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Voltech AT3600 User Manual

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Page 2 AT3600 Automatic Transformer Tester User Manual  Voltech 2000-2008 Voltech Instruments VPN 98 - 024 V17...
Page 3 OLTECH ERIES ANUAL Voltech Instruments are committed to a policy of continuous product development. Hence, product specification and the information given in this manual are subject to change without notice. No part of this publication may be produced, stored in a retrieval system, or transmitted in any form, or by means electronic, mechanical photocopying, recording or otherwise without prior written permission of Voltech Instruments.
Page 4: Table Of Contents
AT3600 U OLTECH ANUAL ABLE OF ONTENTS 1. I NTRODUCTION 1. Introduction ....….........1.1.1 2. AT3600 Features Summary …….…….…….....1.2.1 3. Overview ………..…........1.3.1 2. G ETTING TARTED 1. Introduction ....…........2.1.1 2. Installing the AT3600..…....………………..2.2.1 3. Quick Start Tutorial ...……........2.3.1 4. Firmware Upgrades ..…..…......2.4.1 3.
Page 5 AT3600 U ABLE ONTENTS OLTECH ANUAL AT3600 U OLTECH ANUAL ABLE OF ONTENTS ONTINUED 6. F RONT ANEL PERATION 1. Introduction .……………....…......6.1.1 2. Self Test ………..……......….…....6.2.1 3. Execute Mode ………….…....…....6.3.1 4. Fixture Compensation..…........6.4.1 5. Measure Mode ………..…........6.5.1 6. Program Mode …..…..........6.6.1 7.
Page 6: Table Of Contents
AT3600 Tester. 1. I NTRODUCTION 1. H …..….........1.1.1 OW TO ANUAL 2. G ….........1.1.2 ENERAL AFETY NSTRUCTIONS 3. P ..….…...…......1.1.3 ACKAGE ONTENTS 4. P ………………………………...1.1.3 RODUCT DENTIFICATION 2. AT3600 F EATURES UMMARY ……...….......…...….….......1.2.1 3. O VERVIEW ……………………..….....…......1.3.1 VPN 98-024 NTRODUCTION...
Page 7 AT3600 U ABLE OF ONTENTS OLTECH ANUAL VPN 98-024 NTRODUCTION...
Page 8: Introduction
Voltech reserves the right, however, to change the operation or specification of the AT3600 tester without notice. No liability is accepted for the inappropriate, negligent, or incorrect set-up of the AT3600 tester by the user, by either manual or automated means. The Voltech AT3600 is protected by the following patents:...
Page 9 WARNING: The AT3600 wound component tester can generate voltages that may be LETHAL. The safety interlock is designed to ensure the safety of operators when used with a Voltech approved safety system. To ensure operator safety, this interlock must always be properly connected to a Voltech approved safety system.
Page 10 1.4. AT3600 The AT3600 is one of a family of automatic testers from Voltech that share the same fixture construction and PC editor and server software. ATi’s and AT3600’s can share the same server application, simultaneously recalling test programs and recording test results.
Page 11 7000V Also available for the AT3600, the Voltech 'AC Source Interface' extends the possible test range of the AT3600 test signal generators up 600V, 10A when used with a suitable external supply. Over 35 different tests are available for the AT3600. Check our website at www.voltech.com for details of new tests.
Page 12: At3600 Features Summary
EATURES UMMARY Your AT3600 tester is designed for fast, accurate and reliable testing of transformers and other wound components in a production or goods inwards environment. However, it is a complex instrument with many ways in which it can be set up and used.
Page 13 ROGRAM RCHIVE ANAGEMENT • Windows based Server software for easy management of all test programs. (Chapter 4.) • Optionally, programs may be resident in the AT3600 Tester for stand-alone operation. 1.2.2. VPN 98 - 024 NTRODUCTION...
Page 14 AT3600 U AT3600 F OLTECH ANUAL EATURES UMMARY PERATION • Manual or robotic operation • Barcode input • Footswitch input • Simple PASS / FAIL operation by an unskilled operator • Safe – Light barrier controlled power isolation prevents operator injury from high voltages.
Page 15: Overview
VERVIEW The next section gives a more detailed overview of your AT3600 Tester and how to use it. It is recommended that you read this section before attempting to use your tester.
Page 16 ANUAL VERVIEW AT3600 O VERVIEW OPICS OVERED IN THIS VERVIEW • The features and functionality of the AT3600 tester. • Internal functionality. • How the tester executes each test. • What appears in a test program. • How programs are created, archived and then used in actual test.
Page 17 RONT ANEL The internal functionality of the AT3600 tester is summarized in the following figure: You do not need to know how each block functions in order to use the tester. The following explanation is included for readers who wish to know more.
Page 18 The processors select which one is to be connected to the relay matrix, as each test is executed. Measurement Circuits The AT3600 tester contains a variety of circuits, capable of performing all the following measurements: • Voltages from less than 1mV to greater than 7000V, •...
Page 19 AT3600 U VERVIEW OLTECH ANUAL AT3600 T ESTER UN A Because the programming of each test is done at a high level, it is not strictly necessary for you to know the details of how tests are executed within the tester.
Page 20 AT3600 U OLTECH ANUAL VERVIEW REATING ROGRAMS DITOR The test program is simply the list of tests that you wish to apply to your transformer. Clearly individual transformers will each have their own program, but as an example, a typical program for a three winding switch-mode power supply transformer could...
Page 21 ‘production’ use. This is the function of a second PC program supplied with your AT3600. Usually, the Server would be installed on a PC with access to a large disk, which could be attached to the PC itself, or connected via a network.
Page 22 Directly from the Editor using ‘Save As’ to the directory used by the Server for programs XECUTING ROGRAMS Within your establishment, there are many ways in which an AT3600 and Server may be installed and used. Large Production Facility The standard installation in a large production facility could use several testers,...
Page 23 AT3600 U VERVIEW OLTECH ANUAL Advantages • Convenient storage and management of large numbers of test programs (e.g. >1000). • Easy storage and management of test results. • Importing results into other Windows applications for analysis. • The Server PC could be located away from the test area, for example in a supervisor’s office, allowing results analysis to be performed where it...
Page 24 AT3600 U OLTECH ANUAL VERVIEW Advantages • Requires only occasional use of a PC (which could be a portable) to develop test programs and load them into the AT. • Test programs can be executed by the AT without the PC attached, which may be of advantage if the working space is limited.
Page 25 PERATING THE ERIES ESTERS IN RODUCTION The AT3600 has been designed to work in both manual and robotic production situations. Manual Use In manual use, the tester is simply placed on a work surface in front of the operator. The tester may be connected to a Server PC, or used stand-alone as described previously.
Page 26 AT3600 U OLTECH ANUAL VERVIEW Robotic Situations In robotic situations, the tester's Remote Port provides the following signals for connecting into your system: input PASS output STOP input FAIL output BUSY output BEEPER output Robot Controller Remote Port Again the tester may be connected to a Server PC, or used stand-alone as described above.
Page 27 ANUAL PERATOR AFETY The AT3600 is capable of generating high voltage test signals that could cause operator injury. The AT3600 design includes a Safety Interlock connector on the rear panel. The safety interlocks must be properly connected before any high voltage test is allowed to execute.
Page 28: Getting Started
In a robotic situation, this could take the form of a walled off area with the interlocks in the door. ETTING TARTED The quick start tutorial of Chapter 2 will take you through many of the AT3600 features using a step by step approach to creating and using a program. VPN 98 - 024 1.3.13.
Page 29 AT3600 U VERVIEW OLTECH ANUAL 1.3.14 VPN 98-024 NTRODUCTION...
Page 30: Introduction
2 – G HAPTER ETTING TARTED ABLE OF ONTENTS This chapter will guide you through the process of setting up and becoming accustomed to basic aspects of the AT3600 tester and its associated software. 1. I NTRODUCTION ………………........…......2.1.1 2. I AT3600 NSTALLING 1.
Page 31 AT3600 U ABLE OF ONTENTS OLTECH ANUAL VPN 98 - 024 ETTING TARTED...
Page 32 OLTECH ANUAL NTRODUCTION 1. I NTRODUCTION Welcome to the Voltech AT3600 transformer tester, and its associated editor and server software packages. Once installed: • The AT3600 will enable you to rapidly, accurately and reliably test wound components in your production or goods inwards environment.
Page 33 AT3600 U NTRODUCTION OLTECH ANUAL 2.1.2. VPN 98 - 024 ETTING TARTED...
Page 34 7. This AT3600 user manual. 8. Calibration certificate. 9. A Voltech product registration card. Please report any missing items to your Voltech supplier. Returning your product registration card will ensure that you continue to receive the latest product and application information.
Page 35 AT3600 from producing harmful voltages. For full operation of the testers with high voltage tests, the safety interlocks must be properly connected to a Voltech approved safety system - see Chapters 8 and 10 of this manual.
Page 36 Connect the tester's auxiliary port to a spare COM port on the PC as shown. The cable that is used will be determined by the type of PC connector. For most PC’s this will be a 9-pin female (PC) to 9-pin female (AT3600). Switch on the power supply to the PC...
Page 37 ORT CONFIGURATION When the installation of the Editor has been completed, you will see the Editor icon in the program group ‘Voltech Software’. Double-click with the left mouse button on the Editor icon to start the program. Initially configure the Editor to use the chosen COM Port: 1.
Page 38 AT3600 U OLTECH ANUAL NSTALLING ESTER 2.5. S ERVER ARDWARE CONNECTIONS In some applications, you may wish to position the Server PC some distance away from the tester, which will require a cable longer than the one supplied. The AT Series Server Port connector details are shown in Chapter 8 to enable you to make up a cable of the length you require.
Page 39 ERVER SOFTWARE SET UP When the installation of the Server has been completed, you will see the Server icon in the program group ‘Voltech Software’. Double-click with the left mouse button on the Server icon to start the program. Before you can use the Server, the PC communication channels must be assigned for each tester connected.
Page 40 AT3600 U OLTECH ANUAL NSTALLING ESTER The final stage of setting up the server involves specifying the file location paths. The directory setup dialogue will prompt you with the current directory. Change these settings if you wish to nominate your own program and results storage directories.
Page 41 AT3600 U NSTALLING THE ESTER OLTECH ANUAL 2.2.8. VPN 98 - 024 ETTING TARTED...
Page 42 UICK TART UTORIAL After you have installed the AT3600, together with the editor and server software packages as described in the previous section you may wish to follow through this tutorial before trying to create any programs for actual use.
Page 43 AT3600 U UICK TART UTORIAL OLTECH ANUAL Having started the editor program by double-clicking with the left mouse button on the editor icon, the first thing to do is to ‘draw’ a schematic of the transformer to be tested. Using the left mouse button, click on ‘Schematic’ on the Top Level menu bar, and select ‘Add Winding’...
Page 44 AT3600 U OLTECH ANUAL UICK TART UTORIAL Now you must connect the windings to the test nodes of the tester: Place the mouse pointer over terminal A; press and hold the right mouse button. Continue holding this mouse button down and drag the mouse pointer to test node 9.
Page 45 The schematic window showing the two windings. Right: The available tests window listing all the tests available on your AT3600. (If the tester is connected all unavailable tests will be greyed out). Lower left: The Program window displaying the tests programmed so far.
Page 46 AT3600 U OLTECH ANUAL UICK TART UTORIAL By double clicking the left mouse button, select ‘R Winding Resistance’ from the ‘Available Tests’ window. The following dialogue box will appear. Initially enter the terminal names. Input ‘A’ as the high terminal and ‘B’ as the low terminal, moving between the fill-in boxes using the TAB key.
Page 47 AT3600 U UICK TART UTORIAL OLTECH ANUAL (The ‘Ohm’ units button is selected by clicking with the mouse.) If the "User Offset Enabled" check box is checked, a value can be entered into the edit box. The value entered (in the units shown) is then added to any results returned from the AT tester.
Page 48 AT3600 U OLTECH ANUAL UICK TART UTORIAL The "User Offset Enabled" check box has the same function as before but in units of inductance. Click on the ‘OK’ button. Again the test and its parameters will appear in the ‘Program’ window.
Page 49 AT3600 U UICK TART UTORIAL OLTECH ANUAL The "User Offset Enabled" check box has the same function as before but in units of turns ratio. Click on the ‘OK’ button. Again the test and its parameters will appear in the ‘Program’...
Page 50 Voltage. Having created both the transformer schematic and the test program, the program is now ready to run on your AT3600 tester under the control of the Editor. Before proceeding further, make sure that the interface cable between the tester's Auxiliary Port and the selected PC COM port is correctly fitted, and that the COM Port is correctly configured in the editor (see page 2.2.5).
Page 51 AT3600 U UICK TART UTORIAL OLTECH ANUAL The front panel of the AT will now display: This allows the program to be stored on the AT by pressing the soft key next to 'LOCAL SAVE'. See section 2.3.4. for a description of running the program on the transformer tester.
Page 52 UTORIAL If no transformer is fitted, the results will have no meaning, but you have now successfully installed the AT3600 and the Voltech AT editor software. The results window will give you the options to: 1. Print the test results.
Page 53 EPARATE In many situations the Editor and Server would be installed on separate PC’s (as shown in the illustration on page 2.2.2). In this situation, the AT3600 is used to perform the transfer. Before proceeding further, make sure that all the following have been set up: •...
Page 54 Click on the OK button to close the dialogue box and save the test program in the Server program directory. The next section of the Tutorial demonstrates running the program on the AT3600 tester from the archive on the Server. Before proceeding to that section, if the Server...
Page 55 Having stored the program in the server archive, it is now possible to run the program on your AT3600 in the same way that you would use in production test. (If you do not intend to use the server see also section 2.3.4 - Additional topics to investigate).
