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M4000 Insulation Analyzer User Guide

72A-1230 Rev. F

July 22,

2005

Measurement Principles ..................................................................................................................... 1-1
Safety .................................................................................................................................................. 1-1
M4000 Components ........................................................................................................................... 1-2

Operating with the M4300 Transport ............................................................................................... 1-10

Transport, Storage and Shipping ...................................................................................................... 1-17

Transporting and Storing the M4000 ......................................................................................... 1-17
Shipping Instructions.................................................................................................................. 1-18

Safety Considerations ....................................................................................................................... 1-19

Содержание M4000 series

Страница 1: ...Doble Engineering Company 85 Walnut Street Watertown Massachusetts 02472 4037 USA PN 500 0110 72A 1230 Rev F July 22 2005 M4000 Insulation Analyzer User Guide ...

Страница 2: ... liable for direct indirect incidental or consequential damages arising out of the use or inability to use this Manual Government Restricted Rights Legend Use duplication or disclosure by the U S Government is subject to restrictions as set forth in subparagraphs c 1 and c 2 of the Commercial Computer Software Restricted Rights Clause at FAR 52 227 19 This manual is protected by copyright all righ...

Страница 3: ...n Chapter 3 Running M4000 Tests describes procedures for executing specimen tests Chapter 4 M4100 Instrument Troubleshooting provides initial steps in troubleshooting problems and isolating a problem to either the M4100 or M4200c Appendix A M4000 Components Lists describes accessories included with the M4000 Insulation Analyzer Appendix B Warranty provides Doble warranty provisions applicable to t...

Страница 4: ... mouse button Double click Quickly press and release the left mouse button twice without moving the mouse Select Position the cursor on the desired option and click the left mouse button once Or highlight the desired option using the arrow keys and press ENTER Or press ALT and the underlined letter Press Type a single keyboard key For example press ENTER FN appropriate key Press and hold the FN ke...

Страница 5: ...DTA Software 1 9 M4110 Leakage Reactance Interface 1 9 Operating with the M4300 Transport 1 10 Storage and Moving Mode 1 10 Testing Mode 1 13 When Finished Testing 1 15 M4000 PC Cable 1 16 Transport Storage and Shipping 1 17 Transporting and Storing the M4000 1 17 Shipping Instructions 1 18 Safety Considerations 1 19 Definitions 1 19 Safety Practices General Rules 1 20 Clearances 1 20 Grounding 1 ...

Страница 6: ...are 2 6 What s New 2 6 The M4000 Program 2 7 Icons 2 7 Menu Bar 2 8 Clipboard Test Mode 2 9 Menu Items 2 11 Mode Menu 2 11 Test Menu 2 11 Diagnostics 2 12 View Menu 2 12 Tools Menu 2 12 Temperature Correction 2 12 Configuration 2 13 System Configuration 2 13 Clipboard Configuration 2 14 DTA Field Configuration 2 16 Instrument Configuration 2 18 Advanced Configuration 2 19 Using Help 2 21 Contents ...

Страница 7: ...st Optional Software 3 16 DTA Mode 3 17 DTA Tests 3 17 DTA Data Manager 3 18 Preparing for a DTA Test 3 19 Starting a DTA Test 3 19 DTA Icons and Function Keys 3 24 Using A Resonator 3 25 Operating Procedure of Type C Resonating Inductor 3 26 General Description of Type C 1 Coupler RIV Test Procedure 3 28 4 M4100 Instrument Troubleshooting Assigning A Trouble To The M4100 Instrument Or The M4200c ...

Страница 8: ...age Test Cable 4 42 Checking the Low Voltage Test Leads 4 42 Checking M4100 Guard to Ground Insulation 4 43 Checking Instrument Accuracy in the Field 4 43 Voltage Verification 4 44 Accessing M4100 Components 4 46 Removing the Front and Top Covers 4 46 Removing the Card Cage Cover 4 48 M4100 Internal Checks 4 50 Fan Operation 4 50 Low Voltage Power Checkout 4 51 Guard to Ground Shorting Problems 4 ...

Страница 9: ... 4 76 Replacing the Low Voltage Power Supply Board 4 78 Replacing the Heater Temperature Controller Board 4 80 Replacing the Optional Field Calibration Reference 4 82 Replacing the I O Protection Board 4 83 Replacing the Transformer 4 85 Replacing the HV Pothead 4 91 Replacing the Fan Filter 4 93 Replacing the Fan 4 94 Appendix A M4000 Components Lists M4000 Insulation Analyzer A 1 Accessory Bag A...

Страница 10: ...6 72A 1230 Rev F July 22 2005 M4000 Firmware Application Errors C 2 M4000 Communications Errors C 3 Appendix D Part Numbers ...

Страница 11: ...e M4000 rejects interference through the judicious application of shielding line synchronized reversal and line frequency modulation FM The first two techniques are similar to those employed in the earlier Doble M2H product line The FM technique involves running tests at sinusoidal frequencies 5 or even 10 if necessary above and below the line frequency and averaging the results The choice is user...

Страница 12: ...Leakage Reactance Test Software External Reference Test Software DTA Software M4110 Leakage Reactance Interface M4120 External Reference Module Doble Standard Turns Ratio Capacitor Safety Strobe Temperature and Humidity Probe M4100 Instrument The M4100 instrument supplies test voltage and test current to insulation specimens The M4100 instrument also contains measuring circuits to determine the co...

Страница 13: ...wing circuits and conditions are not satisfied The ground safety circuit verifies that the 6 bare copper safety ground which is attached from the instrument to the apparatus earth ground is at the same potential as the power supply ground Two safety switches must be attached to the M4100 instrument front panel and in the closed or depressed position prior to testing One switch is held by the M4000...

Страница 14: ...nd on the M4100 front panel are the M4151 Field Calibration Reference which will be discussed below and a Temperature and Relative Humidity sensor The Temperature and Relative Humidity Sensor will process temperature and humidity readings at the time of test Front Panel Figure 1 2 M4100 Instrument ...

Страница 15: ...en hardened to electrostatic discharge ESD and radio frequency interference RFI to reduce or eliminate their effects on internal electronic circuits The outer case of the M4200c is made of ABS plastic over an aluminum chassis that makes it rugged and suitable for transporting to remote sites The display is a six inch by eight inch color transflective liquid crystal display LCD that runs in the VGA...

Страница 16: ... M4200c Controller External Connections The M4200c has a pointer device installed below the keyboard on the front panel to allow for the use of mouse control of the display cursor A port on the left hand side of the M4200c allows for the use of an external serial mouse The M4200c has a built in 200 dot per inch dpi graphic printer plotter Paper for the printer plotter is an uncoated thermal FAX pa...

Страница 17: ...0c or available to be loaded onto a Third Party Controller includes a program to run the M4000 Insulation Analyzer and if desired the optional Leakage Reactance Test External Reference Test and Doble Test Assistant DTA programs For more information refer to Chapter 2 Optional M4150 And M4151 Field Calibration References The purpose of the M4150 and M4151 Field Calibration References are to provide...

Страница 18: ...ratus at their full operating voltage using the M4000 providing a suitable external power source and reference are provided by the user M4300 Transport The M4300 Transport is an option for the M4000 Insulation Analyzer that provides a means to move and store the M4000 system It is also a platform for the field from which the M4000 can be easily used and operated Refer to Storage and Moving Mode on...

Страница 19: ...ion assessment See Chapters 2 and 3 for further details M4110 Leakage Reactance Interface This optional interface contains the circuitry necessary to convert the voltage and current measured during a Leakage Reactance test on a transformer into a form that can be measured by the M4100 Instrument It also contains a variac so that the proper test voltage can be obtained The Leakage Reactance test ca...

Страница 20: ...riac provided Figure 1 8 M4110 Leakage Reactance Interface Operating with the M4300 Transport The M4000 Insulation Analyzer is designed to be assembled on the M4300 Transport for storage moving and testing When the M4000 is used with the M4300 Transport it can be set up in the following modes Storage and Moving Mode Testing Mode Storage and Moving Mode The storage and moving mode will allow the us...

Страница 21: ...Controller Support frame from the M4300 Transport Lay the M4300 Transport down on its back on a level surface so that the wheels and handle touch the surface 2 Verify that the cover is installed on the M4100 Instrument front panel Position the M4100 Instrument on the M4300 Transport as shown in the above picture Oil Test Cell High Voltage Cable Controller Support Frame Cable Carry Bag M4100 Instru...

Страница 22: ...100 Instrument top cover Buckle and tighten the strap to secure 6 Place the Oil Test Cell on the brackets provided between the wheels on the rear of the M4300 Transport and secure it with the strap provided 7 Place the High Voltage Cable into the brackets provided on the top rear part of the M4300 Transport and secure it with the strap provided 8 Place the M4200c Controller Support frame into the ...

Страница 23: ...ed cluster of connections providing the user with a comprehensible testing setup and a user friendly environment while testing Figure 1 10 M4000 in Testing Mode M4200c Controller Intercase Communication Cable High Voltage Cable Transporter Safety Ground Diagnostic Test Adapter Cable 120 240 V Power Cable Red Low Voltage Cable Safety Strobe Remote Temperature Humidity Sensor Loopback Test Connector...

