TABLE OF CONTENTS KEYTEK/KEYTEK CE MASTER SYSTEM USERS KEYTEK
User Manual: KEYTEK/KEYTEK CE MASTER SYSTEM USERS
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CEMASTER ® Immunity Tester Operations Manual CEMASTER ® Immunity Tester Operations Manual MA-95-016-005-00 REV D Copyright 1997-2001 Thermo KeyTek All Rights Reserved Thermo KeyTek One Lowell Research Center Lowell, MA 01852-4345 Phone: 978-275-0800 Fax: 978-275-0850 E-mail: customer_service@thermokeytek.com ©Thermo KeyTek 1997-2001 All rights reserved The copyright protection afforded to Thermo KeyTek includes all forms of media material and information including, without limitation, the software*, generated icons and logos etc. and all associated documentation. This operating manual and associated software contained within may not be duplicated in any way without the express permission of Thermo KeyTek. Printable products of the software such as test reports and graphs, and associated files of the same, are the property of the purchaser and may be subject to their own copyright restrictions. *The CEMASTER software described in this manual may be copied by, strictly for the use of, the purchaser in accordance with the furnished license agreement. ™ Trademark Credits CEMASTER is a registered trademark of Thermo KeyTek IBM is a registered trademark of International Business Machines Corporation. Microsoft Windows and MS-DOS are registered trademarks of Microsoft Corporation. Notice In no event will Thermo KeyTek be liable for any damages, consequential, incidental or indirect (including loss of business profits, business interruption, loss of business information, and the like) arising out of the use or inability to use the hardware or software supplied. The author and publisher of the operating manual make no warranty of any kind, expressed or implied, with regard to the instructions and suggestions contained within. The author and publisher of this operating manual shall not be liable in any event of incidental or consequential damages in connection with, or arising out of, the furnishing, undertaking or use while following verbal or written instructions and suggestions in any interpretation of its contents. Thermo KeyTek products undergo continuous development and the company reserves the right to change their specifications without obligation or prior notification. Thermo KeyTek One Lowell Research Center Lowell, MA 01852-4345 USA Tel: 978-275-0800 Fax: 978-275-0850 http://www.thermokeytek.com Amendment History Issue Date Author Amendment 1997 1997 JHB First issue. 3-3-99 3-3-99 JHB unknown A 2-1-00 JBC Added Manual part number,formatted manual to standards including copyright page, Amendment history page, and cover B 05-02-01 MDP Removed TVL logo and other references per ECO-150-00 C 05-02-01 MDP Reformat to Thermo KeyTek standards and changed company name From: KeyTek to Thermo KeyTek per ECO-010-01 D 10-01-01 MDP Add Appendix A per ECO-185-01 TABLE OF CONTENTS OVERVIEW PRODUCT SAFETY 1 SURGE TESTING GUIDELINES 3 SAFETY CONCERNS DURING SURGE TESTING 4 INAPPROPRIATE USES 5 DESCRIPTION 6 INSTALLATION 7 Assembly Instructions Cabling and Interconnections Electrical Supply Requirements Physical Environment Test Area Considerations and Site Preparation Special Considerations for Surge Testing Special Considerations for EFT Testing Special Considerations for ESD Testing Special Considerations for Magnetic Field Testing Handling, Transportation, Storage 7 7 9 11 12 12 13 16 16 17 OPERATION INTRODUCTION 19 User Interface Programming the%'/#56'4 from the Front Panel Map of Front Panel Menu Structure Programming the %'/#56'4from a Personal Computer RUNNING TESTS 21 22 28 31 32 STANDARDS OVERVIEW TEST PROCEDURES AND REPORTS IEC 1000-4-2 -- ESD Testing IEC 1000-4-4 -- EFT Testing IEC 1000-4-5 -- SURGE Testing IEC 1000-4-8 -- POWER-FREQUENCY MAGNETIC FIELD Testing IEC 1000-4-9 -- PULSED MAGNETIC FIELD Testing IEC 1000-4-11 -- POWER QUALITY FAILURE Testing 32 33 35 41 47 55 58 62 %'9#4' SOFTWARE OVERVIEW 67 BASIC OPERATIONS 68 SCREENS AND ORGANIZATION 71 Main Screen New Sequence Definition Screen New Custom Sequence Wizard Screen Sequence Editor Screen The Run Screen MENU, TOOLBAR, AND STATUS BAR 72 76 77 82 83 85 MenuBar Toolbar Status Bar 85 91 92 MAINTENANCE AND TROUBLESHOOTING MAINTENANCE 95 Service and Maintenance Issues Annual Calibration Factory Inspection and Refurbishment Updating Firmware Upgrading Hardware Options Decommission Issues TROUBLESHOOTING 95 95 95 95 95 95 96 System Menu Troubleshooting Guide Error Messages The information on IEC requirements -- figures and diagrams, tables and data, and test levels -- are accurate as of the date of printing of this manual. However, the IEC and EN documents are subject to review and change. The information in this manual is intended as a guideline only. 96 98 99 Product Safety The following safety instructions have been included in compliance with safety standard regulations. Please read them carefully. • Read Instructions -- Read all safety and operating instructions before operating the instrument. • Retain Instructions -- Retain all safety and operating instructions for future reference. • Heed Warnings - Adhere to all warnings on the instrument and in the operating instructions. • Follow Instructions -- Follow all operating and use instructions. • Water and Moisture -- Do not use the instrument near water. • Carts and Stands -- Use the instrument only with a cart or stand that is recommended or included as part of the %'/CUVGT system by the manufacturer. • Wall or Ceiling Mounting -- Do not mount the instrument on a wall or ceiling. • Ventilation -- The instrument should be situated so that its location or position does not interfere with its proper ventilation. Do not install in a cabinet or other situation that may impede the flow of air through the ventilation openings. • Heat -- The instrument should be situated away from heat sources such as heat registers or other instruments which produce heat. • Power Sources -- Connect the instrument only to the type of power source described in the operating instructions or as marked on the instrument. • Grounding or Polarization -- Take precautions to insure that the grounding of the instrument is not defeated. Operate only with grounded power cord. • Power Cord Protection -- Place power supply cords so that they are not likely to be walked on or pinched by items placed on them or against them. Pay particular attention to cords at plugs, convenience receptacles, and the point where they enter and exit the instrument. The cordsets used should be the right-angle cordsets supplied with the unit, to prevent damage to the cordsets when moving the%'/CUVGT. • • Cleaning -- Clean the instrument only as recommended by the manufacturer. Non-Use Periods -- Unplug the power cords of the instrument when it will be left unused for a long period of time. CEMASTER System 1 • Lifting and Carrying -- When moving or installing a %'/#56'4follow the instructions given in the Installation section of this manual. Moving a %'/#56'4 requires two persons. • Object and Liquid Entry -- Take care that objects do not fall and that liquids are not spilled into the enclosure through openings. • Defects and Abnormal Stress -- Whenever it is likely that the normal operation has been impaired, make the equipment inoperable and secure it against further operation. Normal