Page 1 M4000 Insulation Analyzer User Guide Doble Engineering Company 85 Walnut Street Watertown, Massachusetts 02472-4037 (USA) PN 500-0110 72A-1230 Rev. F...
Page 2 Doble Clients under contractual agreement for Doble Test Equipment and Services. In no event does the Doble Engineering Company assume the liability for any technical or editorial errors of commission, or omission; nor is Doble liable for direct, indirect, incidental, or consequential damages arising out of the use or inability to use this Manual.
Page 3 M4100 or M4200c. Appendix A “M4000 Components Lists” describes accessories included with the M4000 Insulation Analyzer. Appendix B “Warranty” provides Doble warranty provisions applicable to the M4000. Appendix C “Error Messages” lists error message numbers and descriptions.
Page 4 Conventions Used in this Manual The following terms and typographical conventions are used in the manual: Convention Description Windows Refers to the Microsoft Windows operating system, Version 98 or later. Click Quickly press and release the left mouse button. Double-click Quickly press and release the left mouse button twice without moving the mouse.
Page 5: Table Of Contents
M4200c Controller ........................1-5 Third-Party Controller........................1-7 M4000 Software ........................... 1-7 Optional M4150 And M4151 Field Calibration References ............1-7 Doble Standard Turns Ratio Capacitor ..................1-8 External Reference ........................1-8 M4300 Transport.......................... 1-8 Doble Test Assistant (DTA) Software ..................1-9 M4110 Leakage Reactance Interface ...................
Page 6 2. M4000 Software Upgrading or Installing M4000 Software ................... 2-1 Software Installation ........................... 2-1 M4000 Software ........................... 2-1 Doble Test Assistant (DTA) Software (Optional)................ 2-5 Optimization ............................2-5 COM port Setting ......................... 2-5 Mouse Settings ..........................2-5 Time/Date Format......................... 2-6 Introduction to M4000 Software......................
Page 7 M4000 Insulation Analyzer User Guide Entering Clipboard Information ......................3-1 Nameplate Information ........................ 3-1 Administrative Information......................3-2 Test Conditions ..........................3-3 Test Results Information ........................3-4 Running Single and Multiple Clipboard Tests ................... 3-6 Raising Test Voltage ........................3-7 Test Results ..........................3-8 Clearing Test Results .........................
Page 8 Troubleshooting from Diagnostics ....................4-21 Running Diagnostics........................4-21 System Status..........................4-23 Calibration Verification......................4-26 Field Recalibration ........................4-31 Subsystem Diagnostics ....................... 4-34 M4100 Component List......................4-38 Thermal Profile........................... 4-39 Communications Loopback Test ....................4-40 Running Other Tests ......................... 4-42 Checking the High Voltage Test Cable ..................4-42 Checking the Low Voltage Test Leads..................
Page 9 M4000 Insulation Analyzer User Guide Replacing M4100 Components ....................... 4-56 Returning Replaced Components....................4-57 Removing and Replacing the Front Panel Assembly..............4-58 Replacing the Guard Front Panel Board ..................4-61 Replacing the Amplifier Assembly .................... 4-63 Replacing the Guard Mode Switch Board.................. 4-66 Replacing the Timing Board ......................
Page 10 M4000 Firmware/Application Errors ....................C-2 M4000 Communications Errors......................C-3 Appendix D. Part Numbers 72A-1230 Rev. F...
Page 11: Introduction
The M4000 Insulation Analyzer is used to determine the insulation quality of high-voltage power apparatus in the field. This portable test set incorporates automated Doble Testing with high accuracy and sensitivity, over a wide range of values, and with minimal susceptibility to electrostatic interference and noise.
Page 12: M4000 Components
Line Sync Reversal or Line Frequency Modulation. When Line Sync Reversal Mode is selected, the time base is synchronized to the power source and the test will use the standard Doble 72A-1230 Rev. F...
Page 13 M4000 Insulation Analyzer User Guide polarity reversal technique to reverse the effects of electrostatic interference. Selecting the Line Frequency Modulation Mode of operation will synchronize the time base generator to the crystal oscillator. Two tests will be run for each programmed test sequence.
Page 14 M4100 Instrument Figure 1.1 Safety Strobe Two optional items found on the M4100 front panel are the M4151 Field Calibration Reference, which will be discussed below, and a Temperature and Relative Humidity sensor. The Temperature and Relative Humidity Sensor will process temperature and humidity readings at the time of test. Front Panel Figure 1.2 M4100 Instrument 72A-1230 Rev.
Page 15: M4200C Controller
M4000 Insulation Analyzer User Guide M4200c Controller Figure 1.3 M4200c Controller • The M4200c Controller is the interface between the operator and the M4000 Insulation Analyzer. The color display, control, data storage, printing and communication functions are all provided by the M4200c Controller.
Page 16 Paper for the printer/plotter is an uncoated thermal FAX paper provided by Doble. • The M4200c is equipped with an internal FAX/Modem board that may be used to transfer data when used with the optional Doble Test Assistant (DTA) program. • The M4200c has a built in ethernet connection.
Page 17: Third-Party Controller
Party Controller includes a program to run the M4000 Insulation Analyzer, and if desired, the optional Leakage Reactance Test, External Reference Test, and Doble Test Assistant (DTA) programs. For more information, refer to Chapter 2. Optional M4150 And M4151 Field Calibration References...
Page 18: Doble Standard Turns Ratio Capacitor
This is an optional small portable capacitor that can be energized at 10 kV for performing turns ratio tests at high voltages with the M4000. Figure 1.6 Doble Turns Ratio Capacitor External Reference This is an optional feature allowing the tester to test apparatus at their full operating voltage using the M4000, providing a suitable external power source and reference are provided by the user.
Page 19: Doble Test Assistant (Dta) Software
M4000 Insulation Analyzer User Guide Figure 1.7 M4300 Transport Doble Test Assistant (DTA) Software ® Optional Doble Test Assistant (DTA) software provides standardized apparatus test procedures and templates, data management, and optional expert system software for insulation condition assessment. See Chapters 2 and 3 for further details.
Page 20: Operating With The M4300 Transport
Storage and Moving Mode When using this interface, the standard M4000 safety switch and safety strobe are used. The necessary current and voltage cables are provided for connection to the transformer, along with the necessary software, so that this becomes a self-contained kit for this test.
Page 21 M4000 Insulation Analyzer User Guide Controller High Support Frame Voltage Cable Cable Carry M4100 Instrument Oil Test Cell M4200c Controller Figure 1.9 M4000 Insulation Analyzer in Storage Mode The recommended assembly steps for the Storage and Moving Mode is as follows: 1.
Page 22 Storage and Moving Mode 3. Position the closed M4200c Controller upside down into the area with the projections of the top cover of the M4100 Instrument. Buckle and tighten the strap snugly around both the M4100 Instrument and the M4200c Controller.
Page 23: Testing Mode
M4000 Insulation Analyzer User Guide Testing Mode When assembled in the Testing Mode, the M4300 Transport serves as the field desk for the M4000 Insulation Analyzer. The Testing Mode (Figure 1.10) was designed to take advantage of the M4100 instrument's concentrated cluster of connections, providing the user with a comprehensible testing setup and a user-friendly environment while testing.
Page 24 Transport. A separate receptacle box is also provided for cases where the M4000 Insulation Analyzer is used away from the M4300 Transport. As shipped from Doble, the 120 VAC receptacle in the M4200c Controller is located under a yellow tag which states, “NOTICE: READ ENCLOSED MICROSOFT SOFTWARE LICENSE BEFORE USING”.
