FULLTEST 3 1. SAFETY PRECAUTIONS AND PROCEDURES CAUTION For your own safety and to avoid damaging the instrument follow the procedures described in this instruction manual and read carefully all notes marked with this symbol. This instrument complies with safety Standards EN61557 and EN61010-1 related to electronic measuring instruments.
FULLTEST 3 1.1 PRELIMINARY INSTRUCTIONS CAUTION The instrument must be connected to a power socket with grounded PE terminal. If this is not assured, the instrument will display PE DISCONNECTED, SWITCH OFF NOW message and will perform no measurement. The instruction manual contains information and references, necessary for safe operation and maintenance of the instrument.
FULLTEST 3 The instrument may only be used within the operating ranges as specified in the technical data section. Disconnect the test leads from the circuit under test before selecting any function. Only touch test leads and test probes at handle surface provided. Never directly touch test probes.
Thanks to a development of newest conception assuring overvoltage category III you will enjoy the highest safety. The Machinery Tester FULLTEST 3 is a measurement instrument used for final inspection of electrical equipment of machines, control cabinets, switchgears as well as other devices complying with IEC/EN60204-1 and IEC/EN61439-1 standards.
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FULLTEST 3 RCD test EN61557-6 - AC, A and B type. - General, selective and delayed characteristic. - Voltage range 100 ... 265 V. - Limit contact voltage 25 or 50 V. = 10, 30, 100, 300, 500, 650 or 1000 mA.
FULLTEST 3 Clamp current - Measurement in combination with HT96U current clamp. - Three ranges 1 A, 100 A and 1000 A. - Limit value adjustable, visual and acoustic warning in case of exceeded value. Leakage current - Measurement of I current on schuko socket (differential method).
FULLTEST 3 Place the unit on to a hard horizontal surface. Press on the case cover with your hands, see the mark 1. Unlock the fixing hooks of the cover, see the mark 2. Open the cover into vertical position.
FULLTEST 3 4. OPERATING INSTRUCTIONS 4.1. INSTRUMENT - DESCRIPTION Figure 2: Instrument description LEGEND Quick instruction label under the cover. Fuse F3, type T12.5A/500V 6.3×32 mm which protects internal circuitry in LOOP, R and RCD measurements. General tester fuse F2, type T16A/250V 5×20 mm which protects internal circuitry in POWER, R and DIELECTRIC measurements.
FULLTEST 3 ON/OFF mains switch (with red pilot lamp). Connector for START/SAVE remote control adapter. Connector SAFETY INPUT for connection of external safety switch (for example protection door). It disables DIELECTRIC tests in case the switch is open. IEC female connector for connection of red WARNING LAMP in DIELECTRIC test. The lamp is active when the test is on (parallel operation to HV lamp on front panel, reference 35).
FULLTEST 3 4.3. MEASUREMENT FUNCTION SELECTION Press the FUNC hard key (yellow), the function selection screen will appear. POWER PE-2WIRE LOOP PHASE PE-4WIRE M CLAMP DIELECT LEAK Figure 3: Function selection screen Select wished function by pressing appropriate touch-screen key, basic measurement screen of selected function will appear, see an example of R basic measurement screen below.
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FULLTEST 3 5. MEASUREMENTS 5.1. CONTINUITY - TWO WIRE METHOD (R PE-2WIRE Complying with EN 60204-1, continuity of protective bonding circuit between PE terminal and relevant points of the protective conductor system must be checked by injecting a measurement current of 0.2 A up to 10 A approx.
FULLTEST 3 5 ..Im touch-screen key to select nominal test current (200 mA or 25 A). Currently selected value is displayed on the bottom of the key. 6 ..LIMIT touch-screen key to select limit value (200 mA measurement) or limit mode (25 A measurement).
FULLTEST 3 The calibration must be done separately for each test current (200 mA and 25 The calibration must be repeated when test leads are changed (replaced, shortened or extended)! Max resistance that can be calibrated is 5 ! ...
