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SPS electronic ST 3820K Manual

Surge tester
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Manual
Surge Tester
ST 3820K
Update status: 03.2024

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  • Page 1 Manual Surge Tester ST 3820K Update status: 03.2024...
  • Page 3 Contents Contents 1 General Information ______________________________________________ 5 1.1 Information on this operating manual ................5 1.2 Requirements for the operation of this device ............. 6 1.2.1 Regulations for application ..................6 1.2.2 Product liability ......................6 1.3 General safety regulations ..................7 1.3.1 Obligations of the operator ..................
  • Page 4 Contents 4.5 Description of Test Parameters ................. 47 4.5.1 General Information ....................47 4.5.2 AA: Start of Test ....................... 48 4.5.3 TV: Text Visual Step ....................50 4.5.4 PV: Picture Visual Step ................... 51 4.5.5 I2: Insulation Test ..................... 52 4.5.6 H2: High Voltage Test DC ..................
  • Page 5 Should you, while perusing this operating manual, find any misprints, any information you do not understand or which are incorrect please do not hesitate to inform SPS electronic GmbH about same. Pictographs and Symbols ...
  • Page 6  use of components, tools, additional installations, supplements and working material which have not been approved or recommended by SPS electronic GmbH  building in of spare parts which are not original SPS electronic GmbH spare parts or of spare parts from suppliers not recommended by SPS electronic GmbH 1.2.2 Product liability...
  • Page 7 Information 1 General 1.3 General safety regulations The surge tester ST 3820L/K has been manufactured according to the state of the art at the time of its delivery. Nevertheless the tester is not without hazards if it is applied by untrained personnel, applied improperly or not applied according to regulations.
  • Page 8 Information 1 General 1.3.3 Safety installations The ST 3820L/K testers are, for the safety of the operating personnel, equipped with below safety equipment:  safety current limiting for insulation test  safety current limiting for high voltage test  charge energy < 350 mJ (only standard device with 18 nF surge capacitor) Capacitive DUTs and DC high voltage When testing with DC high voltage, capacitive DUTs are getting charged.
  • Page 9 Description 2 Hardware Hardware Description 2.1 Device functions The ST 38xx surge testers can be used to perform safety tests on electrical appliances in accordance with standardized test specifications (EN, IEC, VDE, etc.). Winding goods such as stators, rotors, transformers etc.
  • Page 10 - Error area - Differential error area Evaluation methods - Tolerance band - Damping - Inductivity measurement Partial discharge measurement (only ST 3820K) Frequency range 1 GHz … 2 GHz broadband Sensitivity ca. -90 … -30 dBm Attenuation in the...
  • Page 11 Description 2 Hardware HV Test (High Voltage Test) free programmable from 100 up to 6000 V DC (voltage range 100-199 V: Test voltage residual ripple DC: < 1% acc. VDE 0432 / EN 61180 tolerances not specified) Short circuit current <...
  • Page 12 Description 2 Hardware 2.3 Design and functions 2.3.1 Front panel ST 3820 Fig. 1: Front view ST 3820 2.3.2 Rear panel Fig. 2: Rear view ST 3820 1 Connection field for test leads 2 X01: Mains supply for internal PC 3 X02: Mains supply for voltage generator 4 X6: Connector for external measuring probe 5 X4: Connector for measuring antenna / sensor of direction of rotation...
  • Page 13 into operation 3 Putting 3 Putting into operation 3.1 Requirements Tester ST 3820L/K as well as all of the electric connections and lines must be in operational and reliable condition. The General Safety Regulations (pl. see chapter 1.3) and the generally applicable legal rules as well as other binding directives for industrial safety, for accident prevention and for the protection of the environment have to be adhered to and persons staying in the area of operation must be informed respectively.
  • Page 14 into operation 3 Putting 3.4 DUT Connection Schemes 3.4.1 Insulation Test, variant #1 3.4.2 Insulation Test, variant #2 page 14 Surge tester ST 3820L/K...
  • Page 15 into operation 3 Putting 3.4.3 Surge Test ST 3820 3.4.4 Using an external switching matrix ST 3820 Surge tester ST 3820L/K page 15...