Page 25: When Finished Testing
This should be the last connection to be made. 16. The M4000 Insulation Analyzer is ready to be connected to the specimen to be tested. Connections to the specimen are described in the Doble Test Procedures manual. When the M4000 Insulation Analyzer is assembled in the Test Mode it should not be moved.
Page 26: M4000 Pc Cable
Windows 98 or later operating system • Internet Explorer version 5.0 or better • One available serial port See the Doble website (www.Doble.Com) for complete details. Setting Up the The computer must be loaded with the M4000 (and DTA, if a DTA user) software. Controller The COM port setting must be set in accordance with your computer's requirements.
Page 27: Transport, Storage And Shipping
M4000 Insulation Analyzer User Guide Transport, Storage and Shipping Transporting and Storing the M4000 The M4100 Instrument, M4200c Controller, and Accessories should be stored in a reasonably clean and dry location. If the M4100 Instrument, M4200c Controller, and/or the inboard or outboard potheads of the High Voltage Test Cable are exposed to excessive dirt and/or moisture, they should be cleaned and dried before use.
Page 28: Shipping Instructions
Watertown, Massachusetts 02472-4037 Test sets that are transported appreciable distances should be checked upon arrival. This includes sets that have been shipped from the Doble Engineering Company. The test set and its accessories should be examined upon receipt for signs of physical damage. The simplest and most effective method for checking overall performance of the M4000 is to use the Doble Liquid Insulation Cell as described in ”Checking...
Page 29: Safety Considerations
M4000 Insulation Analyzer User Guide The preceding also applies to test sets that have been stored for prolonged periods. Safety Considerations Safety cannot be overemphasized when working on or around high voltage electrical apparatus. Companies that generate, transmit, distribute, or utilize high voltage electricity should, and do, have precise rules for safe practices and procedures for personnel whose working responsibilities involve testing and maintenance of the various types of high voltage apparatus, and their...
Page 30: Safety Practices - General Rules
State, local, and federal regulations, e.g. OSHA, may also apply. Company rules and government regulations take precedence over Doble recommendations. Clearances Proper clearance between the test equipment, crew members, and the apparatus being tested, must be observed at all times during energization.
Page 31: Grounding
3. Exposed terminals of apparatus should not normally be allowed to “float”. They should be grounded directly or through the low voltage leads of the M4000 Insulation Analyzer, unless otherwise specified by Doble recommended test plans. 4. There must be two inches of clearance between conductors (such as bus) that are not part of the tests.
Page 32: M4000 Connections
M4000 Connections M4000 Connections 1. The procedures described in the “Testing Mode” section of this chapter on page 1-13, for connecting and disconnecting the M4000 leads in their proper sequence should be observed and acted upon at all times. In particular, due to the presence of static charges from nearby energized ARNING lines, never touch the live end (hook) of the high voltage cable when moving leads.
Page 33: M4000 Operation
1. A #6 copper conductor is provided by Doble for the purpose of grounding the M4000 Insulation Analyzer. The heavy-duty #6 conductor should be connected to the GROUND RECEPTACLE of the M4000 Insulation Analyzer at one end and to the station grounding system at the other end.
Page 34 7. During operation, an audible beep is heard whenever high voltage is being applied. This beeper is enabled by default. Doble recommends the default, although the beeper can be turned off as part of instrument configuration.
Page 35: Safety Precautions
M4000 Insulation Analyzer User Guide Safety Precautions Doble insulation analyzers require operation by at least two persons. The M4000 Insulation Analyzer operator has his/her own Operator's Safety Switch. A second switch, called the Extension Safety Switch, is provided. The cable for the Extension Safety Switch is equal in length to the High Voltage Test Cable.
Page 36: Safety Precautions For Various Types Of Apparatus
3. Use caution when applying test voltages to a transformer from which the oil has been removed. Recommended test voltages for testing a transformer without insulating fluid are listed in the Doble Test Procedures manual. 4. Under no circumstances should test voltages be applied to oil impregnated insulation while the insulation is under vacuum.
Page 37 M4000 Insulation Analyzer User Guide Instrument In addition to isolating and grounding live terminal(s) of the primary winding, secondary fuses and other leads should be removed in order to completely and Transformers effectively isolate the unit from the system. This is especially important in the case of potential transformers.
Page 38: Safety Summary
Safety Summary Safety Summary In summary, it is worth noting that many of the accidents that happen around high voltage apparatus and its associated conductors involve personnel who are familiar (perhaps too familiar) with high voltage equipment. Staying alert and ever watchful requires constant training and awareness of the inherent hazards.
Page 39: M4000 Software
Your M4200c Controller comes with all necessary software pre-installed. This consists of the Windows XP operating system, the M4000 program, and for users of the Doble Test Assistant, the optional DTA program. You may also request the optional Leakage Reactance Test or External Reference Test software.
Page 40 M4000 Software If you have already installed the current version of the M4000 software, and you only wish to add either or both of the optional features, Leakage Reactance and External Reference/Source testing, each of these disks contains its own setup function and can be installed separately as described below. To install the M4000 software and/or either of the optional features, follow this procedure: 1.
Page 41 M4000 Insulation Analyzer User Guide • Launch M4000 at Startup: Select this option if this computer is dedicated to M4000 tests, since it automatically runs the M4000 program when starting the computer (If you have the icon for the old version of the software in your startup folder, remove it).
Page 42 M4000 Software • Both LV leads must be inserted to run test: requires that both the red and blue leads be inserted into the test set to run a test (rarely used). • Safety strobe is required to run test: In the event there is a failure of the strobe bulb or cable, this should be disabled so as to be able to continue testing without it.
Page 43: Doble Test Assistant (Dta) Software (Optional)
• Copy these 3 files into the directory of the older version you are using. Installation of the M4000 Software is now complete. Doble Test Assistant (DTA) Software (Optional) See instructions found with the DTA software. Optimization COM port Setting If the software has been installed on a PC, you may have to adjust the COM port setting if the wrong choices were made during installation.
Page 44: Time/Date Format
Time/Date Format • From the Windows “Start” button, choose “Control Panel” from the “Settings” menu item. • Double-click on the Mouse Icon, then select the “Motion” tab. • Click the “Show Pointer Trails box, adjust the scale marker to “Long” and click OK.
Page 45: The M4000 Program
“StartUp” group: 1. Select All Programs from the Windows Start button menu. 2. Select the Doble Program Group. 3. Select the M4000 icon. 4. Click the OK button on the “About The M4000 Software” window. You are now at the M4000 clipboard screen.
Page 46: Menu Bar
Menu Bar Icon Description Enter DTA Field System Software, or select DTA from the Mode pull-down menu. With DTA, the second test mode available is DTA. See the DTA instruction manual for use of the DTA option. DTA contains specific forms for different apparatus types, along with an expert system to evaluate results.
Page 47: Clipboard Test Mode
M4000 Insulation Analyzer User Guide Clipboard Test Mode To enter Clipboard test mode, click the icon, or select Clipboard from the Mode pull-down menu item. The following screen will appear: Figure 2.5 Clipboard Screen Clicking on the following icons will perform the described functions: Icon Description Open a File.
