Ametek Ripple NX Installation And Quick Start Manual

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Safety, Installation and

Quick Start Manual

Version:

2.0, 26-September 2024

Replaces:

1.0, 15-May 2023

Filename:

Safety, Installation and Quick Start Manual_Ripple NX-

E-V2.0.docx

Print date:

26 September 2024

Ripple NX

Ripple NX200-1000-2.5

Ripple NX400-1000-2.5

Ripple NX600-1000-5

Ripple NX1000-1000-5

Ripple NX1000-1000-10

RippleSource NX2.5

RippleSource NX5

RippleSource NX10

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Summary of Contents for Ametek Ripple NX

Page 1 Ripple NX Safety, Installation and Ripple NX200-1000-2.5 Quick Start Manual Ripple NX400-1000-2.5 Ripple NX600-1000-5 Ripple NX1000-1000-5 Ripple NX1000-1000-10 RippleSource NX2.5 RippleSource NX5 RippleSource NX10 Version: 2.0, 26-September 2024 Replaces: 1.0, 15-May 2023 Filename: Safety, Installation and Quick Start Manual_Ripple NX- E-V2.0.docx...
Page 2 Switzerland Phone: +41 61 204 41 11 Fax: +41 61 204 41 00 URL : www.ametek-cts.com Copyright © 2024 AMETEK CTS GmbH All rights reserved. Specifications subject to change. Safety, Installation and Quick Start Manual V 2.0 2 / 75...
Page 3: Table Of Contents
Overview ..............................12 Technical Specifications ............................12 Models and Options ..............................13 Scope of supply ................................. 15 3.3.1 Ripple NX 600-1000-x and Ripple NX1000-1000-x ....................15 3.3.2 Ripple NX200-1000-2.5 and Ripple NX400-1000-2.5 ....................16 3.3.3 Connection Box Power CBP 2-1000-1000 ........................ 17 3.3.4...
Page 4 AMETEK CTS Ripple NX RippleSource NX5 and NX10 – Internal Circuit Breakers ..................58 7.4.1 RippleSource NX5 and NX10 – Auxiliary Outputs ..................... 59 7.4.2 7.4.3 RippleCoupler NX600 and NX1000 ........................... 60 7.4.4 CBP and CBM ................................61 Calibration and Verification ............................62 Firmware Update ...............................
Page 5: Introduction And Intended Use
Ripple NX Introduction and intended use The Ripple NX is used to perform a ripple test on devices e.g., high voltage components for electric vehicles (battery, inverter, DC-DC converter, on-board charger, etc.), high power devices for airplanes and others. The Ripple NX generates a disturbance signal (ripple) that is superimposed on the supply lines to the test object. An external source (AC or DC) delivers the supply voltage to the EUT.
Page 6: Safety
AMETEK CTS Ripple NX Safety Safety and warning label on the device Please take note of the following explanations of the symbols used to achieve the optimum benefit from this manual and to ensure safety during operation of the equipment.
Page 7: Safety Aspects
AMETEK CTS Ripple NX Symbols Reference Number Symbol Description IEC 60417-5031 (2002-10) Direct current Alternating current IEC 60417-5032 (2002-10) Both direct and alternating current IEC 60417-5033 (2002-10) Three-phase alternating current IEC 60417-5032-1 (2002-10) Earth (ground) TERMINAL IEC 60417-5017 (2006-08) Protective conductor terminal...
Page 8: Responsibility Of The Operator
Faraday cage. Dangerous voltage can come from the DC source side and/or the EUT side and/or the Ripple NX. It is the responsibility of the user to make sure no DC voltage is present before opening the connection box (CBP) and/or the front door of the RippleCoupler NX.
Page 9: Qualification Of Personnel
Regulary check the covers for damages and replace if required. WARNING The Ripple NX is not able to open the DC path (HV+ and HV-). It is the responsibility of the user to install DC breakers/switches on the source and the EUT side.
Page 10: Safety Functions
Disable the TEST ON button of the RippleCoupler NX Open the external interlock circuit (if available) Push the emergency stop button of the Ripple NX Switch off the RippleSource NX main switch and pull the yellow in- ner part for blocking the main switch...
Page 11: Standard Safety Procedure Ripple Nx600-1000-Xx And Ripple Nx1000-1000-Xx