  • Page 16 of the Software 4 Description Description of the Software The Surge testers ST 3820L/K are controlled by remote software from an external PC. Depending on the application, this can be the DAT3805 or the EM4000 software. 4.1 Program start, program end Starting the program The application software of the ST4000 starts automatically after the operating system has started.
  • Page 17 of the Software 4 Description 4.2 The menu bar Menu Menu item Function To create an all-new, “empty” test program. File Load an existing test program from disk Load Store the current test program to disk Save Store current test program with a new name Save as Prints the current test program, with all parameters Print...
  • Page 18 of the Software 4 Description 4.2.1 Menu "File" All the file functions like e.g. loading or storing of test programs are realized via the W typical file INDOWS dialogs. Fig. 4 shows the dialog for loading or opening test programs: Fig.
  • Page 19 of the Software 4 Description 4.2.2 General Settings Tab "General": Fig. 6: Tab "Test program" The field Internal test number shows the total number of all tests performed so far. In the field Test program selection, it is specified how the required test program is determined: ...
  • Page 20 of the Software 4 Description Tab "Protocol Info": Fig. 8: Tab "Protocol info" In this register it is specified which informations about the DUT will be included in the test protocolling, and where they are taken from. Generally, only positions that have the leftmost checkbox activated are included in the protocol. When unchecked, the respective position is not inclued in the protocol.
  • Page 21 of the Software 4 Description Tab "Printouts": Fig. 9: Tab "Printouts" With the dialog "Header bitmap" you can use a previously created picture file as protocol header. (Note: There is no feature for scaling or positioning of this picture, it will automatically be scaled to reach full width of the paper size.
  • Page 22 of the Software 4 Description 4.2.3 Hardware Settings Notice: The ST 3820L/K is delivered with correctly preset hardware settings. These hardware settings only exist because the EM4000 software is based on our standard DAT3805 software. Do not change any of the default hardware settings without a compelling reason! Tab "Hardware": Fig.
  • Page 23 Tab "Device 1 / Common": Fig. 11: Tab "Device I / Common" – Under Device type, the ST 3820L or ST 3820K tester is selected – Under Communication, the IP address 192.168.0.240 and port 3800 must remain set. – Device Control: The safety control list field can be used to specify how the tester starts the test procedure or how the test object is contacted.
  • Page 24 of the Software 4 Description Tab "Device 1 / ST device": Fig. 12: Tab "Device I / ST device"  Device Configuration - Maximum output voltage Here, the maximum test voltage for the surge test can be limited to a value lower than 6000V (standard).
  • Page 25 of the Software 4 Description  Tab "Device 2" Fig. 13: Tab „Device 2 - Common“ This tab is intended for use if a second SPS test device is to be controlled (e.g. HA 1885B/G/J as an AC high-voltage generator). Surge tester ST 3820L/K page 25...
  • Page 26 of the Software 4 Description Tab "US40": Fig. 15: Tab "US40" Here the set-up of the temperature sensor is done. Most important, the correct IP-address 192.168.0.8 must be specified. (It’s "fixed" in the device) The further options control which environment measurements are shown in the lower status-bar of the testing module.
  • Page 27 The IP address and MAC address are fixed and must not be changed. In the ST 3820K device, partial discharge measurement is already integrated internally. Still, the "Use PD4000" option must also be activated here in order to be able to carry out partial discharge measurements.
  • Page 28 of the Software 4 Description Tab "Milliohmmeter": Fig. 18: Tab "Other" Fig. 19: Tab "Spec" If the ST 3820L/K is operated with an external resistance meter, then "Resistance Meter" must be activated here and the correct measuring device selected. page 28 Surge tester ST 3820L/K...
  • Page 29 of the Software 4 Description 4.2.4 Environment settings Fig. 20: Tab "General" Tab "General":  In Test History it can be set how many test runs will be memorized in the log window of the testing module.  The Buzzer of the testing device can be adjusted. ...
  • Page 30 of the Software 4 Description Tab "Files & folders": This register specifies the default folders where picture and text files will be stored. Fig. 21: Tab "Files & folders" Tab "Logs": In this tab, the debug mode of the application can be activated. This is only required for service matters or troubleshooting, and should be switched off during normal operation.