Page 48 Menu Bar Icon Description Enter the DTA Field System program. This can also be done by selecting DTA from the Mode pull-down menu item. Click to open a Clipboard screen, where tests may be run and recorded. Click to enter External Reference/Source Mode, or select External Reference/ Source from the Mode pull-down menu.
Page 49: Menu Items
M4000 Insulation Analyzer User Guide Icon Description Toggle sheet note. Click this icon to display or hide a note area for the entire clipboard sheet at the bottom of the screen. Toggle Nameplate. Click this icon to display or hide all but the test data.
Page 50: Diagnostics
Diagnostics Diagnostics This menu contains several self-test options, described in ”Running Diagnostics” on page 4-21. View Menu Commands here allow display or hiding of the: • Toolbar (row of icons) • Status Bar (along the bottom of the screen, it includes status of the Caps Lock and Num Lock functions, which should be off) •...
Page 51: Configuration
M4000 Insulation Analyzer User Guide 2. Click the temperature correction icon , or select Temperature Correction from the Tools menu. 3. In the Temperature Correction window, fill in the rows on the clipboard screen to which you wish to apply the temperature correction. These rows must have temperature data associated with them for this function to work.
Page 52: Clipboard Configuration
M4000 Data Directory field. Then, edit the settings to reflect in which directory the Clipboard data is stored. Select a directory other than C:\DOBLE\DTA for data storage for both Clipboard data and DTA data.* Click on the OK button to accept your changes.
Page 53 10 kV were the applied voltage. If results obtained were tested at 2 kV, current and watts measurements will be multiplied by 5. Historically, this is the way all Doble tests have been performed. If Actual Values are selected, all results will be reported in reference to the applied voltage.
Page 54: Dta Field Configuration
DTA Field Configuration Loss Factor - There are two options available, Power Factor and Dissipation Factor, practically identical in routine usage. Dissipation Factor may be chosen when the user wishes to duplicate nameplate data from international manufacturers. However, the two are virtually identical at Power Factor readings below 5%.
Page 55 M4000 Insulation Analyzer User Guide Figure 2.8 DTA Configuration Test Type - See Clipboard Configuration for a description of this item. Voltage Ramp Settings - See Clipboard Configuration for a description of this item. 72A-1230 Rev. F 2-17...
Page 56: Instrument Configuration
Instrument Configuration Instrument Configuration When the Instrument Configuration tab is selected, the following appears: Figure 2.9 Instrument Configuration Serial Port - It may be necessary to change this setting to accommodate laptops being used with the M4100. The M4200c uses COM2, and laptops usually use COM1.
Page 57: Advanced Configuration
M4000 Insulation Analyzer User Guide Settling Time Delay- The time, at maximum test voltage, during which the M4000 samples the data. If it appears that excessive electrostatic interference is affecting test results, the settling time may be increased in order to sample the data over a longer period of time.
Page 58 Language: Choose from English, French, Spanish, and Portuguese, if selected for installation. Filter Type: The default is Slow, and should not be changed without consulting Doble. Capacitor Model: The default is Parallel, and should not be changed without consulting Doble.
Page 59: Using Help
M4000 Insulation Analyzer User Guide Using Help When Help is selected, two options are presented: 1. Contents F1. 2. About M4000 For Windows... Contents The Help/Contents option opens the Help window: Figure 2.11 Help Window When Contents is selected, you can find how to use Help by pressing F1. The contents screen also has a series of buttons along its top: The Glossary button has topics that are specific (such as, Auto Mode Ramp Step).
Page 60: About M4000 For Windows
About M4000 For Windows About M4000 For Windows Selecting this item displays the current version of M4000 Software and firmware. Printer Setup The default printer setting for your M4200c Controller is for a thermal printer. This enables the use of the M4200c Controller's built-in printer. If using a laptop, you must use Windows to add in the necessary printer drivers for your office printers.
Page 61: Running M4000 Tests
3. Running M4000 Tests There are four test modes available with the M4000 software; all but Clipboard require optional software: • Clipboard Mode This is a generic form for recording and storing test results, nameplate information, weather conditions, test parameters, and notes, and is described below.
Page 62: Administrative Information
Administrative Information Entering this information is vital to properly identify the test and the equipment tested. Administrative Information Next to the Nameplate Section is an Administration button. When clicking this button, the following screen will appear: Figure 3.2 Administrative Information The following is an identification of these terms: Checked By The person who checked the results (if different from...
Page 63: Test Conditions
M4000 Insulation Analyzer User Guide Test Conditions Clicking on this button will show the following screen: Figure 3.3 Test Conditions The Weather is a pull down menu item with the selections accessed by clicking on the (down arrow icon). Entering Air Temperature and Humidity is unnecessary if using the Temperature Probe.
Page 64: Test Results Information
Select the desired choice. See “Test Modes Of The M4000 Analyzer, in the Doble Test Procedures manual. Kilovolts – this column indicates the test voltage, in thousands of volts, to be used during the test (for example, 10.00 means 10,000 volts).
Page 65 M4000 Insulation Analyzer User Guide Column Description Corr. Fact. Temperature Correction Factor. This column includes automatic application of temperature correction factors to the Clipboard Form. The default correction factor is 1.00. The Measured Percent Power Factor is multiplied by this Temperature Correction Factor to obtain the Corrected Percent Power Factor in the column to the right of the Corr.
Page 66: Running Single And Multiple Clipboard Tests
Test Conditions Running Single and Multiple Clipboard Tests Either single or multiple tests (up to six at once) may be run. Each row or line of the test form represents one test, and for each test, the following information should be entered into the appropriate columns: •...
Page 67: Raising Test Voltage
M4000 Insulation Analyzer User Guide Raising Test Voltage After making the necessary entries, the following screen appears: Figure 3.4 Safety Screen This screen shows the parameters that will be used when the test is run. Double-check the cable connections and test parameters. If the test parameters are not correct, click on the Abort button or press the ESC key.
Page 68: Test Results
Test Results Figure 3.5 Test in Progress The test will proceed automatically if Auto Ramp Mode is selected in the Clipboard Configuration, or will be ramped up by the operator if Manual Set Voltage is selected in the Clipboard Configuration. The digital values for these parameters will be shown to the right of the meters.
Page 69 M4000 Insulation Analyzer User Guide Figure 3.6 Test Complete There are choices listed at the bottom of the screen. An explanation of each key's function is as follows: Icon Description Pressing F1 will display “Screen Help” which is also available by clicking on this icon.
Page 70: Clearing Test Results
Clearing Test Results Icon Description Pressing F6 will “Discard Results” and returns you to the Clipboard Form. This is also available by clicking on this icon. Clearing Test Results After acceptance of tests, you can clear the test results by selecting Clear/Test Results from the Tools pull-down menu item, or, by pressing F10.
Page 71: Saving Test Results
Save As... item under the File menu. You will be prompted to select a file name. You may save in the selected folder (typically C:\doble\dta\data). Figure 3.8 Saving Clipboard As you add tests in Clipboard, you may want to periodically save the file to include added test data.
Page 72: External Reference/Source Test (Optional Software)
Running A UST Test 3. Click the icon. In the pop-up window, select whether you want a Histogram or a Trend. 4. If a Histogram is chosen, select the value you wish to plot. In Bins, select the number of ranges you wish to use to categorize your data, then click Draw.