Страница 24: ...4100 Instrument top panel The M4100 Instrument is ready for connecting the cables 6 The M4100 Instrument top panel receptacles are designed to only accept the functionally correct cables Place each cable into the respective receptacle The only interchangeable cables are the Safety Switches NOTE Inspect all cables for cracks or other damage before using 7 Connect the Safety Ground cable to the M410...

Страница 25: ...ade to record the most accurate temperature and humidity The M4100 Instrument will operate without this option 14 Connect the High Voltage Cable to the receptacle labeled HIGH VOLTAGE on the front panel of the M4100 Instrument Ensure that the High Voltage Cable is fully inserted and latched into the receptacle 15 Connect the M4000 Power Receptacle box to a 120 or 240 VAC source This should be the ...

Страница 26: ...ntroller Requirements Pentium Celeron 64 megabytes of memory Windows 98 or later operating system Internet Explorer version 5 0 or better One available serial port See the Doble website www Doble Com for complete details Setting Up the Controller The computer must be loaded with the M4000 and DTA if a DTA user software The COM port setting must be set in accordance with your computer s requirement...

Страница 27: ...strument could track along their surfaces if high voltage is applied while they are contaminated with surface dirt and or moisture The M4100 and M4200c should be properly secured within the vehicle when being transported locally and mounted in the normal upright position preferably a location in a van or truck which is not directly above an axle of the vehicle If a padded shipping container or tru...

Страница 28: ...Carrying Case should be shipped in a separate padded cardboard box or better Padding should be installed inside and around the Cell On package write FRAGILE PLEASE DO NOT DROP NOTE When shipped by commercial carrier the M4100 M4200c and Accessories should be properly padded and packed as specified above Suitably padded shipping containers for temporary use or purchase are available from Doble upon...

Страница 29: ...erarchy These terms are Test Set Operator The person who supervises the test and operates the M4000 Insulation Analyzer Operator s Assistant The person who follows the operator s instruction in making test connections Safety Observer The person who is responsible for observing the performance of the test seeing any safety hazard and giving warning to crew members The operator s assistant or the sa...

Страница 30: ...bushings and conductors and with the M4000 Insulation Analyzer cables 3 The test crew must make a visual check to ensure that the apparatus terminals are isolated from the power system Where the possibility of failure of the apparatus under test must be considered a real possibility precautions such as barriers or entrance restrictions to test area must be taken against harm in the event of violen...

Страница 31: ...nt being tested The tailgate meeting should include all personnel who will be working in proximity to the area where testing will be performed In this meeting the tests to be performed the apparatus and the voltage test levels involved potential hazards involved with the work and the individual assignments should all be reviewed with the crew members Test personnel need to remain aware of the work...

Страница 32: ...with grading capacitors across the interrupter contacts are especially prone to build up a high voltage charge Voltages high enough to damage the M4000 Insulation Analyzer have been known to occur on this type of equipment Provisions should be made for draining these charges by applying grounds prior to making your test connections It is a good practice to ground equipment such as capacitors capac...

Страница 33: ... in setting up the M4000 2 After the M4000 Insulation Analyzer is properly grounded the remaining test leads and the HV Test Cable are plugged into their receptacles Do not connect test leads to the apparatus terminals until after the leads are connected to the M4000 3 The power cord should be plugged into a 120V ac or 240V and grounded receptacle This should be the last step in setting up the M40...

Страница 34: ...should be done only if the strobe is not working and cannot be used 7 During operation an audible beep is heard whenever high voltage is being applied This beeper is enabled by default Doble recommends the default although the beeper can be turned off as part of instrument configuration WARNING The M4000 Insulation Analyzer is heavy The M4100 Instrument alone weighs approximately 100 pounds 45 kg ...

Страница 35: ...ch must remain open until all personnel are safely in the clear Personnel should not be allowed to remain on the apparatus while tests are in progress If unauthorized personnel should enter the area or if some other undesirable situation should develop the Extension Safety Switch operator should release the switch immediately and then notify the M4000 Insulation Analyzer operator The two safety sw...

Страница 36: ...he testing of various types of apparatus Bushings When performing either single or multi hot collar tests using rubber Hot Collars be aware that the rubber collar is a conductor and that it is at the test voltage during the test Breakers Prior to any testing steps should be taken to disable the breaker so as to avoid inadvertent operation during testing In a closed breaker test both bushings will ...

Страница 37: ...sters Everyone is instructed to stand clear during the testing of surge arresters because of the possibility of their violent failure Capacitors 1 Close all the grounding switches on the device housing in order to ground the bottom terminals of the capacitor 2 Make sure capacitor stacks are discharged before you come into contact with them Internal resistors should not be relied upon for dischargi...

Страница 38: ...o the obvious dangers personnel should be alert to recognize subtle dangers as well For example during transformer excitation current tests the floating terminals may have significant voltages induced in them by simple transformer action Thus all terminals of an apparatus under test unless grounded should be considered to be live while the test is in progress In the case of potential transformers ...

Страница 39: ...4000 Software Icon Descriptions Configuration Settings see page 2 6 Software Installation WARNING Before starting BACK UP YOUR TEST DATA NOTE If you have customized limit files location txt and division txt files from DTA save them separately so you can transfer the data to the new version M4000 Software NOTE The first time a test is run with newly installed software the M4200c Controller or your ...

Страница 40: ...its drive 4 Type the following in the Run dialog box A setup or corresponding drive letter for the CD drive and press the ENTER key 5 Select the language for the installation instructions After installation any of the listed languages can be chosen at any time from the Advanced tab of the Tools Configuration window as long as they have been installed in step 8 below Figure 2 1 Language Options 6 T...

Страница 41: ... If you have the icon for the old version of the software in your startup folder remove it Set the serial communications port to COM2 select this only if installing the software on an M4200c controller Figure 2 2 M4000 Software Installation Options 8 You will then be asked to select safety options Figure 2 3 Safety Settings Beeper Is Enabled Enables the audible warning feature that signals the beg...

Страница 42: ...t be changed from within the application NOTE Use this last option with care since if a need arises to change one of the above settings a burnt out strobe light bulb you cannot change the settings and continue testing without reinstalling the software 9 A screen will appear where your company name as you wish it to appear in the Nameplate area can be input Leave it blank if you prefer to fill the ...

Страница 43: ...etting if the wrong choices were made during installation If you are not able to run any tests on the M4000 but get a communications error proceed as follows 1 Select Tools Configuration and choose the Instrument tab 2 Set the Serial Port to COM 1 3 Make sure the baud rate is set to 9600 4 Click OK reboot the computer and try again 5 If there is still trouble communicating your laptop may require ...

Страница 44: ...m some behind the scenes changes to make this program a modern up to date 32 bit program here are some features visible to the user Clipboard 1 The clipboard now has 200 lines instead of 36 so that almost any type of testing should be able to fit in one single file 2 The M4000 program now supports English French Portuguese and Spanish 3 Serial Number and Manufacturer fields have been added to the ...

Страница 45: ...s from the test results The M4000 Program To start the M4000 Software turn on the M4200c Controller or if using your laptop and the program executable is not in your StartUp group 1 Select All Programs from the Windows Start button menu 2 Select the Doble Program Group 3 Select the M4000 icon 4 Click the OK button on the About The M4000 Software window You are now at the M4000 clipboard screen The...

Страница 46: ...ond test mode available is DTA See the DTA instruction manual for use of the DTA option DTA contains specific forms for different apparatus types along with an expert system to evaluate results Since this is optional software this icon will not be active if DTA software is not installed Enter Clipboard Mode or select Clipboard from the Mode pull down menu Without DTA the only test mode is Clipboar...

Страница 47: ...lowing icons will perform the described functions Icon Description Open a File If a Clipboard file is saved it can be retrieved by clicking on this icon pressing F9 or selecting Open from the File pull down menu Save a File This can also be done by pressing CTRL S to save the file with the existing name or the F8 key to save with a new name Print the current Clipboard form This can also be done by...

Страница 48: ...om the Test pull down menu item or by pressing F2 Run a multiple test This can also be done by selecting Run A Multiple Test from the Test pull down menu item or pressing FN F11 Enter a note When clicking on this icon the software will ask you which line the note corresponds to The default is for line This can also be done by selecting Edit Test Note from the Edit pull down menu item View the air ...

Страница 49: ...mmands are described in Chapter Six M4100 Instrument Mode Menu Select the type of test desired Choices are Clipboard for Power Factor Exciting Current tests Leakage Reactance Requires optional software External Reference Source Requires optional software DTA Requires optional software Test Menu This menu contains the start single test F2 and start multiple tests F11 commands Toggle sheet note Clic...

Страница 50: ... the cursor sits If the line is not empty a warning message appears Clear command for test results nameplate data test note and sheet note Test Note command which allows access to individual test notes for each line of test data Temp and Humidity command which allows access to the temperature and humidity readings for each line of test data Temperature Correction as described below enables the use...

