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Atec ROD-L M25, Operation And Service Manual

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Atec ROD-L M25 Operation And Service Manual Download Page 1

Advanced Test Equipment Rentals

www.atecorp.com  800-404-ATEC (2832)

®

Established 1981

Summary of Contents for ROD-L M25

Page 1: ...OPERATION AND SERVlCE MANUAL ROD L M25 25 AMP GROUND CONTINUITY TESTER JULY 1984 Advanced Test Equipment Rentals www atecorp com 800 404 ATEC 2832 Established 1981 ...

Page 2: ...Controls 2 4 Operational Check 2 8 Test Time Adjustment Procedure 2 1 0 Automatic Test Procedures 2 1 0 25AMP Ground Tester with M488 Tester Set Up 2 10 ill THEORY O F OPERATION 3 1 Theory of High Current Ground Testing 3 1 3 2 Ground Continuity 3 1 3 3 Instrument Functional Diagram 3 3 3 6 Instrument Assembly Diagram 3 4 3 7 Power Supply Circuit A101 3 4 3 9 A22 Control Logic Board 3 4 IV MAINTEN...

Page 3: ...icators Control And Indicators M25 Hipot Interface Functional Diagram Assembly Diagram Detail Functional Diagram Calibration Equipment Test Set Up A10 Power Supply A22 Control Logic VI SCHEMATICS Wiring Diagram Assembly Drawing Mother Board A10 Power Supply A10 Power Supply Assembly A22 Control Logic A22 Control Logic Assembly W OPTIONS PAGE 1 2 2 2 2 5 2 7 2 1 1 3 3 3 4 3 5 4 1 4 3 5 2 5 3 A8 Rem...

Page 4: ...ikes on power lines of many times nominal line voltage The gnd should be able t o divert any leakage to the chassis without getting damaged 1 5 GENERAL DESCRIPTION 1 6 The ROD L Model 25amp Ground Testers apply low voltage t o the device under test for a duration of time preset from one second to 90 seconds The device under test is plugged into the front panel receptacle or special rear panel conn...

Page 5: ...Manual e Extra fuses f HV Interface Cable 1 13 The ROD L 25amp Ground Testers a r e identified by a part number and a serial number see Figure 2 2 Table 1 1 lists the most important electrical environmental and physical specifications of the Ground Testers TABLE 1 1 SPECIFICATIONS Test Voltage and Current Voltage Shutdown Automatic Test Cycle Initial Turn On Period 3 VAC RMS 25 ARMS 33 60 Hz at 0 ...

Page 6: ...vironmental Operating Condition O to 50 32Oto 1 2 2 Physical Color Mint greyIOlive grey Weight 35 ibs Net 13 5 Kg Dimensions SAFETY FEATURES 1 6 3 4 x 5 4 x 1 3 i inches 43 x 1 3 x 34 cm Sequenced design of operation Loss of ground terminates test cycle Recessed START button Visual and audible alarm at failure Voltage lockout requiring manual reset ...

Page 7: ...hipping carton and the padding material for the carrier s inspection 2 5 LNSTALLATION 2 6 The ROD L Model 25amp Ground Testers are suitable for either bench or rack mounting To rack mount the instrument use Rack Mounting Kit part M100 5001 Rack Mounting Kits may b e ordered from factory 2 7 RACK MOUNTING 2 8 The procedure for installing Rack Mounting Kit M100 5001 on t h e Tester is as follows a P...

Page 8: ...Figure 2 1 Rack Mounting Kit Installation ...

Page 9: ...r Switch on ROD L Tester set the rear panel AC Line 115 230V voltage switch to indicate the number that corresponds t o the line voltage range being used The number visible on the slide switch indicates the line voltage range for which the primary circuit is connected Set the OHMS TRIP control t o full clockwise position With and AC voltmeter check the primary power line for normal line voltage co...

Page 10: ... two inch rubberized foam pads placed along all surfaces of instruments or with a layer of excelsior about six inches thick packed firmly against all surfaces of instrument c Use a strong well sealed shipping container 350 lb sq in bursting test d Mark t h e container FRAGILE DELICATE INSTRUMENT 2 19 Attach a t a g t o t h e instrument giving the following information a Type of service required b ...

Page 11: ...t h e instrument is grounded properly and not already indicating a grounded test failure Resets a failure indication when de pressed also terrni nates a test early Selects Ground Test only or ground test and Hipot Test sequence Connect the chassis of the device under test t o this terminal The lead used should be of low resistance and preferably as short a s possible An instrument t o be tested fo...

Page 12: ...d loop Indicates amount of AC current in AMPS flow during a test Displays a visual warning t h a t test was a failure Indicates a test in progress Comes on a power up Emits a warning sound when a test results in a failure Slide switch t o select either 115 VAC or 230 VAC The exposed number indicates the Line Voltage range selected Connects t o power cable supplied with instrument Provide primary c...

Page 13: ...Rear panel jack for chassis Gnd sense from ROD L Hipot Tester Figure 2 2 Controls and Indicators ...

