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Fluke 433 Service Manual

Fluke 433 Service Manual

Three phase power quality analyzer
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Fluke 433, 434, 435
Three Phase Power Quality Analyzer
Service Manual
4822 872 05396
November 2006
© 2006 Fluke Corporation, All rights reserved. Printed in USA
All product names are trademarks of their respective companies.

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  • Page 1 ® Fluke 433, 434, 435 Three Phase Power Quality Analyzer Service Manual 4822 872 05396 November 2006 © 2006 Fluke Corporation, All rights reserved. Printed in USA All product names are trademarks of their respective companies.
  • Page 2 Limited Warranty & Limitation of Liability Each Fluke product is warranted to be free from defects in material and workmanship under normal use and service. The warranty period is three years for the Analyzer and one year for its accessories. The warranty period begins on the date of shipment.

  • Page 3: Table Of Contents

    Table of Contents Chapter Title Page Introduction and Safety Instructions..........1-1 1.1 Introduction to Manual ................1-3 1.2 Safety ......................1-3 1.2.1 Introduction ..................1-3 1.2.2 Safety Precautions ................1-3 1.2.3 Caution and Warning Statements ............1-3 1.2.4 Symbols ....................1-4 1.2.5 Impaired Safety ..................
  • Page 4 Fluke 433, 434, 435 Service Manual 3.6. Verification of Current Inputs..............3-6 3.6.1 Preparation.................... 3-6 3.6.2 Accuracy....................3-6 3.6.2 Bandwidth check of current channels (*) ..........3-7 3.7 Voltage Inputs....................3-7 3.7.1 Introduction ..................3-7 3.7.2 Verification of voltage inputs in 120 V range ........3-9 3.7.3 Verification of voltage inputs in 230 V range ........

  • Page 5: Introduction And Safety Instructions

    Chapter 1 Introduction and Safety Instructions Title Page 1.1 Introduction to Manual ................1-3 1.2 Safety ......................1-3 1.2.1 Introduction ..................1-3 1.2.2 Safety Precautions ................1-3 1.2.3 Caution and Warning Statements ............1-3 1.2.4 Symbols ....................1-4 1.2.5 Impaired Safety ..................1-4 1.2.6 General Safety Information ..............

  • Page 7: Introduction To Manual

    1.1 Introduction to Manual 1.1 Introduction to Manual The Fluke 433, 434, 435 Three Phase Power Quality Analyzer (hereafter referred to as ‘Analyzer’) offers an extensive and powerful set of measurements to check power distribution systems. This Service Manual provides the information necessary to maintain the Analyzer at customer level.

  • Page 8: Symbols

    Fluke 433, 434, 435 Service Manual 1.2.4 Symbols The following symbols are used on the Analyzer, in the Users Manual, in this Service Manual, or on spare parts for this Analyzer. See explanation in Users Manual DOUBLE INSULATION (Protection Class)

  • Page 9: Specifications

    Chapter 2 Specifications Title Page 2.1 Introduction....................2-3 2.2 Electrical Measurements................2-4 2.3 Wiring Combinations................... 2-13 2.4 General......................2-13 2.5 Mechanical....................2-14 2.6 Power ......................2-14 2.7 Standards...................... 2-14 2.8 Cross talk ..................... 2-15 2.9 Safety ......................2-15 2.10 Environmental.................... 2-15 2.11 Printers and Interface .................

  • Page 11: Introduction

    2.1 Introduction 2.1 Introduction Performance Characteristics Fluke guarantees the properties expressed in numerical values within the tolerances stated. Numerical values without tolerances are typical and represent the characteristics of an average instrument excluding accessories. The Analyzer meets the specified accuracy 30 minutes and two complete acquisitions after power-on. All operational specifications are valid under the restrictions mentioned in section ‘Environmental’...