Страница 51: ...have temperature data associated with them for this function to work 4 Select the Equipment Type and Sub types where applicable 5 Click OK and Clipboard will apply the appropriate correction factor to the selected rows of test data Configuration There are five option tabs available in the M4000 Configuration window accessed from the View menu item They are System Clipboard DTA Instrument and Advan...

Страница 52: ...make the 5 selection If your power line frequency is itself experiencing this degree of variation you may be required to make the 10 selection to avoid the effect of electrostatic interference The M4000 users Line Frequency Modulation to measure above and below power line frequency to avoid measurement of electrostatic interference M4000 Data Directory This is the directory in which the Clipboard ...

Страница 53: ...st at the negative polarity in reference to the input voltage at the base frequency is performed This selection is desirable when performing tests using a resonator or exciting current tests on a transformer Display Mode If Reference to 10 kV is selected all results will be reported as if 10 kV were the applied voltage If results obtained were tested at 2 kV current and watts measurements will be ...

Страница 54: ...ssed when manually bringing up the voltage Manual Mode Slow Step The increment of voltage corresponding to each press of the up and down arrow key for manually setting the voltage To change the default settings click the mouse in this field and enter the desired voltage Manual Mode Fast Step The increment of voltage corresponding to each press of the PGUP and PgDn key for manually setting the volt...

Страница 55: ...er User Guide 72A 1230 Rev F 2 17 July 22 2005 Figure 2 8 DTA Configuration Test Type See Clipboard Configuration for a description of this item Voltage Ramp Settings See Clipboard Configuration for a description of this item ...

Страница 56: ...y use COM1 The bits per second setting should not be changed from the default 9600 USB Converter If using a Serial to USB converter to utilize a USB port on your laptop for connection to the M4100 check your PC settings to obtain the comport that has been set by the converter For Windows XP go to the Start button select Control Panel System or alternately right click My Computer and select Propert...

Страница 57: ...y are not functioning the user should leave the beeper and strobe light operational The settings are Beeper If the beeper is enabled four beeps will sound when voltage is applied to a specimen If the beeper is disabled there will be no audible warning of applied voltage Both Low Voltage Leads must be inserted to run test it is recommended this box be left unchecked since most tests require only on...

Страница 58: ...oble Inductor Model The default is Parallel and should not be changed without consulting Doble Allow Multiple Documents If this box is checked more than one set of test data can be active and displayed at once Current Range The default is Auto and should not be changed without consulting Doble Watts Range The default is Auto and should not be changed without consulting Doble Grid Font Size Allows ...

Страница 59: ... use Help by pressing F1 The contents screen also has a series of buttons along its top The Glossary button has topics that are specific such as Auto Mode Ramp Step If you are unsure which item to select you can use the Search function located on the top of the Help screen to find a specific topic To return to the previous screen press Back located on the top of the Help screen To view each item i...

Страница 60: ... the necessary printer drivers for your office printers Printing To print a Clipboard form select Print from the file pull down menu item or press F7 The following screen will appear Figure 2 12 Clipboard Form Report Generator To print a field select it by clicking on the square adding a a checkmark To print to a file select Save the report to a file by clicking its box adding a checkmark Results ...

Страница 61: ...e Source Mode page 3 12 This test mode enables the user to perform tests using an external source and reference extending the range of test voltage above the 12 kV of the M4000 test set Leakage Reactance Mode page 3 16 This test mode enables the user to measure transformer leakage reactance Auxiliary hardware is required in the form of the M4110 Leakage Reactance Interface or the M4130 Leakage Rea...

Страница 62: ...person who checked the results if different from the user Tested By The user of the M4000 Insulation Analyzer Controller No The serial number is located on the bottom of the M4200c Controller Instrument No The serial number is located on the front panel of the M4100 Instrument Sheet No Identification for each single Clipboard Form is done with filenames when saving the form Sheet number was a form...

Страница 63: ... is necessary to enter data in each field In either case Oil Temperature is required if testing oil filled equipment For transformers use the top oil temperature Click on a Convert button first to enter the temperature in Fahrenheit Clicking the OK button will save the entries In the Clipboard mode each row of test data contains the Test Conditions information Test conditions for all the tests on ...

Страница 64: ... Clicking on the will display a pop up window of all the choices Select the desired choice See Test Modes Of The M4000 Analyzer in the Doble Test Procedures manual kV Kilovolts this column indicates the test voltage in thousands of volts to be used during the test for example 10 00 means 10 000 volts mA Milliamperes this column contains the specimen test current results in milliamps You cannot ent...

Страница 65: ...ctor You cannot enter or change results in this column Cap Ind Capacitance Inductance Whether the current is capacitive or inductive is displayed in this column You cannot enter or change results in this column RT Rating You may enter a one letter rating G B I etc of the insulation in this column N Note If a note is entered for a single line a check mark will show in this box A test note is entere...

Страница 66: ...e Frequency Modulation 60 Hz is the most common use B for a 50 Hz test Use C Reference to 10 kV Line Sync Reversal for testing with a resonator or for excitation current tests regardless of system frequency Circuit Description GST Ground GST Guard UST Test kV The above information may be entered before initiating a test Or a test may be initiated immediately and you will be prompted to enter the l...

Страница 67: ...able connections and test parameters If the test parameters are not correct click on the Abort button or press the ESC key When the parameters are correct proceed with the test by depressing both safety push buttons and either pressing the ENTER key or clicking on the Continue button WARNING High voltage will be present after starting the test Pressing the ESC key or F4 or releasing a safety push ...

Страница 68: ... table on the screen describes test conditions and power factor test results The line on the bottom of the screen displays the status of the test When running multiple Clipboard tests the line number of the test that is running will be displayed on the same line For each test line the voltage will ramp to the required maximum test voltage twice This is required to implement the selected electrosta...

Страница 69: ...een Help which is also available by clicking on this icon Pressing F2 or FN F11 will Restart Test also available by clicking on this icon Pressing F5 will Accept Results of the test s successfully performed return to the Clipboard Form and copy the results into the proper columns When performing multiple tests only tests completed prior to a stopped test will be accepted into the Clipboard Form Th...

Страница 70: ...lts from the Tools pull down menu item or by pressing F10 When this is done the following screen appears Figure 3 7 Clear Test Results You have the option to clear all tests clear a single test line or clear multiple test lines Pressing F6 will Discard Results and returns you to the Clipboard Form This is also available by clicking on this icon Icon Description ...

Страница 71: ...rst time all subsequent saves with the same name will result in the message This file already exists Do you want to replace it Select the Yes button or the new data will be not be saved However if the Serial Number or Special ID fields have been edited since the last save the filename which is based on one of these two fields will have changed and the file will be saved based on the new filename O...

Страница 72: ...t the number of ranges you wish to use to categorize your data then click Draw 5 If a Trend is chosen select values to plot on the X and Y axes then click Draw 6 After you have drawn the graph there are several icons along the top you can select to change the type of graph or to refine it s appearance External Reference Source Test Optional Software Running A UST Test Figure 3 9 External Reference...

Страница 73: ...icking one of the lightning bolt icons single or multiple tests can be run The line frequency will be measured and recorded 6 You will be prompted to select a line number on which to place test results and whether the test is a Normal or Reversal the first test for a given line is by default a Normal test 7 The safety screen is displayed with your selected settings When you are ready to begin the ...

Страница 74: ...000 menu bar or click the External Source icon 2 There are two test types UST Measure Blue and GST Guard Blue Select GST Guard Blue from the Test Mode column 3 There will be one clipboard sheet per test sequence with a maximum number of tests in a sequence of 12 4 Before running a test enter the capacitance and power factor of the reference capacitor and the maximum test voltage 5 Start a test by ...

Страница 75: ...t Since performing the Setup Correction Test requires removing the high voltage cable from the specimen it will be practical to perform a series of Specimen Tests first and then go back remove the high voltage cable from the specimen and perform a series of Setup Correction Tests corresponding to the Specimen tests If the losses of the High Voltage cable and transformer can be guarded it is not ne...

Страница 76: ...t test enter the transformer nameplate impedance in both the impedance and reactance benchmark fields 4 Select the Winding Configuration then the Test Configuration If this is the first test perform a 3 phase equivalent test for comparison to nameplate impedance then three per phase tests one per phase to obtain benchmark values for each phase for comparison to future tests 5 Use the Phase column ...

Страница 77: ...ode is not available unless the DTA software has been purchased and has been loaded onto the M4000 If you are not using DTA all testing with the M4000 will be done in the CIipboard mode as described earlier DTA Tests With no test type selected the main M4000 screen appears as follows Figure 3 11 M4000 Main Window To test in the DTA Mode Click on the icon or Select the Mode item on the menu bar usi...

Страница 78: ...TA DATA If you have been using the DOS version of DTA your working directory is C DTA DATA If you wish to continue using the old directory or wish to change the directory proceed as follows 1 Click the Source button under the icons at the top of the screen 2 From the pop up window select the new directory 3 If using DTA version 4 1 run the program and from the main screen 4 Select Change from the ...