Disable the TEST ON button of the RippleCoupler NX Open the external interlock circuit (if available) Push the emergency stop button of the Ripple NX Switch off the RippleSource NX main switch Disconnect the mains supply cable of the RippleCoupler NX Secure the DC source and EUT from switching back on the DC voltage (i.e., push emergency button or remove input voltage by...
Page 12: Overview
AMETEK CTS Ripple NX Overview Technical Specifications Safety and Quick Start Manual V 2.0 12 / 75...
Page 13: Models And Options
AMETEK CTS Ripple NX Models and Options Model Description Ripple NX600-1000-5-208 Fully integrated ripple generator consisting of: RippleSource NX5 (5kVA, dual range, 160 Vp / 63 Ap and 80 Vp / 126 Ap), RippleCoupler NX600-1000 (600 A, 1000 VDC, incl. coupling transformers, 10 mF shunt capacitor with pre-/discharge circuit, measuring unit), connection box CBP 2-1000-1000 (1000 A, 1000 VDC) and connection cables (RippleCoupler NX to CBP, 3 meter);...
Page 14 Option Description CBP 2-1000-1000-10m Connection box power for Ripple NX, max. 1000 VDC and 1000 A, robust aluminum hous- ing, temperature range -20 to + 80°C, measuring voltage connection with fuse, 10m cable length CBP 2-1000-1000-3m Connection box power for Ripple NX, max. 1000 VDC and 1000 A, robust aluminum hous- ing, temperature range -20 to + 80°C, measuring voltage connection with fuse, 3m cable...
Page 15: Scope Of Supply
AMETEK CTS Ripple NX Scope of supply 3.3.1 Ripple NX 600-1000-x and Ripple NX1000-1000-x Part No. Part Picture RippleSource NX RippleCoupler NX Connection Box Power with cables EMERGENCY STOP SWITCH 101224 Emergency stop master-slave cable 1007608 CBLA STR 2Pol 1500mm GY 2CON MM I 1:1...
Page 16: Ripple Nx200-1000-2.5 And Ripple Nx400-1000-2.5
AMETEK CTS Ripple NX Part No. Part Picture Power mains cable (country specific) Short circuit plate for fuse holder on con- 1007807 nection panel Strain relief for high voltage cables 1005617 Brand Icotek Model CCL 22-32 22 – 32 mm...
Page 17: Connection Box Power Cbp 2-1000-1000
AMETEK CTS Ripple NX Part No. Part Picture Plug 250 A red 1008565 Stäubli 15.0645C4-21 Plug 250 A black 1005866 Stäubli 15.0645C1-22 3.3.3 Connection Box Power CBP 2-1000-1000 Part No. Part Picture Connection box Complete with cables and accessories 1007526...
Page 18: Connection Box Power Cbp 1-400-1000
AMETEK CTS Ripple NX 3.3.4 Connection Box Power CBP 1-400-1000 Part No. Part Picture Connection box Complete with cables and accessories 1008828 1008562 Box only Shielded power connection cable 3 m 1008772 Black 1008773 Measuring cable, 4 m 1008876 Fuse for measurement lines...
Page 19: Overview Ripplesource Nx5 And Nx10
AMETEK CTS Ripple NX Overview RippleSource NX5 and NX10 3.4.1 Front Side Figure 1 Front view of RippleSource NX RippleSource NX control unit with touch panel (see chapter 3.5.3) Main switch, the inner yellow part can be pulled out to lock the switch with a padlock Wheels with brakes 3.4.2...
Page 20 (e.g., amplifiers, sources) 9 and 10 EUT status input to control the behavior of the Ripple NX (i.e., start, stop etc. of test depend on the EUT status), used to connect EUT monitoring outputs (i.e., digital status output)
Page 21 Connector Sub-D 9 pole USB host interface, connection to an external drive (save and load test files, firmware update etc.) This interface cannot be used to remotely control the Ripple NX Safety and Quick Start Manual V 2.0 21 / 75...
Page 22: Overview Ripplecoupler Nx600 And Nx1000
NX and cannot be removed In case of damage to the black or red connection cables, do not replace or repair the cables on your own. Contact AMETEK CTS service center for support. System power, mains connector and switch (see chapter 0 for details) SYS.LINK input, communication interface to connect the RippleCoupler NX to a SYS.LINK controller (i.e.,...
Page 23 AMETEK CTS Ripple NX Emergency switch, MASTER, control input for the emergency circuit (see chapter Emergency Stop Cir- cuit6.2.1.1). Operates the input circuit breaker and disconnects the instrument from mains when open. The RippleCoupler NX is usually connected to the RippleSource NX emergency switch SLAVE connector.