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FULLTEST 3 (result OK) or with red symbol and with longer beep sound (result not OK) or with yellow symbol and with beep-beep sound (result OK, but measurement current was too low). See the display outlook with test result on figure 5.
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FULLTEST 3 5.2. CONTINUITY - FOUR WIRE METHOD (R PE-4WIRE Complying with EN 60204-1, continuity of protective bonding circuit between PE terminal and relevant points of the protective conductor system must be checked by injecting a measurement current of 0.2 A up to 10 A approx.
FULLTEST 3 7 ..Measurement value (in green colour - result lower than or equal to set limit value, in red colour - result is higher than set limit value). 8 ..Real time clock (hh.mm.ss). 9 ..Unit of measurement result ().
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FULLTEST 3 Figure 10: Connection of optional Kelvin test leads 6) Carry out the measurement by pressing the START/STOP button. The measurement will start to run and will be stopped after pressing the START/STOP button again (MANUAL mode) or after elapsing set measurement time (TIMER mode).
FULLTEST 3 5.3. INSULATION RESISTANCE (M) • According to EN 60204-1, the insulation resistance between shorted active conductors of power circuit and the earth bonding system must be checked by applying a test voltage of 500 V DC. The limit value is 1 M.
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FULLTEST 3 5.3.2. R MEASUREMENT Measured quantities and display ranges: 0 100 M (test voltage 100 V) Insulation resistance R 0 250 M (test voltage 250 V) 0 500 M (test voltage 500 V) 0 1000 M (test voltage 1000 V) 0 ...
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FULLTEST 3 CAUTION Connect COM test lead to chassis if the UUT is grounded. In case of reversed test leads measurement result may be affected by instrument’s internal resistance of 10 M! Due to the measurement of insulation resistance, capacitive UUT will be charged with test voltage.
5.4.1. WARNINGS WARNING, DANGER OF ELECTRICAL SHOCK The Machine Tester FULLTEST 3 supplies high voltage of a dangerous power. According to EN 50191 the following precautionary measures must be taken prior to a test: • Block access to danger area.
FULLTEST 3 5.4.2. DIELECTRIC DISPLAY EXPLANATION Adjustable/selectable parameters: MODE - operation mode MANUAL, BURN, RAMP 75% or RAMP 50% 250 5100 V AC nominal test voltage TEST NOM - 1 110 mA LIMIT - current limit CHAR - current character...
FULLTEST 3 5.4.3. DIELECTRIC TEST Measured quantities and display ranges: 0 200 mA Apparent leakage current I 0 200 mA Real leakage current I REAL 250 5.100 V Test voltage Explanation of measurement modes: MANUAL or BURN mode:...
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FULLTEST 3 RAMP 50% mode: Figure 16: Presence of test voltage with regard to pressed START button and set time in RAMP 50% mode 1) Select DIELECTRIC measurement by pressing the FUNC hard key first. 2) Check selected mode and correct it if needed by pressing the MODE (5) touch-screen key first.
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According to EN 50191 the highest level of safety must be undertaken when working with high voltages like used in DIELECTRIC test. For this purpose the FULLTEST 3 offers an output to drive the high voltage warning lamp. Use only the lamps supplied by original supplier of the FULLTEST 3 tester.
FULLTEST 3 5.5. RCD (RCD) 5.5.1. RCD DISPLAY EXPLANATION Adjustable/selectable parameters: TYPE - type of RCD AC, A or B CHARACTERISTIC - RCD characteristic GENERAL, SELECTIVE or DELAYED - nominal differential current 10, 30, 100, 300, 500, 650 or 1000 mA N...
FULLTEST 3 5.5.2. EXPLANATION OF RCD TEST CURRENTS See the figures below for test current shapes with regard to selected RCD type and test current polarity. Figure 19: Test current shapes with regard to selected RCD type and test current polarity in trip time...
FULLTEST 3 5.5.3. RCD MEASUREMENT Measured quantities and display ranges: 0 1000 ms (AC, A, B, general, selective, delayed) Trip out time at I N 0 1000 ms (AC, A, B, general, selective, delayed) Trip out time at I N...