operation is likely to be impaired if, for example, the instrument: Shows visible damage. Fails to perform the intended function. Has been subject to prolonged storage under unfavorable conditions. Has been subjected to severe transport stresses. • Damage Requiring Service -- The instrument should be serviced by qualified service personnel when: The power supply cord or the plug has been damaged. Objects have fallen or liquid has been spilled into the instrument. The instrument has been exposed to rain. The instrument does not appear to operate normally or exhibits a marked change in performance. The instrument has been dropped, or the enclosure has been damaged. • Sitting or Climbing -- Do not sit or climb upon the instrument or use it as a step or ladder. CEMASTER System 2 Surge Testing Guidelines 1 • • DO NOT WORK ALONE. Do not use the equipment in conditions other than reasonable laboratory conditions. There should be no condensing humidity or water standing on the floor or work surfaces; there shouldn’t be significant dust or other contamination. • Ensure that NO ONE is touching the equipment under test (EUT) during the test or immediately after the test until AC power to the EUT has been turned off. • Ensure that there is a barrier to act as protection in case the equipment under test explodes. This may happen due to power-follow1 after a failure. The barrier should be interlocked to prevent surging and to disconnect all AC if the barrier is removed. • The equipment under test must be surrounded by sufficient insulating material to withstand twice the surge voltage. Consider distance to the floor or table and walls if air is the insulating material. • Ensure that the proper supply mains voltages are applied to both Thermo KeyTek equipment and to the equipment under test, and that the AC branch circuit is capable of supplying the current. • The ground (protective earth), neutral and phase lines of the AC supply to the equipment under test supply must be connected properly. Do not defeat the protective earth connection. • The ground (protective earth), neutral and phase lines of the AC supply to the Thermo KeyTek equipment must be connected properly. Do not defeat the protective earth connection. • When surging a powered EUT, the mains supply to the equipment under test must be capable of handling the potential AC fault current (e.g. do not use a UPS to power the EUT). • Never surge an AC mains line other than through the EUT output connector and the %'/#56'4internal filter. • Use only equipment which is designed to be safe for the test being performed. • Do not test in a potentially explosive atmosphere (e.g. gas fumes). • Never use equipment that is operating in a strange manner, or that shows clear indication of abuse. • If probes are in use, be sure they are differential probes which have no ground connection to the surged ground or to the equipment under test. Power-follow is a condition where the Surge event causes a low-impedance path which full mains current may then flow through. One example of this is a gas-tube arrestor, which maintains a high impedance until a surge event switches it to a lowmpedance state; the low-impedance state is maintained until the mains voltage drops below a critical threshold. Similar effects can be seen due to electrical arcs or exploded components. CEMASTER System 3 Safety Concerns During Surge Testing Surge testing is hazardous. The equipment under test (EUT) can ignite, possibly explosively. Noxious, toxic and sometimes fatal fumes can be generated by the burning equipment. Accumulated gases may ignite explosively (i.e., flashover). In an environment where surge testing takes place, it is absolutely crucial that these minimum safety precautions be taken: • Surge testing should be performed only by properly trained test personnel who are experienced in conducting such test, or be observed and supervised by such experienced personnel. No person subject to heart or neurological conditions should be allowed to conduct surge tests. Persons with pacemakers should not be allowed in or near the area where testing is conducted. • Never leave a procedure or a test setup unattended. • All personnel working in the area must be shielded with appropriate eye protection, body protection and electrical protection. They should not be allowed to work in a direct line of a possible explosion of the equipment under test. • The test area should be a clear and unobstructed environment dedicated to such tests. • The test area should be equipped with ventilating hoods and blowers to remove gases that may be caused by exploding or burning components. • The test area should have nonflammable walls and floors plus shielding to contain exploding parts and flames. • There must be fire extinguishers certified for use in electrical and chemical fires readily available at the test site. DO NOT USE WATER TO EXTINGUISH AN ELECTRICAL FIRE. • All flammable materials and debris must be outside the test area, and the area must be well marked, preferably by physical barriers, to prevent accidental intervention by nontest personnel while a test is in progress. CEMASTER System 4 Inappropriate Uses The unit must be kept within the environmental limits of the operating requirements. This includes not using the %'/#56'4 in condensing humidity. The unit must not be operated by wearers of electronic life-support equipment. Personnel with pace-makers, heart problems, nervous disorders, and similar problems should not be allowed to operate the %'/#56'4 or be present during ESD testing. The ESD probe is capable of giving an unpleasant shock -- it is not intended for use as a shock prod, "cattle prod", or as any device designed to shock people or animals. There are no User Serviceable parts inside; do not remove covers. CEMASTER System 5 Description The %'/#56'4 is a single-box test system for those in need of the CE Mark. The %'/#56'4 performs 6 different immunity tests, in accordance with European Norm requirements and the controlling, Basic EMC immunity standards of: • IEC 1000-4-2 ESD • IEC 1000-4-4 EFT • IEC 1000-4-5 Surge • IEC 1000-4-8 Power Frequency Magnetic Field • IEC 1000-4-9 Pulse Magnetic Field • IEC 1000-4-11 Dip and Interrupt The %'/#56'4 is the only combination EMC immunity tester that includes built in dip and interrupt, internal IEC 1000-4-8 capability, computer-controlled ESD tester and simplified, predefined test routines. The CEMASTER is also the only EMC immunity tester that customers configure to meet their own testing needs. Because of the %'/#56'4 's custom configurability, growing companies are now able to afford in-house compliance testing and larger manufacturers may purchase multiple units for various departments. The %'/#56'4 is a perfect solution for test houses seeking to complement their high-end test systems and offer their customers on-site testing capabilities as an additional service. As a user-friendly, portable immunity tester, the %'/#56'4 is the ideal solution for rental companies. CEMASTER System 6 Installation Assembly Instructions %'/#56'4Assembly The %'/#56'4 requires two people for unpacking. Check the packaging materials and follow any special unpacking instructions shipped with your unit. The %'/#56'4comes fully assembled. Save all shipping materials (shipping boxes, foam pieces, bags, and special instructions) for possible future shipments. The