Page 73 M4000 Insulation Analyzer User Guide 1. Select “External Reference” from “Mode” on the M4000 menu bar, or click the External Source icon. 2. There are two test types: UST Measure Blue and GST Guard Blue. Select UST Measure Blue from the Test Mode column. 3.
Page 74: Running A Gst-Guard Test
Running a GST-Guard Test 10. When the message, “Test Done, Line (x)”, where (x) is the selected line number, press the F5 key to accept results. The mA, Watts, Percent Power Factor, and Capacitance/Inductance is recorded on the clipboard sheet. 11.
Page 75 M4000 Insulation Analyzer User Guide 8. The M4000 is now ready to measure. The message “Set Test Voltage, Line (x), Then Press F3 To Measure”, appears (where (x) is the selected line number). 9. When you have set the external source to the desired voltage, press the F3 key.
Page 76: Leakage Reactance Test (Optional Software)
6. Click the Run a Test icon to start the test. For complete details of this test, including test setup and connections, see “Leakage Reactance Testing” in the Doble Test Procedures manual. Always exit Windows before shutting off your M4000 Insulation Analyzer.
Page 77: Dta Mode
M4000 Insulation Analyzer User Guide DTA Mode The remainder of this chapter describes how to run tests in the Doble Test Assistant (DTA) Mode. For a complete description of the DTA program, refer to the DTA Field System for Windows Users Guide. It is recommended that this manual be available for reference.
Page 78: Dta Data Manager
Figure 3.12 DTA Data Manager If you are using the windows version of DTA for the first time, the working directory may appear as “C:\DOBLE\DTA\DATA”. If you have been using the DOS version of DTA, your working directory is “C\DTA\DATA”. If you wish...
Page 79: Preparing For A Dta Test
Overall test form. 7. Connect the test cables to the apparatus to be tested. See the DTA test form for help in making the connections for the tests listed, or see the Doble Test Procedures manual. Starting a DTA Test 1.
Page 80 Running a GST-Guard Test 2. Start a test by clicking the icon, or by selecting from the Test menu, Run Test - M4000. The “Test Conditions” window will appear if you haven’t yet filled it in, with “Prb” in the air temperature field. This indicates that air temperature will be entered automatically by the M4000 Temperature and Relative Humidity Sensor.
Page 81 M4000 Insulation Analyzer User Guide Figure 3.13 Safety Screen 1. Select the “Abort” button to return to DTA and make changes. Make this choice if the test voltage needs to be changed. 2. Select the “Configure” button to change other test parameters, such as Frequency or Test Type.
Page 82 Running a GST-Guard Test The following screen will appear: Figure 3.14 DTA Test In Progress The test will proceed automatically. The test specimen’s current, watts loss, and voltage will be displayed in three analog meters (horizontal bars) on the screen. The digital values for these parameters will be shown to the right of the meters.
Page 83 M4000 Insulation Analyzer User Guide Figure 3.15 End of DTA Test 72A-1230 Rev. F 3-23...
Page 84: Dta Icons And Function Keys
Running a GST-Guard Test DTA Icons and Function Keys A list of function keys is displayed at the bottom of the screen after the test. In addition, a row of icons appears at the top of the screen. An explanation of each icon and key function follows: Selecting this icon or Does this…...
Page 85: Using A Resonator
1.0 microfarads at 60 Hz, and a range of 0.07-1.4 at 50 Hz. It is designed to extend the current range of Doble 10 kV Power-Factor Test Sets up to four Amps, assuming a lossless specimen, at voltages up to 10 kV. It extends the use of the set for testing relatively long cable lengths, large rotating machines, and other high-capacitance specimens.
Page 86: Operating Procedure Of Type C Resonating Inductor
Operating Procedure of Type C Resonating Inductor The Resonator, shown schematically in Figure 3.18, is contained in a metal housing measuring 24 x 17 x 15 inches, and weighs approximately 185 pounds. L adjustable from 7 to 140 Henries @60Hz. Counter dial calibrated per calibration chart supplied with each unit.
Page 87 M4000 Insulation Analyzer User Guide Accurate tuning of the Resonator is obtained by turning the tuning control until the current taken from the 120 volt supply is a minimum. To do this in the Clipboard test mode, follow this procedure: 1.
Page 88: General Description Of Type C-1 Coupler - Riv Test Procedure
Operating Procedure of Type C Resonating Inductor General Description of Type C-1 Coupler - RIV Test Procedure Recommended for M2H only. RIV (Radio-Influence Voltage) measurements may be of value in detecting corona on all types of insulation systems. One of the most common applications of RIV is with reference to rotating machinery insulation.
Page 89 M4000 Insulation Analyzer User Guide Note that the circuit in Figure 3.19 is so arranged that, when the telephone plug is removed from the Coupler, the lower terminal of the coupling capacitor is connected to the test-setguard circuit. In this way, the Coupler may be left connected for power-factor tests.
Page 90 Operating Procedure of Type C Resonating Inductor When the telephone plug is not connected to the Coupling Box, the lower terminal of the Coupling Capacitor is connected to the Test Set Guard Circuit. When the telephone plug is inserted into the receptacle, the Guard connection to the lower terminal of the Coupling Capacitor is removed and ground is applied to the low end of the 600 Ohm resistor via the barrel of the telephone plug.
Page 91: M4100 Instrument Troubleshooting
M4100 Instrument, continue through this chapter. If there is doubt as to the cause of a problem, proceed to the next page. Doble’s Customer Service staff is always available to support its customers if more guidance is required.
Page 92: Troubleshooting Resources
Troubleshooting Resources Table 4.1 Quick Checks: Can You Answer Yes To These Items: Item The communications cable is securely connected between the M4200c (or third-party controller) and the M4100. Both the M4200c and M4100 are turned on and connected to an active, stable power source, appropriately rated and grounded.
Page 93: Isolating Trouble
M4000 Insulation Analyzer is functioning properly. The Diagnostics should also be used to investigate potential causes of error messages. Test results should be sent to Doble if Doble assistance is being requested. Other Tests Certain relatively simple external and internal tests...
Page 94: Avoiding Problems
Avoiding Problems Table 4.3 Isolating the Problem Observation Suggested Action A numbered error message The M4100 is likely to be at fault. See appears in the display. ”Troubleshooting from Error Messages” on page 4-16. Also, click on Help for further guidance. An un-numbered error The M4200c is likely to be at fault.
Page 95: Detailed Troubleshooting Of The M4100 Instrument
M4000 Insulation Analyzer User Guide • Do not drop the instrument. • Do not bend or coil the High Voltage Test Cable too tightly, no smaller than a 12-inch diameter coil. • Do not use test leads for hoisting. • Do not drag the High Voltage Test Cable or other leads across the ground, particularly if the ground surface is crushed stone.
Page 96 Avoiding Problems Section Purpose Page Reference Overview of M4100 Get introduced to the M4100 page 4-7 Instrument Overview of Identify all customer-replaceable page 4-9 Individual components of the M4100 Replaceable Components Troubleshooting from Obtain detailed guidance on page 4-12 Symptoms troubleshooting, starting with observed symptoms of malfunction...
Page 97: Overview Of M4100
M4000 Insulation Analyzer User Guide Section Purpose Page Reference Amplifier Assembly page 4-63 Guard Mode Switch Board page 4-66 Timing Board page 4-68 DSP/CPU Board page 4-70 Safety Board page 4-72 Main Reference Assembly page 4-74 Guard Board page 4-76 Low Voltage Power Supply Board page 4-78 Heater/Temperature Controller...
Page 98 Avoiding Problems Figure 4.1 M4100 Block Diagram 72A-1230 Rev. F...
Page 99: Overview Of Individual Replaceable Components
M4000 Insulation Analyzer User Guide Overview of Individual Replaceable Components An overview of each of the instrument’s replaceable components is provided below. While a few other M4100 components exist, they are not field-replaceable. Front Panel Assembly The Front Panel Assembly includes all front panel-mounted components, including the 03D-1056 Guard Front Panel Board and the I/O...