Page 14: ...rrent Meter should read approximately 30A C OHM Meter should read approximately 005 OHMS Record this reading 7 Set Total OHM Trip pot t o minimum 0 a Depress START button 1 Sonalert should sound 2 Red FAIL lamp should come on b Depress RESET 1 Sonalert should go off 2 Red FAIL lamp should go off If the above conditions a r e met the 25amp ground tester is operating properly and is ready for use If...

Page 15: ...he total resistance of the device under test does not exceed setting of trip pot test will run approximately five seconds The Ammeter will indicate current thru the Ground Loop The OHM meter will indicate the resistance of the ground loop of the device under test If the total resistance of the device under test is higher than the Trip pot setting a failure indication will be given Audible Visual T...

Page 16: ... seconds CAUTION Do not touch any of the other potentiometers on the PC boards otherwise the calibration of the instrument will be destroyed 2 25 AUTOMATIC TEST PROCEDURES The ground tester and hipot tester should be stacked with ground tester on top see Figure 2 3 Connect remote control cable 25 pin connector to ground tester and remote operating device Figure 3 if Tester is equipped with option ...

Page 17: ...omatic reset option The Gnd Tester reset also resets the Hipo Tester If the Hipo tester s chassis Gnd voltage is not connected to BP 2 rear panel Banana Jack the READY light of the Hipo Tester should be OFF and no Hipo Test can be initiated from the Gnd Tester If the Hipo Tester s chassis Gnd voltage is connected to BP 2 the total safety Gnd return from the device under test up to the Hipo Tester ...

Page 18: ...rom the M25 The test light o f the Hipotester should come on The Hipotester should perform as specified in the respective Manual The M25 can at any given moment of time reset the Hipotester by manually depressing the RESET button on the M25 2 27 25AMP GROUND TESTER WITH M488 TESTER SET UP The ground tester and hipot tester should be stacked with ground on top as described before The ground tester ...

Page 19: ...stem is an aid to preclude the malfunctioning of the logic and microelectronic circuits that is it assures the proper functioning of the product Grounding coupled with EMC protective devices can reduce hazards to the customer and product Prototype testing for grounding was instituted in order t o assure the inherent safety of the design of the grounding system Type testing is a design tool in that...

Page 20: ...uately tested if in fact there was any electrical stress applied to the associated insulation Similarly if the grounding conductor were not contiguous to all deal netal parts of the product the detectable leakage current would be substantially less where in fact the hazard is significant If the test operator should come in accidental contact with an ungrounded part it is possible the operator may ...

Page 21: ... solid state optical isolated relay during an AC input line zero crossing after the correspondent signal is given by the General Control 3 5 The General Control performs the coordination of the different activities and monitoring as shown in Fig 3 1 Start Reset dpc dyLight Resistance Sense Fail Current Sense M I R Meter Resistance Trip Start Test I Close Relays HIPO Interface Fig 3 1 Functional Di...

Page 22: ...te Control Board as an option The right side sub assemblies contains the electrical transformers relays and current sense resistors The instrument is divided in two major subassemblies as shown in Fig 3 3 r HV Transformer 1 I Power Supply TransF Control I I I Mother I Solid State Relay I A more detailed diagram of the functions is shown in Fig 3 4 Board Power I I 3 7 POWER SUPPLY CIRCUIT A10 Elect...

Page 23: ...of 8 resistors of 2ohm 5011 each giving a total resistance of 0 25 ohm RESISTORS I I SOLID HIGH CURRENT RELAY I I HIGH CURRENT I STATE TRANSFORMER RELAY OUTPUT FRONT AND REAR PANEL CONTROL FRONT PANEL INDlCATORS Interface ANALOG DIGITAL CONTROL 5V 15V 15V GND 1 1 11 I POWER SUPPLY I I BOARD I Fig 3 3 DETAIL FUNCTIONAL DIAGRAM ...

Page 24: ...pulsing tone drive output for the buzzer An analog input 18 VAC is used t o determine the zero crossing of the AC input line STARTLNG A TEST With t h e start input pin 9 of the edge connector two NAND gates of U5 and U6 provides a hysteresis buffer and the test latch com posed by two NAND gates of U5 is set through pin 13 The output of the test latch pin 11 drives the transistor Q1 to provide a RE...

Page 25: ...est signal is fed through a network that produces a pulse at pin 4 and 5 of U10 a t the end of test resetting all t h e timers and the test latch The system reset is also transmitted t o the AC Hipo Tester when interfaced through the optical isolator U2 3 1 9 A C H I P 0 START At t h e end of successful test the signal from t h e pin 11 of U5 the test latch is fed through a network that produces a...

Page 26: ...or calibration points are required for the M25 Ground Tester They are 1 Meters Mechanical zero 2 Ammeter Calibration 3 Resistance Meter Calibration 4 Test Time Calibration 5 Fail Pot Calibration TABLE No 4 1 TYPE AC DC Digital Ammeter Volt meter floating input RMS reading AC Variac 120 240 VACLine step up trans former MFR Data Tech Model 31 or equivalent General Radio W8MT3VM or equivalent USE Gen...