Страница 79: ...ble click the desired apparatus in the right hand panel of DTA To sort the displayed list click on the column you wish to sort by 3 See the DTA Users Guide on how to arrive at the ID panel of the new test form if necessary 4 If the open file contains previous test data click the Next Test Date icon This creates a new blank set of test sheets 5 Enter the atmospheric conditions by clicking the icon ...

Страница 80: ...ow 4 A Run M4000 Test pop up window will appear 5 Choose to run a single or a multiple test A single test is a test for the line the cursor is on The multiple test will run all tests associated with one set of connections Select the appropriate choice see the DTA manual for details You will most likely select Multiple Tests Default 6 In some types of apparatus such as live tank breakers or three w...

Страница 81: ...elect the Configure button to change other test parameters such as Frequency or Test Type WARNING High voltage will be present after starting the test Pressing the ESC or F4 key or releasing a safety switch button will turn off the high voltage When the parameters are correct proceed with the test by 3 Pressing both safety switch buttons 4 Selecting the Continue button by highlighting it and press...

Страница 82: ...l values for these parameters will be shown to the right of the meters The table on the screen describes test conditions and test results The horizontal bar at the bottom of the screen displays the status of the test For each test being performed the voltage will ramp to the preselected maximum twice This is required to implement the selected interference cancellation technique Line Synchronized R...

Страница 83: ...M4000 Insulation Analyzer User Guide 72A 1230 Rev F 3 23 July 22 2005 Figure 3 15 End of DTA Test ...

Страница 84: ...ould be reviewed for correctness The operator can continue to the next test on the DTA form NOTE Always exit Windows before shutting off your M4000 Insulation Analyzer Selecting this icon or function key Does this icon or F1 key Displays screen Help icon or F2 or F11 key Restarts the test icon or F5 key Accepts test results returns to the DTA form and copies the results into the proper locations W...

Страница 85: ...f 0 07 1 4 at 50 Hz It is designed to extend the current range of Doble 10 kV Power Factor Test Sets up to four Amps assuming a lossless specimen at voltages up to 10 kV It extends the use of the set for testing relatively long cable lengths large rotating machines and other high capacitance specimens The ultimate range of the resonator depends not only on the capacitance of the specimen but also ...

Страница 86: ...es will be found in the rear of the Resonator case and can be used interchangeably see Figure 3 18 The Resonator is equipped with a core clamping arrangement to reduce the noise level when the Resonator is in use and more importantly to minimize vibration A speeder type wrench is provided for use with this clamping arrangement and for use in tuning the Resonator The clamping adjustment is located ...

Страница 87: ...ator until the input current of the M4000 is at a minimum 9 To fine tune raise the voltage to the final test voltage or as close to it as possible and repeat steps 7 and 8 10 Reclamp the Resonator core 11 Lower the voltage The Resonator is tuned and you are ready to enter information on the row in the clipboard you are using for the test 12 When filling in the clipboard row prior to starting the t...

Страница 88: ...chematic of the Test Set complete with Resonator and coupling network i e RIV Coupler arranged for RIV Radio Influence Voltage measurements Note that the three components are arranged physically in series by means of two shielded jumper cables furnished with this equipment One of the cables is connected between the M4100 Instrument and the Resonator The second is connected between the Resonator an...

Страница 89: ...he telephone plug i e the radio noise meter is left connected the Coupler adds only a small watts loss to the measurement being made Despite the shielding some stray capacitive currents are measured The stray currents at 10 kV may be measured with the Coupler connected for test but with no specimen connected For low capacitance specimens this current may be subtracted before the power factor calcu...

Страница 90: ...e Coupling Box the lower terminal of the Coupling Capacitor is connected to the Test Set Guard Circuit When the telephone plug is inserted into the receptacle the Guard connection to the lower terminal of the Coupling Capacitor is removed and ground is applied to the low end of the 600 Ohm resistor via the barrel of the telephone plug ...

Страница 91: ...fixing a majority of the difficulties that might be encountered in the field NOTE If it is clear that a problem is associated with the M4200c Controller refer to the M4200c Controller manual If it is clear that a problem is associated with the M4100 Instrument continue through this chapter If there is doubt as to the cause of a problem proceed to the next page Doble s Customer Service staff is alw...

Страница 92: ...able and these are summarized in Table 4 2 Table 4 1 Quick Checks Can You Answer Yes To These Items Item The communications cable is securely connected between the M4200c or third party controller and the M4100 Both the M4200c and M4100 are turned on and connected to an active stable power source appropriately rated and grounded Both safety switches were held closed during a specimen test and rele...

Страница 93: ... displays corresponding error messages to the operator A Help button is also available in each displayed message box to provide guidance on suggested causes and cures page 4 16 Diagnostics The M4000 supports automated self diagnostic tests that are useful in validating system operation and troubleshooting problems that may occur Diagnostics should be run on a regular basis to ensure that the M4000...

Страница 94: ...oting from Diagnostics on page 4 21 Also click on Help for further guidance The M4000 fails to complete the test of a specimen or yields unusual results The M4100 is likely to be at fault See Troubleshooting from Symptoms on page 4 12 The M4000 does not print as expected The problem lies with the M4200c See the M4200c Controller manual A Diagnostics test has failed If the Communications Loopback T...

Страница 95: ... potheads Examine the inboard connectors of the various leads and accessories periodically Periodically examine the connectors on the instrument case Visually examine the safety switches periodically for worn connections Periodically check that the HV Pothead receptacle on the instrument case is clean and dry Periodically run the Calibration Verification Test page 4 26 to check for proper system o...

Страница 96: ...Troubleshooting from Diagnostics Get help in running and interpreting the results of automated self diagnostic tests page 4 21 Running Other Tests Identifying additional tests that can be run to troubleshoot problems without gaining access to internal components page 4 42 Accessing M4100 Components Learn how to remove the instrument s covers and identify its major components page 4 46 M4100 Intern...

Страница 97: ...t The M4100 contains digital control power analog measurement and safety circuits An overview of the M4100 and its major components gives a good starting point for gaining basic functional knowledge that is helpful in effective troubleshooting A block diagram of the M4100 illustrating its major components appears in Figure 4 1 on page 4 8 Amplifier Assembly page 4 63 Guard Mode Switch Board page 4...

Страница 98: ...h Board 04D 0551 Mode Switch Guard Board 04D 0527 A D Converter 18 Bit 200V 12kV Transformer DSP CPU Board 04D 0520 Timing Board 04D 0533 Sine Wave Generator Time Base Generator Crystal Line Sync Safety Board 04D 0544 Amplifier Assembly 03D 1055 01 Safety Relays Fan I O Protection Board 04D 0546 Heater Temperature Controller Board Low Voltage Power Supply Board 384 0138 5V 5V 15V 15V M4200c Contro...

Страница 99: ...th the power system frequency or derived from a crystal oscillator to AC test stimulus power It drives a 10 kV step up transformer through safety relay contacts Guard Mode Switch Board 04D 0551 The Guard Mode Switch Board consists of an array of semiconductor FET switches that routes the measured specimen and reference currents to the Guard Board in accordance with the desired test mode Timing Boa...

Страница 100: ...ns include shunt selection signal scaling anti alias filtering and A D conversion The optimum current range is selected automatically unless the operator manually specifies a range Low Voltage Power Supply Board 384 0138 The Low Voltage Power Supply Board supplies 5 VDC 5 VDC 15 VDC and 15 VDC for internal use throughout the M4100 Instrument Heater Temperature Controller Board 04D 0547 The Heater ...

Страница 101: ...rovides certain safety features under hardware and software control Transformer 03D 1054 The Transformer steps up the voltage output of the Amplifier Assembly to a maximum of 12 kV for application to the specimen under test HV Pothead 03C 0056 07 The front panel mounted HV Pothead is a connector providing a high voltage connection to the specimen under test Fan 380 0042 The fan cools the interior ...

Страница 102: ...t power up properly In a normal power up sequence Front panel Power indicator comes on and stays on Front panel Processor indicator flashes about once per second until M4200c communications is established then comes on and stays on Front panel Heater indicator remains off If power up is abnormal 1 Check F1 a 4 A fuse as described in LVPS Fuses on page 4 52 2 Check fuses F1 and F2 on the Heater Tem...

Страница 103: ...Checking the High Voltage Test Cable on page 4 42 Replace the High Voltage Test Cable if necessary 2 Check connections to the specimen 3 The size of the specimen may be beyond the capacity of the test set or the point to which the High Voltage Test Cable is connected may be grounded 4 Check the HV Pothead for tracking arcing pothead separation and cleanliness If it is faulty replace it Table 4 4 M...

Страница 104: ...le Reported Current Watts and or Power Factor are zero 1 Check cable and ground connections 2 Insignificant values Power Factor between 0 and 0 04 Watts 10 µW and Current 0 1 µA are rounded to zero These results can occur when measuring across a vacuum or SF6 interrupter or when testing a good oil sample using the UST circuit Tests made using GST circuits yield high negative or unstable readings 1...