Page 100 Avoiding Problems Safety Board The Safety Board latches off the Amplifier Assembly and opens the safety relays when 04D-0544 a potential operator safety hazard or hardware overload is detected. It also reports safety status and receives safety commands from the DSP/CPU Board. Main Reference Assembly The Main Reference Assembly stores calibration standard values used in...
Page 101 M4000 Insulation Analyzer User Guide I/O Protection Board The I/O Protection Board provides serial communications between the M4100 and 04D-0546 M4200c and interfaces with the safety strobe light, temperature/humidity sensors and safety switch. It also provides certain safety features under hardware and software control.
Page 102: Troubleshooting From Symptoms
Avoiding Problems Troubleshooting from Symptoms This section provides M4100 troubleshooting guidance based upon observed malfunction symptoms. Find the observed symptom in Table 4.4, and take the suggested action(s) to solve the problem. Table 4.4 M4100 Troubleshooting from Symptoms Symptom Suggested Action M4100 does not power up In a normal power-up sequence: properly...
Page 103 M4000 Insulation Analyzer User Guide Table 4.4 M4100 Troubleshooting from Symptoms (Continued) Symptom Suggested Action Cannot begin a test; the test 1. Isolate the cause by restarting a test after set trips, with an overcurrent alternately: error message • Disconnecting the High Voltage Test Cable from the M4100 •...
Page 104 Avoiding Problems Table 4.4 M4100 Troubleshooting from Symptoms (Continued) Symptom Suggested Action Instrument takes an 1. Check and clean connections to the unusually long time to make specimen. Use a clip lead between the a measurement or never High Voltage Test Cable and specimen stops ranging to insure good contact.
Page 105 See the paper in 1987 Doble Minutes on negative watts, page 2-501. Communications error If any of a variety of...
Page 106: Troubleshooting From Error Messages
Avoiding Problems Troubleshooting from Error Messages The M4000 Insulation Analyzer automatically recognizes certain exception conditions and displays corresponding error messages to the operator. Most error messages that pertain to the M4100 are numbered. These are described below. A complete list of all M4000 error messages appears in Appendix C. A few messages that point to very simple problems can be displayed, such as not having the M4100 turned on, not having it connected to the M4200c (or your laptop), or attempting to energize a specimen that is at ground potential.
Page 107 M4000 Insulation Analyzer User Guide Table 4.5 Error Messages (Continued) Error Message Suggested Action One or both safety 1. Clean all cable terminations. switch cables 2. If the problem persists, replace the I/O disconnected Protection Board (see”Replacing the I/O Protection Board” on page 4-83) 1.
Page 108 Avoiding Problems Table 4.5 Error Messages (Continued) Error Message Suggested Action Phase Lock Loop 1. If a portable generator is being used to Not Locked power the M4000, stabilize its output frequency by adding a load, such as a space heater, to load the generator. 2.
Page 109 M4000 Insulation Analyzer User Guide Table 4.5 Error Messages (Continued) Error Message Suggested Action One or Both Low 1. If this error is displayed during Voltage Leads Calibration Verification, rerun the test at Disconnected a temperature above freezing. 2. Clean all cable terminations. 3.
Page 110 Invalid Message Number communication to the M4100. Contact Doble for analysis and solution to this problem. To begin with, remove all but the M4000 program from your startup menu. 3. If you are using a laptop PC in place of the M4200c, select “Configuration”...
Page 111: Troubleshooting From Diagnostics
M4000 Insulation Analyzer User Guide Troubleshooting from Diagnostics The M4000 test set supports automated diagnostic tests that are useful in validating system operation and troubleshooting problems that may occur. Diagnostics should be run on a regular basis to ensure that the M4000 Insulation Analyzer is functioning properly.
Page 112 M4200c Controller (or laptop) and the M4100 Instrument. * When contacting Doble by telephone or e-mail (customerservice@doble.com), it will be helpful to have the results from these two tests, including the contents of the Calver.log file, located in the DTA directory.
Page 113: System Status
M4000 Insulation Analyzer User Guide Once the operator specifies a particular diagnostic test to run, the following function keys are available for use: Display Help contents Run the selected diagnostic Following are descriptions of each of the five Diagnostics tests that are applicable to the M4100.
Page 114 System Status Figure 4.3 System Status Test Results This test is passed when every item’s status is reported as Enabled. Any other result has the following implications: Guard Status Critical: This condition must be corrected before testing continues. Disabled Corrective Procedure: Replace the Guard Board and run the Field Recalibration Test.
Page 115 Corrective procedure: Refer to the foregoing results and run the Calibration Verification. * It may be possible to correct an ID PROM checksum failure without replacing the Guard Mode Switch Board; call Doble. ** Calibration dependent assemblies are: • - Guard Board •...
Page 116: Calibration Verification
Calibration Verification For a simple check of the M4000 Insulation Analyzer's measurement system, test the empty Doble Liquid Insulation Cell, energized at 5 kV. See ”Checking Instrument Accuracy in the Field” on page 4-43. A more comprehensive check can easily be performed in the form of the Calibration Verification.
Page 117 M4000 Insulation Analyzer User Guide Figure 4.4 Calibration Verification Initial Screen 2. Press F2. 3. Follow the on-screen directions, as shown in Figure 4.5. Figure 4.5 Calibration Verification Instructions Connections for the Calibration Verification are shown in Figure 4.6 and Figure 4.7.
Page 118 Calibration Verification Figure 4.6 Setup for Blue Resistor Test Figure 4.7 Setup for Red Resistor Test There is a test abort criterion described in the first test of each setup. The test abort allows the operator to correct a setup error and then restart from the point where the error was first detected, without losing successfully completed test information.
Page 119 M4000 Insulation Analyzer User Guide At the conclusion of the Calibration Verification, a summary table like that shown in Figure 4.8 will be displayed. Figure 4.8 Calibration Verification Results The summary table can be printed or saved as a text file. Both options are available on the File pull-down menu.
Page 120 Calibration Verification. The print option, if selected at the end of a test, prints only results from the test just completed. When a failure is encountered, Doble can provide troubleshooting guidance if needed. A copy of the Calver.log file, found in the DTA directory, is essential.
Page 121: Field Recalibration
M4000 Insulation Analyzer User Guide Field Recalibration Run this test if any of the Calibration Verification test ratings are Re-Cal or Fail. With the M4100 Field Calibration feature, calibration can be done in the field for 7 of the current ranges if the optional M4151 Field Calibration Reference is used, and for 3 ranges if the optional M4150 Field Calibration Reference is used.
Page 122 Field Recalibration For situations demanding more complete calibration, Doble offers the M4151 Field Calibration Reference. Using this option, seven current ranges can be checked and calibrated (leaving only the three high current ranges used with a resonator unchecked). The seven ranges tested by the M4151 are 300 µA, 1 mA, 3 mA, 10 mA, 30 mA, 100 mA, and 300 mA.
Page 123 M4000 Insulation Analyzer User Guide Figure 4.13 Field Recalibration Instructions The Field Adapter cable is an accessory cable which connects from the High Voltage Test Cable to the black connectors on the Field Calibration Reference. There is a test abort criterion described in the first test of each setup. The test abort allows the operator to correct a setup error and then restart from the point where the error was first detected, without losing successfully completed test information.
Page 124: Subsystem Diagnostics
Subsystem Diagnostics The summary table can be printed or saved as a text file. Both options are available on the File pull-down menu. Fieldcal.log File Upon completion of the Field Recalibration, the M4000 software creates a file named Fieldcal.log and stores it in the DTA directory. This file summarizes information on test aborts and test failures.