Page 27: ...s pointers on the front panel They should read zero plus or minus one minor division If they do not adjust the zero screw 4 9 AMMETER CALIBRATION 4 10 Turn t h e M25 ON and note that t h e ammeter position is at zero plus or minus one minor division The READY light should be on If not trouble shoot the Power S p p l y Board or the READY light driver on the A22 Board Insure that the calibration loa...

Page 28: ......

Page 29: ...until t h e failure mode is produced PUSH RESET and proceed with RESISTANCE CALIBRATION 4 1 3 TEST TIME CALLBRATION 4 14 Set a specific test time per instruction of paragraph 2 24 To check test time limits turn test time pot R22 on t h e A22 board t o minimum fully clockwise and maximum Minimum should be one second and maximum about 90 seconds If not troubleshoot timer or call ROD L application En...

Page 30: ...LOWS FUSES 1 Are F1 and F2 slow blow fuses Check for shorted varistors on t h e A7 board MOV I MOV 2 2 Troubleshoot A10 board C READY LAMP DOES NOT WORK 1 Check for burned out bulb 2 Check for bad power supply board or driver on the A22 board D NO HIGH CURRENT OUTPUT 1 Check for bad start switch 2 Check wiring harness for frayed wiring 3 Check the solid s t a t e relay K 3 and the triggering signa...

Page 31: ...PARTS LIST SECTION V ...

Page 32: ...MBER BTY 1 l o PCB RAW 00459 02 ROD L 1 3 C4 C5 CAPACITOR E L 47C tf 3 5 V 2 3 c1 CAPACITOR E L 33CrOuf 1 6 V 1 4 C2 CI Cb CAPACITOR EL luf 3 5 V 3 D I O D E B R I D G E CSFO5 COLLMER 5 U l U 3 2 6 VR1 5 V REGULATOR 7805 CLM34vT 1 7 VR2 1 5 V REGULATOR 7915 L M 3 2 0 T 1 5 1 8 VR3 1 5 V REGULATOR 7815 L M 3 4 0 T 15 1 9 CF 1 CR3 D I O D E 1N4C 132 7 10 F1 F U S E i 1 4 1 7 7 ...

Page 33: ...UAD OP AMP 2 INPUT NAND DUAL PERIPH DRIVR 4 INPUT NAND TIMER TIHER TRANSISTOR NPN OPTIONAL NOT USED PARTS LlST RQTING AND OR MFR NUMBER QTY 00446 02 ROD L 1 IOUF 25V TVA1104 4 OlUF 100V 1 6 33UF 6V 1OUF 35V 1OUF 4 7 0 OHM 1 4W 5 36K 1 4W 5 1 2K 1 4W 5 1K 1 4W 5 6 8K 1 4W 5 lOOK 1 4W 5 4 7K 1 4W 5 100 OHM 1 4W 5 20K 1 4W 5 300K 1 4W 5 15M 1 4W 5 OPTIONAL 1M 1 4W 5 10K BOURNES 3006P 1 103 500K BOURN...

Page 34: ...OPTIONS SECTION VII ...

Page 35: ...nput and Outputs are TT L compatible The ANALOG MONITORING option provides buffering and adjustable gain for the resistance and current signals The resistance buffer gain is adjusted to get 10 VDC out of pin 10 of U11 for a load of 0 1 ohms CIRCUIT DESCRIPTION AU IQMATIC RESET OPTION While on TEST a FAIL produces one shot negative pulse in U4 The falling edge produces one shot pulse U5 this pulse ...

Page 36: ...gnal through pin 10 is low U6 is activated and a low level is available from pin L of the board to the remote connector When TEST is low through pin 11 in other words when a TEST is in progress U7 is activated and a low level is available from pin M to the remote connector When U8 is activated with the FAIL signal either from pin 12 or pin B when the automatic reset optionis used a low level is av...

Page 37: ...NTROL OPTION 25 PIN CONNECTOR ASSIGNMENT GND ISOLATED GND CIJASSIS EXT V REF EXT 1 TRIP EXT V TEST EXT V RISE V OUT I OUT EXT 1R OUT 1R OUT RESISTANCE n C TC REM RESET START 5v REJVIOTE rn TEST FAILURE SELECT A ...

Page 38: ... Q2 26 K1 27 CR1 RAW PCB CAPACITOR CAPACITOR CAPACITOR CAPACITOR IC IC IC IC TIMER 8 PINS IC TTL HEX INVERT IC IC RESISTOR CARBON RESISTOR CARBON RESISTOR CARBON RESISTOR CARBON RESISTOR CARBON RESISTOR CARBON RESISTOR CARBON POTENTIOMETER RESISTOR CARBON POTENTIOMETER RESISTOR CARBON POTENTIOMETER 00445 02 ROD L 1 lOuf 25V TANT 2 6 8uf 10V TANT 1 OlUf 3 luf 10V TANT 1 HllBl OR HllB3 6 SN74122 NE5...

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