original shipping materials must be used whenever the %'/#56'4 is returned for calibration or service. Carefully check all shipping materials for accessories which may be packaged with the %'/#56'4. Computer Assembly If your system includes a computer: Unpack the computer and accessories. Verify that the voltage settings of computer and monitor match your mains voltage. Cabling and Interconnections The %'/#56'4has two AC Mains cordsets which plug into the rear of the unit. One, the Systems Power input, powers the circuitry of the %'/#56'4. The second, the EUT Power input, powers the front panel mains connector and the Equipment Under Test. The cordsets used should be the right-angle cordsets supplied with the unit to prevent damage to the cordsets when moving the %'/#56'4. The FiberCom option connects the %'/#56'4 to an external computer running the %'/#56'4 application software under Windows 3.x or Windows-95. The FiberCom option (CM-SW) includes a small module, the FC-11, a short RS-232 cable with a 9-pin Dshell connector, and a fiberoptic cable with a duplex modular connector. The RS-232 connector connects to your computer. The fiberoptic cable connects to the %'/#56'4 front panel; this connector is polarized and can only be inserted in one orientation: with the small tab on the connector facing right. Do not force the connector. The FiberCom option derives power from the RS-232 port of the computer -- no external power source is required.2 The optional ESD probe connector attaches to the front panel. This connector is polarized and can only be inserted in one orientation: align the flat of the connector plug with the flat of the front panel opening. Do not force the connector. Direct Current Power to EUT 2 Some computers use a low-power RS-232 driver with a reduced drive voltage. If the FiberCom fails to work with a computer, an external supply should be used [Thermo KeyTek part #02-701-695-00 (USA) and 62-050-415-00 (European)]. CEMASTER System 7 The CEMASTER can accept a Direct Current (DC) power source at the EUT input and provide it to the EUT output. When connecting to DC it is important to note the assignment of EUT inlet and outlet connectors. EUT Mains Inlet, Panel Wiring The IEC Inlet connector is wired, L1 left, L2 right, PE center. EUT Mains Outlet, Panel Wiring Regardless of nationality, the outlet is always wired, L2 left, L1 right, PE center. For DC use L1 and L2 should be used for voltages or voltage and return; the PE connection should be used for return only. Interlock connector The optional interlock allows the user to connect a remote switch which, when open, removes all AC and high-voltage from the %'/#56'4 front panel outlets, and disables the ESD head. A spare interlock connector is provided in the accessories kit for the %'/#56'4. To use this connector, wire your cable from the connector TIP and RING contacts, and provide a simple switch or contact closure at the other end of the cable. • The interlock operates from an internal, +5V, 20mA, logic level signal. Do not connect the interlock to a power source. • Use a cable with voltage rating of twice the voltage rating of your EUT. • Route the interlock cable away from the EUT output and the EUT. • DO NOT connect the interlock within the EUT, or to circuitry tied to the EUT. Capacitive Cable Clamp Cable A 1 meter long stereo phono plug cable and a 1 meter NH-coaxial cable are provided with the CM-CCL, and CM-CCLC options. The coax cable is screwed onto the CEMASTER coax output, and to either end of the CM-CCL or CM-CCLC cable clamps. The unused coaxial connector on the opposite end of the cable clamp should be left unterminated, or can be used with an optional, coaxial probe to monitor the delivered voltage. The CM-CCLC cable clamp includes an interlocked safety cover. By connecting the stereo phono plug cable between CEMASTER and either end of the cable clamp, the CEMASTER will CEMASTER System 8 operate only if the cover of the cable clamp is properly seated. The unused interlock jack on the opposite end of the cable clamp can be used to wire to additional interlock switches. Magnetic Coil Connections A CEMASTER-to-coil cable is provided with the CM-HCOIL option. The CEMASTER-end of the cable is plugged into the front-panel safety sockets. The coil end of the cable plugs into the sockets on the coil. Other Cables The %'/#56'4 accessories kit includes safety socket connectors and an interlock connector which the user may use to fabricate special test cables. When fabricating cables, always use wire rated for twice the peak, pulse voltage present during testing. Electrical Supply Requirements The %'/#56'4 will automatically configure for your AC Mains voltage, choosing one of two voltage ranges: 100 - 120 Vac, 50/60 Hz 220 - 240 Vac, 50/60 Hz The AC power source for the EUT must have adequate capacity for full power-follow3 in the event that testing causes an equipment failure. Using a supply without sufficient capacity may result in a failure being masked. Acceptable power sources include: • • • A dedicated branch circuit The dedicated output of a motor-generator (MG) set. The output of a properly installed isolation transformer. Use of the %'/#56'4 with Ground-Fault Interrupters (GFI) Problems may result when using the CEMASTER on AC mains protected by Ground-Fault Interrupters (GFIs). Surging the EUT, with a coupling mode to PE (L1-PE, L2-PE, or L1&L2-PE) will cause the GFI to trip, causing an unexpected loss of AC power to the EUT. The problem is due to the coupling network mandated by IEC 1000-4-5; this network connects the surge generator to the AC mains during the surge pulse, and creates a short pulse of mains current in PE, tripping the GFI. This problem only occurs during Surge events with a PE coupling mode selected. 3 Power-follow is a condition where the Surge event causes a low-impedance path which full mains current may then flow through. One example of this is a gas-tube arrestor, which maintains a high impedance until a surge event switches it to a low-impedance state; the low-impedance state is maintained until the mains voltage drops below a critical threshold. Similar effects can be seen due to electrical arcs or exploded components. CEMASTER System 9 There are two solutions to this problem: • The first solution is to power the EUT from a source that does not have a GFI device installed. This solution may not be practical in some locations due to building codes or safety regulations. • The second solution is to install an isolation transformer between the AC mains and %'/#56'4. The isolation transformer should be rated for -- at least -- 1920VA for 120VAC mains, or 3840VA for 220/240VAC mains. The transformer should be wired as diagrammed below. Proper Connection of an Isolation Transformer Note that L2 - Neutral - is bonded back to PE at the output of the transformer Note A solid-state regulated line source such as an uninterruptable power supply (UPS) or a power frequency amplifier will generally not have the instantaneous capacity or full power-follow required for Surge and PQF testing, and therefore should not be used as the AC power source for any equipment being tested. CEMASTER System 10 Physical Environment %'/#56'4 systems are intended for operation in a laboratory environment, protected from excess dust, humidity, and temperature. • No condensing humidity or standing water on the floor or