Page 24: Ripplecoupler Nx Connection Panel Details
AMETEK CTS Ripple NX 3.5.3 RippleCoupler NX connection panel details Figure 5 Overview RippleCoupler NX connection panel and protective cover Voltage test points, used to check the presence of voltage at the DC IN and OUT1 / OUT 2 terminals.
Page 25: Overview Ripple Nx200-1000-2.5 And Ripple Nx400-1000-2.5
AMETEK CTS Ripple NX Cap rail with clamps as strain-relief for the DC source cables Fuses holders for OUT 1 and OUT 2 outputs, used to protect the EUT from overcurrent. Fuses are not part of the standard scope of delivery.
Page 26: Connection Panel For Direct Source Output And Coupler Input
AMETEK CTS Ripple NX 3.6.1 Connection panel for direct source output and coupler input Figure 7 direct output and coupler input Ripple Source direct output for maximum current (not fused). Do not connect output (+) or (-) to ground or earth. Otherwise, the amplifier output is short circuited.
Page 27: Output Connection Panel
AMETEK CTS Ripple NX 3.6.2 Output connection panel Figure 8 direct output and coupler input Main switch, the inner yellow part can be pulled out to lock the switch with a padlock Voltage measurement input, selectable by jumper Internal voltage is measured directly at the output (Nr. 4)
Page 28: Rear Side
(e.g., amplifiers, sources) 9 and 10 EUT status input to control the behavior of the Ripple NX (i.e., start, stop etc. of test depend on the EUT status), used to connect EUT monitoring outputs (i.e., digital status output)
Page 29 CAN remote control interface Connector Sub-D 9 pole USB host interface, connection to an external drive (save and load test files, firmware update etc.) This interface cannot be used to remotely control the Ripple NX External relay control Connector Hirschmann STAKEI 2...
Page 30: Ripplesource Nx Control Unit Details
AMETEK CTS Ripple NX RippleSource NX control unit details Figure 9 Front view of control unit RippleSource NX Touch panel for local control and status information for remote control. TEST ON button and indicator WHITE TEST ON button is inactive, no test can be...
Page 31 AMETEK CTS Ripple NX Indicator for the interlock circuit (see chapter 6.2.1.2 for details) CLOSED Interlock circuit is closed, and ripple generator can be used OPEN Interlock circuit is open, and the ripple gener- ator is in safety mode (coupling capacitor dis- charged, transformers short-circuited and ext.
Page 32: Connection Boxes
AMETEK CTS Ripple NX Connection Boxes 3.9.1 CBP 2-1000-1000 Figure 11 Connection Box Power CBP, protective cover and accessories Voltage test points, used to check the presence of voltage at the DC IN and OUT1 / OUT 2 terminals. A voltage tester with a rated voltage of 1000VDC or more must be used to check the voltage.
Page 33: Cbp 1-400-1000
AMETEK CTS Ripple NX Ground plate with fixation notch Dimensions ground plate (in milimeter): Protective cover with test points Copper bar bridge for parallel configuration of channel 1 and channel 2 Silicon stoppers to seal the cable fittings Rubber reduction rings for the cable fittings 3.9.2...
Page 34 AMETEK CTS Ripple NX Ground plate with fixation notch Dimensions ground plate (in milimeter): Channel 1 – HV (+) connection point Bolt Channel 1 and channel 2 – HV (-) connection point Bolt Fuse holders with fuse to protect the voltage measuring input...
Page 35: Cbm 1-1000
AMETEK CTS Ripple NX 3.9.3 CBM 1-1000 Figure 13 CBM 1-1000 Connection to RippleCoupler NX Cable fitting Hummel HSK-M-PVDF 1.699.2000.30 Connection to DUT Cable fitting Hummel HSK-M-PVDF 1.699.2000.30 Screw terminal to connect (+) and (-) measurement cable 2.5 – 25 mm...
Page 36: Unpacking
AMETEK CTS Ripple NX Unpacking Inspect the packaging and the units for any possible shipping damage immediately upon receipt. If damage is evident, notify the carrier. DO NOT return an instrument to the factory without prior approval. Do not destroy the packing container until the unit has been inspected for damage in shipment.