Page 56 AT3600 U OLTECH ANUAL UICK TART UTORIAL Before running any new test program, return the tester to the top-level menu by pressing the FINISH soft-key (i.e. the 2nd soft-key from the top). Use the following sequence of key-presses to ensure that the AT is configured to use the Server as the source for test programs: •...
Page 57 If the list of programs fails to appear after a few seconds, check that the server is running and that the COM port and file folder are correctly configured. Is the cable from the AT3600’s server port to the PC fitted correctly? Use the...
Page 58 AT3600 U OLTECH ANUAL UICK TART UTORIAL • As the fixture is already fitted, and compensation is not required with the example transformer, simply press the NO COMP. soft-key to move on to the RUN-FINISH display: • Press the RUN soft-key to start program execution.
Page 59 This is the end of the step-by-step tutorial, which forms only a very brief introduction to the features available on your AT3600. Please study and browse through the rest of this manual (or the on-line help for the Windows software) to get the best from your transformer tester.
Page 60 ROGRAMS NSIDE ESTER The AT3600 contains memory for the storage of test programs. The programs are stored even when the tester is switched off. Once a program is stored, the tester may be used without PC editor or server software.
Page 61 AT3600 U UICK TART UTORIAL OLTECH ANUAL To run the program at any time, return the tester to the top level display, press EXECUTE at the top level display: Then press LIST to choose the program and press the RUN key and continue as before.
Page 62: Firmware Upgrades
IRMWARE PGRADES The firmware of the AT3600 controls how tests are carried out, which tests are available and how the interfaces (including the front panel) function. New versions of the firmware are made available periodically and electronic copies are available free of charge.
Page 63 AT3600 U OLTECH ANUAL ABLE OF ONTENTS 3 - T HAPTER ROGRAM DITOR ABLE OF ONTENTS This chapter will guide you through the operation and functional aspects of the test program editor. 1. I NTRODUCTION ………………............3.1.1 2. S CHEMATIC DITING 1.
Page 64 AT3600 U ABLE OF ONTENTS OLTECH ANUAL ABLE OF ONTENTS ONTINUED 4. P ROGRAMMING ESTS 1. C ........….......3.4.2 ONTINUITY 2. W ......…….....3.4.3 INDING ESISTANCE 3. E .....3.4.4 QUIVALENT ERIES OR ARALLEL ESISTANCE 4. W ......…….....3.4.6 INDING NDUCTANCE 5. I …………....….….…..3.4.8 NDUCTANCE WITH 6.
Page 65: Introduction
NTRODUCTION 1. I NTRODUCTION Welcome to the Voltech test program editor. Using the editor enables you to quickly and easily create test programs for your AT series tester without any specialized knowledge of computer programming. The editor will guide you through the programming of the tests you wish to carry out, helping you ensure that programming errors are eliminated.
Page 66 AT3600 U NTRODUCTION OLTECH ANUAL 3.1.2. VPN 98 - 024 ROGRAM DITOR...
Page 67: Schematic Editing
CHEMATIC DITING The Voltech AT series schematic editor allows you to recreate the configuration of the transformer on the fixture as a schematic diagram on the screen. Using the schematic as a visual reference, you may create your test program.
Page 68 AT3600 U CHEMATIC DITING OLTECH ANUAL 2.1. A DDING A RANSFORMER INDING To add a transformer winding onto the screen: 1. Select ‘Add Winding’ from the Schematic menu on the menu bar. 2. Place the winding on the screen: A selected winding will now be displayed attached to the mouse pointer on the screen.
Page 69: Eleting A Winding
AT3600 U OLTECH ANUAL CHEMATIC DITING To change a connection, simply use the right button to pick it up and move it to either another test node or to another transformer terminal. To delete a connection, again use the right mouse button to pick up the connection, but this time release it when it is not over either a node or a terminal.
Page 70 AT3600 U CHEMATIC DITING OLTECH ANUAL You may change a name by: 1. Selecting the appropriate terminal box with the mouse, or by moving between the boxes with the TAB key on the keyboard and then typing the new name.
Page 71: Eleting A Terminal
AT3600 U OLTECH ANUAL CHEMATIC DITING 2.6. D ELETING A ERMINAL ROM AN XISTING INDING To remove a terminal from a transformer winding: 1. Select the terminal which you would like to be removed by using the mouse pointer and clicking the left mouse button once.
Page 72: Eleting A Core Connection
AT3600 U CHEMATIC DITING OLTECH ANUAL 2.8. D ELETING A ONNECTION To delete a core connection: 1. Choose ‘Delete Core Connection’ from the ‘Schematic’ menu. The connection from the core will be removed from the schematic. 2.9. A DDING A...
Page 73: Creating The Program
AT3600 U OLTECH ANUAL REATING THE ROGRAM 3. C REATING THE ROGRAM Section 3 describes the procedures used when creating the test program with the AT Series Test Program Editor. By the end of this chapter you will be able to: •...
Page 74: Etting The Program Options
AT3600 U REATING THE ROGRAM OLTECH ANUAL 3.1. S ETTING THE ROGRAM PTIONS 3.1.1. O VERVIEW After you have created the program schematic, before starting to insert any tests in the program, you should set up which program options you would like to use.
Page 75 AQL monitoring is an optional feature of the Voltech PC Server, which displays live summary results from multiple AT testers. When the AQL set here is reached or exceeded, the Server will display a warning.
Page 76 Using an external source extends the power and voltage range available. The source must be coupled to the tester via a Voltech AC Source Interface (contact your supplier for details). This option allows you to choose and configure the type of external source you will be using;...
Page 77 AT3600 U OLTECH ANUAL REATING THE ROGRAM 3.1.2. S With this function enabled, the tester will stop program execution whenever a fail is detected, rather than carrying out all the tests in the test program and reporting the passes and fails at the end.
Page 78 AT3600 U REATING THE ROGRAM OLTECH ANUAL File except those for the final execution run, i.e. the one that produces the pass or fail front panel display. If you wish to see the measured results from each retry in your Server Results File, then you should enable the program option ‘Send Retry Results to Server’...
Page 79 AT3600 U OLTECH ANUAL REATING THE ROGRAM 3.2. P ROGRAM After you have created the program schematic, and selected the program options, you may then start creating the actual program of tests. To edit the test program, you must first switch to the Program Editor.
Page 80 AT3600 U REATING THE ROGRAM OLTECH ANUAL Bottom Left: The Program Window. This is the list of tests which currently make up the test program. Normally, for a new program, this window would initially be empty. The display above shows the program of one resistance test created in the Quick Start Tutorial.
Page 81 AT3600 U OLTECH ANUAL REATING THE ROGRAM 3.3. A DDING ESTS A test program is a list of tests chosen from the Available Tests list. To create a new program, you simply add tests to the list. To add a test, use the mouse to select the test you require from the Available Tests list, and double click on that test with the left button.
Page 82: Tests
AT3600 U REATING THE ROGRAM OLTECH ANUAL 3.4. I NSERTING ESTS Normally, if you are creating a new test program, you would add the tests in the correct order of execution, as described in the previous section. You would also use this procedure for modifying an existing program, if you needed to append further tests at the end.
Page 83: Tests
AT3600 U OLTECH ANUAL REATING THE ROGRAM You will now see the new test inserted into the Program. 3.5. M ODIFYING ESTS As part of creating a new test program, you would normally experiment by running it with a sample batch of transformers. At this point, you may find that some tests need to be modified, a typical example being that you need to change the test limits.
Page 84 AT3600 U REATING THE ROGRAM OLTECH ANUAL 3.6. D ELETING ESTS To delete a test from the Program, with the Editor software is very simple. 1. In the Program window, click with the left mouse button to highlight the test you wish to delete.
Page 85 AT3600 U OLTECH ANUAL REATING THE ROGRAM 3.7. T ARAMETERS Some tests such as the R-Winding Resistance test (as used in the quick start tutorial – chapter 3) are relatively simple to program because you do not have to set up any test conditions.
Page 86 AT3600 U REATING THE ROGRAM OLTECH ANUAL 3.8. T IMITS In the Quick Start Tutorial (section 3 of chapter 2), it was stated that for the R - Winding Resistance - test the limits could be entered in four different ways. The R test is not unique in this respect.
Page 87 AT3600 U OLTECH ANUAL REATING THE ROGRAM Many of the tests available for the AT Series have all four limit types. There are obviously some tests where it is not sensible to have four limits, IR - Insulation Resistance - being a clear example where only a minimum limit is applicable, as the perfect insulation between windings has no upper limit to its resistance.
Page 88 AT3600 U REATING THE ROGRAM OLTECH ANUAL ← nom dB – neg dB dB +/- ← min > < ← upp < ← nom + pos% < ← nom dB – neg dB ← max > < ← low >...
Page 89 AT3600 U OLTECH ANUAL REATING THE ROGRAM Where: nom dB = the nominal value for the [ dB ] limits neg dB = the negative error for the [ dB ] limits pos dB = the positive error for the [ dB ] limits...
Page 90 In fact, most tests have a Measure button within the dialogue box. It is included there to allow you to fill in various fields in the dialogue box by using the AT3600 to measure the value from a sample transformer.
Page 91: Dit
AT3600 U OLTECH ANUAL REATING THE ROGRAM 4. Have available both a sample transformer, and possibly a shorting header if you wish to add tests to the program for which you will be applying short-circuit compensation. XAMPLE OF SING THE...
Page 92 AT3600 U REATING THE ROGRAM OLTECH ANUAL If the value of inductance is high, then compensation may not be needed, and you may click on ‘OK’ with ‘Measure without Fixture Compensation’ selected. If you click on ‘OK’ with ‘Compensate Fixture’ selected, then there will be an additional message, which in general depends on whether the test requires short- or open-circuit compensation.
Page 93 AT3600 U OLTECH ANUAL REATING THE ROGRAM When the measurements have finished, the display will return to the dialogue box for the LS test, with values entered for the test signal, the frequency and the nominal inductance: From this point, it is very easy for you to complete the dialogue box by simply entering the values you require for the Negative and Positive percentage limits.
Page 94 AT3600 U REATING THE ROGRAM OLTECH ANUAL ESTRICTIONS FOR UTOMATICALLY BTAINING THE ARAMETERS As shown above, the LS - Winding Inductance (Series Circuit) - test is one where both the test voltage (or current) and frequency may be obtained automatically by using the Measure button.
Page 95 AT3600 U OLTECH ANUAL REATING THE ROGRAM APPENS WITH IFFERENT YPES OF IMIT In the example shown above, percentage limits were chosen before clicking on the Measure button. In this case, the measured result from the tester is inserted as the nominal value, allowing you to set the limits for the test as a percentage either side of this nominal value.
Page 96 AT3600 U REATING THE ROGRAM OLTECH ANUAL δnp (δns) the ± error number of primary (secondary) turns for the [ # ] limits a factor to make #np and #ns whole numbers in the range 1 to 99999 Notes: 1. The conversions in the above table are written in a form to make it easier to understand the conversion process;...
Page 97: Erifying Your Program
AT3600 U OLTECH ANUAL REATING THE ROGRAM 3.10. V ERIFYING ROGRAM Typically in production use, your program would be downloaded to AT Series Tester from the Server, which is a PC resident software package, described in detail in Chapter 4. However, before you transfer your program to the Server archive, you should always verify it by running it on an actual transformer.
Page 98 AT3600 U REATING THE ROGRAM OLTECH ANUAL When it is finished, you will see a dialogue box containing the results of the test. From the results, you should be able to see any tests where there may be problems. Return to the Program Editor to make the necessary changes, then download the program again, and run the corrected version.
Page 99: Codes
3.11 E RROR ODES Voltech AT Series testers provide the operator with two types of error detection: • An electrically sound hardware integrity test, called self-test, with the provision of error codes, should an electrical fault be detected. • Return of an error code during transformer testing to assist in diagnosing whether incorrect test parameters have been used or poor connections have caused the fault.
Page 100 ROGRAM OLTECH ANUAL Important Note: Should self-test fail for any reason, contact Voltech technical support immediately, providing the following information: • Serial number of the instrument • Status error codes (the four-digit number and the one or two-digit number in...
Page 101 HPAC, HPDC, ACRT, DCRT and IR) (AT3600 only). A STOP interrupt has terminated the test from the STOP flag of the remote port. An 8kV interrupt has terminated the test - voltage > 8kV (AT3600 only). An over-temperature interrupt has terminated the test; unit has become too hot (AT3600 only).
Page 102: Compensation
AT3600 U REATING THE ROGRAM OLTECH ANUAL 3.12 F IXTURE OMPENSATION Often when measuring small values of resistance, inductance or capacitance, the effects of the fixture can add significant errors to the results. To allow you to make more accurate measurements, the AT Series Testers have built-in firmware to compensate for the fixture parasitics.
Page 103 AT3600 U OLTECH ANUAL REATING THE ROGRAM When the compensation measurements have been successfully completed, the compensation values for each test in the program will be stored inside the tester. Any subsequent measurements (started as described above by clicking on Tester - Run Program) will return compensated results to the Editor.
Page 104: Rogramming Ints And Ips
AT3600 U REATING THE ROGRAM OLTECH ANUAL 3.13. P ROGRAMMING INTS AND The following is a list of points that should be remembered when you are creating your test programs. Create your schematic first. When you are creating your test programs, you should work in the following order: a.
Page 105 AT3600 U OLTECH ANUAL REATING THE ROGRAM For many tests, the dialogue box for the test contains a button labeled ‘Measure’. If, when you are creating your test program, you have a tester connected to your PC, fitted with the appropriate test fixture containing a specimen transformer, clicking on the Measure button will signal the tester to measure the actual parameter of the test.
Page 106 AT3600 U REATING THE ROGRAM OLTECH ANUAL 3.3.34. VPN 98 - 024 ROGRAM DITOR...
Page 107 This section describes in more detail how to fill in the data for the dialogue boxes for each of the tests available for your AT3600. By the end of this chapter you will be able to program any of the following tests :...