work surfaces. • No significant dust or other contamination. Operating limits Temperature: Humidity: Altitude: 15 - 40° C 10 - 85%, non-condensing 10,000 feet max. Storage limits Temperature: Humidity: Altitude: 0 - 60° C 10 - 90%, non-condensing 10,000 feet max. Note: If your %'/#56'4 system has been subjected to temperatures or humidity outside of the normal operating limits for a period exceeding four hours, place the %'/#56'4 in an environment of the proper temperature and humidity, and allow the %'/#56'4 to stabilize in that environment for a period of 24 hours; during stabilization, the unit should be unpacked, but not powered nor operating. The %'/#56'4 CM-ESD option may require as much as 48 hours stabilization time if the period outside the humidity limits exceeds four hours. CEMASTER System 11 Test Area Considerations and Site Preparation Conduct pulsed EMI testing under sound laboratory conditions. Verify the following: • • • • • • • • • No condensing humidity or standing water on the floor or work surfaces No significant dust or other contaminants Clear and unobstructed vision Adequate ventilation, including ventilating hoods and blowers to remove gases Nonflammable walls and floors Barriers surrounding the EUT to contain exploding parts and flames Appropriate fire extinguishers for electrical and chemical fires. DO NOT USE WATER TO EXTINGUISH AN ELECTRICAL FIRE. No flammable materials or debris inside the test area. The area must be well marked, preferably by physical barriers Keep unauthorized personnel out of the area during testing Allow at least six inches clearance from the wall or other equipment on both sides of the instrument for proper air flow. The system must be mounted on a level surface. For EFT testing the %'/#56'4 should be mounted on the floor, on the ground reference plane. For other testing, the %'/#56'4 may be placed on a table that can support the weight of the unit. It may also be placed on a sturdy cart. However, since the unit is heavy, make certain that the instrument and cart combination is stable, and cannot be easily tipped particularly if the wheels strike a bump on the floor such as the edge of a rug, a pebble or a small piece of hardware. Special Considerations for Surge Testing Pulsed-EMI testing is best done in an area cleared of obstructions. Clearly mark the boundaries of the area. There is the possibility that the surge may flash over to circuits or metal objects not directly under test, and that components in the equipment being tested may explode or ignite under the stress of the surge test. Whenever possible, enclose the equipment under test within a fireproof and explosion-proof barrier having insulation capable of withstanding at least twice the maximum surge voltage. Never allow direct line-of-site view of components that may explode or ignite. If visual observation is required, use a robust transparent barrier of suitable thickness for protection. Pulsed-EMI testing should only be carried out by fully trained personnel who are informed of the hazards of such testing, and who have full control over all of the test equipment in the area. CEMASTER System 12 Special Considerations for EFT Testing Note While the possibility of component destruction is less of a concern during EFT testing, it should not be ignored. EFT testing involves the use of very high frequency pulses. For this reason the testing standards specify the use of a ground reference plane in the area where EFT testing is performed. In addition, the standards specify the minimum and maximum spacings among the various equipment present in the test area. This device complies with the requirements of the EMC Directive, 89/336/EEC, as stated in the declaration of Conformity. However, EFT test pulses are by nature an interference test and can therefore create a possible source of disturbance to other electronic equipment that is not intended for test. This device should be used in an environment free of other equipment that could be affected by these emissions, or in a shielded room. The floor of the test area is to be covered with copper or aluminum with a minimum thickness of 0.01 inch, which must be bonded to building Protective Earth (PE) ground. In addition, the cabinet of the %'/#56'4must be directly tied to the ground reference plane. Provision for a mounting bracket is made on the rear and bottom of the %'/#56'4 and the bracket and screws are provided. EFT Grounding Bracket Location CEMASTER System 13 EFT Connection to Equipment Under Test for Floor-standing EUT When used with table-top equipment, the equipment should be placed on an insulating table of 0.8 meters height. EFT Connection to Equipment Under Test for Table-top EUT CEMASTER System 14 Data and signal cables are tested using the EFT Capacitive Coupling Clamp (CM-CCL). When performing these tests, the EUT and any auxiliary equipment should be powered from the %'/#56'4 EUT output, to provide isolation between the test setup and building power mains. The minimum spacing required between the clamp and the equipment in the test area is shown in the figure below. Use of the Capacitive Cable Coupler for EFT Testing CEMASTER System 15 Special Considerations for ESD Testing ESD testing involves the use of high-voltage, fast-rising pulses. For this reason the testing standards specify the use of a ground reference plane in the area where ESD testing is performed. This device complies with the requirements of the EMC Directive, 89/336/EEC, as stated in the declaration of Conformity. However, ESD test pulses are by nature an interference test and can therefore create a possible source of disturbance to other electronic equipment that is not intended for test. This device should be used in an environment free of other equipment that could be affected by these emissions, or in a shielded room. IEC 1000-4-2 requires the use of a ground plane which must be bonded to building Protective Earth (PE) ground. The minimum size of the ground plane is 1 m2, the exact size depending on the dimensions of the EUT; the ground plane shall extend beyond the EUT by at least 0.5 m on all sides. The ground plane shall be sheet copper or aluminum of 0.25 mm minimum thickness, or 0.65 mm minimum thickness if another metal is used. For ESD testing, the %'/#56'4need not be connected to the ground plane. The EUT shall be positioned at least 1 m from walls and any metallic structures. For table-top equipment, a non-conducting table 0.8 m high is placed on the ground plane. A ground plane (HCP) 1.6 m by 0.8 m will be put on the table, and the EUT and any cables shall be placed on an insulating support 0.5mm thick placed on top of the HCP. The HCP shall connect to the ground reference plane with a resistive cable with two, 470,000 ohm resistors, one resistor at each end of the cable. Special Considerations for Pulsed Magnetic Field and Power-Frequency Magnetic Field Testing IEC 1000-4-8 and IEC 1000-4-9 require the use of a ground plane which must be bonded to building Protective Earth (PE) ground. The minimum size of the ground plane is 1 m2, the exact size depending on the dimensions of the EUT; the ground plane shall extend beyond the EUT by at least 0.5 m on all sides. The ground plane shall be sheet copper or aluminum of 0.25 mm minimum thickness, or 0.65 mm minimum thickness if another metal is used. For Magnetic Field testing, the %'/#56'4 need not