Страница 105: ... of a variety of communications related error messages see Appendix C is displayed take the following steps in sequence until the cause of the problem is identified 1 Run the Communications Loopback Test described in Communications Loopback Test on page 4 40 2 Check the communications cable between the M4100 and M4200c for bent connector pins and breaks or frayed areas in the cable jacket Replace ...

Страница 106: ...or more suggested actions to take in response to the message A Help button is also available in each displayed message box to provide guidance on suggested causes and cures Table 4 5 Error Messages Error Message Suggested Action 20 Watchdog Reset Error 1 After installing new software and when performing the first test thereafter an interruption in firmware download may have occurred i e the test s...

Страница 107: ...run its diagnostic Rerun the original specimen test at rated voltage see Replacing the Amplifier Assembly on page 4 63 35 Overcurrent on Power Amp Output The instrument s output current limit has been exceeded 1 Repeat the test at a lower voltage 2 Check all test connections 3 Check for an inadvertently grounded specimen 36 Power Amp DC Supply High Check the AC power source for abnormally high vol...

Страница 108: ... Replace the strobe lamp If the fixture needs replacing temporarily operate the instrument without a strobe 1 Select Instrument from the Tools Configuration menu in the M4000 software 2 Disable the strobe requirement 50 Lead Changed During Test 1 Clean all cable terminations 2 If the problem persists replace the Guard Front Panel Board see Replacing the Guard Front Panel Board on page 4 61 51 Safe...

Страница 109: ... guide for internal separation or tracking 56 Input Current Peak Maximum Exceeded Input current is excessive 1 Try a 240 V AC power source instead of a 120 V source 2 Check the HV Pothead guide for internal separation or tracking 57 Transformer Overtemperature Occurred Wait several minutes and repeat the test leaving the test set on until the fan turns on to cool it If the fan does not eventually ...

Страница 110: ...C in place of the M4200c select Configuration from the Tools menu click the Instrument tab and select Com1 for Serial Port save and exit 4 If using a USB to Serial adapter make sure the software driver has been installed 5 Run the Communications Loopback Test as described in Communications Loopback Test on page 4 40 6 Check the voltage between either safety switch s Pin 3 third from left and the c...

Страница 111: ... from the Diagnostics pull down menu Access the menu by clicking on Diagnostics in the menu bar as shown in Figure 4 2 The following seven tests are available NOTE The M4150 and M4151 Calibration References are optional and the Calibration Verification and Field Recalibration diagnostic tests cannot be run if they are unavailable Furthermore certain remedial procedures described in the System Stat...

Страница 112: ...s test if you are experiencing any malfunction or error Calibration Verification 1 Run this test periodically to run a mock specimen measurement which checks all system connections including high and low voltage cables 2 Run this test after replacing a component or otherwise repairing the M4100 Field Recalibration Run to calibrate the test set when one of the calibration verification tests results...

Страница 113: ... this test when the temperature is below freezing The System Status diagnostic determines and reports the calibration status of the Guard Board Main Reference Assembly Field Calibration Reference and Backplane It also performs a checksum test of the Guard Mode Switch Board s ID PROM To run the System Status diagnostic 1 Select System Status from the Diagnostics pull down menu 2 Press F2 to start t...

Страница 114: ...ecalibration Test The consequences of continued testing in the uncorrected state are Calibration Verification cannot be performed Measurement error uncertainty 2 Capacitance relative and 0 1 Power Factor absolute Guard failure in Subsystem Diagnostics Main Reference Status Disabled Critical This condition must be corrected before testing continues Corrective Procedure Replace the Main Reference As...

Страница 115: ... assembly has been changed Corrective procedure Run the Calibration Verification 2 Guard Mode Switch IDPROM checksum test failed Corrective procedure Replace the Guard Mode Switch Board and run the Calibration Verification 3 Either the Guard status or Main Reference status is disabled Corrective procedure Refer to the foregoing results and run the Calibration Verification It may be possible to cor...

Страница 116: ...cation be performed providing the optional M4150 or M4151 Calibration Reference is available Upon receipt of an M4000 Insulation Analyzer from Doble or from another location within your company At monthly intervals When questionable readings are obtained The Calibration Verification provides the quickest assurance that the measurement system and the test leads are working correctly It exercises th...

Страница 117: ...ctions as shown in Figure 4 5 Figure 4 5 Calibration Verification Instructions Connections for the Calibration Verification are shown in Figure 4 6 and Figure 4 7 The Field Adapter cable shown in these figures is an accessory cable found in the cable bag which connects from the High Voltage Test Cable to the black connectors on the Field Calibration Reference ...

Страница 118: ...st Figure 4 7 Setup for Red Resistor Test There is a test abort criterion described in the first test of each setup The test abort allows the operator to correct a setup error and then restart from the point where the error was first detected without losing successfully completed test information ...

Страница 119: ...ation Verification Results The summary table can be printed or saved as a text file Both options are available on the File pull down menu Calver log File Upon completion of the Calibration Verification the M4000 software creates a file named Calver log and stores it in the DTA directory This file summarizes information on test aborts and test failures An example of such a file is shown in Figure 4...

Страница 120: ...ads Disconnected Final Error Code 00 00 00 00H End of Test Test Date 04 26 96 Test Time 10 50 43 System Serial Number 59400175 Test Abort Error 53 Test Not Running One or Both Low Voltage Leads Disconnected Final Error Code 00 00 00 00H End of Test Figure 4 9 Example of Calver log File Contents Additional data are continually added to the file by each subsequent Calibration Verification The print ...

Страница 121: ...und in the fieldcal log and currfcal log files both found in the DTA directory The Optional M4150 Field Calibration Reference Figure 4 10 M4150 Field Calibration Reference This is the reference box that has been used since the inception of the M4000 Using the M4150 the M4000 software performs a reference test on the test set for the three middle current ranges 10 30 and 100 mA The M4100 calibratio...

Страница 122: ...ed The seven ranges tested by the M4151 are 300 µA 1 mA 3 mA 10 mA 30 mA 100 mA and 300 mA These three high current ranges not tested require both a resonator and an external capacitor for checking and field calibration and are not available To perform a Field Recalibration test 1 Select Field Recalibration from the Diagnostics pull down menu The screen shown in Figure 4 12 appears Figure 4 12 Fie...

Страница 123: ... the Field Calibration Reference There is a test abort criterion described in the first test of each setup The test abort allows the operator to correct a setup error and then restart from the point where the error was first detected without losing successfully completed test information At the conclusion of the Field Recalibration a summary table like that shown in Figure 4 14 will be displayed F...

Страница 124: ...omponents It first verifies proper communications between the M4200c Controller and the M4100 Instrument then runs tests on the following M4100 components DSP CPU Board Backplane Low Voltage Power Supply Board Heater Temperature Controller Board Timing Board Safety Board Amplifier Assembly Guard Board Guard Mode Switch Board Main Reference Assembly Field Calibration Reference To perform these diag...

Страница 125: ...July 22 2005 Figure 4 15 Subsystem Diagnostics Results Results can be printed either in brief or in full To print the test results 3 Select Print from the File menu The screen shown in Figure 4 16 appears allowing a choice of the level of detail to be printed ...

Страница 126: ...fields shown above become active allowing the operator to select which specific components test results to print In the example above since the Safety Board diagnostic failed that result is selected for a full printout The printed test result resulting from a typical choice is provided in Figure 4 17 Such a printout is useful if the operator finds it necessary to consult Doble for assistance ...

Страница 127: ...M4000 Insulation Analyzer User Guide 72A 1230 Rev F 4 37 July 22 2005 Figure 4 17 Component Test Result Subsystem Diagnostics ...

Страница 128: ...in diagnosing certain problems The listing characterizes each component as to its identity and calibration history To generate this list 1 Select M4100 Component List from the Diagnostics pull down menu 2 Press F2 Figure 4 18 shows an example of the resulting list Figure 4 18 M4100 Component List Results This summary can be printed or saved to a file via the File menu ...

Страница 129: ...must be connected to the M4100 To run a Thermal Profile 1 Select Thermal Profile from the Diagnostics pull down menu 2 Press F2 As the profile is running continuously updated temperature and humidity values are displayed on the screen as exemplified in Figure 4 19 Figure 4 19 Thermal Profile Results 3 Stop the monitoring by pressing F4 or ESC Once the update process is stopped results can be print...

Страница 130: ...Loopback Test is run by selecting that option Figure 4 20 from the Diagnostics pull down menu and following the on screen instructions Figure 4 20 Running the Communications Loopback Test The M4000 Software prompts the operator to perform the same test twice with and without the communications cable in place If both tests pass and a communications problem still exists the M4100 LVPS is probably at...

Страница 131: ...ed in Figure 4 21 i e remove the test plug and connect the communications cable in its place then attach the other test plug to the far end of the cable Press OK to continue A screen like that shown in Figure 4 22 will appear when the second test is complete In this example both loopback tests passed Figure 4 22 Communications Loopback Test Final Results ...