Page 108 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.1. CTY - C ONTINUITY The continuity test can be placed as the first test in the program to check that the transformer has been inserted correctly into the test fixture. The test checks that every winding has a resistance less than a user specified limit, the same limit being applied to all windings.
Page 109 INDING ESISTANCE To check that the resistance of a winding is correct, the AT3600 applies a dc test signal to the selected winding. It then measures both the current through and the voltage across the winding, and calculates the resistance.
Page 110 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.3. RLS RLP - E QUIVALENT ERIES OR ARALLEL ESISTANCE The equivalent series or parallel resistance is obtained from a measurement of the complex impedance. An ac voltage is applied across the selected winding. The voltage across and current through the winding are then measured using harmonic analysis.
Page 111 AT3600 U OLTECH ANUAL ROGRAMMING ESTS (If in doubt, refer to Chapter 7 - ‘Test Conditions’, which lists recommended test conditions based on the values of winding inductance.) Note also that the Measure button may be used here as outlined in section 3.9,...
Page 112 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.4. LS LP – W INDING NDUCTANCE ERIES OR ARALLEL IRCUIT The inductance of a transformer winding may be tested using series or parallel equivalent circuit models. An ac voltage is applied across the selected winding. The voltage across and current through the winding are then measured using harmonic analysis.
Page 113 AT3600 U OLTECH ANUAL ROGRAMMING ESTS (If in doubt, refer to Chapter 7 - ‘Test Conditions’, which lists recommended test conditions for different values of inductance.) Note also that the Measure button may be used here as outlined in section 3.9,...
Page 114 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.5. LSB LPB - I NDUCTANCE ERIES ARALLEL IRCUIT The inductance of a transformer winding when a bias current is flowing may be tested using series or parallel equivalent circuit models. Initially the (dc) bias current is set up and allowed to stabilize.
Page 115 AT3600 U OLTECH ANUAL ROGRAMMING ESTS Note that the signal is normally entered as a voltage by selecting the 'mV' or 'V' button; but you may optionally enter it as a current by selecting the 'mA' button. (If in doubt, refer to Chapter 7 - ‘Test Conditions’, which lists recommended test conditions for different values of inductance.)
Page 116 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.6. QL - Q UALITY ACTOR To test for Q factor, an ac voltage is applied across the selected winding. The voltage across and current through the winding are then measured using harmonic analysis.
Page 117 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 3. Enter the high and low terminal names. Use the mouse to pull down the menu along side the fill-in box, and double click to select the terminal. 4. Select (mouse click the button) the type of limits you require and enter the values.
Page 118 Choosing the test signal For optimum accuracy and performance, use the test conditions chosen for capacitance in a later section of this chapter. The test conditions can also be determined automatically by the AT3600 according to this table: Signal Specified voltage Specified current...
Page 119 AT3600 U OLTECH ANUAL ROGRAMMING ESTS Choosing the test limits The test limits can be: A nominal value together with + and – percentage limits. >< Minimum and maximum values > A minimum value only < A maximum value only Use the PC Editor’s ‘measure’...
Page 120 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.8. LL LLO - L EAKAGE NDUCTANCE The Leakage Inductance for a particular transformer is tested by measuring the inductance of a ‘primary’ winding when one or more ‘secondary’ windings have short-circuits applied. Select either ‘LL Leakage Inductance’ or ‘LLO Leakage Inductance with Offset’...
Page 121 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 3. Select the high and low terminals of the coil to be energized (primary terminals). By clicking on the arrow to the right of the fill-in box, you will be provided with a choice of possible terminals.
Page 122 ANUAL 4.9. C - I NTERWINDING APACITANCE Your AT3600 can test the capacitance present between windings, screens and core. Select ‘C Interwinding Capacitance’ from the list of available tests, to give the following dialogue box: To program the test : 1.
Page 123 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4. Select (mouse click the button) the type of limits you require and enter the values. Enter a nominal value and then the limits as negative and positive percentage values. >< Enter minimum and maximum values.
Page 124 4.10. TR - T URNS ATIO You may program the AT3600 Tester to test the turns ratio between one winding and any other. To measure turns ratio, a test source voltage is applied to one winding, the energized winding, and the voltages across two other windings (one of which may also be the energized winding) are measured using harmonic analysis.
Page 125 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 3. Select the high and low terminals of the coil to be energized. (Click on the arrow to the right of the fill-in box and you will be provided with a choice of the available terminals.
Page 126 AT3600 U ROGRAMMING ESTS OLTECH ANUAL Choosing the test limits The limits may be entered as : 1. A nominal value together a percentage tolerance.(%) Enter the nominal Primary to Secondary ratio, together with the limits as positive and negative percentage values.
Page 127: Programming Tests
AT3600 U OLTECH ANUAL ROGRAMMING ESTS What happens if I set both absolute limits for both primary and secondary windings? If you want to detect up to a 10 turn error on the primary and 1 turn on the secondary in the above example, set 91/2 (pri) and 1/2 (sec).The tester uses the equivalent ratio...
Page 128 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.11. TRL - T URNS ATIO NDUCTANCE The TRL test measures the turns ratio between a pair of windings by comparing their inductance. This is different from the TR test, which compares the voltage used to energize one winding, with the voltage induced on a second.
Page 129 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 3. Select the high and low terminals of the primary winding. (Click on the arrow to the right of the fill-in box and you will be provided with a choice of the available terminals. Click the required terminal.) Select the high and low terminals of the secondary winding.
Page 130 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.12. Z, ZB – I MPEDANCE The Winding Impedance test measures the impedance of a selected winding using specified voltage (or current) and frequency conditions. An AC voltage is applied across the winding under test and the complex impedance is determined from measurement of the test voltage and the flowing current.
Page 131 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4. Set the impedance limits. Enter a nominal value and then the limits as negative and positive values. >< Enter minimum and maximum values. > Enter just a minimum value. < Enter just a maximum value.
Page 132 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.13. L2 - I NDUCTANCE ATCH The inductance match test calculates the ratio between two inductance's on two windings. An equivalent series inductance measurement is performed on each winding by measuring the complex impedance.
Page 133 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.14. C2 – C APACITANCE ATCH The Interwinding capacitance match test calculates the ratio between two capacitance measurements on two groups of windings. It is measured by applying a specified ac voltage between two separate windings and the voltage across and current flow between the two windings is measured to obtain a complex impedance.
Page 134 X and Y for the first and second measurements respectively. The preferred method of measurement is the LBAL test for which Voltech provide a separate test specifically for this measurement. This test is suitable for audio & telecommunication transformers and checks the effective common mode rejection ratio of the transformer.
Page 135 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 3. Enter the names for the energised and measured terminals for the X measurement. 4. Similarly configure Y terminals. 5. When required the "Optional 2nd Energised Hi" allows an additional terminal connection to the energised high node.
Page 136 ONGITUDINAL ALANCE The longitudinal balance test is Voltech's preferred method to measure what is effectively the Common Mode Rejection Ratio of a transformer designed to connect to a balanced line. Two measurements are performed each by applying a voltage to the transformer and measuring the resulting voltage to calculate the CMRR.
Page 137 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 5. Set the longitudinal balance limits. Enter a nominal value and then the limits as negative and positive values. >< Enter minimum and maximum values. > Enter just a minimum value. 6. Select OK. The test specification will then be displayed in the program window.
Page 138 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.17. ILOS – I NSERTION The Insertion loss test measures the output power delivered by a transformer to a load, relative to the maximum power theoretically available. A voltage is applied to the input winding and the input/output voltages are measured to calculate the loss.
Page 139 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.18. RESP – F REQUENCY ESPONSE The frequency response test, RESP, may be used to check that the variation in power loss of a telecommunications or audio transformer over a specified frequency range is less than specified limits.
Page 140 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.19. RLOS – R ETURN The Return loss test measures the impedance mismatch between the transformer and a transmission line of a specified impedance. RLOS is calculated from a measurement of the complex impedance and the specified impedance This test is suitable for audio &...
Page 141 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.20. ANGL – I MPEDANCE HASE NGLE The Impedance Phase Angle test can measure the impedance of a selected winding using specified voltage (or current) and frequency conditions, and then reports the equivalent impedance phase. An AC voltage is applied across the winding under test and the complex impedance is determined from measurements of the voltage across the winding and the current flowing through it.
Page 142 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4. Enter the phase limits. For phase tests, the convention of the result returned by the AT depends on the minimum limit requested. If this limit is >0 the result returned is between 0 .
Page 143 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.21. PHAS – I NTERWINDING HASE The interwinding phase may be tested between one winding and another. A test source voltage is applied to one winding, and the voltages across two other windings (one of which may be the driven winding) are measured. The interwinding phase is measured by finding the phase difference between the voltages measured on the primary and secondary windings.
Page 144 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 3. Enter the terminal names of the winding to be energized. Enter the terminal names of the primary and secondary windings on which the PHAS test is to be performed. Note: either of these windings can be the energized winding.
Page 145 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.22. TRIM - T RIMMING DJUSTMENT This test allows the operator to make adjustments to the transformer under test, at selected points in the test program. The TRIM test is inserted immediately following the test for the property that may need to be adjusted.
Page 146 4.23. OUT – O UTPUT The User Port on the AT3600 has 6 ‘Relay Driver’ outputs associated with it. The OUT test allows programming of the User Port relay driver outputs to perform additional relay switching as part of the test program.
Page 147 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.24. IR - I NSULATION ESISTANCE The insulation resistance may be measured between any number of windings. A dc voltage is applied across two groups of windings, with the windings in each group being shorted together. The voltage and current are measured; dividing the voltage by the current gives the insulation resistance.
Page 148 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4. Enter the minimum insulation resistance value in the bottom section. Note: The combination of test voltage and minimum resistance must be equivalent to a test current less than 1 mA. The Measure button may be used here as outlined in section 3.9.
Page 149 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.25. HPDC - DC H (EHT) The dc high-pot (or EHT) test is used to check for safety isolation between windings, or between windings and the core or screens. During the test, a dc voltage is applied across two groups of windings with the windings in each group being shorted together.
Page 150 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.26. HPAC - AC H (EHT) The ac high-pot (or EHT) test is used to check for safety isolation between windings, or between windings and the core or screens. During the test, an ac voltage is applied across two groups of windings with the windings in each group being shorted together.
Page 151 1. Enter the desired test voltage. 2. Enter either a nominal winding inductance or select AUTO mode. When a fixed inductance is entered, the AT3600 uses this value to estimate the frequency and duration of the transient waveform and thus determine the digital waveform sampling rate that is used.
Page 152 AT3600 U ROGRAMMING ESTS OLTECH ANUAL In AUTO mode, the tester automatically determines the ideal sample rate and duration after testing the first sample in a batch. AUTO mode is recommended for new test programs. If you are converting an existing test program from fixed to AUTO surge testing mode, beware that under some conditions the measured result may change.
Page 153 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.28 W ATTAGE The Wattage test is a measure of the input power required to energize a transformer at no load. During the test, a constant, user specified ac voltage is applied across the winding in question;...
Page 154 Voltech AC Source Interface (contact your supplier for details). See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT3600.
Page 155 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.30. STRW – S TRESS ATTAGE The Stress Wattage test tests the transformer for breakdown of insulation by measurement of the energizing power of a winding, usually the primary, with the remaining windings open circuit. This test applies the voltage, usually twice the normal operating voltage, and continually measures the power to determine any breakdown by changes in the measurement.
Page 156 This test uses an external source to provide the test signal which must be coupled to the tester via a Voltech AC Source Interface (contact your supplier for details). See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT3600.
Page 157 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.32. MAGI - M AGNETIZING URRENT Magnetizing current is measured by applying an ac test voltage to the selected winding, and measuring the resulting current. You may program the test to use either an rms, or a mean-sense (rms scaled) type of measurement to obtain a value for the current.
Page 158 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 5. Select (mouse click the button) the type of limits you require and enter the values. >< Enter minimum and maximum values. < Enter just a maximum value. Note that the Measure button may be used here as outlined in section 3.9.
Page 159 This test uses an external source to provide the test signal which must be coupled to the tester via a Voltech AC Source Interface (contact your supplier for details). See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT3600.
Page 160 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 5. Select OK. The test specification will be displayed in the program window on the screen. Note: The measure button may be used to determine typical test results. 3.4.54. VPN 98 - 024 ROGRAM...
Page 161 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.34. VOC - O IRCUIT OLTAGE Open circuit voltage is measured by applying an ac test voltage to a selected winding (usually a primary winding), and measuring the resulting voltage produced on another winding.
Page 162 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 3. Select (mouse click the button) the integration time you require. 'Medium' is the default setting. 'Long' will give more stable readings (for tighter limits) at the expense of an increased test time, and 'Short' will test at the maximum speed, but may give a slightly noisier reading.
Page 163 This test uses an external source to provide the test signal which must be coupled to the tester via a Voltech AC Source Interface (contact your supplier for details). See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT3600.
Page 164 AT3600 U ROGRAMMING ESTS OLTECH ANUAL Click on the arrow to the right of the fill-in box, and you will be provided with a choice of available terminals; double-click on the one required. Similarly, enter the names for the Measured Terminals.
Page 165 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.36. LVOC – L OLTAGE IRCUIT Applying an ac voltage to the primary of the transformer will produce an ac voltage in the secondary. Low Voltage Open Circuit measures the ‘open circuit’ voltage produced when the specified test signal is applied.
Page 166 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 7. Choosing the test limits. The test limits can be: A nominal value together with + and – percentage limits. >< Minimum and maximum values > A minimum value only < A maximum value only Use the Editor’s ‘measure’...
Page 167 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.37. ILK – L EAKAGE URRENT A leakage current test is needed for transformers used in certain applications, mainly medical, where it is an additional safety requirement. The leakage current to be measured is that which flows between primary windings and secondary windings under normal operating conditions due to interwinding capacitance.
