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Microtest 6235 User Manual

3 in 1 transformer comprehensive tester
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User Manual
3 in 1 Transformer Comprehensive Tester
6235+7721+7605
S/W Ver
Firmware Ver
Date
1.0
APR 2020

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Summary of Contents for Microtest 6235

  • Page 1 User Manual 3 in 1 Transformer Comprehensive Tester 6235+7721+7605 S/W Ver Firmware Ver Date APR 2020...
  • Page 2 Microtest Corporation will be responsible for repairing or replacing products proven to be flawed (MICROTEST will test whether the product was flawed or not) during the warranty period. Microtest Corporation guarantees that the software and hardware used with the instrument can execute their program instructions once they are properly installed on the instrument.

  • Page 3: Table Of Contents

    Precautions before booting up ..............12 Operation ....................12 Chapter 3. 6235 System Settings ................12 7605 System Settings ................14 6235 test item creation ................14 3.3.1 Entering the main menu of test items ..........15 3.3.2 WINDING/FIXTURE editing description ........16 3.3.3 SEQUENCE / BIN editing description ........

  • Page 4: Chapter 1. Precautions

    Precautions Chapter 1. This tester outputs voltage as high as 6000V DC for external testing; accidents will happen if this tester is used incorrectly or improperly. Therefore, in consideration of your own safety, please read the precautions described in this chapter carefully and memorize them in order to prevent accidents from occurring.

  • Page 5: Connect The Testing Cable To The High Voltage Output Terminal

    1.5 Connect the testing cable to the high voltage output terminal While the tester is powered off, insert the high voltage testing cables to the high voltage output terminals on the tester respectively, and confirm that the exteriors of the testing cables are not ruptured or shed. 1.6 Warm up The tester can operate normally once the power is turned on;...

  • Page 6: Chapter 2. Start

    Start Chapter 2. 2.1 Setting process Start Machine Installation and Wiring 6235 tester and fixture connection 7721 tester and fixture connection 6235 corresponding settings and test item creation 7721 test item creation Using fixtures to perform component characteristics test Using fixtures to perform...

  • Page 7: How To Set The Hardware Architecture

    Comprehensive Tester The three-in-one transformer comprehensive tester mainly consists of the three instruments 6235, 7721 and 7605, and the F7721 high/low voltage test fixture; the following will describe how to connect the accessories in order. Figure 2-2-1 Full front view of the 6235, 7721 and 7605 tester...
  • Page 8 6235, 7721 and 7605 front wiring description: (Please refer to Figure 2-2-1) This is the four-wire measuring connector of 6235; please connect the four-wire measuring fixture connector at the end of the F7721 fixture Test Line here. 7721 high voltage output port; use the dedicated high voltage cable...
  • Page 9 6235, 7721 and 7605 rear wiring description: (Please refer to Figure 2-2-2) Handle: 6235 control cable port; please use the included RJ-45 cable from our company and connect this port to the Remote Control port on the F7721 fixture. RS-232: 7721 communication port; please connect the RS-232 cable included from our company to this port, and connect the other end to the RS-232 communication port of 7605.
  • Page 10 Full view of the Dedicated Fixture Box for the Three-in-one Transformer Comprehensive Tester ⚫ F7721: Transformer fixture. Figure 2-2-3 Top view of the F7721 transformer test fixture...
  • Page 11 Foot Switch: Foot switch connector. (This can only be used by purchasing the dedicated foot switch from our company) Remote Control: 6235 control cable port; please use the included RJ-45 cable from our company and connect this port to the Handler port on the rear panel of 6235.
  • Page 12 DC24V: Please connect the dedicated adapter connector included from our company here.

  • Page 13: Precautions Before Booting Up

    Operation Chapter 3. 3.1 6235 System Settings Press the Menu control key and the main menu will be displayed on the screen. Press System to enter system settings; the up and down keys can be used to select the item to change, as shown in Figure 3-1-1.
  • Page 14 5. Trigger delay: Trigger delay time setting. 6. Display test data: Test result display setting. a. All Steps: Display all test data. b. Fail Steps: Only display test failed data. 7. Display font: Display font size setting. a. Small: Set small font size. b.