  • Page 12: Electrical Measurements

    Fluke 433, 434, 435 Service Manual 2.2 Electrical Measurements The following specifications of the instrument are verified using the “implementation verification” table 3 as specified in 61000-4-30 chap-6-2. INPUT CHARACTERISTICS Voltage inputs Number of inputs 4 (3 phases + neutral) DC coupled...
  • Page 13 Specifications 2.2 Electrical Measurements DISPLAY MODES Waveform display Available in Scope and Transient mode Captures 8 waveforms simultaneously Display update rate 5x per second Up to 10/12 times horizontal zoom Cursors: Single vertical line showing min, max, avg reading at cursor position. Phasor Shows real time phasor diagram Available in Scope and Unbalance mode...
  • Page 14 Fluke 433, 434, 435 Service Manual MEASUREMENT MODES Scope Vrms, Arms, Vcursor, Acursor, Vfund, Afund, Hz, V phase angles, A phase angles Volts/Amps/Hertz Vrms, Vpk, V Crest Factor, Arms, Apk, A Crest Factor, Hz Dips and Swells Vrms½, Arms½ Captures up to 1000 events with date, time, duration, magnitude and phase...
  • Page 15 0,001…10 Arms ± 0.5% ± 5 counts Fluke 433/434 0…20.00 kArms 0,001…10 Arms ± 1% ± 5 counts Fluke 433/434 with i400s 0…40 / 400 Arms 0.1 and 1 Arms ± 1% ± 5 counts Fluke 435 with I430flex 30…3000 Arms 1 Arms ±...
  • Page 16 Fluke 433, 434, 435 Service Manual Harmonics Measurement Range Resolution Accuracy Harmonic order (n) DC, 1..50 Grouping: Harmonic groups according to IEC 61000-4-7 Inter-Harmonic order Off, 1..49 Grouping: Harmonic and Interharmonic subgroups according to IEC 61000-4-7 Vrms Relative (%f): 0.0 … 100.0% 0.1%...
  • Page 17 Measurement Range Resolution Accuracy Volts Fluke 435 (neg. 0.0 … 5.0% 0.1% ± 0.15% and zero seq.) Volts Fluke 433/434 neg. 0.0 … 5.0% 0.1% ± 0.5% and zero seq.) Current (neg. and zero 0.0 … 20% 0.1% ± 1% seq.)
  • Page 18 Fluke 433, 434, 435 Service Manual Inrush mode Measurement Range Resolution Accuracy Arms (AC+DC) 0.000 … 20.00 kArms 0.001.. 10 Arms ± 1% of meas ± 5 counts Inrush Duration mm:ss:mmm between 10ms ± 20 ms (Fnominal = 50 7.5s … 30minutes...
  • Page 19 Depends on selected readings and averaging time Zoom Two zoom positions, display all or 1x Memory User configurable shared memory, upt to 15 MB on Fluke 435, Up to 7 MB on Fluke 434 Nr of readings on 3 phases + N Averaging time 0.5 s...
  • Page 20 Fluke 433, 434, 435 Service Manual MEASUREMENT METHOD Vrms, Arms 10/12 cycle contiguous non overlapping intervals using 500/416 samples per cycle in accordance with IEC 61000-4-30 Vpeak, Apeak Absolute highest sample value within 10/12 cycle interval with 40µs sample resolution...

  • Page 21: Wiring Combinations

    Specifications 2.3 Wiring Combinations Mains Signaling Measurement are based on: either the corresponding 10/12-cycle r.m.s. value interharmonic bin or the rms of the four nearest 10/12-cycle rms value interharmonic bins per IEC 61000-4-30 Limit setup for Monitor mode follows EN50160 “Meistercurve” Time Synchronisation Optional GPS430 timesync module provides time uncertainty ≤...
  • Page 22 Data 10 data memories for storing data including recordings (5 in Fluke 433) Logger User configurable shared memory, up to 15 MB on Fluke 435, Up to 7 MB on Fluke 434 Limit templates 2 preprogrammed, 2 administrator (programmable via FlukeView), 2 user...

  • Page 23: Cross Talk

    Specifications 2.8 Cross talk 2.8 Cross talk Between V inputs -60 dB @ Fnominal Voltage to current input -95 dB @ Fnominal 2.9 Safety Compliance IEC/EN61010-1-2001, with CAN/CSA C22.2 No 61010-1-04, UL std No 61010-1, Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use, Part 1: General requirements, Rated: 600V CAT IV 1000V CAT III Pollution Degree 2 Max voltage on...