Page 168 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 3. Select the terminals to be included for both high and low terminals. For both high and low terminals, select each terminal in turn and click on the ‘Add’ button at the bottom of the list. Terminals can be removed from the used list by selecting them and clicking on the ‘Remove’...
Page 169 0.2% @ Q>10 250A This test requires the use of one or more Voltech DC1000 Precision DC Bias Current Sources. Contact your Voltech sales office for details. The inductance of a transformer winding while an external bias current is flowing through it may be tested using series or parallel equivalent circuit models.
Page 170 AT3600 U ROGRAMMING ESTS OLTECH ANUAL To program the test: Enter the signal, frequency and bias current required for the test. Note that the signal is normally entered as a voltage by selecting the ‘mV’ or ‘V’ button; but you may optionally enter it as a current by selecting the ‘mA’...
Page 171 0.2% @ Q>10 250A This test requires the use of one or more Voltech DC1000 Precision DC Bias Current Sources. Contact your Voltech sales office for details. The inductance of a transformer winding while an external bias current is flowing through it may be tested using series or parallel equivalent circuit models.
Page 172 AT3600 U ROGRAMMING ESTS OLTECH ANUAL To program the test: 1. Enter the signal, frequency and bias current required for the test. Note that the signal is normally entered as a voltage by selecting the ‘mV’ or ‘V’ button; but you may optionally enter it as a current by selecting the ‘mA’ button.
Page 173 0.2% 1mΩ to 1MΩ 3MHz This test requires the use of one or more Voltech DC1000 Precision DC Bias Current Sources. Contact your Voltech sales office for details. The Winding Impedance with External Bias test measures the impedance of a selected winding while applying a DC current from the DC1000 through the winding.
Page 174 AT3600 U ROGRAMMING ESTS OLTECH ANUAL To program the test: 1. Enter the value of a voltage (or current) for the signal and the required frequency of the test. Also enter the bias current you would like to apply. Please note that the Measure button may be used here. For information, refer to the ‘Test Program Editor’...
Page 175 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.41. ACRT - AC H The ac high-pot Ramp test is used to check for safety isolation between windings, or between windings and the core or screens. During the test, an ac target voltage is applied across two groups of windings with the windings in each group being shorted together.
Page 176 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 4.42. DCRT - DC H The dc high-pot Ramp test is used to check for safety isolation between windings, or between windings and the core or screens. During the test, an ac target voltage is applied across two groups of windings with the windings in each group being shorted together.
Page 177 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.43. ACVB - AC V OLTAGE REAK This test may be used to check the action of devices such as metal oxide varistors (MOV) that are used to protect transformer windings from transient over-voltages that may be present on the ac supply system.
Page 178 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 5. Select OK. The test specification will then be displayed in the program window. 3.4.72. VPN 98 - 024 ROGRAM DITOR...
Page 179 AT3600 U OLTECH ANUAL ROGRAMMING ESTS 4.44. DCVB - DC V OLTAGE REAK This test may be used to check the action of devices such as metal oxide varistors (MOV) that are used to protect transformer windings from transient over-voltages that may be present on the ac supply system.
Page 180 AT3600 U ROGRAMMING ESTS OLTECH ANUAL 3. Enter the maximum current value in the bottom section. 4. Select the user offset enabled, if required and enter the voltage value. 5. Select OK. The test specification will then be displayed in the program window.
Page 181 AT3600 U OLTECH ANUAL ABLE OF ONTENTS 4 - U HAPTER SING THE ERVER ABLE OF ONTENTS This chapter will guide you through the operation and functional aspects of the server application. 1. I NTRODUCTION .……………............4.1.1 2. T ROGRAM ANDLING 1.
Page 182 AT3600 U ABLE OF ONTENTS OLTECH ANUAL VPN 98 - 024 SING ERVER...
Page 183 AT3600 U OLTECH ANUAL NTRODUCTION 1. I NTRODUCTION The server program supplied with your AT series tester may be considered as an on- line storage system. The server will handle two types of data: - TEST PROGRAMS - TEST RESULTS Test programs that are created using the editor application may be uploaded into the server central file store.
Page 184 AT3600 U NTRODUCTION OLTECH ANUAL 4.1.2. VPN 98 - 024 SING ERVER...
Page 185: Using The Server
AT3600 U OLTECH ANUAL ROGRAM ANDLING 2. T ROGRAM ANDLING 2.1. S TORING ROGRAMS After a test program has been created using the program editor application it will be ready for use with your AT series tester. The diagram below shows a potential connection scheme for use with a single tester and two PCs.
Page 186 AT3600 U ROGRAM ANDLING OLTECH ANUAL This will transfer the current program from the editor to the server. The program will be sent via the tester's serial link if present, by direct file transfer if both applications are resident on the same PC or by network file transfer if a network link is present and is identified to the server.
Page 187: Test
AT3600 U OLTECH ANUAL ROGRAM ANDLING 2.2. V IEWING A ROGRAM Each test program has a part name. To view a particular test program you will need to know its part name. Select FILE, PART and then OPEN from the menu bar. You may select the part to open from the list displayed, or change the path and drive to search for other parts.
Page 188 AT3600 U ROGRAM ANDLING OLTECH ANUAL 2.3. S AVING A OPY OF A Using the SAVE AS function under the PART menu you are able to save a new copy of the same test program under a new part name.
Page 189: Test
AT3600 U OLTECH ANUAL ROGRAM ANDLING 2.4. D ELETING A ROGRAM When the Server stores the test program on your PC hard disk, the DOS filename used differs from the part name specified. The Server uses an algorithm to encode a unique filename for each part.
Page 190: Rouping Test Programs
AT3600 U ROGRAM ANDLING OLTECH ANUAL 2.5. G ROUPING ROGRAMS Programs that are used on the transformer tester at similar times may be grouped for convenience. For example, a number of transformers all based on the same bobbin may be tested at the same time.
Page 191: Esults
AT3600 U OLTECH ANUAL ESULTS ANDLING 3. T ESULTS ANDLING 3.1. R ECEIVING ESULTS By default, the AT series tester does not automatically send test results back to the server. Results will only be sent back for test programs that have been set up with the ‘Send Results to Server’...
Page 192 What follows is an example of the first part of a batch result file. Note the DOS file name (c6200697.atr) and the part name (“Part #” “2”) are both listed within the file. "VOLTECH AT3600 RESULTS FILE" "Server Program Version: 2.1” "Communication Channel: 6"...
Page 193: Test Results Handling
AT3600 U OLTECH ANUAL ESULTS ANDLING 3.2. R ESULT ISPLAY AND NALYSIS Four approaches have been provided to allow observation of your test result data: • On-Line monitoring • On-Line analysis via a Database • On-Line analysis via OLE •...
Page 194 ANUAL Select 'Display Basic Statistics' to save results to a database. For this feature to operate a licence for use must first be obtained from your Voltech supplier. All results formats can be saved simultaneously. Basic statistics displays, on-line, a summary of the results for the current batch of transformers that is being tested on every AT connected to the Server.
Page 195 Normally, you would select 'No' to leave the AQL checking active for the rest of the batch. When a new batch is started, the AQL level is reset according to the level entered for the part using the Voltech AT Editor.
Page 196: Database
AT3600 U ESULTS ANDLING OLTECH ANUAL 3.2.3. O NALYSIS VIA A ATABASE The AT Server software can store test results in an electronic database. This provides a very powerful and versatile method of recording and analysing test results historically or on-line. The Server uses standard Windows methods (including OLE DB and ODBC) to connect to a variety of databases that conform to these specifications.
Page 197 AT3600 U OLTECH ANUAL ESULTS ANDLING Click on 'Advanced' to set up your database connection: To connect to your database, the Server software uses a connection string that contains (amongst other things) the name of a provider, the name and location of the database and a valid database user name and password (if required).
Page 198 AT3600 U ESULTS ANDLING OLTECH ANUAL Several different types of provider are installed along with the Server software, others may be available if you have a database application installed on the same PC as the Server. If the provider you need is not available and the database is installed on...
Page 199 AT3600 U OLTECH ANUAL ESULTS ANDLING Select the database name that you will be using by clicking on 'Select'. If you wish to create a new database for AT Server results, do so now using your database program. The default user name 'Admin' with no password may be adequate. Consult your database administrator if you need a specific user name and password.
Page 200 AT3600 U ESULTS ANDLING OLTECH ANUAL Check that the 'Access permissions' for the database are as required. 'Share Deny None' is the default and is usually the most suitable setting. 4.3.10. VPN 98 - 024 SING ERVER...
Page 201 AT3600 U OLTECH ANUAL ESULTS ANDLING Under the 'All' tab all of the individual settings can be reviewed and adjusted if necessary. Click on OK to complete the setting of the data link properties. A typical AT Server advanced database results dialogue would be: Click on OK to return to the results dialogue.
Page 202 Note that new data is not necessarily appended to the end of a table; it may appear anywhere within. Table: tblVoltechATUnitID Field Format Notes ATUnitID Text (25) Index ID UnitType Text (10) AT3600, AT1600, ATi UnitID Text (10) Unit Serial Number FirmwareID Text (10) Unit Firmware Version Table: tblVoltechResults Field Format Notes...
Page 203 AT3600 U OLTECH ANUAL ESULTS ANDLING Table: tblVoltechRunID Field Format Notes RunID Text (25) Index ID Date Date/Time Date of Test Run (Short Date) Time Date/Time Time of Test Run (Long Time) ATUnitID Text (25) As tblVoltechATUnitID.ATUnitID PartID Text (25)
Page 204 AT3600 U ESULTS ANDLING OLTECH ANUAL * Notes: (CheckType = NONE) If there are no Min or Max limits, MinLimit = 0 and MaxLimit = 0 (CheckType = MIN) If there is a Min limit only, MaxLimit = 0 (CheckType = MAX)
Page 205 (or offline) data analysis. The example reports presented here were created using PQ Systems ChartRunner, but many other charting and analysis programs are available. Voltech does not recommend one package more than any other. You should choose to use the one that best meets your needs.
Page 206 AT3600 U ESULTS ANDLING OLTECH ANUAL Resistance Distribution Analysis Overall Pass/Fail Analysis 4.3.16. VPN 98 - 024 SING ERVER...
Page 207 AT3600 U OLTECH ANUAL ESULTS ANDLING ChartRunner Example Database Connection The chart will show the trend of inductance measurements over time - an 'Individuals' chart type. See the ChartRunner help system for how to set up control limits, change the display appearance or set up any of the other available chart types.
Page 208 AT3600 U ESULTS ANDLING OLTECH ANUAL Under the 'Data Definition' tab: Select the table of the database that holds the data that you want to chart. (You may also select a query that has been written in the database or write a 'Custom Query').
Page 209 AT3600 U OLTECH ANUAL ESULTS ANDLING Next, click on 'Filtering' and filter the data for 'TestNo' = 2. This selects only the results for test number 2 of the AT test program (which is an inductance test). VPN 98 - 024 4.3.19.
Page 210 AT3600 U ESULTS ANDLING OLTECH ANUAL Next click on the 'Limits' tab and enter appropriate specification limits which will appear on the chart. The ChartRunner software can automatically select appropriate control limits from the data. This is the default and recommended setting.
Page 211 AT3600 U OLTECH ANUAL ESULTS ANDLING Under the 'Control Chart' tab, display options (including axis scaling) can be altered. Other options including chart titles and size can be altered by selecting the 'Titles' and 'Misc.' tabs. Click on 'OK' when finished. Double click on the chart definition to display the chart.
Page 212 AT3600 U ESULTS ANDLING OLTECH ANUAL Free trial versions ChartRunner available from PQSystems www.pqsystems.com or any of their regional offices. United States PQ Systems Inc. Corporate Headquarters Toll free: 1-800-777-3020 Phone: 937-885-2255 E-mail: sales@pqsystems.com Europe PQ Systems Europe Ltd. Phone: +44 1704 871465 E-mail: sales@pqsys.demon.co.uk...
Page 213: Ole
AT3600 U OLTECH ANUAL ESULTS ANDLING 3.2.4. O NALYSIS VIA The MS Windows environment provides a system of transferring data between active applications in real-time known as Object Link Embedding (OLE). OLE2 is the latest version of the transfer standard and is fully supported by the Server application.
Page 214 “INVALID RESULT NUMBER” the requested result number is out of range “NO RESULT” no updated result data available Further Voltech Server OLE functions are described below. They use the same format and failure strings as 'GetVariant Result'. Only function specific responses and return values are shown.
Page 215 AT3600 U OLTECH ANUAL ESULTS ANDLING This call returns the tester serial number on success or a failure string: “NO UNIT ID” no valid AT serial number found GetTransformerSerialNo (LPCSTR ComPort) This call returns the transformer serial number on success or a failure string: “NO SERIAL NO”...
Page 216 The number returned is a float representing the value of the result measured or a zero if no result was available. This function is included for compatibility with older versions of the Voltech AT Server. It is not recommended for new applications.
Page 217 AT3600 U OLTECH ANUAL ESULTS ANDLING This section shows available functions for controlling an attached instrument via the server. This is to allow basic instrument control in applications where the AT is being used entirely remotely. The functions available allow a program to be loaded into an AT, and give the ability to run and stop it.
Page 218 AT3600 U ESULTS ANDLING OLTECH ANUAL XAMPLE OF NALYSIS This section contains a simple example to illustrate how you may use OLE to transfer the measured results into a spreadsheet as they happen in real-time. The spreadsheet used in the example is Microsoft Excel 97, and the module of code illustrated is written in the Visual Basic supplied with the spreadsheet.
Page 219 = 3 sComPort = "COM2" 'Dummy read to clear any previous result vntResult(nTest) = objServerResult.GetVariantResult(sComPort, nTest) MsgBox ("Press the RUN soft-key on the AT3600") For nRun = 1 To nNumRuns 'Get the results vntResult(nTest) = objServerResult.GetVariantResult(sComPort, nTest) Loop Until (vntResult(nTest) <> "NO RESULT") And _ (vntResult(nTest) <>...