be connected to the ground plane. The EUT is placed on the ground reference plane, on an insulating support 0.1 meter thick. The coil and EUT shall be positioned at least 1 meter from walls and metallic objects. CEMASTER System 16 Handling, Transportation, Storage Save all shipping materials (shipping boxes, foam pieces, bags, and special instructions) for possible future shipments. The %'/#56'4 requires two people for unpacking. Follow the instructions in the INSTALLATION section of this manual and any special instructions shipped with the unit. Issues related to transportation of %'/#56'4 models are identical to those for installation; the weight of the unit requires that two people help in packing and movement. When packing the unit for transportation the original shipping materials should be used, or new materials of equivalent strength and durability. An optional transport case -- CM-CASE -- is available for the unit. For long storage intervals, unplug the power cords of the instrument and cover the instrument to protect from dust and liquid spills. CEMASTER System 17 This page left blank intentionally. CEMASTER System 18 Introduction All features of the %'/#56'4, and all connections to the Equipment Under Test, are made from the front panel of the %'/#56'4. The front panel controls and features are broken into three major groups: the System Interconnections, the Equipment Under Test Connections, and the User Interface. CEMASTER System Interconnections -- ESD and Computer Interface On the left, bottom side of the %'/#56'4front panel are connectors for the FiberCom serial port, the ESD test probe, and the power switch for the %'/#56'4 Note that both connectors are polarized. On the FiberCom connector the small tab on the connector faces right. On the ESD probe connector, align the flat of the connector plug with the flat of the front panel opening. Do not force the connectors. CEMASTER System 19 Connections to the Equipment Under Test On the top, right side of the %'/#56'4 front panel are the connections to the Equipment Under Test. These include: The EFT output coax, at upper left, connects to the Capacitive Cable Clamp and is used for waveform verification. The Safety Interlock connector allows the user to connect a remote switch which, when open, removes all AC and high-voltage from the %'/#56'4front panel outlets, and disables the ESD head. The Safety socket outputs, at upper right, couple surge pulses to the magnetic coil, communication lines, and can be used for component testing. These sockets also provide power frequency magnetic field output to a test coil. The EUT Power connector provides AC Mains to the Equipment Under Test. The EUT Power switch energizes the EUT Power connector. The Voltage Present LED is lit when the AC Mains outlet is energized or when high voltage is present. The Reference Ground Connector is a chassis connection provided for waveform verification of the EFT waveform; it is not used during normal testing. For safety, a positive, operator-action is required to energize the EUT; i.e. if the EUT power switch is ON when the CEMASTER is first turned on, the switch must be toggled OFF and then ON to energize the EUT Power connector. CEMASTER System 20 User Interface When purchased with the CM-FP option, the %'/#56'4 front panel includes a liquid crystal display with seven function keys, and a 15-key keypad to the right of the display. The liquid crystal display and seven function keys provide quick user input. The function keys are mapped to the bottom line of the display. Pressing a function key executes that command. LCD Display Typical commands are EXIT (go back one menu), RUN, and scroll through menu selections. The numeric keypad is used to select menu items and enter numeric data into edit fields. The keys are defined as follows: 0 thru 9 +/CE ENTER enter numeric data or select menu items change polarity Clear Entry; erase a numeric field accept the current input or menu item scroll through selection list boxes, and increment or decrement numeric fields CEMASTER System 21 Programming the CEMASTER from the Front Panel When purchased with the CM-FP option, the front panel display shows status and the display and keypad allow convenient programming of the %'/#56'4 via screen menus. Programming is intuitive and easy. There are four basic menu types. The Main Menu is the 'top' menu; this is the menu seen after the %'/#56'4initializes, and this is the menu returned to after exiting all lower menus. The Main Menu allows selecting the test type to perform: Surge, EFT, ESD, etc. You select a test type either by moving a highlight bar down the screen using the arrow function keys, then pressing ENTER, or by pressing the number key associated with the test type. MAIN 1. 2. 3. 4. EFT/B Surge Power Frequency ESD EUT OFF 5. 6. 7. 8. PQF Pulse Magnetic Calibration System Setup ↑ ↓ The Main Menu shows all possible options, however, you can only select an option if it is installed in the %'/#56'4system. Attempting to select an option which is not installed will display an error message that the option is not available. After selecting a test type, a Test Menu opens. The Test Menu offers a user-defined option, and usually one or more pre-programmed tests to speed setup and testing per European Norms. The user-defined option gives access and control of every test parameter; this is the most powerful option, and allows engineering and debugging tests of EUT. The pre-programmed tests are a fast way to perform certification testing to European Norms, as most parameters default to the proper values and cannot be changed -- by locking these parameters the user can be certain that the tests are performed according to the European Norms, and performed the same way every time. Many pre-programmed tests perform a sequence of tests; for example, at several voltage levels, at several mains synchronizations, and in several coupling modes. As with the Main Menu, you select a test either by moving a highlight bar down the screen using the arrow function keys, then pressing ENTER, or by pressing the number key associated with the test. SURGE: TESTS 1. User defined 2. Pre-Qual A 3. Pre-Qual B 4. Class 1 Fast 5. Class 2 Fast 6. 7. 8. 9. Class Class Class Class ↑ CEMASTER System 3 1 2 3 EUT OFF Fast Full Full Full ↓ EXIT 22 After selecting either the User-Defined test option, or a pre-programmed test, a Parameter Definition Menu opens. The Parameter Definition Menu has edit fields, for waveform, voltage, etc. To change a field you first move the highlight bar to that field, using the function keys. After selecting a field there are different editing steps, depending on the type of field. • • • List fields have a limited number of specific values. An example is the line synch field which can accept "L1" or "RAND". With a list field selected, the value is changed by using the keypad arrow keys to scroll through the options. Numeric fields are edited by typing a value at the keypad. The keypad input fills the available field from right to left (If the field allows a decimal place, such as "##.