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FULLTEST 3 READY message will appear as soon as the tester is properly connected to the installation and mains voltage is present, see the “Input conditions” above. 8) Carry out the measurement by pressing the START button. 9) Test result will be displayed in green colour equipped with green symbol and with beep-beep sound if it is within limit range, see the table of allowed trip out times below.
FULLTEST 3 5.6. LOOP IMPEDANCE / SHORT-CIRCUIT CURRENT (LOOP) • According to EN 60204-1, the conditions for protection against electric shock in installations with automatic disconnection of mains voltage are: • Measurement or evaluation of fault loop impedance and testing the over-current protection device involved in the fault loop.
FULLTEST 3 8 ..PROT. (protection) touch-screen key to select the type of protection (MCB B, MCB C, MCB D, MCB K, FUSE gG or FUSE aM) and nominal current of selected protection. Currently selected type is displayed on the bottom of the key.
FULLTEST 3 TRIP CURR. ISC MIN L/PE Trip time T, T < ISC MIN L/PE Trip time T, T < Tlim Tlim ISC MIN L/PE > N × In ISC MIN L/PE > N × In Where: T ... Trip out time according to the characteristic and nominal current of used protection device K ...
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FULLTEST 3 Figure 24: Connection of test cable to schuko socket for LOOP or LOOP measurement L/PE Figure 25: Connection of test leads to tested wiring for LOOP measurement Figure 26: Connection of test leads to tested wiring for LOOP...
FULLTEST 3 7) READY message will appear when mains voltage U (LOOP L/N) or U (LOOP L/PE) within L/PE 100 265 V or U (LOOP L/L) within 100 460 V is present. Carry out the measurement by pressing the START button.
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FULLTEST 3 5.7.1. R LIMIT VALUE CALCULATION The global resistance R should be lower than or equal to U , where limit contact voltage U N C LIM can be set to 25 or 50 V. Example: Selected U = 50 V...
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FULLTEST 3 5.7.3. R MEASUREMENT Measured quantities and display ranges: 0 2.000 (I Global earth resistance R = 10 or 30 mA) N 0 1.000 (I = 100 mA) N 0 300 (I = 300 mA) N...
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FULLTEST 3 5) Carry out the measurement by pressing the START/STOP button. Test result will be displayed after elapsing measurement time in green colour equipped with green symbol and with beep- beep sound if it is lower than or equal to limit value (see the explanation of limit value above). If the...
EN 60204-1 must be taken. • With FULLTEST 3 tester the residual voltage can be measured 1 s or 5 s after switching off tested machine. Measurement of residual voltage can be carried out in linear or non-linear mode, see the section "EXPLANATION OF LINEAR MODE"...
Up = 415 V × 1.1 × 1.41 = 644 V ....... system voltage 415 V is recognized If actual mains voltage differs from nominal system voltage more than 10%, the FULLTEST 3 scales the result to peak value of actual input voltage.
FULLTEST 3 5.8.3. U DISPLAY EXPLANATION Selectable parameters: MODE - measurement mode LINEAR or NONLINEAR CON - connection INT (measurement on internal components) or PLUG (measurement on 1P/3P plug) LIMIT t - limit time 1 s or 5 s Figure 33: Display with U test result 1 ..
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FULLTEST 3 5.8.5. U MEASUREMENT Measured quantities and display ranges: 10 460 V AC or 10 650 V DC Residual voltage on power plug U 10 460 V AC or 10 650 V DC Residual voltage on internal components U Input requirements: 43 ...
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FULLTEST 3 8) Test result will be displayed in green colour equipped with green symbol and with beep-beep sound if it is lower than or equal to 60 VRMS (may be AC or DC, see the unit). If the result is higher...
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FULLTEST 3 The following specific information can be shown on the display during the measurement: Information displayed Description Mains voltage was disconnected at too low LOW TRIGGER VOLTAGE momentary voltage (< 20% of peak value). The REPEAT message may appear in LINEAR mode only.