Page 220 AT3600 U ESULTS ANDLING OLTECH ANUAL When you have finished typing the code, return to the ‘Sheet 1’ of the spreadsheet. To run the code, again from the Excel top-level menu bar, select: Tools > Macro At the dialog box, select the name of the macro ‘OLE_Demo’, and click on the RUN button.
Page 221 AT3600 U OLTECH ANUAL ESULTS ANDLING In the code example shown above, it is worth noting the following points: • vntResult(1 To 99) is declared as a variant type because the GetVariantResult method can return either a numerical value corresponding to a valid result, or a string corresponding to an error message.
Page 222 AT3600 U ESULTS ANDLING OLTECH ANUAL 3.2.5. O LINE NALYSIS If you have no requirement for real-time analysis but are interested in post test analysis of test results, off-line data analysis should be adopted. An example of this would be to view the results file created the previous day.
Page 223 AT3600 U OLTECH ANUAL ESULTS ANDLING Excel will then bring up the ‘Open File’ dialogue box. Select the results file you wish to view and click on ‘Open’. After clicking ‘Open’, the Text Import Wizard dialog box will appear: Ensure that the ‘Delimited’ option is checked and click on ‘Next >’ to move to step two.
Page 224 AT3600 U ESULTS ANDLING OLTECH ANUAL In the ‘Delimiters’ section of this screen, ensure that only the ‘Comma’ option is checked. Click on ‘Next >’ and proceed to step three: Check that the ‘Column Data Format’ option is checked as ‘General’ and click on finish.
Page 225 AT3600 U OLTECH ANUAL ESULTS ANDLING The results will now be displayed as shown below: You may need to adjust the Cell number format of the spreadsheet, and the width of the columns, in order to display the required number of decimal places.
Page 226 AT3600 U ESULTS ANDLING OLTECH ANUAL 4.3.36. VPN 98 - 024 SING ERVER...
Page 227: Fixtures
AT3600 U OLTECH ANUAL ABLE OF ONTENTS 5 - F HAPTER IXTURES ABLE OF ONTENTS This chapter will guide you through the fixture system designed for use with the at series testers. Detailed and comprehensive instructions and applications guidance for the construction of your own custom fixtures are supplied with every custom fixture kit.
Page 228 AT3600 U ABLE OF ONTENTS OLTECH ANUAL VPN 98 - 024 IXTURES...
Page 229: Introduction
Voltech recognize the importance of well constructed test fixtures. These benefits include minimizing operator fatigue, ensuring optimum repeatability, preventing unnecessary rejects and increasing throughput of the AT Series testers.
Page 230 AT3600 U NTRODUCTION OLTECH ANUAL 5.1.2. VPN 98 - 024 V07 IXTURES...
Page 231: Description Of The Fixture System
YSTEM 2.1 D ESCRIPTION The Voltech AT Series fixture system allows you freedom and flexibility when considering your fixturing needs. All fixtures are mounted on fixture boards, which are available as a blank fixture plate and also as fixture kit which contains parts to help you.
Page 232 1.27mm apart. OMPATIBLE CONNECTION TYPES Kelvin clips Kelvin blades (Automech type) 4mm sockets ATE pin types Rotary point Castellated Point Crown A list of known suitable ATE pin types is available from Voltech. 5.2.2. VPN 98 - 024 V07 IXTURES...
Page 233 AT3600 U OLTECH ANUAL ESCRIPTION IXTURE YSTEM HE COMPONENTS VPN 98 - 024 V07 5.2.3. IXTURES...
Page 234 AT3600 U ESCRIPTION IXTURE YSTEM OLTECH ANUAL 1. B LATE This fits into the top of the transformer tester and has the following features: • Fitted with 40 node contacts which connect to the 40 test node pins on the top of the tester.
Page 235 AT3600 U OLTECH ANUAL ESCRIPTION IXTURE YSTEM 4. B EZEL This provides an accurate location for the probe housing box and the test piece interface plate. The design also includes support areas for the rear of the guides. 5. G UIDES The guides help to locate the test piece into the fixture quickly and accurately.
Page 236 AT3600 U ESCRIPTION IXTURE YSTEM OLTECH ANUAL To hold the drilling templates in place for drilling, clips are provided to hold the drilling templates in place. They clip into holes provided at the corners of the interface plate and the probe housing box.
Page 237 AT3600 U OLTECH ANUAL ESCRIPTION IXTURE YSTEM 2.2 F IXTURE ARTS VAILABLE OLTECH 1. F IXTURE LATE Designed for mounting existing fixtures to an AT series tester the fixture plate comprises: • Item 1, Base plate (including contact pins) with cover.
Page 238 AT3600 U ESCRIPTION IXTURE YSTEM OLTECH ANUAL 5.2.8. VPN 98 - 024 V07 IXTURES...
Page 239: Kelvin Connections
AT3600 U OLTECH ANUAL ELVIN ONNECTIONS 3. K ELVIN ONNECTIONS In testing many transformer parameters, such as winding resistance or inductance, it is necessary to measure electrical impedance. The normal method of measuring impedance is to pass a test current through the unknown component, and to measure the resulting voltage produced across it.
Page 240 AT3600 U ELVIN ONNECTIONS OLTECH ANUAL The ‘common’ lead length is shown as AA’ and BB’ in the diagram below. The AT series testers provide all the connections required to take advantage of Kelvin measurements. A test node may be considered to be a pair of connections consisting of one power and one sense terminal.
Page 241 EWARE OF OLTAGES The AT3600 can apply AC voltages up to 5000 Vrms during the course of a test. This must be kept in mind when constructing test fixtures. If possible, always design the fixture with the nodes that experience the same high voltages grouped together.
Page 242: Wire Stripping
AT3600 U ENERAL OTES OLTECH ANUAL Terminals or interconnections, which have exposed (high voltage) metal in contact with the surface of the fixture board, should be avoided where possible, as there may be creepage along the surface. If such a terminal is necessary, you must ensure that there are no sharp points or corners on the metal pieces, that the surface between them is scrupulously clean, and that a separation of at least 3mm per kV is used.
Page 243 AT3600 U OLTECH ANUAL ABLE ONTENTS 6 – F HAPTER RONT ANEL PERATION ABLE ONTENTS This chapter will guide you through the operation of your tester via the integral keyboard and display. 1. I NTRODUCTION 1. T AT S ……………...………..6.1.1...
Page 244 AT3600 U ABLE ONTENTS OLTECH ANUAL VPN 98 - 024 RONT ANEL PERATION...
Page 245: Introduction
AT3600 U OLTECH ANUAL 1. I NTRODUCTION 1.1. T AT S ERIES RONT ANEL RUN Indicator PASS Indicator Soft-keys Backspace key FAIL Indicator Liquid Crystal Display (LCD) The front panel of the AT Series testers is designed with a membrane type keyboard and liquid crystal display.
Page 246: Ther Ata Nputs
AT3600 U OLTECH ANUAL 1.2. O THER NPUTS To give you the greatest ergonomic flexibility, at certain points in the tester's menu system, as well as the keyboard, other methods of entering data are possible: OOTSWITCH The ‘Run’ input of the ‘Remote Port’ on the tester's rear panel can be optionally connected to a footswitch.
Page 247 ANUAL 1.3. P OWER When the AT3600 tester is switched on it performs a self-test which lasts for about 10 seconds. After power on you should see the following display: The tester is now at the Top Level menu, and the soft-keys allow you to select which...
Page 248 AT3600 U OLTECH ANUAL 6.1.4. VPN 98 - 024 RONT ANEL PERATION...
Page 249: Self Test
AT3600 U OLTECH ANUAL 2. S Self-test is a sequence of checks made by the tester to ensure the unit is functioning correctly. You may run Self-test at any time by pressing the SELF-TEST soft-key in the Top Level menu.
Page 250 The message shown on the lower two display lines will depend on what caused the failure. In the unlikely event that your tester continues to fail, please make a note of the failure message and contact your Voltech supplier for service. 6.2.2. VPN 98 - 024...
Page 251: Execute Mode
XECUTE 3. E XECUTE This is the normal operating mode of the AT3600 when used for production testing of transformers. Before you try to use the tester in EXECUTE MODE, make sure that all the following have been carried out: •...
Page 252: Xecute Mode With N O Optionse
The program name can now be typed at the keyboard, entered by swiping a barcode or chosen from a list. Press the soft-key LIST to see a list of the programs available on the PC server or in the AT3600’s own memory (see section 6.6.2) Enter Program Name or Select...
Page 253 AT3600 U OLTECH ANUAL XECUTE If the FAIL indicator illuminates at this point this indicates a problem with the compensation procedure, check the fixture and short-circuit header connection, then re-try the fixture compensation. Illumination of the PASS indicator represents a successful compensation.
Page 254 AT3600 U XECUTE OLTECH ANUAL Cause: The directory set-up in the server application as the location of test programs does not contain a test program file with the requested part name. Local program store (see chapter 2, section 2.3.4) Cause: The requested part number is not resident in the group of programs that have been downloaded into the AT.
Page 255 AT3600 U OLTECH ANUAL XECUTE The RUN-FINISH displays seen after a previous component has been tested. Both the front panel LED’s (green = ‘Pass’ and red = ‘Fail’) and output lines of the remote port indicate the test result of the previous transformer, so that it may be placed in the appropriate ‘Pass’...
Page 256 AT3600 U XECUTE OLTECH ANUAL MEASURING THE IXTURE OMPENSATION If you think that fixture compensation needs to be re-measured at any time, at the RUN-FINISH display, press the ‘SEETINGS’ soft-key to reveal: Press COMPENSATE to repeat the fixture compensation measurements, or ‘Back’ to return to the RUN-FINISH display without re-compensating.
Page 257 AT3600 U OLTECH ANUAL XECUTE 3.2. E XECUTE ODE WITH PTIONS NABLED As stated in Chapter 3 ‘The test program editor’, programs may be created with the following three options enabled or disabled: Operator name Batch numbers Serial numbers In each case, if the option is enabled, the data entered by the operator for that option is included with the results which are sent back to the server.
Page 258 AT3600 U XECUTE OLTECH ANUAL The following flow diagram summarizes the possibilities: Top-Level Display Select EXECUTE Mode Enter Part Number or Select from List FIT and COMPENSATE the Fixture Enter Operator Name Enter Batch Number Enter Serial Number New BATCH...
Page 259 AT3600 U OLTECH ANUAL XECUTE OTES DDITIONAL ISPLAYS AFTER NTERING THE UMBER As when entering the part number: • Use either the keyboard or a barcode reader to type in the operator/batch/serial number, then press the ENTER key, the ENTER soft-key or a footswitch.
Page 260 AT3600 U XECUTE OLTECH ANUAL ERIAL UMBER NTRY AFTER THE IRST RANSFORMER When the serial number option is enabled, after the measurements for each transformer have been completed, the following display will be seen (with the fourth line indicating ‘Pass’, ‘Fail’ or ‘Stop’ as appropriate): If the next serial to be used simply follows on in sequence after the previous one, then press the LAST + 1 soft-key (or the footswitch).
Page 261 AT3600 U OLTECH ANUAL XECUTE Note that pressing the ABORT soft-key will also take you back to the RUN-FINISH display, but with no serial number having been entered. This would be the correct action if the next soft-key you wish to press is FINISH. (subsequently pressing RUN would merely return you to the ‘Enter the serial number’...
Page 262 AT3600 U XECUTE OLTECH ANUAL 3.3. S TOP ON ‘Stop on Fail’ is another program option that is either enabled or disabled when the program is created (see Chapter 3 - ‘The Test Program Editor’). When enabled, it will cause the measurements to be terminated after each test which has produced a ‘Fail’...
Page 263 AT3600 U OLTECH ANUAL XECUTE Pressing the ABORT soft-key stops the program and allows the operator to discard the failing component at the earliest opportunity to minimise test times. (The ABORT is also reported to the server when the program option 'Send retry results to server' is enabled and printed out, when a results printing option is set.)
Page 264 AT3600 U XECUTE OLTECH ANUAL After pressing the CONTINUE soft-key, the remaining tests in the program will be executed, and at the end of the measurement, the component will be classed as a ‘Fail’. Pressing the RE-RUN soft-key will re-start the test sequence from the beginning.
Page 265: Fixture Compensation
OMPENSATION 4. F IXTURE OMPENSATION AT3600 tester fixture compensation is equivalent to short-circuit and open-circuit correction on a component analyzer. It eliminates errors due to stray parasitic components on the fixture board itself. These are usually a combination of parallel capacitance between adjacent wires and sockets or pins, and series resistance and inductance along the lengths of wires.
Page 266 AT3600 U IXTURE OMPENSATION OLTECH ANUAL PERATOR NSTRUCTIONS After you have entered the name of a program where compensation can be applied, at the next display: • Fit the shorting bobbin into the test fixture on the tester. • Press the COMPENSATE soft-key.
Page 267: Measure Mode
5.1. M EASURE PERATION In MEASURE Mode, the AT3600 tester is set up to operate like a component bridge. It repeatedly makes measurements for one selected test, and continuously updates the front panel display with results. To access MEASURE mode, press the MEASURE soft key at the top-level display: the following display lists the tests that are available for your tester in MEASURE mode.
Page 268 AT3600 U EASURE OLTECH ANUAL pressing ENTER takes you to the relevant set up display: The details of the set up display will vary depending on which test you have selected. For the capacitance test, the list of parameters to enter is: Test voltage, Test frequency, Integration, Hi node(s), and Lo node(s).
Page 269 AT3600 U OLTECH ANUAL EASURE Because node numbers (1 to 20) are used in the MEASURE Mode, the test nodes are entered using the keyboard number pad. After each node number has been typed, proceed to the next by using the cursor (↑ or ↓) soft-keys, or by using the ENTER key ( ↵ ).