  • Page 24: Electro Magnetic Compatibility (Emc)

    1:1 50Hz/60Hz nominal frequency according to IEC 61000-4-30 Add clamp accuracy and phase shift The logger and Mains Signaling function are optional for the Fluke 434 and standard available on the Fluke 435 Measured on reference voltage input A/L1...

  • Page 25: Performance Verification

    Chapter 3 Performance Verification Title Page 3.1 Introduction....................3-3 3.2 Equipment Required For Verification ............3-4 3.3 General Instructions ..................3-4 3.4 Operating Instructions.................. 3-4 Resetting the Analyzer .................. 3-4 3.5 Display And Backlight Test................. 3-4 3.6. Verification of Current Inputs..............3-6 3.6.1 Preparation....................

  • Page 27: Introduction

    Analyzer performance can be checked with single phase 50 and 60 Hz test signals such as generated by a Calibrator Fluke 5500A or 5700A. For Fluke 433/434 you can use a standard Calibrator (e.g. Fluke 5500A); for the more accurate model Fluke 435 you must use Fluke 5700A.

  • Page 28: Equipment Required For Verification

    Service Manual 3.2 Equipment Required For Verification The primary source instrument used in the verification procedures of Fluke 433/434 is the Fluke 5500A. For Fluke 435 you must use Fluke 5700A. If not available, you can substitute another Calibrator as long as it meets the minimum test requirements.
  • Page 29 Performance Verification 3.5 Display And Backlight Test • Do NOT press now! If you did, turn the Analyzer off and on, and start at 5. Press three times. The Analyzer shows PREVIOUS Contrast (CL 0100): 6. Press CALIBRATE The Analyzer shows a dark display; the test pattern as shown in Figure 3-1 may be not visible or hardly visible.

  • Page 30: Verification Of Current Inputs

    Fluke 433, 434, 435 Service Manual 3.6. Verification of Current Inputs 3.6.1 Preparation Proceed as follows: • Reset the Analyzer. • SETUP Press . Set the Analyzer to 3-phase WYE, 60 Hz, 120 V. Set Clamp for Phase and Neutral to 1 mV/A, 400 A, 1:1.

  • Page 31: Bandwidth Check Of Current Channels (*)

    10 + 5 A = 15 A). Fluke 435: check for a readout between 990 ... 1010 A (tolerance 5 + 5 A = 10 A). (Voltage readout V rms must be approx. 0 V at A/L1, B/L2, C/L3 and 172 V at N inputs, frequency approx.
  • Page 32 Fluke 433, 434, 435 Service Manual Proceed as follows: 1. To check the A/L1, B/L2, C/L3 inputs, connect the N input to Ground (See Figure 3- 3). N now will give zero reading. CALIBRATOR NORMAL POWER ADAPTER BC 430 A/L1...

  • Page 33: Verification Of Voltage Inputs In 120 V Range

    3. Set the Calibrator to 0 Hz, 0 V and then to OPR. 4. Fluke 433/434: check for a voltage readout V rms between 0.0 ... 0.6 V. Fluke 435: check for a voltage readout V rms between 0.00 ... 0.12 V.

  • Page 34: Verification Of Voltage Inputs In 230 V Range

    12. Set the Calibrator to 0 Hz / 0 V and then to OPR. 13. Fluke 433/434: check for a voltage readout V rms between 0.0 ... 0.6 V. Fluke 435: check for a voltage readout V rms between 0.00 ... 0.12 V.
  • Page 35 Optional Test. Bandwidth Check of Channel A/L1, B/L2, C/L3 (*): Note: for Fluke 435 you must use the Fluke 5700A Calibrator. This instrument is able to generate 219.99999 V as a maximum at 3 kHz. Therefor a 50 Hz reference voltage of 215 V must be adjusted.