  • Page 31 of the Software 4 Description Fig. 23: Tab "Test programs" Tab "Test programs": Here one can choose whether the test programs shall be saved as XML data files (each test program is saved in an individual *.xml file), or if all test programs shall be stored in a data base. Depending on the choice, the according options are enabled, where the storage path for the XML files, resp.
  • Page 32 of the Software 4 Description Fig. 24: Tab "Results" Tab "Results": Here one can choose whether the test results shall be saved as XML data files (each result protocol is saved in an individual *.xml file), be stored in a data base, or both together. Depending on the choice, the according options are enabled to specify the base folder (parent folder) for the storage location of the result files.
  • Page 33 of the Software 4 Description Tabs "Product List" & "Users": Fig. 25: Tab „Product list“ Fig. 26: Tab „Users“ In these tabs, the databases are defined in which the product list and the list of registered users with their passwords are saved. Surge tester ST 3820L/K page 33...
  • Page 34 of the Software 4 Description Tab "ST3800": Fig. 27: Tab "ST3800"  Within the field S the following settings can be made: URGE - Under »Show measured curves« one can choose under which conditions the curves measured during a surge test actually shall be displayed. Possible settings are A , and N LWAYS EVER...
  • Page 35 of the Software 4 Description - "include evaluated PD data in XML": With this, the evaluated data of the partial discharges are included in the XML log of the surge curve. - "include PD in pictures": If the surge curves are also saved as an image file, the measurement of the partial discharges will also be included in the image here.
  • Page 36 of the Software 4 Description Tab "PD4000": Fig. 28: Tab "PD4000" page 36 Surge tester ST 3820L/K...
  • Page 37 of the Software 4 Description In this tab, settings are made as to how and what data is stored during the partial-discharge evaluation. PD display: determines which graphic is displayed during a high-voltage test: Record diagram – only shows the graphs of the individual measurement intervals, Summary diagram –...
  • Page 38 of the Software 4 Description Fig. 29: Tab "Dummy" Tab "Dummy": With the options of this tab, the execution of a regular dummy test can be forced, e.g. to ensure that the system is functioning correctly. In the field D the execution interval of the dummy test can be chosen.
  • Page 39 of the Software 4 Description Tab "Colors": In the multi-tab "Colors", you can change the colors used for the result protocols, as well as for the print and screen display of the graphics module: Fig. 30: Tab „Colors / Protocol print“ Fig.
  • Page 40 of the Software 4 Description 4.2.5 User Administration The software has a built-in User administration. Here all users of the software must be registered. To get into the program for the first time, you have to enter "SPS" as user and password both. After this, you can enter new users with their depending passwords and rights (see Fig.
  • Page 41 of the Software 4 Description 4.3 The Product List The product list contains the assignments between devices/article numbers and the test program to use for each kind of device. Hereby it is possible to automatically load the correct test program for each DUT by scanning its barcode.
  • Page 42 of the Software 4 Description 4.4 Module "Editor" 4.4.1 General With the editor module you arrange the test, parametrize the single test steps and archivate the test programs. All test programs created with the editor are stored in the built-in hard disk and are available for later testing.
  • Page 43 of the Software 4 Description 4.4.2 Editor: Testinfo Fig. 35: Program editor  In the title bar you see the path and name of the actual test program.  Below there is the menu bar (see paragraph 4.2, p.17).  The list window to the left shows all test steps that are available to be used. ...
  • Page 44 of the Software 4 Description 4.4.2.1 Protocol Print The program allows the output of the test results on a printer. Same happens after each test run. Via the drop-down list "Protocol print" this procedure can be controlled. Below print possibilities are available to the user: List element Function No protocol will be printed...
  • Page 45 of the Software 4 Description 4.4.2.4 Protocol settings : Fig. 37: Dialog window "Protocolling" After each test the test and measuring results are stored in a protocol file. By pressing the button "C " beneath the "P " field, the user can determine the naming scheme of the HANGE ROTOCOLLING protocol.
  • Page 46 of the Software 4 Description 4.4.3 Editor: Test steps The organisation of the test steps and the definition of the test run is managed directly in the main window of the program editor: Fig. 38: Editing of a test program The list window on the left shows all the test steps available in the program.
  • Page 47 of the Software 4 Description 4.5 Description of Test Parameters 4.5.1 General Information The test steps have all common dialog elements or test parameters. With the following example, the make up of the dialog windows for the common test parameters is explained: Fig.