Page 270 AT3600 U EASURE OLTECH ANUAL The next display will depend on the particular test. For the ‘C Capacitance’ test, it is: If you wish to apply Fixture Compensation to the measurements, ensure that the fixture is empty, and press the COMPENSATE soft-key. When the Compensation is finished, the display will return to one similar to the one above, but with the COMPENSATE soft-key and message omitted.
Page 271: Ront Anel Easure Ode Rror
The measurement conditions displayed on the front panel are the actual values of the voltage/current and frequency sensed at the AT3600’s nodes. If voltage or current and frequency test conditions have been specified it may not be possible for the AT to maintain these conditions.
Page 272 AT3600 U EASURE OLTECH ANUAL For low power tests that include dc bias you may see the following message: Measuring LSB NEW MEASURE NEW SET UP Nodes : 1 2 Overload : reduce bias 0.0000pF FINISH In which case, you should reduce the dc bias level until this message no longer appears.
Page 273: Program Mode
AT3600 U OLTECH ANUAL ROGRAM 6. P ROGRAM PROGRAM mode has two main functions: • To change the tester's set up options (including setting up for server operation). • To download a group of programs from the server PC to the tester's internal memory.
Page 274 AT3600 U ROGRAM OLTECH ANUAL 6.1 S Pressing the soft-key SET-UP at the ‘Program Mode’ display above will reveal: This display is the start of a list of options under the title ‘Set-Up’. To modify an option: • Press the cursor soft-keys ( ↑ and ↓ which appear in context) to scroll up and down the list, so that the option you wish to modify is positioned on the third line (‘Fail Beeper’...
Page 275 AT3600 U OLTECH ANUAL ROGRAM Three of the options require more than just pressing the third soft-key. For ‘Beeper Volume’, pressing the soft-key CHANGE brings up an additional display: • Press the ↑ and ↓ soft-keys until the beeper makes the level of sound you require, then press the EXIT soft-key to return to the Set-Up list.
Page 276: Rograms
AT3600 U ROGRAM OLTECH ANUAL 6.2. P ROGRAMS When the tester is set up to use the LOCAL program store, and after you have entered the part name, it will search for that name in the programs that are stored in its own non-volatile RAM.
Page 277: Essages
AT3600 U OLTECH ANUAL ROGRAM Press ‘CONTINUE’ to return to the top level display. Your program group has now been loaded into the tester’s internal store and the server PC may be disconnected. These programs will be stored during power off, and will only be overwritten by another group download.
Page 278 OWNLOAD SING DITOR A single program may be stored in the AT3600 using the PC editor. Once a program has been entered using the editor and downloaded to the tester, the tester will display: Press LOCAL SAVE and the program that has been downloaded from the PC editor will be saved in the tester’s local program store.
Page 279 AT3600 U OLTECH ANUAL ABLE ONTENTS 7 - T & T HAPTER ESTS ONDITIONS ABLE ONTENTS This chapter will guide you through the selection of tests and the appropriate test conditions. 1. T RANSFORMER ESTS 1. A ……..……………………………..7.1.1 PPLICATION OF TESTS 2.
Page 280 AT3600 U ABLE ONTENTS OLTECH ANUAL 34. M ………….……………………..7.1.56 AGNETIZING URRENT 35. M ) ………….7.1.58 AGNETIZING URRENT XTERNAL OURCE 36. O ………….……………………..7.1.60 IRCUIT OLTAGE 37. O ) ……….7.1.62 IRCUIT OLTAGE XTERNAL OURCE 38. L …………………………... 7.1.64 OLTAGE IRCUIT 39. L ……………….……………………..7.1.66...
Page 281: Transformer Tests
RANSFORMER ESTS 1. T RANSFORMER ESTS 1.1. A PPLICATION OF ESTS The following table summarizes the tests available for the AT3600 and indicates where they might be used Test Description Main Application Winding Tested Reason for Test Continuity All transformers...
Page 282: Dc Resistance Match
AT3600 U RANSFORMER ESTS OLTECH ANUAL Test Description Main Application Winding Tested Reason for Test All transformers, especially SURG Surge Stress Test Selected windings To identify shorted turns those using fine wire Transformers with variable / To adjust transformer to give...
Page 283 OLTECH ANUAL RANSFORMER ESTS * These tests require the use of one or more Voltech DC1000 Precision DC Bias Current Sources. Contact your Voltech sales office for details. ESONANT REQUENCY Practical inductive components are not perfect inductors; they have stray resistances and capacitances associated with them.
Page 284 AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.2. CTY - C ONTINUITY HERE The continuity test is available to be placed as the first test in the program to check that the transformer has been inserted correctly into the test fixture. The test checks that every winding has a resistance less than a user specified limit, with the same limit being applied to all windings.
Page 285 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.3. R - W INDING ESISTANCE HERE The measurement of the resistance of all windings should generally be the first group of tests carried out for any type of transformer. It checks that the wire is of the correct diameter, and has not been over-tensioned during winding.
Page 286 AT3600 U RANSFORMER ESTS OLTECH ANUAL URRENT The test current is set according to the value specified as maximum in the test limits:- Maximum <0.1Ω <1Ω <10Ω <100Ω <1kΩ <10kΩ Resistance Test current 400mA 200mA 100mA 30mA 300µA NOTE: Above 10kΩ, a constant voltage source of 8.0V is used.
Page 287 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.4. RLS RLP - E QUIVALENT ERIES OR ARALLEL ESISTANCE HERE The equivalent series or parallel resistance measurements are alternatives to a Q factor measurement to follow the inductance test in the program. As with the Q factor measurement, an equivalent series or parallel resistance test...
Page 288 IRCUIT HERE The AT3600 offers two basic alternative ways to confirm that the transformer has been assembled properly, with the appropriate number of primary and secondary turns, the right grade of magnetic material for the core, and the correct air gap if required.
Page 289 AT3600 U OLTECH ANUAL RANSFORMER ESTS The following table suggests suitable test conditions for different values of expected primary inductance: Preferred test signal Inductance range Frequency Voltage → 100nH 300KHz 10mV → 10uH 100KHz 30mV → 10uH 100uH 30KHz 50mV →...
Page 290 This can be a problem when trying to compare measurements made on commercially available impedance bridges, or component testers, with measurements made using the AT3600. The test signal in such bridges is usually determined within the instrument, and is often at a fixed frequency and at a voltage level which is not guaranteed to be constant for all value of inductance.
Page 291 IRCUIT HERE With the LSB and LPB tests, the AT3600 offers two further ways to confirm that the transformer has been assembled properly, with the appropriate number of turns, the right grade of magnetic material for the core, and the correct air gap if required.
Page 292 AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.7. QL - Q UALITY ACTOR HERE The Q factor measurement would normally follow a measurement of the inductance of the primary winding in the test program. As with an inductance measurement, the Q factor test would normally be used for...
Page 293 AT3600 U OLTECH ANUAL RANSFORMER ESTS δ 1.8. D – D ISSIPATION ACTOR OR Measurement Test Test Basic Voltage Frequency Accuracy Range 0.001 to 1000 1mV to 5V 20Hz to 3MHz 0.5% AT Series Tester The parameter ‘D’ is most often used as a measurement of the losses in a capacitor. It is analogous to Q for a transformer winding.
Page 294 Choosing the test signal For optimum accuracy and performance, use the test conditions chosen for capacitance in a later section of this chapter. The test conditions can also be determined automatically by the AT3600 according to this table: Specified voltage Specified current...
Page 295 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.9. LL LLO- L EAKAGE NDUCTANCE HERE Leakage inductance is important in many applications. One example is flyback designs for high frequency switched mode power supplies, where the leakage inductance must be less than a specified critical value for proper operation.
Page 296 AT3600 U RANSFORMER ESTS OLTECH ANUAL NOTE: Because leakage inductance is measured with a secondary winding shorted out, be careful to choose a test signal that will not cause excessive currents to flow. This is particularly significant in transformers where the turns ratio is very high and the shorted winding has only a few turns.
Page 297 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.10. C - I NTERWINDING APACITANCE HERE Capacitance occurs in transformers due to the physical proximity of, and electrostatic coupling between, different turns of wire. In general, the capacitance is distributed between the different layers within a winding, and between the outside layer of one winding and the inside layer of the next.
Page 298 AT3600 U RANSFORMER ESTS OLTECH ANUAL The test voltage can be in the range of 1mV to 5V at a frequency of 20Hz to 1MHz. The table below gives the recommended test conditions for different values of capacitance: Preferred test signal...
Page 299 AT3600 U OLTECH ANUAL RANSFORMER ESTS QUIVALENT IRCUIT As with inductance, capacitance is actually measured as a complex impedance, and therefore the result can be expressed in terms of either a series or a parallel equivalent circuit. It was explained in section 1.5 of this chapter that parallel and series equivalent inductance do not necessarily have the same values.
Page 300 ATIO HERE The AT3600 offer two basic alternative ways to confirm that the transformer has been assembled properly, with the appropriate number of primary and secondary turns. Turns ratio is the preferred test for signal, pulse and switched mode power transformers, where the normal operating conditions require only small excursions of the B-H curve, never extending beyond the linear regions.
Page 301 AT3600 U OLTECH ANUAL RANSFORMER ESTS The recommended test conditions depend on the inductance of the energised winding; they are given in the table below assuming that the energised winding is the one with the highest number of turns: Inductance of the...
Page 302 AT3600 U RANSFORMER ESTS OLTECH ANUAL HERE ATCHING IN ROUPS IS MPORTANT In some transformer designs, the turns ratio between a primary winding and a secondary winding is not as important as the ratio between different primaries or different secondaries.
Page 303 ATIO BY NDUCTANCE HERE The AT3600 offers two basic alternative ways to confirm that the transformer has been assembled properly, with the appropriate number of primary and secondary turns. Turns ratio is the preferred test for signal, pulse and switched mode power transformers, where the normal operating conditions require only small excursions of the B-H curve, never extending beyond the linear regions.
Page 304 AT3600 U RANSFORMER ESTS OLTECH ANUAL SING THE EASURE UTTON TO ARAMETERS To do this you must be programming the test from a computer that is connected to the tester’s auxiliary port. Select the integration period you require, enter the primary and secondary terminals, then click on the measure button.
Page 305 AT3600 U OLTECH ANUAL RANSFORMER ESTS Intermediate Inductance Preferred test signal Frequency Voltage → 100nH 300KHz 10mV → 10uH 100KHz 30mV → 10uH 100uH 30KHz 50mV → 100uH 10KHz 100mV → 10mH 1KHz 100mV → 10mH 100mH 100Hz 100mV →...
Page 306 AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.13. Z, ZB – I MPEDANCE MPEDANCE WITH HERE The impedance test measures the impedance of a transformer winding by applying a specified voltage and frequency and by measuring the current that flows, calculating the magnitude of the complex impedance.
Page 307 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.14. R2 – DC R ESISTANCE ATCH HERE The DC resistance match test – as opposed to an ordinary DC resistance measurement (R) - is used on audio and telecommunications transformers, where it is important that the resistance of different pairs of windings is controlled and matched to a specified ratio.
Page 308 AT3600 U RANSFORMER ESTS OLTECH ANUAL • Select the integration time required. • Enter the terminal names between which the X resistance is to be measured. • Enter the terminal names between which the Y resistance is to be measured.
Page 309 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.15. L2 – I NDUCTANCE ATCH HERE The inductance match test calculates the ratio between two inductances on two windings. An equivalent series inductance measurement is performed on each winding by measuring the complex impedance.
Page 310 AT3600 U RANSFORMER ESTS OLTECH ANUAL The following table suggests suitable test conditions for different values of expected average inductance: Average Inductance Preferred test signal (Geometric Mean) Frequency Voltage → 100nH 300KHz 10mV → 10uH 100KHz 30mV → 10uH 100uH...
Page 311 AT3600 U OLTECH ANUAL RANSFORMER ESTS Normally to get a good measurement of inductance, the test frequency should be less than 20% of the resonant frequency of the transformer. In general high values of inductance will have a high inter-turn capacitance and hence a low resonant frequency.
Page 312 AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.16. C2 – C APACITANCE ATCH HERE The interwinding capacitance match test calculates the ratio between two capacitance measurements on two groups of windings. It is measured by applying a specified ac voltage between two separate windings and the voltage across and current flow between the two windings is measured to obtain a complex impedance.
Page 313 AT3600 U OLTECH ANUAL RANSFORMER ESTS When choosing the test conditions, the following potential problems should be considered: URRENT LEVELS For larger capacitances, particularly at higher frequencies, the current flowing during the measurement can be very high, and similarly the measured current could also be very small for small capacitances at lower frequencies and voltages.
Page 314 X and Y for the first and second measurements respectively. The preferred method of measurement is the LBAL test for which Voltech provide a separate test specifically for this measurement. This test is suitable for audio & telecommunication transformers and checks the effective common mode rejection ratio of the transformer.
Page 315 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1. Preferred method (the method of the LBAL test, used by many transformer manufacturers) Measurement Energised Measured 2. IEEE 455 method (used in Canada, Europe and ROW) Measurement Energised Measured Fixture 3. FCC 68.310 method (used in USA)
Page 316 AT3600 U RANSFORMER ESTS OLTECH ANUAL The source and load resistors (and the fixture transformer for the IEEE and FCC methods) are assumed to be on the fixture, but are not shown on the Editor schematic. They are switched in circuit using an OUT test that must be inserted in the program before the GBAL test.
Page 317 ALANCE HERE The longitudinal balance test is Voltech's preferred method to measure what is effectively the Common Mode Rejection Ratio of a transformer designed to connect to a balanced line. Two measurements are performed each by applying a voltage to the transformer and measuring the resulting voltage to calculate the CMRR.
Page 318 AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.19. ILOS – I NSERTION HERE The Insertion loss test measures the output power delivered by a transformer to a load, relative to the maximum power theoretically available. A voltage is applied to the input winding and the input/output voltages are measured to calculate the loss.