Страница 132: ...ield and ground shield measured with a low voltage ohmmeter should be less than 1 ohm If any conductor s resistance is greater replace the High Voltage Test Cable DC Insulation Resistance The DC resistance of insulation between cable circuits i e center conductor to guard shield and guard shield to ground shield measured with a low voltage instrument 500 V or less at either end of the cable should...

Страница 133: ...rmally low insulation resistance is observed the condition of the insulation between the center conductor and shield at the clip end of the lead should be checked If any insulation resistance is less than 100 megohms replace that Low Voltage Test Lead Checking M4100 Guard to Ground Insulation The DC insulation resistance between the Guard and Ground circuits of the M4100 should be in the range 2 5...

Страница 134: ...ween different cells however the current reading should be repeatable when using the same cell properly assembled with electrode spacings unchanged The measured current and watts loss will be slightly higher when the calibration is checked by the GST method owing to stray capacitive coupling to ground Voltage Verification The factory performs voltage accuracy tests at 5kV using a high voltage RMS ...

Страница 135: ...to perform the test and configure a test with the potential of 500V The test must be performed in Manual mode and any test circuit will do Raise the test voltage to 500V and record the DVM reading on the Calibration Verification Certificate The setup for the test is shown in the following diagram ...

Страница 136: ...lways disconnect AC power before gaining access to internal M4100 components If re application of power is necessary to perform an internal check follow the procedural instructions carefully to minimize the risk of electrical shock In particular make certain that only voltmeter probes come in contact with internal test points Furthermore the High Voltage Test Cable and Safety Switch extension must...

Страница 137: ...top view of the instrument is as shown in Figure 4 23 Figure 4 23 M4100 Interior View Transformer Cover ground Amplifier Assembly chassis ground Transformer connected to guard chassis Main Reference Assembly connected to guard Card Cage Low Voltage Power Supply Board under corner brace ...

Страница 138: ... a PC board discharge your body s static charge by wearing a wrist strap or touching a grounded surface Do not remove a replacement board from its anti static packaging until it is ready to be installed Handle boards by their edges and their extractors clips Avoid touching components on the board and any edge connectors that plug into backplane slots Take the following steps to remove the card cag...

Страница 139: ...ou need to remove may be underneath a cable attached to another board If this is the case release the cable note where it was connected and later reconnect it connectors lowvolt power supply Low Voltage Power Supply W8 Connector DSP CPU Board W11 Connector Timing Board W9 Connector Safety Board Guard Mode Switch Board Guard Board Board ...

Страница 140: ...m the Transformer case during internal measurement and inspection Fan Operation With AC power applied the fan typically does not run continuously Specifically the fan is supposed to run only when the instrument s internal temperature exceeds 40 C as measured by a thermostat located on the Heater Temperature Controller Board To check for proper fan operation depress and hold the push button switch ...

Страница 141: ...4 78 Guard to Ground Shorting Problems Guard to ground shorts can be detected by following the procedure in Checking M4100 Guard to Ground Insulation on page 4 43 A short is most likely to be found in one of the following areas Check each possible cause in turn until the source of the problem is isolated 1 Check the clearance between the Amplifier Assembly and Transformer They must not be touching...

Страница 142: ...ard and Heater Temperature Board Assembly Figure 4 25 is then removed after disconnecting the cable from the top of the board Figure 4 25 Heater LVPS Assembly as Removed from 4100 Check the fuses visually and if necessary with an Ohmmeter Replace any fuse that has blown and monitor system performance for recurrence of the symptom W46 Cable Low Voltage Power 250V 4A Fuse 2 250V 5A fuses on other si...

Страница 143: ...yzer User Guide 72A 1230 Rev F 4 53 July 22 2005 W8 W9 W11 Cable Checkout Check and reseat the W8 W9 and W11 cable connectors which are identified in Figure 4 26 Figure 4 26 Card Cage W11 Connector W9 Connector W8 Connector ...

Страница 144: ... chassis ground while the reference box is at guard potential The two should not be forced together making contact with each other at any point The transformer beneath the grounded metal cover is also at guard potential It should not be short circuited to a grounded point such as the amplifier box next to it near the bottom of the M4100 An inadvertent short can develop here if the M4100 has been d...

Страница 145: ...e Controller Board which is mounted to the Low Voltage Power Supply Board Take the following steps to check the W46 cable 1 Locate and remove the Low Voltage Power Supply Board referring to LVPS Fuses on page 4 52 2 Disconnect and reseat both connectors on the W46 cable Figure 4 25 on page 4 52 3 Replace the Low Voltage Power Supply Board see Replacing the Low Voltage Power Supply Board on page 4 ...

Страница 146: ...lacement of an internal M4100 component requires removal of the instrument s covers and may also require removal of the internal card cage cover Follow the instructions in Accessing M4100 Components on page 4 46 to accomplish these initial steps That section also includes photographs to assist in identifying each component Locate the section that applies to the particular M4100 component to be rep...

Страница 147: ...ial The unit serial number which provides warranty information Contact Name Customer name Problem symptoms Contact Tel Customer telephone number If a Material Return Tag was not supplied please provide the above information separately and include the date and the part number as well as any observed problems or symptoms and other relevant comments 2 Attach the Material Return Tag to the old part 3 ...

Страница 148: ...are removed together in a safe location for re assembly Take the following steps to remove and replace the Front Panel Assembly 1 Unscrew four captive screws Figure 4 28 that secure the optional Field Calibration Reference if present to the Front Panel Assembly using a Phillips head screwdriver Figure 4 28 Field Calibration Reference Screw Locations 2 Pull out the Field Calibration Reference 3 Rem...

Страница 149: ...ny of them binds during extraction lubricate its front and the rear surfaces with a drop of machine oil Then use vise grip pliers to remove the binding screws if necessary Later when replacing the front panel use new screws if available These can be obtained from Doble if required 8 Pull the Front Panel Assembly out only slightly Then disconnect the ribbon cable W12 that attaches to the I O Protec...

Страница 150: ... 11 Replace the ten self locking screws that hold the front panel in place using a 8 Torx screwdriver 12 Replace one nut Figure 4 29 on page 4 59 located behind the HV Pothead using a nut driver 13 Replace the Main Reference Assembly cover and secure it by replacing four screws using a Phillips head screwdriver 14 Replace the Field Calibration Reference and secure it by tightening four captive scr...

Страница 151: ...ement board from its anti static bag until instructed to do so See the Note on page 4 48 for additional ESD precautions 2 Remove six 8 nuts Figure 4 31 that secure the Guard Front Panel Board to the Front Panel Assembly using a 11 32 socket wrench The nuts are located at the corners of the board Figure 4 31 Guard Front Panel Board Nut Locations 3 Remove two 8 nuts Figure 4 31 that secure the groun...

Страница 152: ... a 11 32 socket wrench 10 Replace two 8 nuts that secure the ground connectors to the Guard Front Panel Board after placing the wires back into position on the board 11 Connect two connectors on cables W27 and W28 Each connector has three wires W27 has one red and two black wires W28 has one blue and two black wires 12 Connect two ground wires one orange and one white green 13 Connect two ribbon c...

Страница 153: ...sembly Grasp a corner of the shield and pull it out using a pair of needle nose pliers 3 Insert a 15 flat blade screwdriver into each of the four notches on top of the Amplifier Assembly to unscrew the four captive screws Figure 4 32 The four screws attach the Amplifier Assembly to the bottom of the chassis Figure 4 32 Amplifier Assembly Captive Screw Locations NOTE Do not remove the screws on the...

Страница 154: ...mbly closest to the Transformer Work from right to left ending with the white connector closest to the card cage 8 Insert two fingers into the two notches at the top of the Amplifier Assembly to ease it out Then grasp the edges of the assembly and carefully lift it out of the instrument NOTE The clearance around the Amplifier Assembly is only about 1 8 inch If the assembly is difficult to remove i...

Страница 155: ...panel using the Phillips head screwdriver NOTE Since you have already removed two of the screws holding the fan assembly in place now is a good time to inspect the Fan filter See Replacing the Fan Filter on page 4 93 14 Replace the top two screws holding the fan filter in place using the Phillips head screwdriver 15 Connect the ribbon cable to the Guard Board 16 Reconnect the three cables to the A...

Страница 156: ... Cover on page 4 48 The Guard Mode Switch Board will be visible as in Figure 4 34 Figure 4 34 Guard Mode Switch Board NOTE Do not remove the replacement board from its anti static bag until instructed to do so 2 Detach the two ribbon cables W8 and W12 from the board 3 Detach the four cables W9 W11 W13 and one unlabeled for future use from the board 4 Use your index fingers to unlatch both PC board...

Страница 157: ...xtractors until the board is firmly seated 6 Reattach the two ribbon cables to the board W8 to J8 and W12 to J5 7 Reattach the four cables to the board W9 to J2 W11 to J1 W13 to J3 and the unlabeled cable to J6 8 Replace the card cage cover by reversing the steps in Removing the Card Cage Cover on page 4 48 9 Replace the top and front covers by reversing the steps in Removing the Front and Top Cov...