  • Page 48 of the Software 4 Description 4.5.2 AA: Start of Test Fig. 40: Test parameters "Start of Test" When "Info Dialog" is checked, a window with information about the DUT will be shown at the start of each test. If the user shall be able to edit certain DUT data when a test starts, the wished positions have to be checked here.
  • Page 49 of the Software 4 Description Tab "Ambient Measurement" In the "Ambient Measurement" tab you can specify which measured values of the environmental sensor should be recorded right at the beginning of the test program. These measured values are stored in the XML results files listed in the introductory header.
  • Page 50 of the Software 4 Description 4.5.3 TV: Text Visual Step Fig. 44: Test parameters "Text visual step" In the test step Text visual step the dialog elements have below functions: Dialog element Function Contents of this field is displayed when step is executed. The message has to Text consist of a minimum of five characters.
  • Page 51 of the Software 4 Description 4.5.4 PV: Picture Visual Step Fig. 45: Test parameters "Picture visual step" In the test step Text visual step the dialog elements have below functions: Dialog element Function Opens standard »open file« dialogue to choose an image Load Have a look on how things will look on paper Show...
  • Page 52 of the Software 4 Description 4.5.5 I2: Insulation Test Fig. 46: Test parameters "Insulation Test" (I2) This is the dialog for the "I2" insulation test: Dialog element Function Time for voltage to be increased to maximum (when »0«, no ramp is used) Ramp time If checked, at the test’s end the voltage will be decreased instead of just switched off Ramp down...
  • Page 53 of the Software 4 Description 4.5.6 H2: High Voltage Test DC Fig. 47: Test parameters "High Voltage Test" (H2) This is the dialog for the "H2" high voltage test: Dialog element Function Time for voltage to be increased to maximum (when »0«, no ramp is used) Ramp time If checked, at the test’s end the voltage will be decreased instead of just switched off Ramp down...
  • Page 54 of the Software 4 Description 4.5.7 SG: Surge Test Choosing the test step »Surge Test«, the following window appears: Fig. 48: Test parameters "Surge test" Dialog element Function Chooses which comparison method to use: OMPARE ETHOD (See: "Fehler! Verweisquelle konnte nicht gefunden werden. - Fehler! Verweisquelle konnte nicht gefunden werden.", p.Fehler! Textmarke nicht definiert.ff.) The curve obtained from the DUT is compared with a reference curve...
  • Page 55 of the Software 4 Description Parameters for method "Master curve": Fig. 49: Tab "Error area" Fig. 50: Tab "Diff. area" Fig. 51: Tab „Tolerance“ Fig. 52: Tab „Damping“ Fig. 53: Tab „Inductivity“ Dialog element Function Chooses the method of curve evaluation: The values "minimum"...
  • Page 56 of the Software 4 Description Partial discharge evaluation during surge test: In addition, the partial discharge measurement during surge test can be activated in the SG step using the "Partial discharge" checkbox: Fig. 54: Test parameters for partial discharge evaluation Min.
  • Page 57 of the Software 4 Description 4.5.8 SP: IEC PD Surge Test Fig. 55: Test parameters "IEC PD surge test" (SP) In this test step, surge impulses are carried out with successively increasing test voltage, whereby the evaluation is oriented to resulting partial discharges. This is a standardised test procedure described in the IEC 61934 standard.
  • Page 58 of the Software 4 Description 4.5.9 AM: Ambient measurement step Fig. 56: Test parameters "Ambient measurement" (AM) With this step, all available data from the “weather station” US40 can be read in. The measured values are thereby explicitely included in the test protocols. page 58 Surge tester ST 3820L/K...
  • Page 59 of the Software 4 Description 4.5.10 LV: List&Label Variable Definition Fig. 57: Test parameters "List&Label variable definition" (LV) By means of this step, it is possible to create additional variables that can be handed over to the List & Label module and can be used there.
  • Page 60 of the Software 4 Description 4.5.11 BC: Barcode Read Test Fig. 58: Test parameters "Barcode Read Test" (BC) By means of this test step, a barcode can be read during a test run. The read barcode then is included in the test protocol.