Page 319 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.20. RESP – F REQUENCY ESPONSE HERE The frequency response test, RESP, may be used to check that the variation in power loss of a telecommunications or audio transformer over a specified frequency range is less than specified limits.
Page 320 AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.21. RLOS – R ETURN HERE The Return loss test measures the impedance mismatch between the transformer and a transmission line of a specified impedance. RLOS is calculated from a measurement of the complex impedance and the specified impedance. This test is suitable for audio &...
Page 321 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.22. A – I MPEDANCE HASE NGLE HERE The impedance phase angle test measures the angle ∅ of the impedance vector Z, as shown in the phasor diagram. It represents the phase difference between the fundamental current...
Page 322: Interwinding Phase
AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.23. P – I NTERWINDING HASE HERE This test is useful for most types of transformer, although unusual with line frequency transformers and tests for the phase angle between windings. It is most useful for determining the phase effect of audio and telecommunications transformers when placed in a transmission line.
Page 323: Trimming Adjustment
AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.24. TRIM - T RIMMING DJUSTMENT HERE TRIM is used on transformers with adjustable or variable components where it is desirable to adjust the transformer at various points within the test program to give specific measured values.
Page 324 AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.25. OUT – O UTPUT HERE OUT is used where additional switching (other than performed by the nodes of the AT) is required for parts of the test program. The User Port on the tester has associated with it 6 ‘Relay Driver’ outputs. The OUT test allows programming of the User Port relay driver outputs to perform additional relay switching as part of the test program.
Page 325 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.26. IR - I NSULATION ESISTANCE HERE An Insulation Resistance check is recommended as good practice for most transformers to check the integrity of the insulation between separate windings, or between a winding and a screen.
Page 326: H Ipot
AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.27. HPDC - DC HI-POT (EHT) HERE Hi-Pot or EHT testing (to check for insulation breakdown between windings or between windings and the screen or core) is often specified for power line transformers or for switched mode power transformers in applications where safety is important.
Page 327 AT3600 U OLTECH ANUAL RANSFORMER ESTS Many transformer specifications require Hi-Pot testing to be carried out with a dwell time of 60 seconds. Although the transformer must be designed and constructed to meet this, it is common practice to reduce the dwell time for production testing.
Page 328: H Ipot
AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.28. HPAC - AC HI-POT (EHT) HERE Hi-Pot or EHT testing (to check for insulation breakdown between windings or between windings and the screen or core) is often specified for power line transformers or for switched mode power transformers in applications where safety is important.
Page 329 Under certain test conditions the measured current will be higher than the allowed minimum limit due to parasitic effects on the AT3600 and any connected fixture system. The maximum parasitic effect created by the AT3600 with every node being used on an HPAC test can be calculated by: = V*(4.614*10...
Page 330 The time of releasing the impulse The peak voltage just after switch-on At the start of the surge test, the AT3600 performs an initial run to compensate for the effect of the capacitance of the transformer winding. Without this compensation, the...
Page 331 RANSIENT NALYSIS During the decay phase after the impulse has been fired, the AT3600 measures both the voltage amplitude along the transient, and the time of decay. A good transformer will have a clean and sustained transient, with a long decay period.
Page 332 During the Wattage test, a constant, user specified ac voltage is applied across the winding in question. All other windings are held open circuit during this test. The AT3600 measures the voltage across and current through the winding. The Wattage is the product of the in phase components of the current and voltage.
Page 333 This test uses an external source to provide the test signal which must be coupled to the tester via a Voltech AC Source Interface (contact your supplier for details). See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT3600.
Page 334 AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.32. STRW – S TRESS ATTS HERE The Stress Wattage test tests the transformer for breakdown of insulation by measurement of the energising power of a winding, usually the primary, with the remaining windings open circuit. This test applies the voltage, usually twice the normal operating voltage, and continually measures the power to determine any breakdown by changes in the measurement.
Page 335 This test uses an external source to provide the test signal which must be coupled to the tester via a Voltech AC Source Interface (contact your supplier for details). See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT3600.
Page 336: Transformer Tests
URRENT HERE The AT3600 offers two basic alternative ways to confirm that the transformer has been assembled properly, with the appropriate number of primary and secondary turns, the right grade of magnetic material for the core, and the correct air gap if required.
Page 337 RANSFORMER ESTS PECIFYING THE IMITS The AT3600 offers you two ways to specify the test limits: Using a true rms measurement Using a mean-sense measurement, which is scaled to rms for sinewaves. Generally the rms value would be used. However, you may wish to use the second method if, for example, your test limits have been established by a previous measurement on a low cost multimeter which uses this technique.
Page 338: Agnetizing Urrent
Voltech AC Source Interface (contact your supplier for details). See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT3600. EASUREMENT...
Page 339 AT3600 U OLTECH ANUAL RANSFORMER ESTS In practice, the magnetising current waveform may have a transient component following the switch-on of the test voltage. To give you repeatable accurate results, the measurement does not start until any transient has settled.
Page 340 1.36. VOC - O IRCUIT OLTAGE HERE The AT3600 offers two basic alternative ways to confirm that the transformer has been assembled properly, with the appropriate number of primary and secondary turns. Open circuit voltage measurements are the preferred tests for line frequency transformers, designed to operate over the full extent of the B-H curve, including the non-linear regions.
Page 341 WARNING: While the AT3600 is able to test transformers fitted with a rectifying diode, a capacitor must not be fitted as part of the rectifying circuit. Any charge remaining in the capacitor could damage the AT3600's relay matrix at the end of the test.
Page 342 Voltech AC Source Interface (contact your supplier for details). See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT3600. EASUREMENT...
Page 343 WARNING: While the AT3600 is able to test transformers fitted with a rectifying diode, a capacitor must not be fitted as part of the rectifying circuit. Any charge remaining in the capacitor could damage the AT3600's relay matrix at the end of the test.
Page 344 B-H curve, never extending beyond the linear region. On the AT3600 only, a high voltage open circuit test is available for testing line frequency transformers at their operating point (up to 270V, 1kHz and 2A).
Page 345 50Hz → 100H 50Hz → 100H 50Hz → 10kH 20Hz The test conditions can also be determined automatically by the AT3600 according to this table: Voltage Specified Auto Auto Frequency Specified Specified Auto Note that a ‘fixed’ voltage signal cannot be used with an ‘Auto’ frequency.
Page 346: Eakage Current
AT3600 U RANSFORMER ESTS OLTECH ANUAL 1.39. ILK – L EAKAGE URRENT HERE The leakage current test is needed for transformers used in certain applications, mainly medical, where it is an additional safety requirement. EASUREMENT ONDITIONS The test is typically carried out by applying the test voltage between all the primary terminals shorted together, and all the secondary terminals and screen shorted together.
Page 347 0.2% @ Q>10 250A This test requires the use of one or more Voltech DC1000 Precision DC Bias Current Sources. Contact your Voltech sales office for details. The inductance of a transformer winding while an external bias current is flowing through it may be tested using series or parallel equivalent circuit models.
Page 348 0.2% 1mΩ to 1MΩ 3MHz This test requires the use of one or more Voltech DC1000 Precision DC Bias Current Sources. Contact your Voltech sales office for details. The Winding Impedance with External Bias test measures the impedance of a selected winding while applying a DC current from the DC1000 through the winding.
Page 349 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.43. ACRT - AC HI-POT R HERE Hi-Pot Ramp testing (to check for insulation breakdown between windings or between windings and the screen or core) is often specified for power line transformers or for switched mode power transformers in applications where safety is important.
Page 350 OLTECH ANUAL In programming the AT3600 you may select the voltage (from 100V to 5.5kVrms), the frequency (50Hz / 60Hz at the full voltage, or up to 1kHz at reduced voltage), the current trip level (10µA to 5mApeak), and the ramp up times (1 to 30sec), all to suit the specification of the transformer under test.
Page 351 AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.44. DCAT - DC HI-POT R HERE Hi-Pot Ramp testing (to check for insulation breakdown between windings or between windings and the screen or core) is often specified for power line transformers or for switched mode power transformers in applications where safety is important.
Page 352 AT3600 U RANSFORMER ESTS OLTECH ANUAL In programming the tester you may select the voltage (from 100V to 7KVdc), the current trip level (1µA to 3mA), and the ramp up times (1 to 2sec), all to suit the specification of the transformer under test.
Page 353: Oltage Break Down
AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.45. ACVB - AC V OLTAGE REAK HERE This test may be used to check the action of devices such as metal oxide varistors (MOV) that are used to protect transformer windings from transient over-voltages that may be present on the ac supply system.
Page 354 OLTECH ANUAL In programming the AT3600 you may select the voltage (from 100V to 5kVrms), the frequency (50Hz / 60Hz at the full voltage, or up to 1kHz at reduced voltage), the current trip level (10µA to 5mApeak), and the ramp up times (1 to 30sec), all to suit the specification of the transformer under test.
Page 355: Oltage Break Down
AT3600 U OLTECH ANUAL RANSFORMER ESTS 1.44. DCVB - AC V OLTAGE REAK HERE This test may be used to check the action of devices such as metal oxide varistors (MOV) that are used to protect transformer windings from transient over-voltages that may be present on the ac supply system.
Page 356 OLTECH ANUAL In programming the AT3600 you may select the voltage (from 100V to 7kVdc), the current trip level (10µA to 3mA), and the ramp up times (1 to 2sec), all to suit the specification of the transformer under test.
Page 357 AT3600 U OLTECH ANUAL ABLE OF ONTENTS 8 - S HAPTER PECIFICATION ABLE OF ONTENTS This chapter will provide all specification and technical details for your AT3600 tester. 1. SPECIFICATION 1. Specification Summary - Available Tests ....8.1.1 2. Accuracy Specifications - Available Tests ....8.1.3 2.
Page 358 AT3600 U ABLE OF ONTENTS OLTECH ANUAL VPN 98 - 024 PECIFICATION...
Page 359: Pecification
AT3600 U OLTECH ANUAL PECIFICATION 1. S PECIFICATION 1.1. S PECIFICATION UMMARY VAILABLE ESTS User Entered Test Data Test Measurement Range Test Signal Test Frequency Continuity 10kΩ 10MΩ DC Resistance 0.1% 10µΩ 10MΩ Inductance 20Hz 3MHz 0.05% (series circuit) Inductance...
Page 360 AT3600 U PECIFICATION OLTECH ANUAL User Entered Test Data Test Measurement Range Test Signal Test Frequency Wattage 270V 20Hz 1500Hz 0.3% WATT WATX Wattage 600V 20Hz 5kHz 0.3% (External Source) SURG Surge Stress 1mVs 1kVs 100V 3.0% TRIM Trimming Adjustment...
Page 361 AT3600 U OLTECH ANUAL PECIFICATION Notes: 1. A = The basic relative accuracy (see over for the full specification). 2. Depends on external source type. 3. 650Vrms for AC measurements, or 1000V for DC measurements. 4. Peak value. 5. 1MHz may be the maximum bandwidth for some testers manufactured before 1999. Consult your supplier for details.
Page 362: Accuracy Specifications - Available Tests
AT3600 U PECIFICATION OLTECH ANUAL 1.2. A – CCURACY PECIFICATIONS VAILABLE ESTS The accuracy is based on the test conditions chosen to measure the winding resistance, and is given as: +A +A +A where is the total accuracy (%) is the basic relative accuracy (%)
Page 363 AT3600 U OLTECH ANUAL PECIFICATION LS, LP, RLS, RLP, LL, LLO ESTS The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test, and is given as: +A +A +A +A where is the total accuracy (%)
Page 364 AT3600 U PECIFICATION OLTECH ANUAL ESTS The accuracy of measuring Q factor and D factor is given as: where is the basic total accuracy (%) is the basic relative accuracy (%) is the correction for current level (%) is the correction for Q or D factor (%) The value of A is given in the table in section 1.1 of this chapter.
Page 365 AT3600 U OLTECH ANUAL PECIFICATION TR T The accuracy is based on the test conditions chosen to measure the turns ratio, and is given as: +A +A +A +A where is the total accuracy (%) is the basic relative accuracy (%)
Page 366 AT3600 U PECIFICATION OLTECH ANUAL MAGI T The accuracy for the test voltage is given by: ) = 1% TEST The accuracy for measuring magnetizing current is given as: +A +A where is the total accuracy (%) is the basic relative accuracy (%)
Page 367 (Hz) is the measured current (A) During a MAGX test, the AT3600 automatically applies the test voltage to the part under test and checks that the voltage has stabilised before recording measurements. The time that the voltage takes to stabilise will vary with the source type used and the nature of the part under test.
Page 368 AT3600 U PECIFICATION OLTECH ANUAL VOC T The accuracy for measuring open circuit voltage is given as: +A +A where is the total accuracy (%) is the basic relative accuracy (%) is the calibration accuracy (%) is the correction for voltage level (%) The value of A is given in the table in section 1.1 of this chapter...
Page 369 (Hz) is the measured voltage (V) During a VOCX test, the AT3600 automatically applies the test voltage to the part under test and checks that the voltage has stabilised before recording measurements. The time that the voltage takes to stabilise will vary with the source type used and the nature of the part under test.
Page 370 AT3600 U PECIFICATION OLTECH ANUAL LVOC T The accuracy for measuring open circuit voltage is given as: where is the total accuracy (%) is the basic relative accuracy (%) is the calibration accuracy (%) is the correction for voltage level (%) The value of A is given in the section 1.1 of this chapter.
Page 371 AT3600 U OLTECH ANUAL PECIFICATION IR T The accuracy is based on the test conditions chosen to measure the insulation resistance, and is given as: +A +A +A where is the total accuracy (%) is the basic relative accuracy (%)
Page 372 AT3600 U PECIFICATION OLTECH ANUAL HPDC T The accuracy for the test voltage is given by: ) = 3% TEST The accuracy for the peak current detection is given by: +A +A where is the basic relative accuracy (%) is the total accuracy (%)
Page 373 Under certain test conditions the measured current will be higher than the allowed minimum limit due to parasitic effects on the AT3600 and any connected fixture system. The maximum parasitic effect created by the AT3600 with every node being used on an HPAC test can be calculated by: = V*(4.614*10...