  • Page 15: 7605 System Settings

    7721 and then sent to 7605 through RS-232. When operating the machine individually, please refer to the 7605 manual. 3.3 6235 test item creation After setting the system settings of each machine, you can start editing all test items to...

  • Page 16: Entering The Main Menu Of Test Items

    First press the Set key on 7721, and then select comprehensive test to enter the comprehensive test programming Next, press the Set key on the front panel of 6235, and the screen will display the function setting menu, as shown in Figure 3-2-2.

  • Page 17: Winding/Fixture Editing Description

    3.3.2 WINDING/FIXTURE editing description WINDING/FIXTURE: Sets the corresponding positions of the transformer pins and fixtures, as shown in Figure 3-3-2-1. Figure 3-2-2-1 Transformer Fixture / Winding Setting Description: Transformer Fixture Setting: Sets the corresponding positions of the transformer pins and fixtures. TF Pin: Transformer pin;...

  • Page 18: Sequence / Bin Editing Description

    Figure 3-2-2-2 3.3.3 SEQUENCE / BIN editing description Teat Sequence Setting: Sets the test order and whether to test that test item, as shown in Figure 3-3-3-1. Figure 3-3-3-1 Teat Sequence Setting Description: : Moves the test item highlighted by the cursor one item up. : Moves the test item highlighted by the cursor one item down.
  • Page 19 BIN Sort Setting: Component classification determination function setting; select SET BIN to enter the BIN Sort Setting screen, as shown in Figure 3-3-3-1 below. There are four classification settings: Equal, Sequential, Tolerance and Random. The quality of the components is determined based on the conditions you set. Figure 3-3-3-1 BIN Sort Setting Description: BIN function: Component classification test item setting;...
  • Page 20 ⚫ Equal: Equal distribution of levels. As shown in Figure 3-3-3-2 below, four classification levels are used for explanation; users only need to set the maximum and minimum limits (BIN 1 and BIN 4 Limit), and the system will automatically distribute the levels BIN 1 - BIN 4 equally based on your settings.
  • Page 21 ⚫ Tolerance: Uses error value to set the levels. As shown in Figure 3-3-3-5 below, three levels are used for explanation; users must first set the Nominal value, and then select Prog to enter and set the positive and negative error values for the levels of each segment (as shown in Figure 3-3-3-6).
  • Page 22 ⚫ Random: Allows users to use random and irregular settings for levels. As shown in Figure 3-3-3-7 below, three levels are used for explanation; first select Prog to enter and set the BIN range. Users can freely set the range of levels BIN 1 - BIN 3 (Figure 3-3-3-8).

  • Page 23: L/Lk/Q/Rac/Z/D/Ø/X/Y Test Item Editing Description

    Limit mode: BIN (level) maximum and minimum limit setting mode; they both have two modes Abs and %. Abs: Absolute value mode; values will be used for setting when setting BIN Limit. ％: Percentage mode; the Nominal (nominal value) setting field will appear after selecting this mode (as shown in Figure 3-3-3-9).
  • Page 24 L/Lk/Q/Rac/Z/D/Ø/X/Y Setting Description: Wind: Test coil group setting; select the Wind function key to the left to enter settings. Function Key Descriptions: Wind: Pressing this function key allows selecting previously set coil groups; you only need to select the coil group to test. Meas: Measure key;...
  • Page 25 Std: Sets the nominal value as shown in Figure 3-3-4-3; use the Meas key to measure and acquire the nominal value, press the Accept key to save this test value, and Quit discards this test value entry. Figure 3-3-4-3 Max: Sets the maximum limit of the nominal value, as shown in Figure 3-3-4-4. It is set using the % key.

  • Page 26: Rdc Test Item Edit Description

    3.3.5 Rdc test item edit description Rdc Test Setting: DC resistance test item setting; the setting screen is as shown in Figure 3-3-5-1. Figure 3-3-5-1 Rdc Test Setting Description: Wind: Pressing this function key allows selecting previously set coil groups; you only need to select the coil group to test.