  • Page 61 of the Software 4 Description 4.5.12 ZZ: End of Test Fig. 59: Test parameters "Test Closing" (ZZ) With this test step, several options can be changed about what will happen when a test run has finished: Dialog element Function Decision what to do in case of test result "Fail": After Failed Test Repetition of the test, serial number remains the same Repeat dialog...
  • Page 62 of the Software 4 Description 4.6 Program Module "Testing" When programing of the test programs has be done, testing can begin. With the button "Test" one gets to the menu Testing. Now it is possible to work with either the actual program (as shown in the window’s title bar), or to load a different program by means of the button "Load".
  • Page 63 of the Software 4 Description 4.6.1 Start of Test When pushing the "Test info" button, or when "Info dialog" has been set in test step AA, the below window will open. Which of the individual fields are open to be edited, or are non-changeable shown in grey, is dependent on the chosen settings in the AA-step.
  • Page 64 of the Software 4 Description 4.6.2 Testing mode "Step" The step by step test run guarantees that the DUT can e.g. be connected somewhere else or that changes can be made between the test steps. When starting the test, the Start Window will appear first in which - if it was activated in the editor - you can make changes.
  • Page 65 of the Software 4 Description 4.6.6 Failed Test Run A faulty test run is indicated by a "FAILED" message on the monitor. In the power panel N5 and in the connection panel A1 the red "fail" lamp lights up until the test is restarted or until the device is reinitialized. Fig.
  • Page 66 of the Software 4 Description 4.7 Test Runs 4.7.1 Text / Picture Visual Step When one of these test steps is executed, a new dialog window is opened, showing the text or the picture as well as the "Yes"/"No" buttons, which the user must use to confirm the dialog: Fig.
  • Page 67 of the Software 4 Description 4.7.3 IEC Surge- / Partial Discharge Test During this test, a graph is drawn showing the various voltages and measurements: e.g. surge voltage level (red, 10 pulses each), green/yellow (vertical) partial discharges below/above the limit value, blue (vertical) number during surge...
  • Page 68 of the Software 4 Description 4.7.5 Other test steps For other test steps, only the momentary reading and the remaining test time are shown beside the test step's name. Exemplary, the resistance measuring R5 during execution: Fig. 71: View during e.g. "Resistance test R5" page 68 Surge tester ST 3820L/K...
  • Page 69 of the Software 4 Description 4.8 Program Module "Results" After starting the "Results" module, an "empty" program window appears first. The "Load results" function button (top left) opens a dialog with which the previously saved results can be searched and filtered according to various criteria: Fig.
  • Page 70 Annex A: About the Surge Test Annex About the Surge Test The most significant difference between the surege test and all other EST tests (high voltage tests, GOOD FAIL insulation tests, etc.) is that there are no fixed thresholds to judge the test results as Instead, an electric oscillation gets excited within the DUT by a line surge.
  • Page 71 Annex A: About the Surge Test A-1 Methods of evaluation The Surge Tester ST3820 offers several methods of curve evaluation. In the following, the currently implemented evaluation methods are described. (More evaluation methods are planned.) A-1-1 Error Area Fig. 74: Curve with evaluation of error area Relevant for this method is the area included between a curve and the time axis.
  • Page 72 Annex A: About the Surge Test A-1-2 Differential error area Fig. 75: Curves with differential error area This method determines the difference area of master curve and specimen curve, then calculates the ratio of that difference and the area of the master curve. This method is more stringent than the error area method, in that it also evaluates phase shifts caused by winding tolerances.
  • Page 73 Annex A: About the Surge Test 4.8.1 Tolerance band method Fig. 76: Tolerance band method With this evaluation method – also called "envelope method" – the surge curve has to be located inside of a programmable tolerance band. The tolerance band is given as a percentual value. By adding and subtracting this percentage from each sample of the master curve, two curves are derived: these are the envelope curves.
  • Page 74 Annex A: About the Surge Test A-2 The Mastercurve Editor For the test step "surge test", the configuration dialog consists of two different windows. In the 1st window, the general evaluation parameters for the test are set. These parameters correspond to the actually chosen master curve, the name of which is shown in the Field M ASTER URVE...
  • Page 75 Annex A: About the Surge Test A-2-1 The Main Window of the Master Curve Editor: Fig. 78: Master curve editor At the top of the screen, the name of the actual mastercurve is shown, as well as the file in which the master curve is saved.