Page 125 M4000 Insulation Analyzer User Guide Figure 4.15 Subsystem Diagnostics Results Results can be printed either in brief or in full. To print the test results: 3. Select Print from the File menu. The screen shown in Figure 4.16 appears, allowing a choice of the level of detail to be printed.
Page 126 The printed test result resulting from a typical choice is provided in Figure 4.17. Such a printout is useful if the operator finds it necessary to consult Doble for assistance. 4-36 72A-1230 Rev. F...
Page 127 M4000 Insulation Analyzer User Guide Figure 4.17 Component Test Result, Subsystem Diagnostics 72A-1230 Rev. F 4-37...
Page 128: M4100 Component List
M4100 Component List M4100 Component List The M4100 Component List provides a listing of recognized system components, which is helpful in diagnosing certain problems. The listing characterizes each component as to its identity and calibration history. To generate this list: 1.
Page 129: Thermal Profile
M4000 Insulation Analyzer User Guide Thermal Profile The Thermal Profile diagnostic displays internal and external temperatures measured by the M4100. To monitor external parameters the Remote Sensor must be connected to the M4100. To run a Thermal Profile: 1. Select Thermal Profile from the Diagnostics pull-down menu. 2.
Page 130: Communications Loopback Test
This test verifies the serial link between the M4200c and the M4100 using two external Burndy connector pieces (male and female types) included in the Accessories Bag. If these connectors cannot be located, contact Doble (see items 29 & 30, page A-3).
Page 131 M4000 Insulation Analyzer User Guide Figure 4.21 Communications Loopback Test, First Result 2. Follow the directions provided in Figure 4.21, i.e., remove the test plug and connect the communications cable in its place, then attach the other test plug to the far end of the cable. Press OK to continue. A screen like that shown in Figure 4.22 will appear when the second test is complete.
Page 132: Running Other Tests
Checking the High Voltage Test Cable Running Other Tests Certain additional tests can be run without gaining access to the M4100 interior. Any of the following tests can and should be run based upon an indicated error message, symptom or diagnostic test result. Checking the High Voltage Test Cable Most of the difficulties encountered with the High Voltage Test Cable are of a mechanical nature, external, and easily identified.
Page 133: Checking M4100 Guard-To-Ground Insulation
Checking Instrument Accuracy in the Field In lieu of elaborate laboratory checks, it has been found that the Doble Liquid Insulation Cell, properly cleaned and dried, is a reliable standard that can be used in the field for a quick, simple accuracy check.
Page 134: Voltage Verification
Voltage Verification The characteristic charging current (capacitance) and watts-loss of the Liquid Insulation Cell should be measured whenever a new instrument or cell is received, and the test data should be recorded for future reference. The test connections and procedure are the same as for testing a liquid-insulation sample, except that the test is conducted in both the UST and GST modes.
Page 135 M4000 Insulation Analyzer User Guide • Select the Clipboard mode to perform the test and configure a test with the potential of 500V. The test must be performed in Manual mode, and any test circuit will do. • Raise the test voltage to 500V and record the DVM reading on the Calibration Verification Certificate.
Page 136: Accessing M4100 Components
Removing the Front and Top Covers Accessing M4100 Components Ensure that the AC power cable is disconnected prior to removing any of ANGER the M4100 covers. To avoid static discharge, ground yourself and the test set before handling any circuit boards. The following procedures require access to internal M4100 components: •...
Page 137 M4000 Insulation Analyzer User Guide The resulting top view of the instrument is as shown in Figure 4.23. Amplifier Assembly Low Voltage Power Supply Board (chassis ground) (under corner brace) Transformer (connected to guard) Card Cage Transformer Cover (chassis ground) Main Reference Assembly (connected to guard) Figure 4.23 M4100 Interior View...
Page 138: Removing The Card Cage Cover
Removing the Card Cage Cover Removing the Card Cage Cover The card cage cover must be removed to gain access to any of the following components: • DSP/CPU Board • Guard Board • Guard Mode Switch Board • Safety Board •...
Page 139 M4000 Insulation Analyzer User Guide Low Voltage Power Supply Board W8 Connector DSP/CPU Board W11 Connector Timing Board W9 Connector Safety Board Guard Mode Switch Board Guard Board connectors, lowvolt. power supply Figure 4.24 M4100 Card Cage When replacing boards, the board you need to remove may be underneath a cable attached to another board.
Page 140: M4100 Internal Checks
Fan Operation M4100 Internal Checks Certain internal checks can be performed quite easily, avoiding more complicated measures. Many of these checks can be done with the M4100 unpowered. A few require that AC power be applied with the covers off. If re-application of power is necessary to perform an internal check, ANGER follow the procedural instructions carefully to minimize the risk of...
Page 141: Low-Voltage Power Checkout
M4000 Insulation Analyzer User Guide Low-Voltage Power Checkout Outputs of the Low Voltage Power Supply Board are readily measured at test points accessible on the Heater/Temperature Controller Board (Figure 4.41 on page 4-80), which is mounted directly on the Low Voltage Power Supply Board.
Page 142: Lvps Fuses
LVPS Fuses LVPS Fuses The fuses for the Low Voltage Power Supply Board (LVPS) are located on that board. To access the board, remove the triangular metal plate from the left rear corner of the M4100. The Low Voltage Power Supply Board and Heater/Temperature Board Assembly (Figure 4.25) is then removed after disconnecting the cable from the top of the board.
Page 143: W8/W9/W11 Cable Checkout
M4000 Insulation Analyzer User Guide W8/W9/W11 Cable Checkout Check and reseat the W8, W9 and W11 cable connectors, which are identified in Figure 4.26. W8 Connector W11 Connector W9 Connector Figure 4.26 Card Cage 72A-1230 Rev. F 4-53...
Page 144: Orange Cable Checkout
Orange Cable Checkout Orange Cable Checkout Check the Orange Cable (Figure 4.27) for proper seating. It should not be shorting to the chassis, and its insulation should be intact. Amplifier Transformer (cover removed) Main References Assembly HV Pothead Field Calibration Reference box Orange Cable...
Page 145: W46 Cable Checkout
M4000 Insulation Analyzer User Guide W46 Cable Checkout The W46 cable is a 12-conductor cable with a white connector on each end. It is located on the Heater/Temperature Controller Board, which is mounted to the Low Voltage Power Supply Board. Take the following steps to check the W46 cable: 1.
Page 146: Replacing M4100 Components
If a replacement component is packaged in an anti-static bag, do not remove it from the bag until instructed to do so. Return all failed components to Doble. Replacement of an internal M4100 component requires removal of the instrument’s covers and may also require removal of the internal card cage cover.
Page 147: Returning Replaced Components
M4000 Insulation Analyzer User Guide Returning Replaced Components To gain full credit for a replaced component, it must be returned to Doble within 30 days of the replacement component’s delivery. To return a replaced component: 1. Complete the Material Return Tag supplied with the new component. The following entries are required: •...
Page 148: Removing And Replacing The Front Panel Assembly
Removing and Replacing the Front Panel Assembly Removing and Replacing the Front Panel Assembly The Front Panel Assembly is located on the front of the instrument. The Front Panel Assembly must be removed in order to replace it and to gain access to the Main Reference Assembly, the Guard Front Panel Board, and the I/O Protection Board.
Page 149 Then, use vise grip pliers to remove the binding screws if necessary. Later, when replacing the front panel, use new screws if available. These can be obtained from Doble if required. 8. Pull the Front Panel Assembly out only slightly. Then, disconnect the ribbon cable (W12) that attaches to the I/O Protection Board as well as the white cable (W11).