FULLTEST 3 5.9. POWER (POWER) Measured appliance is supplied by mains voltage applied to schuko test socket. Switching the voltage on/off as well as selection of phase position is done by internal switch of the tester. 5.9.1 POWER DISPLAY EXPLANATION Adjustable/selectable parameters: 00:05 ...
FULLTEST 3 5.9.2. POWER MEASUREMENT Measured quantities and display ranges: 0 5.06 kVA Apparent power P 0 5.06 kW Real power P 253 V Mains voltage U 0 20 A Load current I 0.00 1.00 Power factor PF 0.25 mA ...
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FULLTEST 3 CAUTION Measurement at both phase positions (phase at left terminal and phase at right terminal) must be carried out when leakage current IPE is measured and the highest value must be evaluated. Switch on the UUT in order full power of the unit and total leakage current to be measured! ...
FULLTEST 3 5.10. PHASE SEQUENCE (PHASESEQ) Correct phase sequence is important when e.g. 3-phase machines with mechanical rotation are connected to 3-phase mains installation. 5.10.1. PHASE SEQUENCE DISPLAY EXPLANATION Adjustable/selectable parameters: There are no adjustable/selectable parameters available! Figure 39: Display with PHASE SEQUENCE test result 1 ..
FULLTEST 3 5.10.2. PHASE SEQUENCE MEASUREMENT Measured quantities and display ranges: Phase sequence 1.2.3. or 2.1.3. 360 460 V Phase-to-phase voltage U L1/2 360 460 V Phase-to-phase voltage U L2/3 360 460 V Phase-to-phase voltage U L3/1 1) Select the PHASE function by pressing the FUNC hard key first.
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FULLTEST 3 5.11. CURRENT MEASUREMENT USING CURRENT CLAMP (I CLAMP 5.11.1. I DISPLAY EXPLANATION CLAMP Adjustable/selectable parameters: RANGE - measurement range 1000 mA, 100.0 A or 1000 A 0.1 1000 mA (range 1000 mA) LIMIT - limit value 0.1 100.0 A (range 100.0 A) 1 ...
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FULLTEST 3 5.11.2. I MEASUREMENT CLAMP Measured quantities and display ranges: 0 1000 mA (range 1000 mA) Clamp current I CLAMP 0 100 A (range 100 A) 0 1000 A (range 1000 A) 1) Select I function by pressing the FUNC hard key first.
FULLTEST 3 5.12. LEAKAGE CURRENT (I LEAK 5.12.1. LEAKAGE CURRENT DISPLAY EXPLANATION Adjustable/selectable parameters: MODE - measurement mode CLAMP or SOCKET 0.1 100.0 mA, 101 1000 mA (CLAMP mode, range 1000 mA) LIMIT - leakage current limit value 0.1 ...
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FULLTEST 3 Figure 44: Display with I test result in SOCKET mode LEAK 1 ..Selected function. 2 ..Sub-result, mains voltage U 3 ..Measurement screen touch-screen key. 4 ..MODE touch-screen key to select measurement mode (SOCKET or CLAMP). Currently selected mode is displayed on the bottom of the key.
FULLTEST 3 5.12.2. LEAKAGE CURRENT MEASUREMENT USING CURRENT CLAMP Measured quantities and display ranges: 0 1000 mA (1000 mA range) Leakage current I measured by clamp LEAK 0 100 A (100 A range) 0 1000 A (1000 A range) 1) Select I function by pressing the FUNC hard key first.
FULLTEST 3 5.12.3. LEAKAGE CURRENT MEASUREMENT ON SCHUKO SOCKET Measured quantities and display ranges: 0.25 mA 10 A Leakage current I on schuko socket 195 253 V Mains voltage U 1) Select I measurement by pressing the FUNC hard key first.
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FULLTEST 3 The following specific information can be shown on the display during the measurement: Information displayed Description If I current is higher than 10 A for 10 s, the measurement CURRENT OVERRANGE! will be stopped and this message will appear.