  • Page 76 Annex A: About the Surge Test A-2-2 Recording a new master curve Once that curve name and recording parameters are set, the recording of a new master curve may begin. Only for ST 4000A/B: (ST 3820 devices don’t have an internal switching matrix) First, the phases between which the surge voltage curve is to be determined must be defined via "Matrix": Fig.
  • Page 77 Annex A: About the Surge Test After recording a curve, one will get a display similar like this: Fig. 80: Recorded curve Typically, one will build up a master curve by doing several recordings of different DUTs. Since the software will calculate the avarage of all recordings, the resulting mastercurve will be the representative mean of all DUTs that were used to build the master curve.
  • Page 78 Annex B: Interface configuration Interface configuration B-1 External I/O-Interface X1 plug ext. I/O (Dsub25, male, on rear panel) Signal Assignment ext_out_0 Output 1 ext_out_1 Output 2 ext_out_2 Output 3 ext_out_3 Output 4 ext_out_4 Output 5 ext_out_5 Output 6 ext_out_6 Output 7 ext_out_7 Output 8 Analog Input 1...
  • Page 79 Annex B: Interface configuration B-2 Second external I/O Interface X2 Socket ext. I/O (Dsub37) Signal Assignment Out_0 Output 1 Out_2 Output 3 Out_4 Output 5 Out_6 Output 7 Out_8 Output 9 Out_10 Output 11 Out_12 Output 13 Out_14 Output 15 Out_16 Output 17 Out_18...
  • Page 80 Annex B: Interface configuration Basic circuit for I/O interface X1: (+24V) PIN 20,21 Inputs 1-8 Max. 200 mA je Ausgang Outputs 1-8 (GND) PIN 24,25 Basic circuit for interface X2: (+24V) PIN 17,36 Max. 200 mA je Ausgang Ausgänge 1-24 (GND) PIN 18,19,37 page 80 Surge tester ST 3820L/K...
  • Page 81 Annex B: Interface configuration B-3 Supply Interface X3 Wiring to use internal 24V Assignment Wiring to use external 24V (either … ↓ ) (… or ↓ ) 24 V intern 24 V intern 24 V extern 24 V extern 0 V intern 0 V intern +24V 0 V intern...
  • Page 82 C: Microwave Antenna MW 40 Microwave Antenna MW 40 This measuring antenna can be used in conjunction with an ST 3820K (integrated partial discharge measurement), or with an ST 3820L in conjunction with an external PD 4010L partial discharge measuring device.
  • Page 83 Annex C: Microwave Antenna MW 40 C-1 Technical Data MW 40 Mid-band frequency 1575.5 MHz ±0,5 MHz Receiver channel range 2.4 MHz Input level min. max. min.: -90 dBm / 3 dB max.: +27 dBm Channel-selection 90 dB ±65 MHz Video bandwidth 2 MHz Pulse demodulation edges...
  • Page 84 Annex C: Microwave Antenna MW 40 C-2 Function Description The active microwave antenna MW40 is used to detect and contactless level determination of partial discharge (PD) pulse spectra. The high-voltage pulse-loaded insulating materials generate an electric (PD) field that can be measured in the SHF frequency range without interference from the high-voltage source.
  • Page 85 D: Active Line Coupling HW 40 Active Line Coupling HW 40 This measuring antenna can be used in conjunction with an ST 3820K (integrated partial discharge measurement), or with an ST 3820L in conjunction with an external PD 4010L partial discharge measuring device.
  • Page 86 Annex D: Active Line Coupling HW 40 Technical Data HW 40 Mid-band frequency 317 MHz ±1 MHz Receiver channel range 13 MHz Input level min. max. min.: -90 dBm / 3 dB max.: +27 dBm Channel-selection 90 dB ±35 MHz Video bandwidth 2 MHz Pulse demodulation edges...
  • Page 87 Annex D: Active Line Coupling HW 40 Function Description The active cable decoupler HW40 is used to detect and contactless level determination of partial discharge (PD) pulse spectra. The high-voltage pulse-loaded insulating materials generate an electric (PD) field that can be measured in the VHF frequency range without interference from the high-voltage source.