  • Page 36: Verification Of Voltage Inputs In 400 V Range

    Fluke 433, 434, 435 Service Manual 13. Fluke 433/434: check for a voltage readout V rms between 0.0 ... 1.2 V. Fluke 435: check for a voltage readout V rms between 0.00 ... 0.23 V. 14. Check the 230 V range according to the table below.
  • Page 37 Optional Test. Bandwidth Check of Channel A/L1, B/L2, C/L3 (*): Note: for Fluke 435 you must use the Fluke 5700A Calibrator. This instrument is able to generate 219.99999 V as a maximum at 3 kHz. Therefor a 50 Hz reference voltage of 215 V must be adjusted.

  • Page 38: Verification Of Voltage Inputs In 6 Kv Range (Transients)

    Fluke 433, 434, 435 Service Manual 13. Fluke 433/434: check for a voltage readout V rms between 0.0 ... 2.0 V. Fluke 435: check for a voltage readout V rms between 0.00 ... 0.40 V. 14. Check the 400 V range according to the table below.
  • Page 39 Optional Test. Bandwidth Check of Channel A/L1, B/L2, C/L3 (*): Note: for Fluke 435 you must use the Fluke 5700A Calibrator. This instrument is able to generate 219.99999 V as a maximum at 3 kHz. Therefor a 50 Hz reference voltage of 215 V must be adjusted.

  • Page 40: Channel Isolation (*)

    Optional Test. Bandwidth Check of Channel N (*): Note: for Fluke 435 you must use the Fluke 5700A Calibrator. This instrument is able to generate 219.99999 V as a maximum at 3 kHz. Therefor a 50 Hz reference voltage of 215 V must be adjusted.
  • Page 41 Performance Verification 3.8 Channel Isolation (*) 7. Disconnect all test leads. CALIBRATOR NORMAL POWER ADAPTER BC 430 A/L1 B/L2 C/L3 ANALYZER A/L1 B/L2 C/L3 INPUT BLOCK 50 OHM 50 OHM 50 OHM 50 OHM PIECE PIECE PIECE PIECE Figure 3-5. Checking the Channel isolation. 3-17...
  • Page 42 Fluke 433, 434, 435 Service Manual 3-18...

  • Page 43: Calibration Adjustment

    Chapter 4 Calibration Adjustment Title Page 4.1 General......................4-3 4.1.1 Introduction ..................4-3 4.1.2 Calibration number and date..............4-3 4.1.3 General instructions................4-4 4.1.4 Equipment required for calibration............4-4 4.2 Calibration Procedure Steps................. 4-4 4.3 Starting The Calibration................4-5 4.4 Contrast Calibration Adjustment ..............4-7 4.5 Warming Up ....................

  • Page 45: General

    4.1.1 Introduction The following information, provides the complete Calibration Adjustment procedure for the Fluke 433/434/435 Power Quality Analyzer (referred to as Analyzer). The Analyzer allows closed-case calibration using known reference sources. It measures the reference signals, calculates the correction factors, and stores the correction factors in RAM. After completing the calibration, the correction factors can be stored in FlashROM.

  • Page 46: General Instructions

    Power the Analyzer via the BC430 Battery Charger/Power Adapter 4.1.4 Equipment required for calibration The primary source instrument used in the calibration procedures for Fluke 433/434 is the Fluke 5500A; for Fluke 435 you must use the Fluke 5700A Calibrator because of its higher accuracy.

  • Page 47: Starting The Calibration

    Press to leave the SETUP DATE menu. • Fluke 435: in the SETUP menu adjust the Current Clamp for Phase and Neutral to 1 mV/A, 400 A, 1:1. 3. Select the calibration mode. The Calibration Adjustment Procedure uses built-in calibration setups, that can be accessed in the calibration mode.
  • Page 48 Fluke 433, 434, 435 Service Manual Cal Name Name of the selected calibration step, e.g. Warming Up (CL nnnn) Number of the calibration step Status (...) can be: After (re)entering this step, the calibration process is not started. IDLE (valid) The calibration data of this step are valid.