Page 150 Removing and Replacing the Front Panel Assembly Guard Front Panel Board I/O Protection Board HV Pothead Field Calibration Box Chassis Figure 4.30 M4100 Interior View, Front Panel Removed 10. To reinstall the Front Panel Assembly, first unpack the replacement unit (or locate the existing one).
Page 151: Replacing The Guard Front Panel Board
M4000 Insulation Analyzer User Guide Replacing the Guard Front Panel Board Note the location of the Guard Front Panel Board in Figure 4.30 on page 4-60. It is located immediately behind the Front Panel Assembly. Take the following steps to replace it: 1.
Page 152 Replacing the Guard Front Panel Board 6. Disconnect two connectors on cables W27 and W28. Each connector has three wires; W27 has one red and two black wires; W28 has one blue and two black wires. 7. Carefully lift the Guard Front Panel Board out, easing the wires through the holes.
Page 153: Replacing The Amplifier Assembly
M4000 Insulation Analyzer User Guide Replacing the Amplifier Assembly Note the location of the Amplifier Assembly in Figure 4.23 on page 4-47. Take the following steps to replace it: 1. If it has not already been done, remove the card cage cover. See ”Removing the Card Cage Cover”...
Page 154 Replacing the Amplifier Assembly Top Fan Screws Side Screws Figure 4.33 Amplifier Assembly, Additional Screw Locations 5. Remove two Phillips screws (Figure 4.33) holding the top cover of the amplifier and chassis in place using a Phillips-head screwdriver. 6. Disconnect the ribbon cable (W7) from the Guard Board, which is located in the card cage.
Page 155 M4000 Insulation Analyzer User Guide 11. Tighten one of the captive screws by inserting the 15”-long, flat-blade screwdriver into one of the notches at the top of the assembly, and reach down to tighten the screw. With the first screw in place, use your hands to push the assembly towards the opposite end (away from the screw).
Page 156: Replacing The Guard Mode Switch Board
Replacing the Guard Mode Switch Board Replacing the Guard Mode Switch Board Note the location of the Guard Mode Switch Board in Figure 4.24 on page 4-49 and in Figure 4.34 below. Take the following steps to replace it: 1. If it has not already been done, remove the card cage cover. See ”Removing the Card Cage Cover”...
Page 157 M4000 Insulation Analyzer User Guide 5. Remove the replacement Guard Mode Switch Board from its anti-static bag and guide it into the slot. Press down evenly on the insides of the PC extractors until the board is firmly seated. 6. Reattach the two ribbon cables to the board (W8 to J8 and W12 to J5). 7.
Page 158: Replacing The Timing Board
Replacing the Timing Board Replacing the Timing Board Note the location of the Timing Board in Figure 4.24 on page 4-49 and in Figure 4.35 below. Take the following steps to replace it: 1. If it has not already been done, remove the card cage cover. See ”Removing the Card Cage Cover”...
Page 159 M4000 Insulation Analyzer User Guide 4. Replace the card cage cover by reversing the steps in ”Removing the Card Cage Cover” on page 4-48. 5. Replace the top and front covers by reversing the steps in ”Removing the Front and Top Covers” on page 4-46. 72A-1230 Rev.
Page 160: Replacing The Dsp/Cpu Board
Replacing the DSP/CPU Board Replacing the DSP/CPU Board Note the location of the DSP/CPU Board in Figure 4.24 on page 4-49 and in Figure 4.36 below. Take the following steps to replace it: 1. If it has not already been done, remove the card cage cover. See ”Removing the Card Cage Cover”...
Page 161 M4000 Insulation Analyzer User Guide 5. Reattach the ribbon cable (W5) to the board. 6. Replace the card cage cover by reversing the steps in ”Removing the Card Cage Cover” on page 4-48. 7. Replace the top and front covers by reversing the steps in ”Removing the Front and Top Covers”...
Page 162: Replacing The Safety Board
Replacing the Safety Board Replacing the Safety Board Note the location of the Safety Board in Figure 4.24 on page 4-49 and in Figure 4.37 below. Take the following steps to replace it: 1. If it has not already been done, remove the card cage cover. See ”Removing the Card Cage Cover”...
Page 163 M4000 Insulation Analyzer User Guide 5. Reattach the three ribbon cables to the board (W4 to J1, W6 to J3, and W7 to J2). 6. Replace the card cage cover by reversing the steps in ”Removing the Card Cage Cover” on page 4-48. 7.
Page 164: Replacing The Main Reference Assembly
Replacing the Main Reference Assembly Replacing the Main Reference Assembly Note the location of the Main Reference Assembly in Figure 4.30 on page 4-60. Take the following steps to replace it: 1. If it has not already been done, remove the Front Panel Assembly. See Steps 1-8, ”Removing and Replacing the Front Panel Assembly”...
Page 165 M4000 Insulation Analyzer User Guide 5. Remove six screws, along with internal lock washers and flat washers, using a flat-blade screwdriver. These screws are located on the perimeter of the board (Figure 4.38). 6. With your fingers on the edges of the board, lift the board slightly, tilt it back, then lift it straight up and out.
Page 166: Replacing The Guard Board
Replacing the Guard Board Replacing the Guard Board Note the location of the Guard Board in Figure 4.24 on page 4-49 and in Figure 4.39 below. Take the following steps to replace it: 1. If it has not already been done, remove the card cage cover. See ”Removing the Card Cage Cover”...
Page 167 M4000 Insulation Analyzer User Guide 5. Remove the replacement Guard Board from its anti-static bag and guide it into the slot. Press down evenly on the insides of the PC extractors until the board is firmly seated. 6. Reattach the two connectors to the board (W9 to J2 and W9 to J3). 7.
Page 168: Replacing The Low Voltage Power Supply Board
Replacing the Low Voltage Power Supply Board Replacing the Low Voltage Power Supply Board Note the location of the Low Voltage Power Supply Board in Figure 4.23 on page 4-47. Take the following steps to replace it: Do not remove the replacement board from its anti-static bag until instructed to do so.
Page 169 M4000 Insulation Analyzer User Guide 6. Lift the board out. 7. Remove the replacement Low Voltage Power Supply Board from its anti-static bag and place it in the Instrument. 8. Reconnect the two cables and reposition any other cables previously moved as necessary.
Page 170: Replacing The Heater/Temperature Controller Board
Replacing the Heater/Temperature Controller Board Replacing the Heater/Temperature Controller Board The Heater/Temperature Controller Board is the green board attached to the Low Voltage Power Supply Board. Before replacing the Heater/Temperature Controller Board, you must first remove the entire, two-board assembly from the instrument.
Page 171 M4000 Insulation Analyzer User Guide 3. Release the two connectors leading to cables W45 and W46. 4. Remove the new Heater/Temperature Controller Board from its anti-static bag and position it onto the Low Voltage Power Supply Board. Place a spacer between the two components at each screw position. 5.
Page 172: Replacing The Optional Field Calibration Reference
Replacing the Optional Field Calibration Reference Replacing the Optional Field Calibration Reference The Field Calibration Reference, if present, is mounted to the instrument’s front panel. Take the following steps to replace it: 1. Unscrew four captive screws (Figure 4.42) using a Phillips-head screwdriver.
Page 173: Replacing The I/O Protection Board
M4000 Insulation Analyzer User Guide Replacing the I/O Protection Board Note the location of the I/O Protection Board in Figure 4.30 on page 4-60. Take the following steps to replace it: 1. If it has not already been done, remove the Front Panel Assembly. See Steps 1-8, ”Removing and Replacing the Front Panel Assembly”...
Page 174 Replacing the I/O Protection Board Ground Upper Left Standoff Figure 4.44 I/O Protection Board, Cable Connections 5. Carefully lift the I/O Protection Board off the Front Panel Assembly. 6. Unpack the replacement I/O Protection Board from its anti-static bag and place the new board onto the Front Panel Assembly.
Page 175: Replacing The Transformer
Replacing the Transformer Note the location of the Transformer in Figure 4.23 on page 4-47. Due to the vibration the instrument encounters in the field, Doble now recommends replacing the originally installed whiz nuts with elastic stop nuts. When replacing the Transformer, check to see if it is mounted using whiz nuts.