##" and thus a value between 0 and 99.99, to enter a value of 10, press "1", "0", "0", "0"). Press "+/-" after the number to make it negative. Press ENTER or move the highlight bar to another field to accept the value; the value must be accepted before a test can be run. Some fields combine Numeric and List fields. When selected, the keypad arrow keys change the list portion (L1,RND) and the keypad number keys replace the numeric value. When all entries have been made and accepted the test can be started by pressing the F1 key -the RUN function key. To exit this menu without starting a test, press the F7 key -- the EXIT function key. SURGE: USER DEF Waveform .......... Voltage ........... Output:Coupling ... Phase Sync:Angle .. Number of Tests ... Time Between Tests RUN EUT OFF 12 Ohm +2000 V MAINS:L1,L2/PE L1:180 deg 500 60 s ↑ ↓ EXIT When a pre-programmed test has been selected, many parameters assume default values and cannot be changed by the user; these fields cannot be selected or highlighted. The fields for these parameters are replaced with the an AUTO symbol. SURGE: PREQUAL A EUT OFF Waveform .......... AUTO AUTO Voltage ........... AUTO Output:Coupling ... AUTO Phase Sync:Angle .. AUTO Number of Tests ... Time Between Tests 60 s RUN ↑ ↓ EXIT When a test is running, a RUN Menu is displayed. The RUN Menu shows the test type (Surge, EFT, etc.) and the EUT status (EUT ON, EUT OFF) on the top line of the display. The right side of the display shows the test parameters you programmed: waveform, voltage, coupling mode, line synch, number of tests, and time remaining in this test step (For example, the Surge Run Menu will display the test steps -- or test states -- on the STATUS line of CHARGING, FIRING, CEMASTER System 23 and WAITING. During each of these states, the time remaining field will count down and display the time remaining in that state.). Some tests, such as ESD, will not display time remaining as the time remaining depends on how the operator uses the ESD probe. The left side of the display shows status; from top to bottom this is; Status (of test: charging, running, etc.), Time (secs remaining in this test; if this test is one of a sequence this is the time for the individual test and not the time for the entire sequence), Test (the present test in a sequence, or test n of total tests), and Comm (or communications status: local, remote). SURGE: RUN Status: Time: Test: Comm: STOP Charging 37s 1/90 Local EUT OFF 12 Ohm +2000 V MAINS:L1,L2/PE L1:180 deg 3 60 s PAUSE In the RUN Menu, the STOP function key -- the F1 key -- terminates a test immediately and returns to the Parameter Definition Menu. The PAUSE function key -- the F3 key -- causes a temporary suspension of the test. Once a test has paused, press the F3 key a second time to resume the test (not all tests can be paused and restarted; if critical timing makes this impossible, the system will treat a pause as a stop, and the test must be restarted from the beginning). Pause is useful for checking EUT status. Selections 7 and 8 of the Main Menu -- Calibration and System Menus -- do not run tests, but perform special functions. The Calibration Menu allows calibration of the CEMASTER by a Thermo KeyTek authorized service representative. The System Menu provides troubleshooting and diagnostic tools to the user, and provides access to run-time options. For more information on the Calibration and System Menus see the TROUBLESHOOTING chapter. CEMASTER System 24 At power-up a standard message screen is shown while the system initializes and are performs self-tests. STATUS: INITIALIZING EUT OFF Hazardous voltages and emissions present by design when this equipment is operating. Take safety precautions at all times.MAIN 1. 2. 3. 4. EUT OFF EFT/B Surge Power Frequency ESD 5. 6. 7. 8. PQF Pulse Magnetic Calibration System Setup ↑ SURGE: TESTS 1. User defined 2. Pre-Qual A 3. Pre-Qual B 4. Class 1 Fast 5. Class 2 Fast 6. 7. 8. 9. Class Class Class Class 3 1 2 3 ↑ Press any key to show the Main Menu screen below. The Main Menu allows selecting a test type; move the highlight bar using the arrow function keys and press ENTER, or press the number key associated with the test type. As example, press 2 to open the Surge menu. ↓ EUT OFF Fast Full Full Full ↓ The Test Menu offers pre-defined tests to speed setup and a user defined mode for control of every parameter. Press 1 to open the user defined menu. The EXIT function key moves back one menu level. EXIT SURGE: USER DEF Waveform .......... Voltage ........... Output:Coupling ... Phase Sync:Angle .. Number of Tests ... Time Between Tests RUN . EUT OFF 12 Ohm +2000 V MAINS:L1,L2/PE L1:180 deg 500 60 s ↑ ↓ EXIT Parameter Definition Menus have edit fields, for waveform, voltage, etc. Move the highlight bar using the function keys to select a field. Edit a field by typing in a number, or use the keypad arrow keys to scroll through a list of options. The RUN function key starts the test. SURGE: RUN EUT OFF 12 Ohm +2000 V MAINS:L1,L2/PE L1:180 deg 3 60 s The RUN Menu identifies the test and shows status. The screen shows test parameters, and EUT status (ON,OFF), unit status (charging, waiting, firing), test status (time remaining, and test 1 of 90), and communications status (Local, remote). Stop and Pause keys end the test or causes a temporary hold. Status: Time: Test: Comm: STOP Charging 37s 1/90 Local PAUSE Front Panel Screens showing the Initializing screen and Four Menu Types CEMASTER System 25 The Status bar indicates the active test menu; Surge EUT status shows the front panel outlet is ON or OFF SURGE: USER DEF EUT OFF Waveform .......... 12 Ohm Voltage ........... +2000 V Output:Coupling ... MAINS:L1,L2/PE Phase Sync:Angle .. L1:180 deg Number of Tests ... 500 Time Between Tests 60 s RUN ↑ ↓ The bottom line of text maps to the seven function keys The RUN / STOP function key starts or stops tests The arrow function keys select a field to edit EXIT The EXIT function key moves to the previous menu List fields are selected by the function keys and edited using the keypad arrow keys to scroll through the options. SURGE: USER DEF EUT OFF Waveform .......... 12 Ohm Voltage ........... +2000 V Output:Coupling ... MAINS:L1,L2/PE Phase Sync:Angle .. L1:180 deg Number of Tests ... 500 Time Between Tests 60 s RUN ↑ ↓ Numeric fields are selected by the function keys and edited by typing a value at the keypad. Press ENTER to accept the value. EXIT Some fields combine Numeric and List fields. When selected, the keypad arrow keys change the list portion (L1,RND) and the keypad number keys replace the numeric value. Editing Functions Within the Parameter Definition Menus CEMASTER System 26 The left column shows test information: The Status bar indicates the active test; Surge, and the menu; RUN. Status (charging, running, etc.) Time (secs left in this test step) Comm (local, remote) Test (test n of total tests) SURGE: RUN Status: Time: Test: Comm: STOP The STOP -F1- function key halts the test EUT status shows the front panel outlet is ON or OFF EUT ON Charging 37s 1/90 Local 12 Ohm +2000 V MAINS:L1,L2/PE L1:180 deg 3 60 s PAUSE The PAUSE -F3- function key pauses the test. Press F3 again to resume The right column shows programmed test parameters: waveform, voltage, coupling mode, line synch, number of tests, and time between tests (or length of test). Definition of the Run Screen Menu CEMASTER System 27 Map of Front Panel Menu Structure The next two pages show the structure of the front panel menus. Selection Flow, from Main Menu through Test Menu, Parameter Definition Menu, and Run Menu VALUE is set to 125V VALUE is set to 0, then 90, then 270 VALUE may be edited by user VALUE is set to 60, but may be