  • Page 27: Turn Ratio Test Item Editing Description

    3.3.6 Turn Ratio test item editing description Turn Ratio Setting: Turn ratio test setting; the setting screen is as shown in Figure 3-3-6-1. Figure 3-3-6-1 Turn Ratio Setting Description: Wind: Pressing this function key allows selecting previously set coil groups; you only need to select the coil group to test.

  • Page 28: C Test Item Editing

    3.3.7 C test item editing Capacitance Test Setting: Parasitic capacitance test item setting; the setting screen is as shown in Figure 3-3-7-1. Figure 3-3-7-1 Capacitance Test Setting Description: (※The other function settings will only be displayed after entering pin+) Wind: Pressing this function key allows selecting previously set coil groups; you only need to select the coil group to test.

  • Page 29: Balance Test Item Editing Description

    3.3.8 BALANCE test item editing description Balance Test Setting: Coil balance test item setting; the setting screen is as shown in Figure 3-3-8-1. Figure 3-3-8-1 Balance Test Setting Description: RefA: Sets the reference coil A. Move this and the Wind selection key will appear at the top-left of the screen;...

  • Page 30: Pin Short Test Item Editing Description

    3.3.9 PIN SHORT test item editing description Pin Short Test Setting: Transformer short-circuit test item; the setting screen is as shown in Figure 3-2-12. Figure 3-2-12 Pin Short Test Setting Description: Pin+: Sets the positive pin of the transformer coil you want to short-circuit; set using the number keys.

  • Page 31: Correction Fixture Correction

    3.3.10 CORRECTION fixture correction Correction: Fixture error correction test; the purpose of the correction is to eliminate the errors caused by the parasitic capacitance or series impedance on the fixture or testing cable; the correction screen is as shown in Figure 3-3-10-1. The data after the correction and reset will be saved in the flash memory of the instrument;...

  • Page 32: Deviation Error Compensation Setting Description

    3.3.11 DEVIATION error compensation setting description Complete Deviation: Uses GOLDEN SAMPLE as the standard to perform error compensation setting and compensates the measured value to the value you identified; the setting screen is as shown in Figure 3-3-11-1 below. Figure 3-3-11-1 Complete Deviation Setting Description: ※This compensation setting requires placing the GOLDEN SAMPLE in the F7721 testing fixture.

  • Page 33: 7721 And 7605 Test Item Setting

    3.4 7721 and 7605 test item setting 3.4.1 Layer short-circuit and high voltage tester setting Before performing setting, first confirm whether the instruments 7721, 7605 and the F7721 three-in-one testing fixture are properly connected. The following is a brief explanation of the test item settings for 7721 and 7605. Figure 3-4-1-1...
  • Page 34 7721 Setting Description: Confirm whether the 7605 high voltage output safety plug is properly plugged in before performing tests; if the plug is not plugged into the high voltage output safety seat, no high voltage can be outputted and the string H I - POT LOCK will appear on the screen.
  • Page 35 ⚫ Mapping: Test steps; displays the test step currently used. The test item and order can be set. Pin mapping sets the correspondence between the fixture and the DUT. ⚫ Insulation Test Setting: Voltage: This item sets the test voltage size; use the number keys to perform setting.
  • Page 36 Hipot Test Setting: V/Freq: This item sets the test voltage size and frequency; the voltage setting can be performed using the number keys. The maximum voltage that can be set is AC 3.0kV and DC 3.0kV, and the minimum voltage is 0.1kV. After setting the voltages, press the down direction key to move the cursor to frequency, where the select key can be used to select the frequency needed.
  • Page 37 The mode can be selected by pressing Mode on the setting screen. ⚫ WIRE: Winding check used to check whether each WIND is conducted as set; it can check whether WIND has disconnected or has connection errors. ⚫ L,LK,Rdc,TR,C: Test modes; enter comprehensive test programming for 6235 to set test items.

  • Page 38: Test Program Data And Statistical Data Storage Management

    3.5 Test program data and statistical data storage management Your test data will be saved in the 6235 and 7721 testers according to the different test items of each instrument; 7605 does not have the function to keep statistics for test data.

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