FULLTEST 3 6. MENU FUNCTIONS For further selection, entry and display of instrument’s settings press the MENU hard key, the following MAIN MENU will appear. MAIN MENU MEMORY LANGUAGE SETUP OPERATOR TESTER INFO SOUND Figure 47: MAIN MENU Press wished submenu touch-screen key for further settings.
FULLTEST 3 6.1.2. CLEAR menu In order to clear saved results the CLEAR menu shall be used. CLEAR TOTAL LAST RESULT Figure 50: CLEAR menu The whole memory (TOTAL) or only the last saved result (LAST RESULT) can be cleared. If the last result is cleared, then the result saved before the last one become to be the last and can be cleared too etc.
FULLTEST 3 Figure 52: ADD OPERATOR menu 5. Create new operator’s name. Use the 123 / ABC key to select figure or character selection screen. 6. Confirm entered name by pressing the ENTER touch-screen key. OPERATOR screen will appear again and last entered operator will be selected.
FULLTEST 3 6.5. SETUP menu SETUP LEVEL NAMES DATE/TIME NOMINAL VOL. CONTACT VOL. SAFET INPUT RESET Figure 55: SETUP menu 6.5.1. LEVEL NAMES menu Three levels are available when saving test results i.e. LEVEL1, LEVEL2 and LEVEL3. In production the three levels are dedicated to CUSTOMER, LOCATION and MACHINE, but operator can rename them freely for example to DEVICE, DEPARTMENT and LOCATION.
Time starts to run on this confirmation. 6.5.4. RESET menu There are many adjustable parameters in the FULLTEST 3 tester. If an operator due to any reason wishes to reset all adjustable parameters to factory-set values, the operation can be done by using the RESET menu.
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FULLTEST 3 The following parameters have been reset. Function Parameter GENERAL - OPERATOR = Default - LANGUAGE = ITALIAN - CONTACT VOLTAGE = 50 V - NOMINAL VOLTAGE = 230 V - SAFETY INPUT = ENABLED - SOUND = ON...
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FULLTEST 3 DIELECTRIC - MODE = MANUAL = 250 V TEST NOM - LIMIT value = 1 mA - CHAR = I 1 = 250 V TEST NOM 2 = 1000 V TEST NOM 3 = 2500 V TEST NOM...
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FULLTEST 3 POWER - TIMER = 10 s - LIMIT apparent power = 6 VA L POS = RIGHT - TIMER 1 = 10 s - TIMER 2 = 30 s - TIMER 3 = 1 min - TIMER 4 = 10 min...
FULLTEST 3 6.5.5. NOMINAL VOLTAGE menu This menu shall be used in order to select nominal mains voltage. The voltage may be either 230 or 240 V. It is used in LOOP and U measurements. In LOOP measurements it is used for calculation of prospective short-circuit current, see the “LOOP IMPEDANCE / SHORT-CIRCUIT CURRENT (LOOP)”...
FULLTEST 3 6.6. SOUND menu In order to turn the acoustic signals off/on SOUND menu shall be used. SOUND Figure 62: SOUND menu Select the SOUND status by pressing appropriate touch-screen key, screen will turn to SETUP menu. EN - 70...
FULLTEST 3 7. MEMORY FEATURES Any memory address consists of three levels i.e. LEVEL 1 (in production set to CUSTOMER), LEVEL 2 (in production set to LOCATION) and LEVEL 3 (in production set to MACHINE). The memory address (at least LEVEL 1 i.e. CUSTOMER) should be entered after the first pressing the SAVE hard key.
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FULLTEST 3 8. MEMORIZING EXAMPLE In order to save measurement result to a particular storage address, follow the next steps: 1) Carry out the measurement. 2) Press the SAVE hard key, the following display will appear (example): SAVE CUSTOMER COMPANY A...