Page 37 AMETEK CTS Ripple NX By forklift: 1. Slide the forks from the side of the rack. Pay attention to stay between the wheels by adjust- ing the distance between the forks to 2. Lift the rack from the wooden platform...
Page 38: Installation
If you have any questions or concerns, please consult the manufacturer's instructions, or contact a qualified technician. 5.1.2 Heat dissipation, cooling requirements and overtemperature protection Appropriate cooling of the room where the Ripple NX is installed must be maintained all time during operation. CAUTION Heat dissipation (worst case operating point)
Page 39: Airflow
AMETEK CTS Ripple NX 5.1.3 Airflow Figure 17 Airflow and distance to wall 5.1.4 Tightening Torque Use a torque wrench to tighten the screws. See below table for recommended standard torque if not otherwise specified. CAUTION When tightening a screw, use a torque wrench to apply the correct amount of force. Adjust the wrench to the desired setting and turn it until it clicks.
Page 40: Power Requirements
AMETEK CTS Ripple NX 5.1.5 Power Requirements Do not connect other mains voltage than specified. Incorrect voltage can damage the unit. The EARTH connection of the power plug (CEE type) must be always connected to proper ground of mains. CAUTION Always use appropriate mains cable.
Page 41: Ripple Nx600-1000-X And Ripple Nx1000-1000-X
AMETEK CTS Ripple NX Model Mains Volage Nominal current Input connector 230 V ± 10 % / 50 – 60 Hz RippleCoupler NX1000-1000 Appliance inlet C20 110 V ± 10 % / 50 – 60 Hz Mains cable 3 lines (L-N-PE), 3 x 1.5 mm2 Min.
Page 42 AMETEK CTS Ripple NX Here are some guidelines to follow for proper sizing of the ground cable: • Equipment Rating: The size of the ground cable should be based on the rating of the equipment it is connected to. Check the manufacturer's instructions or equipment rating plate for the appropriate size of the ground cable.
Page 43: Cabling Of Racks
AMETEK CTS Ripple NX 5.2.2 Cabling of racks Figure 20 Overview inter-wiring of racks Figure 21 Picture of inter-wiring of racks RippleSource NX RippleCoupler NX Cable / Connector EMERGENCY SWITCH Emergency stop button MASTER EMERGENCY SWITCH EMERGENCY SWITCH Emergency master-slave cable...
Page 44: Overview Of Connections To Source And Eut
AMETEK CTS Ripple NX 5.2.3 Overview of connections to source and EUT Figure 22 General setup The output of the external source is connected to the RippleCoupler NX source inputs by high voltage cables (not included in the scope of supply). The Connection Box Power CBP is connected to the RippleCoupler NX with the included cables (4x power cable and 1x measurement cable).
Page 45: Cabling Connection Box
AMETEK CTS Ripple NX 5.2.5 Cabling connection box Always check the absence of voltage before removing the protective cover of the RippleCoupler NX connection panel. CAUTION Figure 24 Details of RippleCoupler NX connection panel Note: output fuses are not included in scope of supply Mounting instructions Start with the cable “OUT 2 HV (-)”...
Page 46: Cabling Of Supply Source
AMETEK CTS Ripple NX 5.2.6 Cabling of supply source Figure 25 Detail for source input cables Mounting instructions Pass the cables from the bottom of the rack through the whole in the bottom plate Slip the cable strain relief pieces over the cable and insert them in the cap rail from the bottom.
Page 47: Setup For Direct Source Output
AMETEK CTS Ripple NX 5.2.7 Setup for direct source output The RippleSource NX can also be used standalone as a four quadrant amplifier. Typical use cases are: auxiliary EUT voltage supply, magnetic field tests (requires option). The RippleCoupler NX needs to be disconnected and switched off.
Page 48: Ripple Nx200-1000-2.5 And Ripple Nx400-1000-2.5
AMETEK CTS Ripple NX Ripple NX200-1000-2.5 and Ripple NX400-1000-2.5 5.3.1 Grounding Before using the equipment, ensure that it is properly grounded. Failure to ground the equipment can result in electrical shock, serious injury, or even death. WARNING Recommended minimum cross section of earthing cable: 25mm2 CAUTION Figure 28 Earthing Ripple NX200/400-1000-2.5...
Page 49: Overview Of Connections To Source And Eut