  • Page 49: Contrast Calibration Adjustment

    Calibration Adjustment 4.4 Contrast Calibration Adjustment 4.4 Contrast Calibration Adjustment After entering the calibration mode the display shows: WarmingUp (CL 0200):IDLE (valid) Do not press now! If you did, turn the Analyzer off and on, and enter the calibration mode again. Proceed as follows to adjust the maximum display darkness (CL 0100), the default contrast (CL 0110) , and the maximum display brightness (CL 0120).

  • Page 50: Warming Up

    Fluke 433, 434, 435 Service Manual Note: After having left calibration step CL 0120 in instruments with V01.00 software, the display contrast stays in the state as adjusted for maximum brightness. Because of this, menu visibility is insufficient. For instruments where this occurs it is recommended to save calibration data and exit as explained in Chapter 4.7.

  • Page 51: Final Calibration

    Calibration Adjustment 4.6 Final Calibration 4.6 Final Calibration Before starting the final calibration you must have done the Warming Up (section 4.5)! The final calibration is simple and straightforward and consists of the following elements: - Offset adjustment of voltage and current inputs (0 V input signal). - Low voltage adjustment of voltage and current inputs (0.67 V rms, 50 Hz input signal).

  • Page 52: Low Voltage And Current Gain Adjustment

    Fluke 433, 434, 435 Service Manual 2. The display must show step CL 0300. If it does not, then press to select the first calibration step in Table 4- 3. Set the Calibrator output to source the signal 0 Hz, 0 V required for the calibration steps in Table 4-1.
  • Page 53 Calibration Adjustment 4.6 Final Calibration CALIBRATOR NORMAL POWER ADAPTER BC 430 A/L1 B/L2 C/L3 ANALYZER A/L1 B/L2 C/L3 INPUT BLOCK Figure 4-4. Voltage Gain Adjustment 3. Set the Calibrator to supply 120 V, 50 Hz. Warning Dangerous voltages will be present on the calibration source and connection cables during the following steps.

  • Page 54: Save Calibration Data And Exit

    Fluke 433, 434, 435 Service Manual Table 4-2. Voltage Gain Adjustment Cal step Description Calibrator Setting CL 0410 Gain125Volt 120 V, 50 Hz, OPR CL 0420 Gain250Volt 230 V, 50 Hz, OPR CL 0430 Gain500Volt 480 V, 50 Hz, OPR...
  • Page 55 Calibration Adjustment 4.7 Save Calibration Data And Exit Possible error messages. The following messages can be shown on the Analyzer display: WARNING: Calibration data not valid. Save data and exit maintenance mode? Proceed as follows: • If you did the Warming Up and Pre-Calibration successfully (section 4.5), and you want to store the Pre-Calibration data before continuing with the Final Calibration: ⇒...
  • Page 56 Fluke 433, 434, 435 Service Manual 4-14...

  • Page 57: Disassembling The Analyzer

    Chapter 5 Disassembling the Analyzer Title Page 5.1. Introduction....................5-3 5.2. Disassembly & Reassembly Procedures ............. 5-3 5.2.1 Required Tools ..................5-3 5.2.2 Removing the Tilt Stand & Hang Strap..........5-3 5.2.3 Replacing the Side-Strap, Changing the Side-Strap Position ....5-4 5.2.4 Opening the Analyzer, Removing the Battery........

  • Page 59: Introduction

    Disassembling the Analyzer 5.1. Introduction 5.1. Introduction This section provides the required disassembling procedures. The printed circuit assembly removed from the Analyzer must be adequately protected against damage. Warning To avoid electric shock, disconnect test leads, probes and power supply from any live source and from the Analyzer itself. Always remove the battery pack before completely disassembling the Analyzer.

  • Page 60: Replacing The Side-Strap, Changing The Side-Strap Position

    Fluke 433, 434, 435 Service Manual 5.2.3 Replacing the Side-Strap, Changing the Side-Strap Position The side-strap (figure 5-6, item 16) can be attached at the right or left side of the Analyzer. Use the following procedure to replace the strap, or to change the strap position.
  • Page 61 Disassembling the Analyzer 5.2. Disassembly & Reassembly Procedures Figure 5-3. Loosen 2 Bottom Holster Screws Figure 5-4. Opening the Analyzer Figure 5-5. Removing the Battery Pack...