Страница 158: ...ing Board will be visible as in Figure 4 35 Figure 4 35 Timing Board NOTE Do not remove the replacement board from its anti static bag until instructed to do so See the Note on page 4 48 for additional ESD precautions 2 Use your index fingers to unlatch both PC board extractors Then pull the board straight up 3 Remove the replacement Timing Board from its anti static bag and guide it into position...

Страница 159: ...72A 1230 Rev F 4 69 July 22 2005 4 Replace the card cage cover by reversing the steps in Removing the Card Cage Cover on page 4 48 5 Replace the top and front covers by reversing the steps in Removing the Front and Top Covers on page 4 46 ...

Страница 160: ...ible as in Figure 4 36 Figure 4 36 DSP CPU Board NOTE Do not remove the replacement board from its anti static bag until instructed to do so See the Note on page 4 48 for additional ESD precautions 2 Detach the ribbon cable W5 from the board 3 Use your index fingers to unlatch both PC board extractors Then pull the board straight up 4 Remove the replacement DSP CPU Board from its anti static bag a...

Страница 161: ...ly 22 2005 5 Reattach the ribbon cable W5 to the board 6 Replace the card cage cover by reversing the steps in Removing the Card Cage Cover on page 4 48 7 Replace the top and front covers by reversing the steps in Removing the Front and Top Covers on page 4 46 ...

Страница 162: ...n Figure 4 37 Figure 4 37 Safety Board NOTE Do not remove the replacement board from its anti static bag until instructed to do so See the Note on page 4 48 for additional ESD precautions 2 Detach the three ribbon cables W4 W6 and W7 from the board 3 Use your index fingers to unlatch both PC board extractors Then pull the board straight up 4 Remove the replacement Safety Board from its anti static...

Страница 163: ...tach the three ribbon cables to the board W4 to J1 W6 to J3 and W7 to J2 6 Replace the card cage cover by reversing the steps in Removing the Card Cage Cover on page 4 48 7 Replace the top and front covers by reversing the steps in Removing the Front and Top Covers on page 4 46 ...

Страница 164: ...ut the two assemblies are not attached NOTE Do not remove the replacement board from its anti static bag until instructed to do so See the Note on page 4 48 for additional ESD precautions 2 Remove the cover of the Main Reference Assembly Do this by removing the two screws using a Phillips head screwdriver Removing one screw releases an orange cable 3 Disconnect the W12 ribbon cable 4 Remove two sc...

Страница 165: ... of the assembly 8 Replace six screws with internal lock washers and flat washers using a flat blade screwdriver These screws are located on the perimeter of the board 9 Replace the screws two or three depending on your instrument one in each front corner of the Main Reference Assembly using a Phillips head screwdriver 10 Connect the W12 ribbon cable 11 Replace the cover of the Main Reference Asse...

Страница 166: ...n page 4 48 The Guard Board will be visible as in Figure 4 39 Figure 4 39 Guard Board NOTE Do not remove the replacement board from its anti static bag until instructed to do so See the Note on page 4 48 for additional ESD precautions 2 Detach the ribbon cable W8 from the board 3 Detach the two connectors on cable W9 from the board 4 Use your index fingers to unlatch both PC board extractors Then ...

Страница 167: ...e insides of the PC extractors until the board is firmly seated 6 Reattach the two connectors to the board W9 to J2 and W9 to J3 7 Reattach the ribbon cable to the board W8 to J1 8 Replace the card cage cover by reversing the steps in Removing the Card Cage Cover on page 4 48 9 Replace the top and front covers by reversing the steps in Removing the Front and Top Covers on page 4 46 ...

Страница 168: ...1 Remove four screws Figure 4 40 using a Phillips head screwdriver Two screws secure the corner brace to the rear panel of the Instrument and two screws secure the brace to the side panel Figure 4 40 Low Voltage Power Supply Board Screw Locations 2 Lift off the corner brace to access the board 3 Remove the white Nomex insulator shield located between the Low Voltage Power Supply Board and the chas...

Страница 169: ... it in the Instrument 8 Reconnect the two cables and reposition any other cables previously moved as necessary 9 Replace the Nomex insulator shield 10 Place the corner brace back into position and replace the four screws to secure the brace using a Phillips head screwdriver 11 Replace the top and front covers by reversing the steps in Removing the Front and Top Covers on page 4 46 ...

Страница 170: ...ard NOTE Do not remove the replacement board from its anti static bag until instructed to do so See the Note on page 4 48 for additional ESD precautions 1 Remove the Low Voltage Power Supply Board from the Instrument by following Steps 1 6 in Replacing the Low Voltage Power Supply Board on page 4 78 2 Remove the four screws that attach the Heater Temperature Controller Board to the Low Voltage Pow...

Страница 171: ... bag and position it onto the Low Voltage Power Supply Board Place a spacer between the two components at each screw position 5 Reconnect the two connectors 6 Replace the four screws that join the components together using a Phillips head screwdriver 7 Re install the Low Voltage Power Supply Board into the instrument by following Steps 8 11 in Replacing the Low Voltage Power Supply Board on page 4...

Страница 172: ... it 1 Unscrew four captive screws Figure 4 42 using a Phillips head screwdriver Figure 4 42 Field Calibration Reference Screw Locations 2 Pull out the Field Calibration Reference 3 Unpack the replacement Field Calibration Reference and place it in position in the front panel 4 Tighten the four captive screws using a Phillips head screwdriver 5 Replace the top and front covers by reversing the step...

Страница 173: ...cement board from its anti static bag until instructed to do so See the Note on page 4 48 for additional ESD precautions 2 Remove six screws Figure 4 43 that attach the I O Protection Board to the Front Panel Assembly using a Phillips head screwdriver Note that one of the screws also secures a black and white grounding wire Figure 4 43 I O Protection Board Screw Locations 3 Release one W21 and two...

Страница 174: ...d in place Before replacing the screw that secures the grounding wire first insert the black and white wire between the I O Protection Board and the standoff Then tighten the screw 8 Reconnect one W21 and two W24 ribbon cables The W24 cable located closest to the Field Calibration Reference connects to J2 The other W24 cable located furthest away from the Field Calibration Reference connects to J3...

Страница 175: ...s Take the following steps to replace the Transformer 1 If it has not already been done remove the card cage cover See Removing the Card Cage Cover on page 4 48 The Transformer cover will be visible as in Figure 4 45 2 Remove the Transformer cover being careful not to drop any screws inside the unit Remove five screws Figure 4 45 using a 15 Phillips head screwdriver These screws are located inside...

Страница 176: ... screws washers and grommets together in a safe place Figure 4 27 on page 4 54 shows the instrument with the Transformer cover removed 3 Replace the whiz nuts with elastic stop nuts if necessary Otherwise proceed to Step 4 Remove the four whiz nuts located at the corners of the Transformer where the it attaches to the bottom of the chassis Figure 4 47 Do this by inserting a 7 16 socket wrench into...

Страница 177: ...to position using a 15 screwdriver as a guide Place a nylon washer a metal washer and then the elastic stop nut on the screwdriver Figure 4 48 Hold these pieces in place while inserting the screwdriver into each corner of the Transformer Assembly Figure 4 49 then release the washers and nuts Figure 4 48 Preparing The Screwdriver Whiz Nut Whiz Nut ...

Страница 178: ...s Do not overtighten them 4 Remove the cover of the Main Reference Assembly Do this by removing the two screws Figure 4 50 using a Phillips head screwdriver Figure 4 27 on page 4 54 shows the instrument with the Main Reference Assembly cover removed Remove the four screws Figure 4 50 where the Main Reference Assembly joins the chassis using a Phillips head screwdriver ...

Страница 179: ... shield and pull it out 7 With two people one on each side lift the Transformer straight up and remove it from the Instrument WARNING The Transformer is heavy Two persons are required to safely lift it out of the instrument This step is best accomplished with the M4100 relocated to the floor 8 Unpack the new Transformer Again using two people place the new Transformer into position in the instrume...

Страница 180: ...d white grommets Replace the five screws near the top inside edge of the card cage using a 15 Phillips head screwdriver Replace the five screws on the outside of the instrument next to the fan using a Phillips head screwdriver Replace four screws and washers on the top of the Transformer cover using a flat blade screwdriver 14 Replace the card cage cover by reversing the steps in Removing the Card...

Страница 181: ...Steps 1 8 Removing and Replacing the Front Panel Assembly on page 4 58 Place the Front Panel Assembly face down on the bench 2 Remove one 1 4 elastic nut Figure 4 51 on the back of the Front Panel Assembly to release the W30 cable using a socket wrench Figure 4 51 HV Pothead W30 Screw and Nut Locations 3 Remove four 632 nuts with flat washers Figure 4 51 found in the corners of the black plate ben...

Страница 182: ...ers of the black plate beneath the HV Pothead using an 11 32 socket wrench 8 Grasp the ground wire and the power outlet wire Figure 4 52 and place them back onto the side of the HV Pothead Secure these wires by replacing the screw and washer using a Phillips head screwdriver 9 Replace the 1 4 elastic nut on the back of the Front Panel Assembly to secure the W30 cable using a socket wrench 10 Repla...