AMETEK CTS Ripple NX 5.3.2 Overview of connections to source and EUT Figure 29 General setup Ripple NX200/400-1000-2.5 without CBP The output of the external source is connected to the RippleCoupler NX source inputs by high voltage cables (not included in the scope of supply).
Page 50: Cabling Connection Box Cbp 1-400-1000 (Optional)
AMETEK CTS Ripple NX 5.3.3 Cabling connection box CBP 1-400-1000 (optional) Always check the absence of voltage before removing the protective cover inside the connection box CBP. CAUTION To RippleCoupler NX Figure 31 connection box power CBP To EUT Mounting instructions Pass the connection cables of the EUT through the cable fittings.
Page 51: Setup For Direct Source Output
AMETEK CTS Ripple NX 5.3.4 Setup for direct source output The RippleSource NX can also be used standalone as a four quadrant amplifier. Typical use cases are: auxiliary EUT voltage supply, magnetic field tests (requires option). The RippleCoupler NX is internally disconnected if the Source Mode is used.
Page 52: Equipment Operation Indication
Identification, description and use from operating controls in all mode The devices can be identified by the nameplate sticker on the back panels. Check chapter 9 for details about the use of the Ripple NX. Instruction for interconnection to accessories and other equipment 6.2.1...
Page 53 Connect the delivered Safety Circuit Adapter SCC AD to the SYSLINK plug. The Ripple NX does not start any test if the safety circuit is not connected and closed. IMPORTANT NOTE: The short circuit is already short-circuited at the delivered and Safety...
Page 54 AMETEK CTS Ripple NX When delivered, a wire bridge is set inside the SCC AD. Take out the wire bridge and use a cable instead to connect to external safety interlock contactor (e.g. relay contact of safety cell manager or safety PLC): SWL AD serves as a sys.link terminator plus includes a potential free contact...
Page 55: Warning Lamp
6.2.2 Warning Lamp The safety warning lamp does not reflect the status of the applied voltage from the external source. It only shows the status of the Ripple NX. CAUTION The warning lamp offers a voltage free contact that indicates the status of the generator system.
Page 56: Maintenance, Adjustments, Replacement Of Parts
EM TEST and TESEQ devices can be returned to AMETEK CTS in Switzerland or to their agency for adequate disposal. Alternatively, the equipment can be handed over to a specialized enterprise for disposal of electronic devices.
Page 57: Cleaning
A deactivated circuit breaker has the switch in the bottom position and a red indicator showing. In case of a deactivated circuit breaker, do not use the RippleSource NX. Contact AMETEK CTS service center. Safety and Quick Start Manual V 2.0...
Page 58: Ripplesource Nx5 And Nx10 - Internal Circuit Breakers
AMETEK CTS Ripple NX RippleSource NX5 and NX10 – Internal Circuit Breakers 7.4.1 Figure 34 Location of the automatic circuit breaker in the RippleSource NX RippleSource NX 5-400 RippleSource NX 10-400 Name Function Name Function PSU1 (X1) PSU1 (X1) PSU1 (X1)
Page 59: Ripplesource Nx5 And Nx10 - Auxiliary Outputs
AMETEK CTS Ripple NX RippleSource NX5 and NX10 – Auxiliary Outputs 7.4.2 Figure 35 Location of the fuse for the auxiliary output Fuse type 30 A slow blow, 230 V Procedure for the replacement of the fuse Make sure the TEST ON button of the RippleSource NX is disactivated...
Page 60: Ripplecoupler Nx600 And Nx1000
RippleCoupler NX600 and NX1000 Figure 36 Location of the output fuses on the RippleCoupler NX Note: the Ripple NX is delivered without fuses mounted. The fuses must be matched to the EUT and within the limits of the RippleCoupler NX maximum current.
Page 61: Cbp And Cbm
AMETEK CTS Ripple NX 7.4.4 CBP and CBM Figure 37 Location of the fuses in the CBP 2-1000-1000 Fuse LittleFuse SPXV 001 Figure 38 Location of the fuses in the CBP 1-400-1000 Fuse LittleFuse SPXV 001 Figure 39 Location of the fuses in the CBP 1-400-1000...
Page 62: Calibration And Verification
