage or Return 3l ult MANUAL OPERATIONS The Channel setting will start from Channel 1 on the left end and stop at Channel 16 on the right end The analyzer will set any unassigned channel s to OPEN after pressing the ENTER key and advance to Offset parameter setting The Scanner Status LED will lit according to the channel selected When more than 8 channels of AC Withstand test are required an external scanner is used the channel status are shown on the external scanner For example you wish to set Channel and 5 to High and Channel 3 6 and 7 to Low you will press 17 7 07 1 7 0 0 and the display will show HOLOHLL 3 2 1 9 Offset setting The display will show Offset X XXXmA lt Test gt to Auto Set If you do not
87. w the LO Limit of Insulation Resistance test and the resistance is below the metering range the display will show IR LO Limit XXX X s XXXX V IMO 3 4 3 6 Pass 3 4 3 6 1 When the DUT passed the Insulation Resistance test when the test process is complete the display will show Pass XXX Xs MXX X XXXX V XXXX MO 3 4 4 GROUND CONTINUITY TEST model 7440 only 3 4 4 1 Abort 3 4 4 1 1 If the test in process is Aborted with the RESET button or remote control the display will show GND Abort XXX Xs MXX X XX XXA 3 4 4 1 2 If the test in process is Aborted with the RESET button or remote control before the meter readings are taken the display will show GND Abort XXX Xs or GND Abort XXX Xs MXX X A MXX X 3 4 4 2 Dwell 3 4 4 2 1 At the beginning of the Ground Continuity test before the meter readings are taken the display will show 53 CX MANUAL OPERATIONS GND Dwell XXX X s A 3 4 4 2 2 During the Ground Continuity test when the values are being updated real time the display will show GND Dwell XXX X s MXX X XX XXA XXX mQ 3 4 4 3 HI Limit 3 4 4 3 1 If the DUT failed the HI Limit of the Ground Continuity test and the ground continuity resistance is within the metering range the display will show GND HI Limit XXX X s MXX X XX XXA XXX mQ 3 4 4 3 2 If the DUT failed the HI Limit of the Ground Continuity
88. warning sound and the display will show Password ERROR Range 0 9999 And then the program will return to the original screen and wait to enter the new password If the Password is Disabled Password is set 0 the display will show Key Lock ON or Key Lock OFF lt ENTER gt to Select lt ENTER gt to Select Press ENTER key to select the Key Lock mode ON or OFF then press the EXIT key to advance the program to the Operation mode This will toggle the Key Lock function from LOCK to UNLOCK or vice versa When the tester is in LOCK mode the LOCK indicator on the front panel will lit Pech MANUAL OPERATIONS If the Memory Lock function MR Lock is selected to ON the Memory selection Menu will be disabled when in the Lock Mode If the MR Lock is selected to OFF the Memory selection Menu will be enabled when in the Lock Mode Different memories can be recalled but the test parameters or steps cannot be changed The MR Lock default is preset to ON at the factory 3 1 4 LOCAL PRINT KEY When the analyzer is under remote operation GPIB or RS232 the BUS REMOTE LED is lit All the keys are inactive except Local Key Press the Local Key will return the analyzer to manual operation When Printer Port Card is installed a 80 column RS232 printer can be connected to the analyzer Press the Local Print button will output the test data to the printer 3 2 FUNCTION KEYS Before going to

CHAPTER 6 : SERVICE MAINTENANCE

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