Page 374 AT3600 U PECIFICATION OLTECH ANUAL LPB T ESTS The accuracy for measuring inductance with bias is given as: The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test, and is given as:...
Page 375 AT3600 U OLTECH ANUAL PECIFICATION WATT STRW T ESTS The accuracy for the test voltage is given by: = 2% TEST The accuracy for the wattage measurement is given by: +A +A +A +A where is the basic relative accuracy (%)
Page 376 (PF = W / VA) is the measurement frequency (Hz) When performing either of the above tests, the AT3600 automatically applies the test voltage to the part under test and checks that the voltage has stabilised before recording measurements.
Page 377 AT3600 U OLTECH ANUAL PECIFICATION SURG T The accuracy of the Volts-seconds ‘area’ under the curve of the decaying transient curve is based on the chosen test conditions, and is given as: +A +A where is the basic relative accuracy (%)
Page 378 AT3600 U PECIFICATION OLTECH ANUAL GBAL T The accuracy is based on the test conditions chosen to measure the longitudinal balance of the transformer under test, and is given as: +0.87(A +A +A ) where is the total accuracy (dB)
Page 379 AT3600 U OLTECH ANUAL PECIFICATION LBAL ILOS T ESTS The accuracy is given as: +0.87 A +A +A where is the total accuracy (dB) is the basic relative accuracy (dB) is the correction for calibration is the correction for the input voltage level...
Page 380 AT3600 U PECIFICATION OLTECH ANUAL RESP T The accuracy is given as: +1.74 A +A +A where is the total accuracy (dB) is the basic relative accuracy (dB) is the correction for calibration is the correction for the input voltage level...
Page 381 AT3600 U OLTECH ANUAL PECIFICATION ZB T The accuracy is given as: +A +A +A where is the total accuracy (%) is the basic relative accuracy (%) is the calibration accuracy (%) is the correction for voltage level (%) is the correction for current level (%) The value of A is given in the table in section 1.1.
Page 382 AT3600 U PECIFICATION OLTECH ANUAL ANGL T The accuracy is given as: +A +A +A where is the total accuracy (°) is the basic relative accuracy (°) is the calibration accuracy (°) is the correction for voltage level (°) is the correction for current level (°) The value of A is given in the table in section 1.1 of this chapter.
Page 383 AT3600 U OLTECH ANUAL PECIFICATION PHAS T The accuracy is given as: +A +A +A where is the total accuracy (°) is the basic relative accuracy (°) is the calibration accuracy (°) is the correction for voltage level (°) is the correction for turns ratio (°) The value of A is given in the table in section 1.1 of this chapter.
Page 384 AT3600 U PECIFICATION OLTECH ANUAL ILK T The accuracy is given as: +A +A where is the total accuracy (%) is the basic relative accuracy (%) is the calibration accuracy (%) is the correction for current level (%) The value of A is given in the table in section 1.1.
Page 385 AT3600 U OLTECH ANUAL PECIFICATION LSBX LPBX T ESTS The accuracy for measuring inductance with bias is given as: The accuracy is based on the test conditions chosen to measure the impedance of the parameter under test, and is given as:...
Page 386 AT3600 U PECIFICATION OLTECH ANUAL ZBX T The accuracy is given as: +A +A +A where is the total accuracy (%) is the basic relative accuracy (%) is the calibration accuracy (%) is the correction for voltage level (%) is the correction for current level (%) The value of A is given in the table in section 1.1.
Page 387 Under certain test conditions the measured current will be higher than the allowed minimum limit due to parasitic effects on the AT3600 and any connected fixture system. The maximum parasitic effect created by the AT3600 with every node being used on an ACRT test can be calculated by: = V*(4.614*10 + 9.1*10...
Page 388 AT3600 U PECIFICATION OLTECH ANUAL DCRT T The accuracy for the test voltage is given by: where is the total accuracy (%) is the calibration accuracy (%) is the correction for current level (%) 00006 Range where is the maximum test current (A)
Page 389 Under certain test conditions the measured current will be higher than the allowed minimum limit due to parasitic effects on the AT3600 and any connected fixture system. The maximum parasitic effect created by the AT3600 with every node being used on an ACRT test can be calculated by: = V*(4.614*10 + 9.1*10...
Page 390 AT3600 U PECIFICATION OLTECH ANUAL DCVB T The accuracy for the test voltage is given by: ) = 3% TEST The accuracy for the test current is given by: where is the total accuracy (%) is the calibration accuracy (%)
Page 391: Interface Details
No connection No connection No connection No connection No connection The recommended barcode reader for the AT3600 is the ‘Smart Wand’ Barcode Reader from Hewlett Packard, available from Farnell Electronic Components Hewlett-Packard List No: HBSW-8300 VPN 98 - 024 8.2.1.
Page 392: Server Port
The HP ‘Smart Wand’ reader connects directly to the AT3600’s barcode port; no extra interfacing is required to configure the HBSW-8300. Plug the barcode reader into the port and switch the AT3600 on. The barcode reader is configured by simply scanning the three barcodes printed below: 19 200 Baud 0’s Parity (none)
Page 393: Auxiliary Port
AT3600 U OLTECH ANUAL NTERFACE ETAILS 2.3. A UXILIARY RS232 interface for connection to a PC running the Voltech editor software. 9-pin male D-type connector. Signal name Signal name No connection No connection No connection No connection 2.4. P RINTER Standard parallel printer interface.
Page 394: Remote Port
AT3600 U NTERFACE ETAILS OLTECH ANUAL 2.5. R EMOTE TTL compatible interface for operation with various peripherals including foot switch, remote controller and monitor output. 9-pin male D-type connector. Signal name Signal name BEEP !BUSY / Bin0 !PASS / Bin1...
Page 395: Safety Interlock
2.7. S AFETY NTERLOCK The AT Series safety interlock has been designed to be used with the Voltech Safety System, which is based on the use of a light curtain. Details of this accessory are available from your Voltech distributor.
Page 396 If any of the circuits are ‘broken’ during use, dangerous voltages, which could be applied to the transformer under test, are actively reduced and quickly made safe. *NOTE: A slim connector shell is required to fit the AT3600 aperture. Example type: McMurdo 51218-1...
Page 397 AT3600 U OLTECH ANUAL NTERFACE ETAILS Connection to Your Safety System The following diagram shows the principles of how to construct your own safety system based on the signals available on the Safety Interlock connector. NOTES: Your safety system must contain all three switches, as shown in the diagram.
Page 398: User Port
User Port. Such a flash-over would cause extensive damage to the circuits inside the Tester. If in any doubt, contact your Voltech supplier for advice on which relay to use in your application.
Page 399 AT3600 U OLTECH ANUAL NTERFACE ETAILS ONNECTOR ETAILS 9-pin female D-type connector. Signal name Signal name User Relay Drive 0 User Relay Drive 1 User Relay Drive 2 User Relay Drive 3 User Relay Drive 4 User Relay Drive 5...
Page 400 AT3600 U NTERFACE ETAILS OLTECH ANUAL NPUTS PINS The User Inputs have the following equivalent circuit: Specification: Maximum input voltage: Minimum input voltage: Minimum logic 1 input: Maximum logic 0 input: 0.25V The zero reference voltage for these inputs is the 0V(ground) 4mm socket situated to the left of the User Port.
Page 401: Environmental Conditions
AT3600 U OLTECH ANUAL NVIRONMENTAL ONDITIONS 3. E NVIRONMENTAL ONDITIONS NPUT IEC 3-pin socket 90 to 265V ac 50 or 60Hz @200VA Fuse 3.15AT IELECTRIC TRENGTH 2kV ac 50Hz for 1 minute, line input to case. Storage Temperature -40° to +70°C...
Page 402 AT3600 U NVIRONMENTAL ONDITIONS OLTECH ANUAL 8.3.2 VPN 98 - 024 V05 PECIFICATION...
Page 403: Emc Compliance
The product herewith complies with the requirements of the EMC Directives 89/336/EEC and 92/31/EEC and the Low Voltage Directive 73/23/EEC Signed for on behalf of Voltech Instruments Ltd Martin Whitley, Quality Manager Abingdon, United Kingdom, December 16, 1996 VPN 98 - 024 8.4.1.
Page 404: Emc Precautions
The AT3600 may be susceptible to Fast Electrical Transients on the power line and Electrostatic Discharges, which can disrupt the operation of the unit. In the event of such an occurrence, to return the AT3600 to normal operation: 1) Switch off the power...
Page 405: Warranty And Service
HAPTER ARRANTY ERVICE ABLE OF ONTENTS This chapter of the manual will introduce the terms of warranty, service and calibration for the AT3600 transformer tester. 1. WARRANTY INFORMATION 1. Warranty Information …………..…....…9.1.1 2. Service and Calibration ………..…....…9.1.2 3. Voltech AT Calibration System………………………….9.1.2...
Page 406 AT3600 U ABLE OF ONTENTS OLTECH ANUAL VPN 98 - 024 ARRANTY ERVICE...
Page 407: Warranty Information
Shipment from the customer address will be the responsibility of the customer. Voltech reserve the right to waive this benefit in any event where it is clear upon inspection that the cause of the failure is due to customer misuse.
Page 408 1.2. S ERVICE AND ALIBRATION To confirm the accuracy of your AT3600 tester, a calibration check should be carried out every 12 months. Calibration is carried out using a special fixture as described in the next section. The calibration can be performed by an authorized Voltech service center or at your own...
Page 409 DMM S PECIFICATION FOR UTOMATIC The Voltech calibration system relies on the accuracy of the DMM used to achieve the published specification of the tester. The meter must measure: AC Volts to 0.04% @100Hz and 3% @1MHz DC Volts to 0.003% @2V and 0.005% @600V DC resistance using a four terminal connection to 0.05% for 500mΩ...
Page 410 AT3600 U ARRANTY NFORMATION OLTECH ANUAL 9.1.4. VPN 98 - 024 ARRANTY ERVICE...
Page 411: Safety Systems
AT3600 U OLTECH ANUAL AFETY YSTEMS 10 – S HAPTER AFETY YSTEMS ABLE OF ONTENTS This chapter describes the recommended safety enclosure for the AT3600. 1. S ………………………………………..3 AFETY YSTEMS 1.1. I ………………………………………………….3 NTRODUCTION 1.2. R . …………………………….4 ECOMMENDED AFETY YSTEM 1.3.
Page 412 AT3600 U AFETY SYSTEMS OLTECH ANUAL 10.2. VPN 98 - 024 AFETY YSTEMS...
Page 413: Safety Systems
With this in mind, the rear panel of the AT3600 and some AT accessories have been designed with a safety interlock connector, which is described in the user manual of those products.
Page 414: Ystem
AFETY YSTEM For optimum safety, ease of use and test speed, Voltech recommends the use of a safety light curtain with the AT3600 and other Voltech products that can generate dangerous voltages during routine production testing. This provides a ‘light curtain’ of infrared beams positioned in front of the tester.
Page 415: Oltech Safety Interlock
NTERLOCK ABLE The Safety Interlock Cable is a robust and convenient way of connecting the AT3600 and other Voltech products to a safety interlock system. Although other safety systems may be suitable, the cable has been optimised for direct and quick connection to the Banner product described in the previous section.
Page 416 The cable carries 3 pairs of color-coded wires. Each pair must be linked together by the safety system before the AT3600 will operate a high voltage test. If any one of the three pairs is becomes un-linked during a test, the AT3600 very quickly switches off any high voltage that is being produced.
Page 417: Safety Notices
AT3600 is the yellow indicating light on its front panel. This light will be lit when the AT3600 is running a test and may be generating dangerous voltages. (External indicating devices can also be used to show that the AT3600 is in a hazardous condition.
Page 418: Ypical Installation
AT3600 U AFETY SYSTEMS OLTECH ANUAL 3. T YPICAL NSTALLATION The safety system is based on the use of an infrared light curtain as a barrier between the operator and the dangerously high voltages present on the transformer under test.
Page 419 AT3600 U OLTECH ANUAL AFETY YSTEMS The following show plan and side views of a typical installation: The dimensions are as follows: Width of the light curtain: 1.8m to 2.0m Cable length from control box to vertical columns: Cable length from control box to tester: 1.5m...
Page 420: Peration With Ir S
Note: This section describes the various operating and warning messages that may be observed on the AT3600 when it is being used with a safety light curtain. Please consult the documentation supplied with your safety system for its operating instructions.
Page 421 AT3600 U OLTECH ANUAL AFETY YSTEMS Where ‘XXXX’ is the appropriate test mnemonic. Operation will remain suspended at this point until the safety system indicates that it is safe to proceed, after which test execution will carry on as normal. If you do not wish to continue from this point, pressing the STOP soft-key will halt the test execution and return the display to the appropriate higher level menu selection.
Page 422 AT3600 U AFETY SYSTEMS OLTECH ANUAL There is no way that the measurement can be recovered from this point. For program execution, this means that the entire program has to be re-run from the first test; and for measure mode, the test has to be re-entered. In the case of fixture compensation, either the compensation for the entire program must be re-run, or (in measure mode) the compensation for the required test.
Page 423: Ixtures
AT3600 U OLTECH ANUAL AFETY YSTEMS 5. C ONSTRUCTING IXTURES As described in the previous section, when the light curtain of the safety system is broken, the tester will stop the execution of a high voltage test, and remove the dangerous voltages, to protect the operator from the dangers of electric shock.
Page 424 AT3600 U AFETY SYSTEMS OLTECH ANUAL 10.14. VPN 98 - 024 AFETY YSTEMS...