AMETEK CTS Ripple NX Calibration and Verification Calibration should be performed regularly based on the user’s internal policy. AMETEK CTS recommends calibration every year. Verification must be performed, according to the applicable standard, regularly. Consult the applicable standard for details about regular verification.
Page 63: Firmware Update
Procedure for a firmware update by memory stick Safe the firmware “RippleNX.usp” on the root directory of the memory stick Start the Ripple NX and wait until the start-up is finished Connect the memory stick to the USB connector on the back of the RippleSource NX Click on “HOME”...
Page 64: Periodical Check
DC voltage. Therefore, the ca- problem with the pre-charge circuit. pacitor was properly pre-charged. Measure Vcap voltage. Contact AMETEK CTS GmbH ser- Check Vcap voltage measurement. vice. Discharge the capacitor through the Vcap is not zero. This means that Vcap shows zero.
Page 65: Support And Service
AMETEK CTS Ripple NX Support and Service If you have any questions or concerns about the safety of our products, please do not hesitate to contact our support team at the following address: AMETEK CTS GmbH Sternenhofstrasse 15 4153 Reinach BL...
Page 66: Risk Mitigation
AMETEK CTS Ripple NX Risk Mitigation Safety and Quick Start Manual V 2.0 66 / 75...
Page 67: Quick Start Guide
Quick Start Guide Output configuration, DC source and EUT connection Step Details Remark Chose the appropriate output configura- tion Setup of basic Ripple NX configuration Used measurement channels, disturbance limiters, test method, etc. Connect the EUT General switch on procedure Step Function...
Page 68: Switch-Off Procedure
AMETEK CTS Ripple NX Switch-off procedure Step Function Remark Discharge capacitor Discharges the internal shunt capacitor through an active discharge circuit; Disable external DC supply Motors: disable DC source output VDC indicator changes from yellow to white; Battery: open battery Vdc measurement shows “<...
Page 69: Operation By The Web Access
AMETEK CTS Ripple NX Operation by the web access Establish an Ethernet connection between Ripple NX and computer. The IP address of the Ripple NX and the com- puter must be in the same range. Example: Ripple NX IP address: 10.0.0.2 Computer IP address: 10.0.0.1...
Page 70: Front Panel Control
AMETEK CTS Ripple NX 10 Front Panel Control 10.1 Main Ripple Settings HOME button to return to main screen Signal settings to define the disturbance signal: amplitude of the generated disturbance signal (in V, Vp or Vpp) frequency of the generated disturbance signal (in Hz or kHz)
Page 71: Disturbance Limiter Settings
AMETEK CTS Ripple NX 10.3 Disturbance limiter settings Sets the behavior in case a disturbance limit is reached CONTINUE the disturbance signal is maintained for the dwell time STOP the disturbance signal is stopped Set the disturbance limiter per channel. Several limiters operate in parallel.
Page 72: Info And Error Codes
AMETEK CTS Ripple NX 11 Info and Error Codes 11.1 Type of errors Information and error codes and texts are displayed in the page header in a card: Additionally, error codes trigger the appearance of an error dialog which has three types: Errors are displayed with title “Error”...
Page 73 AMETEK CTS Ripple NX No-critical error Error text code (0x0…) 0072 Measuring module : Configuration parameter error 0080 RippleSource NX : Source not ready 0081 RippleSource NX : Source busy 0082 RippleSource NX : Cannot start signal 0083 RippleSource NX : Source initialization failed...
Page 74: Info Signals
AMETEK CTS Ripple NX Critical reboot error Error text code (0x8…) 8060 RippleCoupler NX : Capacitor switch stuck. Restart required 8061 RippleCoupler NX : Cannot discharge. Restart required 8101 RippleSource NX : Source missing. Restart required 8102 RippleSource NX : Signal generator missing. Restart required 8103 RippleSource NX : Interface module missing.
Page 75: Results And Notes
AMETEK CTS Ripple NX Info code Info text 0605 Regulation limit : Power source current derating 0609 Regulation : Limit reached 0700 Measure instrument : frequency out of range of current probe 0701 Measure instrument : frequency out of range of coil...

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