  • Page 62: Removing The Main Pca Unit

    Fluke 433, 434, 435 Service Manual (2x) (4x) (2x) (2x) (2x) Figure 5-6. Final Assembly Details 5.2.5 Removing the Main PCA Unit Caution To avoid contaminating the flex cable contacts with oil from your fingers, do not touch the contacts (or wear gloves).

  • Page 63: Removing The Display Assembly

    Disassembling the Analyzer 5.2. Disassembly & Reassembly Procedures using a small screw-driver, see Figure 5-7. The latch remains attached to the connector body. ST8682.WMF Figure 5-7. Flex Cable Connectors 3. Unplug the two-wire backlight cable. Warning If the battery pack or the power adapter is connected, the LCD backlight voltage on the wire cable is 400V ! (when the Analyzer is on).

  • Page 64: Replacing The Lcd Window/Decal

    Fluke 433, 434, 435 Service Manual 5.2.7 Replacing the LCD Window/Decal The LCD window/decal (Figure 5-6, item 2) is glued on the top cover. To replace it do the following: 1. From the inside of the top cover push the window outwards until it comes of.

  • Page 65: Reassembling The Main Pca Unit

    Disassembling the Analyzer 5.2. Disassembly & Reassembly Procedures Figure 5-8. PCA Unit Assembly 5.2.10 Reassembling the Main PCA Unit Reassembling the main PCA unit is the reverse of disassembly (see figure 5.8). However you must follow special precautions when reassembling the main PCA unit. 1.
  • Page 66 Fluke 433, 434, 435 Service Manual 6. Slide the Main PCA unit into the Top Case. Lock the plastic clamps at the inputs side on to the Top Case. Fasten with the 2 screws (item 19). 7. Stick the flaps of the keypad foil (item 4) to the metal shielding box 8.

  • Page 67: List Of Replaceable Parts

    Chapter 6 List of Replaceable Parts Title Page 6.1 Introduction....................6-3 6.2 How to Obtain Parts..................6-3 6.3 Service Centers .................... 6-3 6.4 Final Assembly Parts ................... 6-4 6.5 Main PCA Unit Parts ................... 6-6 6.7 Accessories ....................6-7...

  • Page 69: Introduction

    6.1 Introduction 6.1 Introduction This chapter contains an illustrated list of replaceable parts for the models 433, 434, and 435 Power Quality Analyzer. Parts are listed by assembly; alphabetized by item number. Each assembly is accompanied by an illustration showing the location of each part and its item number.

  • Page 70: Final Assembly Parts

    4022 244 90862 Input cover 0040 243 00041 Main PCA unit for Fluke 433/434 or 435. The Main PCA in this Analyzer is only available to Fluke Service Centers due to the programming that is necessary after installation. Bottom case assembly, incl. isolation foil for optical RS232 port...
  • Page 71 List of Replaceable Parts 6.4 Final Assembly Parts (2x) (4x) (2x) (2x) (2x) Figure 6-1. Final Assembly Details...

  • Page 72: Main Pca Unit Parts

    Fluke 433, 434, 435 Service Manual 6.5 Main PCA Unit Parts See Table 6-2 and Figure 6-2 for the main PCA Unit parts. Table 6-2. Main PCA Unit Parts Item Description Ordering Code Input block 0040 240 00011 Shielding box assy...

  • Page 73: Accessories

    AC Current Clamp Set (set of 4 pieces): 400 A (1 mV/A) and 40 A (10 mV/A) i400s switcheable. Supplied with Fluke 434. Flexible AC Current Clamp Set (4 pieces). Supplied with Fluke 435. i430flex-4pk Set with Color Coding Clips for Test Leads...
  • Page 74 AC/DC Current Clamp 100 A (10 mV/A) and 10 A (100 mV/A) switcheable. 80i-110s AC Current Clamp 5 A (400 mV/A, 3 pack) i5s PQ3 (*) CD with Service Manual for Fluke 433/434/435 (English), Revision 2 (Sept. 2006) 4822 872 05392...

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