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FULLTEST 3 Figure 66: ADD CUSTOMER menu 13. Create new customer’s name. Use the 123 / ABC key to select figure or character selection screen. 14. Confirm entered name by pressing the ENTER touch-screen key, SAVE – SELECT CUSTOMER screen will appear again and last entered operator will be selected.
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FULLTEST 3 9. RECALL RESULTS In order to recall saved measurement result, follow the next steps: 1) Press the RCL hard key, the following screen will appear (example). Figure 67: RECALL menu 2) Check offered customer and if needed, select another one by pressing the CUSTOMER touch- screen key first.
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FULLTEST 3 10. ENTRY OF DATA BY USING AN EXTERNAL KEYBOARD The optional USB keyboard is a welcome accessory when inserting memory address construction (customer, machine and location) as well as comment, in order to do the job quickly and simply.
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Before first using the above mentioned barcode reader it is required to configure it as follows: - Connect the barcode reader to FULLTEST 3 (or to PC) and switch on the FULLTEST 3 (or PC) in order to assure proper power supply.
The FW update can be done through USB drive, follow the next steps: Download new FW version for example B03.M04.V02 from PC to USB drive. Connect the USB drive to USB2 or USB3 connector of the FULLTEST 3, label DO YOU WISH TO UPDATE TO VERSION B03.M04.V02? will appear.
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In case mains switch pilot lamp (5) does not illuminate after connecting the Machinery-Tester FULLTEST 3 to mains outlet and switching on the mains switch and neither the LC-Display (24) shows any indication, it is very likely mains fuse F1 (4) or F2 (3) or both to be blown.
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FULLTEST 3 Dielectric withstanding test (DIELECTRIC) Nominal test Output Resolution Accuracy of Overvoltage voltage U output voltage protection 250 800 COM & 0.250.80 kV 810 2500 COM & 0.812.50 kV ± 3% U CAT III 300 V 2510 5100 COM &...
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FULLTEST 3 RCD test (RCD) RCD types / characteristics: AC, A or B / General, Selective or Delayed Measurement modes: x1/2I , x1I , x2I , xKI (K = 4 B type, K=5 AC, A type), N N N N (RAMP), AUTO (sequence: x1/2, x1, xK) ...
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FULLTEST 3 LOOP impedance / Short-circuit current (LOOP) Display range Resolution Accuracy Overvoltage protection () (M) *0.000 2.000 0.001 0.00 9.99 0.01 ± (3% rdg. + 3 dgt) CAT III 300 V 10.0 99.9 100 200 * With optional accessory IMP57 only! 100 ...
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FULLTEST 3 TRMS Residual voltage (U Resolution Accuracy Display range Overvoltage protection (general) 10 460 V ± (3% rdg. + 3 V) CAT III 300 V 10 650 V 0 460 V AC Input voltage (U TRIG...
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FULLTEST 3 Power factor (POWER) Display range Resolution Accuracy Overvoltage protection 0.00 1.00 0.01 Respect the accuracy of P and P CAT II 300 V TRMS Leakage Current I (POWER) Display range Resolution Accuracy Overvoltage protection 0.25 19.99 mA 0.01 mA...
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FULLTEST 3 TRMS Leakage current using current clamp (I LEAK Accuracy Range Display range Resolution Overvoltage protection (w/o clamp error) 0.0 99.9 mA 0.1 mA 1000 mA 100 1000 mA 1 mA 0.00 9.99 A 0.01 A One measurement 100.0 A...
FULLTEST 3 14.2. GENERAL SPECIFICATION POWER SUPPLY 207 253 V / 50/60 Hz ± 5% Mains voltage: Current consumption: 16 Amax MECHANICAL SPECIFICATIONS Dimensions (L x W x H): 400 x 300 x 170 mm Weight: 15 kg MEMORY AND INPUT/OUTPUT INTERFACES...
FULLTEST 3 15. SERVICE 15.1. WARRANTY CONDITIONS This instrument is guaranteed against material or production defects, in accordance with our general sales conditions. During the warranty period the manufacturer reserves the right to decide either to repair or replace the product.
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