Page 176 Replacing the Transformer Screws Figure 4.46 Transformer Cover, Screw Locations on Side Panel • Remove four screws and washers, located on the top of the Transformer cover, using a flat-blade screwdriver • Lift the cover off. White grommets will come off with the cover. Keep all screws, washers, and grommets together in a safe place.
Page 177 M4000 Insulation Analyzer User Guide Whiz Nut Whiz Nut Figure 4.47 Transformer Mounting Nut Locations • Place the elastic stop nuts into position using a 15” screwdriver as a guide. Place a nylon washer, a metal washer, and then the elastic stop nut on the screwdriver (Figure 4.48).
Page 178 Replacing the Transformer Figure 4.49 Guiding the Transformer Mounting Nuts into Position • Use the 7/16” socket wrench to tighten the nuts. Do not overtighten them. 4. Remove the cover of the Main Reference Assembly. Do this by removing the two screws (Figure 4.50) using a Phillips-head screwdriver. Figure 4.27 on page 4-54 shows the instrument with the Main Reference Assembly cover removed.
Page 179 M4000 Insulation Analyzer User Guide Cover Screws Screws Figure 4.50 Main Reference Assembly, Screw Locations 5. Release the three connectors on cables W2, W3 and W4 (which lead to the Amplifier Assembly) by grasping them and pulling the cables away from the Transformer.
Page 180 Replacing the Transformer 12. Replace the cover of the Main Reference Assembly and secure it by replacing the screws using a Phillips-head screwdriver. Notice that there is a blue grommet attached to the cable that connects to the Guard Mode Switch Board. When replacing the screw that secures this cable, set the blue grommet into the notch on the Main Reference Assembly cover.
Page 181: Replacing The Hv Pothead
M4000 Insulation Analyzer User Guide Replacing the HV Pothead Note the location of the HV Pothead in Figure 4.30 on page 4-60. Take the following steps to replace it: 1. If it has not already been done, remove the Front Panel Assembly. See Steps 1-8, ”Removing and Replacing the Front Panel Assembly”...
Page 182 Replacing the HV Pothead Ground Screw Figure 4.52 HV Pothead, Ground Screw Location 4. Remove one screw and washer (Figure 4.52), that secure the ground wire and the power outlet wire to the side of the HV Pothead, using a Phillips-head screwdriver.
Page 183: Replacing The Fan Filter
M4000 Insulation Analyzer User Guide Replacing the Fan Filter Note the location of the fan filter in Figure 4.53. Inspect the filter from time to time to check for accumulated dust or scale. Take the following steps to replace it: 1.
Page 184: Replacing The Fan
Replacing the Fan Replacing the Fan The fan is part of the Amplifier Assembly, which is shown in Figure 4.23 on page 4-47. Take the following steps to replace it: 1. Remove the Amplifier Assembly from the instrument by following Steps 1-8 in ”Replacing the Amplifier Assembly”...
Page 185 M4000 Insulation Analyzer User Guide 9. Replace the Amplifier Assembly back into the instrument by following Steps 10-19 in ”Replacing the Amplifier Assembly” on page 4-63. Hot air exhausts from the fan outlet. Do not block it. 72A-1230 Rev. F 4-95...
Page 186 Replacing the Fan 4-96 72A-1230 Rev. F...
Page 187: Appendix A. M4000 Components Lists
Appendix A. M4000 Components Lists M4000 Insulation Analyzer Components that may be included with the M4000 Insulation Analyzer are as follows: Number Description 010-0097-01 Type M4200c Controller (optional) 010-0096-01 Type M4000 Instrument Case 02D-0024-02 Type M2 Cable, HV, 60 ft. 02C-5200-01 Liquid Insulation Cell (w/carrying case) 03D-1070-02...
Page 188: Accessory Bag
Accessory Bag Number Description Revision Level D 0 EA 181-0452 Power Cord, 6 ft. #14/3, Receptacle box 2 EA to Instrument & Controller 181-0499 Power Cord, 50 ft. #14/3 1 EA 181-0117 Cord, Adapter, 1EC320 to Nema5, 1 EA Receptacle box to female plug (for laptop) 05B-0430-01 P/A, Cable, Int-Con.
Page 189 M4000 Insulation Analyzer User Guide Number Description 09C-0614-01 Temp. & Humid. Sensor (old) (optional) 1 EA 03C-1318-01 Temp. & Humid. Sensor (new) 1 EA (optional) 05B-0492-01 Cable, Strobe Light (optional) 1 EA 05B-0493-01 Cable, Temp./Humid Sensor (optional) 1 EA 03C-1074-01 P/A, Box, Power Receptacle.
Page 190: Documentation Bag
Documentation Bag Number Description Revision Level C 0 EA 2FB-2464-01 Bag, Gray Document 1 EA 401-0051 Paper 8 3/4 x 100 ft. Thermal Bl 2 EA 903-0023 Paper Tube, 2 in x 9 1/2 in White 2 EA 401-0076 Software MS DOS 6 x 3.5 Fullman 1 EA 903-0026 Diskette Box M4000...
Page 191: Appendix B. Warranty
During the one year warranty period, DOBLE will repair or replace, at its option, any defective products or components thereof at no additional charge, provided that the product or component is returned, shipping pa paid, to DOBLE.
Page 192: Software Limited Warranty
AND THE USER MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. DOBLE warrants the disks on which the software product is furnished to be free from defects in materials and workmanship under normal use for a period of one hundred and twenty (120) days from the date of shipment from DOBLE.
Page 193: For Equipment Maintenance, Contact
M4000 Insulation Analyzer User Guide IN NO EVENT WILL DOBLE BE LIABLE TO PURCHASER FOR ANY DAMAGES, INCLUDING ANY LOST PROFITS, LOST SAVINGS, OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH SOFTWARE...
Page 194 For Equipment Maintenance, Contact: 72A-1230 Rev. F...
Page 195: Appendix C. Error Messages
Appendix C. Error Messages M4100 Instrument Run Time Error Messages This appendix lists the error messages displayed while using the M4000 Insulation Analyzer. Error # Description of Error Invalid Message Number Invalid Message Length Unsupported Message Test is Currently Running Not Enough Free Space in FLASH for Application Unused FLASH Did Not Program Properly...
Page 196 Error # Description of Error Unused Internal Amp Cable Disconnected One or Both Safety Switch Cables Disconnected Power Amp Power Bad Overcurrent on Power Amp Output Power Amp DC Supply High Power Amp DC Supply Low M4000 Synchronization Error Phase Lock Loop Not Locked Strobe Cable Not Plugged In Strobe Not Flashing 42 - 49...
Page 197 M4000 Insulation Analyzer User Guide Error # Description Of Error Application file is corrupted Error downloading application Error programming FLASH ROM. application not found in FLASH. M4100 FLASH ROM has been corrupted Unable to open M4100 Firmware file. Tests cannot be run M4100 Firmware file is corrupted.
Page 198 Error # Description of Error Error Accessing Comm. Port Xmodem Exception User Keyboard Abort File I/O Error Xmodem Protocol Error Widetrack Rx Not On Shared-Interrupt Parameter Wrong Crc Mode Error Modem Didn’t Send Ok No Modem Response Function Not Supported Illegal Baud Rate Illegal Parity Illegal Word Length...
Page 199 M4000 Insulation Analyzer User Guide Error # Description of Error Board slot not found Illegal stop bits Illegal word length Illegal parity setting Timed out Function not supported Handshake Line in use Port Settings failed Windows OS error COM Port not found COM Port in use 72A-1230 Rev.
Page 200 72A-1230 Rev. F...
Page 201 Appendix D. Part Numbers Doble part numbers of replaceable M4100 components are provided in this appendix. Description Part Number Front Panel Assembly 03D-1056 Guard Front Panel Board 04D-0536 Amplifier Assembly 03D-1055-01 Guard Mode Switch Board 04D-0551 Timing Board 04D-0533 DSP/CPU Board...
Page 202 72A-1230 Rev. F...
Page 203 Laptop Use 1-16 Diagnostics 4-21 Leakage Reactance Disconnecting Leads 1-26 Interface 1-9 Display mode 2-15 Test 3-16 Doble ship to address 1-18 Line Frequency Modulation 2-14 Downloading firmware 2-1 Line Sync Reversal 1-2, 2-15 Log Files Configuration 2-16 Calver.log 4-29 Test mode 3-17 Fieldcal.log 4-34...
Page 204 Index Moving mode 1-11 Time/Date format 2-6 Trapped Charges 1-22 Troubleshooting Common user errors 4-1 Guide 4-2 Connector Cable 1-16 HV Cable 4-42 Requirements 1-16 Liquid Insulation Cell 4-43 Printer setup 2-22 LV leads 4-42 M4100 Diagnostics 4-21 M4100 Instrument 4-5 Ramp mode 2-14 M4100 or M4200c? 4-3 Recalibration 4-31...

This manual is also suitable for:

M4200c M4100 M4300 M4150 M4151

doble M4000 series User Manual

1 Introduction

2 M4000 Software

3 Running M4000 Tests

4 M4100 Instrument Troubleshooting

Appendix A. M4000 Components Lists

Appendix B. Warranty

Appendix C. Error Messages

Quick Links

Troubleshooting

Related Manuals for doble M4000 series

Summary of Contents for doble M4000 series

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Table of Contents