Страница 183: ... the following steps to replace it 1 Remove the four screws that hold the fan s grill in place Figure 4 53 using a Phillips head screwdriver Figure 4 53 Fan Filter Screw Locations 2 Remove the old fan filter and replace it with a new one 3 Replace the four screws using a Phillips head screwdriver Use the screwdriver to tuck the new filter in place if necessary NOTE Hot air exhausts from the fan ou...

Страница 184: ...by removing the two screws that hold it in place Figure 4 54 using a Phillips head screwdriver Then lift the cover off Figure 4 54 Amplifier Assembly Cover Fan Screw Locations 3 Remove four screws with washers at the corners of the fan Figure 4 54 4 Release two connectors at the top of the fan 5 Cut the tie wrap holding the connectors in place using a pair of wire cutters 6 Unpack the replacement ...

Страница 185: ...r Guide 72A 1230 Rev F 4 95 July 22 2005 9 Replace the Amplifier Assembly back into the instrument by following Steps 10 19 in Replacing the Amplifier Assembly on page 4 63 NOTE Hot air exhausts from the fan outlet Do not block it ...

Страница 186: ...Replacing the Fan 4 96 72A 1230 Rev F July 22 2005 ...

Страница 187: ...ulation Analyzer are as follows No Number Description Qty 1 010 0097 01 Type M4200c Controller optional 1 2 010 0096 01 Type M4000 Instrument Case 1 3 02D 0024 02 Type M2 Cable HV 60 ft 1 4 02C 5200 01 Liquid Insulation Cell w carrying case 1 5 03D 1070 02 Transporter optional 1 6 02C 5798 09 Accessory Bag 1 7 2FB 2464 01 Documentation Bag 1 ...

Страница 188: ...able Safety SW 65 ft 1 EA 9 02B 0020 02 Lead LV Blue 65 ft 1 EA 10 02B 0020 03 Lead LV Red 65 ft 1 EA 11 02B 0026 01 Lead Ground 3 ft 1 EA 12 02B 0026 02 Lead Ground 5 ft 5 EA 13 02B 0017 01 Red Jumper Cable Insulated LD 2 EA 14 02B 0089 01 P ASY Prong Test Type O bushing tap adapter 1 EA 15 O20 0048 01 P A Collar Cond Set 1 Ea 16 02B 0012 01 P ASY Adapter Bushing Type S bushing tap adapter 1 EA 1...

Страница 189: ...Cable Strobe Light optional 1 EA 25 05B 0493 01 Cable Temp Humid Sensor optional 1 EA 26 03C 1074 01 P A Box Power Receptacle 1 EA 27 05B 0495 01 Diagnostic Test Cable W51 Fld Adapter 1 EA 28 181 0095 Power Cord 10 ft 18 3 Nemas IEC 320 1 EA 29 05B 0508 01 Conn Loopback Plug 1 EA 30 05B 0509 01 Conn Loopback Rcpt 1 EA 31 05B 0503 01 PC to Instrument Cable 1 EA No Number Description Qty ...

Страница 190: ...ube 2 in x 9 1 2 in White 2 EA 5 401 0076 Software MS DOS 6 x 3 5 Fullman 1 EA 6 903 0026 Diskette Box M4000 1 EA 7 903 0026 Diskette Box DTA 1 EA 8 903 0026 Diskette Box User 1 EA 9 500 0100 Manual Oper M4K Insul Analyzer 1 EA 10 903 0030 Drive 5 64 5 in Lg Allen HD 1 EA 11 08A 0021 01 Disk Set Software 1 EA 12 08A 0022 01 Disk Util Root 1 EA 13 401 0121 Windows 3 1 Diskettes 14 Patch Cable Modem...

Страница 191: ...purchaser is responsible for insuring any product or component so returned and assumes the risk of loss during shipment All replaced products and components become the property of DOBLE THIS LIMITED WARRANTY DOES NOT EXTEND TO ANY PRODUCTS WHICH HAVE BEEN DAMAGED AS A RESULT OF ACCIDENT MISUSE ABUSE OR AS A RESULT OF MODIFICATION BY ANYONE OTHER THAN DOBLE OR AN AUTHORIZED DOBLE REPRESENTATIVE EXC...

Страница 192: ...VICING REPAIR OR CORRECTION SOME STATES DO NOT ALLOW THE EXCLUSION OF IMPLIED WARRANTIES SO THE ABOVE EXCLUSION MAY NOT APPLY THIS WARRANTY GIVES THE PURCHASER SPECIFIC LEGAL RIGHTS AND THE USER MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE DOBLE warrants the disks on which the software product is furnished to be free from defects in materials and workmanship under normal use for a per...

Страница 193: ...DUCT EVEN IF DOBLE OR AN AUTHORIZED DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES OR FOR ANY CLAIM BY ANY OTHER PARTY SOME STATES DO NOT ALLOW THE LIMITATION OR EXCLUSION OF LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY For Equipment Maintenance Contact Contact your Doble Representative Doble Engineering Company 85 Walnut Street P...

Страница 194: ...For Equipment Maintenance Contact B 4 72A 1230 Rev F July 22 2005 ...

Страница 195: ...ce in FLASH for Application 6 Unused 7 FLASH Did Not Program Properly 8 FLASH Did Not Erase Properly 9 Invalid Number of Application Bytes Received 10 FLASH Execute Checksum Error 11 Boot Block Checksum Test Failed 12 Static RAM Test Failed 13 UART Internal Loopback Test Failed 14 19 Reserved for Future Use 20 Watchdog Reset Error 21 Invalid Message Parameter 22 Unused 23 Safety Switch 1 Open 24 S...

Страница 196: ...d Changed During Test 51 Safety Switches Not Released Between Tests 52 Software Buffer Overrun 53 One or Both Low Voltage Leads Disconnected 54 Overcurrent Occurred 55 Amplifier OverTemperature Occurred 56 Input Current Peak Maximum Exceeded 57 Transformer OverTemperature Occurred 58 Test Stopped By Controller 59 Comm Timeout Detected By Instrument 60 Main Reference OverTemperature Occurred 61 Cal...

Страница 197: ...Firmware Tests cannot be run Error programming FLASH ROM M4100 Firmware not found in FLASH Tests cannot be run M4100 FLASH ROM has been corrupted tests cannot be run M4100 Firmware file requires an updated version Tests cannot be run Error Description Of Error Error Description of Error 100 No Errors 101 Undefined Error 102 Requested Port Out Of Range 103 Port Already Set Up 104 Invalid Buffer Siz...

Страница 198: ...right Notice 130 Driver Not Installed 131 User Buffer Overflow 132 Failure To Connect To Port 133 No Response From M4000 Check Connections 134 Communications Parity Error Check Connections 135 Communications Overrun Error Check Connections 136 Communications Framing Error Check Connections 137 Invalid Message Number 138 Invalid Message Checksum 139 Invalid Message Length 140 Invalid Message ACK NA...

Страница 199: ...oard slot not found 195 Illegal stop bits 196 Illegal word length 197 Illegal parity setting 198 Timed out 199 Function not supported 295 Handshake Line in use 296 Port Settings failed 297 Windows OS error 298 COM Port not found 299 COM Port in use Error Description of Error ...

Страница 200: ...C 6 72A 1230 Rev F July 22 2005 ...

Страница 201: ...ifier Assembly 03D 1055 01 Guard Mode Switch Board 04D 0551 Timing Board 04D 0533 DSP CPU Board 04D 0520 Safety Board 04D 0544 Main Reference Assembly 04D 0583 Guard Board 04D 0527 Low Voltage Power Supply Board 384 0138 Combined Assembly LVPS H TC 03D 1057 01 Heater Temperature Controller Board 04D 0547 Field Calibration Reference 04D 0524 I O Protection Board 04D 0546 Transformer 03D 1054 HV Pot...

Страница 202: ...D 2 72A 1230 Rev F July 22 2005 ...

Страница 203: ...messages 4 16 External Keyboard 1 6 Monitor 1 5 Mouse 1 6 External Reference test 3 12 F Field Calibration Reference 1 7 4 31 4 82 Field Recalibration 4 31 Fieldcal log file 4 34 Fuses 4 52 G Grounding 1 21 1 23 H Help files 2 21 I Induced Voltage 1 22 Insert a test line 2 12 Instrument configuration 2 18 Interference 1 1 K Keyboard External 1 6 L Languages 2 20 Laptop Use 1 16 Leakage Reactance I...

Страница 204: ...n 2 1 Storage mode 1 11 Subsystem Diagnostics 4 34 System Configuration 2 13 Status 4 23 T Temperature Correction 2 12 Test Clipboard mode 3 1 Conditions 3 3 DTA 3 17 External reference 3 12 Leakage Reactance 3 16 Mode M4000 1 13 Options 2 16 Resonator 3 25 RIV 3 28 Type 2 15 Thermal profile 4 39 Time Date format 2 6 Trapped Charges 1 22 Troubleshooting Common user errors 4 1 Guide 4 2 HV Cable 4 ...

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