edited. Indicates a sequence of tests; first test 12-ohm, 250V; second test 2-ohm, 125V Legend, Map Of Front-Panel Menus CEMASTER System 28 Map of Front-Panel Menus, Page 1 of 2 CEMASTER System 29 Map of Front-Panel Menus, Page 2 of 2 CEMASTER System 30 Programming the CEMASTER from a Personal Computer When purchased with the CM-SW option, the %'/#56'4may be programmed and controlled from a Personal Computer (PC) running Windows. The PC software gives full access to all the features and capabilities of the %'/#56'4, including running a single test, running a pre-defined test sequence, and running diagnostics. In addition, the PC software adds a number of useful features: • • • • • Create tests and easily edit them. Chain tests into a test sequence. A test sequence can be constructed from a single test type (e.g. Surge) or can combine test types (e.g. do one Surge test followed by one EFT test, etc.). Store and recall tests and test sequences to disk. Print or file text descriptions of tests and test sequences (for inclusion in reports). Log test -- print or file what tests are executed. Full instructions for the software are described in the %'9CTG section. CEMASTER System 31 Running Tests STANDARDS OVERVIEW The European Union’s EMC Directive requires that electronic and electrical products be tested for immunity to both man-made and natural phenomena and to insure that products do not emit unintentional signals that may interfere with the continued, reliable operation of other products. Compliance with the EMC Directive requires that products be tested in accordance with European Norms, or ENs, issued by CENELEC. These ENs are not developed by CENELEC but are IEC and CISPR standards redesignated as ENs. There are three types of EMC Publications: • • • Product EMC Standards Product Family Standards (including Generic Standards) Basic EMC Publications Product EMC Standards relate to a particular type of product, system or installation for which specific conditions must be considered. Product EMC Standards include: • • Resistance Welding equipment Measuring Relays and Protection equipment Product Standards have priority over Product Family and Generic Standards; however, where no Product Standard or Product Family Standard exists for a particular product, the relevant Generic Standard will apply. Product Family Standards apply to products of a particular category such as: • • • Household appliances and portable tools ITE (Information Technology Equipment) Audio, video, audio-visual and entertainment lighting control apparatus for professional use Product Family Standards have priority over Generic Standards; however, where no Product Family EMC Standard exists for a particular product family, the relevant Generic Standard will apply. Generic EMC Standards are a special type of Product Family Standard which apply to products operating in a particular environment for which no dedicated Product or Product Family Standard exists. They specify a set of essential requirements, test procedures and generalized performance criteria applicable to products or systems operating in this environment. CEMASTER System 32 The Generic EMC Standards include: EN 50082-1, EN 50082-2, EN 50081-1, and EN 50081-2 which cover immunity and emissions testing for commercial, residential and light industrial environments, as well as for industrial environments. Basic EMC Publications may be standards or technical reports which, by definition, are NOT dedicated to specific product families, products, systems or installations. They may concern: • • • • • • • Terminology Descriptions of electromagnetic phenomena Specification of compatibility levels (NOT compliance levels) General requirements for the limitation of emissions Recommendations for test levels for immunity Measurement techniques Descriptions and classification of the environment Basic EMC Publications include Basic EMC standards such as the IEC 1000-4-X Series, CISPR 22, CISPR 11, and others TEST REQUIREMENTS The Basic EMC Publications (IEC 1000-4-2, IEC 1000-4-4, etc.) set the waveforms, test environment, and measurement techniques. The CEMASTER was designed to meet the requirements of these publications. Test levels are set by the Generic EMC Standards and Product Family Standards. The preprogrammed tests stored in the CEMASTER are designed to meet the test levels of: • • EN 50082-1 EN 50082-2 Generic Immunity, Residential, commercial, and light industrial Generic Immunity, Industrial WRITING A TEST PROCEDURE AND THE TEST REPORT Before starting testing, you should create a test procedure. This should identify which European Norms or other test requirements you are testing to. This should include the test levels, polarities, and number of tests. Most of the remainder of a test procedure is set by the Basic EMC Publications (IEC 1000-4-2, IEC 1000-4-4, etc.) which define the test setup and environmental limits, in detail. The test procedure should also describe how the EUT is setup and connected to test equipment and ancillary equipment. If the EUT involves software, a description of which software and software revisions should be included. CEMASTER System 33 An important part of both the test procedure and the test report is to establish how the EUT is exercised during the test. Most test procedures recommend that the EUT be operated in "the most sensitive mode". Preliminary testing will usually be required to determine what the most sensitive mode of operation is, which may vary with configuration, software, and operations performed. Finally, the test procedure should consider what level of disturbances of operation is allowed. Ideally the EUT should operate through testing without disturbance, however there may be disturbance which are considered acceptable, in that they do not result in damage. As example, the following are four levels of system disturbance: • Normal performance within specification limits; • Temporary degradation or loss of function which is self-recoverable; • Temporary degradation or loss of function which is requires operator intervention or system reset; • Degradation or loss of function which is not recoverable due to damage to equipment or components or loss of data. In no case is it acceptable that the equipment become dangerous or unsafe as a result of testing. The test report should present all of the information of the test procedure, report the test results, and give explanation of the results, as required. For acceptance tests, the test report is a required result of testing. The remainder of this section covers the basic EMC publications in detail; explains the waveforms and testing requirements; and explains how to use the %'/#56'4 to meet the requirements of the Basic EMC Publications. The information on IEC requirements -- figures and diagrams, tables and data, and test levels -- are accurate as of the date of printing of this manual. However, the IEC and EN documents are subject to review and change. The information in this manual is intended as a guideline only. CEMASTER System 34 IEC 1000-4-2 -- ESD Testing What is Electrostatic Discharge (ESD) Testing? These tests relate to equipment, systems, sub-systems, and peripherals which may be involved in static electricity discharges (either from persons or adjacent equipment), owing to environmental and installation conditions, such as relative low humidity, use of low-conductivity (artificial fiber) carpets, vinyl garments, etc. Two different types of tests can be performed with the ESD head - Contact or Air. Contact discharges are tests in which a sharp metal ESD tip physically touches the EUT. This method is regarded as the most repeatable method, and is the only acceptable method for waveform verification and calibration. Air discharges are tests in which a rounded ESD tip is quickly thrust toward the EUT until an ESD event occurs by "leaping" from the ESD tip to the EUT through the air. This method does not yield as repeatable results, but can be used if a contact discharge cannot be performed for some reason or another. The ESD waveform is characterized by the current in Contact-mode discharge, as defined in the figure and table below: Typical ESD Current Waveform Level 1 2 3 4 Set Voltage 2 kV 4 kV 6 kV 8 kV Peak Current (± 10%) 7.5A 15 A 22.5 A 30 A Current (±30%) at 30nS 4 8 12 16 Current (±30%) at 60nS 2 4 6 8 Waveform Parameters for ESD Pulse CEMASTER System 35 General Guidelines for Testing Place the air-discharge or contact-mode output tip into the ESD probe output tip receptacle. The TPA-2 probe tip is used for air discharge. The rounded tip of this probe prevents corona (which reduces applied voltage) and ensures most consistent results. The TPC-3 probe tip is used for contact discharge. The sharp point of this tip will penetrate surface oxidation and -- where necessary -- paint. Connect the ESD probe to the %'/#56'4using the 8-pin DIN cable. Connect the discharge return cable from the ESD probe to ground (an indicator on the ESD probe will light if the discharge return cable is not connected to the ESD probe). The bargraph indicator on the ESD probe is intended as a rough guide to the actual test voltage, and can serve in many applications as a pulse -- discharge -- indicator. The bargraph display is not calibrated, and can be affected by high humidity; for precise readings of probe tip voltage or periodic calibrations, Thermo KeyTek's DCA-2, high-voltage divider should be used. The ESD probe can be operated in manual triggering mode -- normal -- or automatic triggering mode -- tripod. Normal triggering is intended for handheld applications; in normal mode the probe will fire once for each time the probe button is pressed if the repetition is set to one, or fire continuously at 1pps or 20pps while the button is depressed if the repetition is set higher. Tripod triggering mode is intended for tripod operation; in this mode the probe will start triggering when the probe button is pressed and released and operation continues until either: the test ends, the operator ends the test by pressing the STOP -- F1 function -- key, or the probe button is pressed a second time. For safety, in all modes of operation, the operator must select a program and press run from the %'/#56'4 front panel or application software, THEN press the probe button to start the test. For Contact discharges the TPC-3 contact tip should physically touch the EUT. For Air discharge the rounded, TPA-2 tip is thrust toward the EUT at a constant rate until an ESD event occurs by "leaping" from the ESD tip to the EUT through the air. The probe is then pulled back away from the EUT - in preparation for the next test. Some practice is required to obtain consistent results with air discharge. Certification testing per European Norms uses 1pps for compliance testing. Use 20 pulses per second mode for quick scans to determine the most sensitive areas; then switch to 1pps for compliance testing. In 20 pps mode the pulse-detection and pulse counting features of the %'/#56'4 are disabled -- after the first pulse event, the ESD probe will free-run at 20pps whether or not there is a discharge. CEMASTER System 36 Testing Requirements per IEC 1000-4-2 Testing to IEC 1000-4-2 has the following requirements: • Testing takes place in climatic conditions as follows: Ambient temperature: Relative Humidity: Atmospheric Pressure: 15 °C to 35 °C 30 % to 60 % 86 kPa (860 mbar) to 106 kPa (1060 mbar) • A ground reference plane (GRP) is required. • The EUT shall be positioned at least 1 m from walls and any metallic structures. • Positioning of power and signal cables shall be representative of good installation practice. • The EUT shall be connected to the grounding system, representative of good installation practice; no additional earthing connections are allowed. • The discharge return cable should, where possible, be placed off the ground reference plane, and should not come closer than 0.2 m to other conductive parts of the test setup. • Vertical Coupling Planes (VCP) and Horizontal Coupling Planes (HCP) may be used for indirect application of the ESD pulse. These planes shall be constructed from the same material and thickness as the ground plane, and should be connected to the ground plane by a cable with two, 470,000 ohm resistors, one resistor at each end of the cable. • For table-top equipment, a non-conducting table 0.8 m high is placed on the ground plane. A ground plane (HCP) 1.6 m by 0.8 m will be put on the table, and the EUT and any cables shall be placed on an insulating support 0.5mm thick placed on top of the HCP. The HCP shall connect to the ground reference plane with a resistive cable as in the previous paragraph. IEC 1000-4-2 requires the use of a ground plane which must be bonded to building Protective Earth (PE) ground. The minimum size of the ground plane is 1 m2, the exact size depending on the dimensions of the EUT; the ground plane shall extend beyond the EUT by at least 0.5 m on all sides. The ground plane shall be sheet copper or aluminum of 0.25 mm minimum thickness, or 0.65 mm minimum thickness if another metal is used. For Floor-standing EUT the EUT is placed on a non-conducting mat of 0.1 mm minimum thickness placed on the ground plane. ESD testing may be direct -- applied to the EUT -- or indirect -- applied to the ground plane or to a vertical plane bonded to the ground plane. CEMASTER System 37 Typical ESD Test Setup for Floor-standing EUT Typical ESD Test Setup for Table-Top EUT During testing, the EUT is operated in a normal fashion. Compliance testing is typically performed with the EUT continually operating in the most sensitive mode, as determined by preliminary testing. Pulses are applied to points and surfaces which are accessible to personnel during normal usage. The voltage is increased from the minimum to the selected test level, in order to determine the threshold of failure (if any). The final test level is set by the product specification and the test class. The test is applied with single discharges, at preselected points. At least ten discharges of the most sensitive polarity shall be applied, and a rest interval of at least one second is recommended (or longer, as required to verify continued operation of the EUT). CEMASTER System 38 The %'/#56'4 supports 1000-4-2 testing to class 3 in Air-discharge mode and class 2 in contact discharge mode. The following table lists the test capabilities of the ESD hardware: Peak Voltage kV Contact Air 2 2 4 4 N/A 8 Class 1 2 3 User-defined ESD Tests The user-defined test option allows individual control of all test parameters required for ESD testing; this allows testing at different levels, modes, and repetition rates. The test parameters are: Surge Test Parameter Range/Units Voltage [-8800...-250, +250...+8800] V; resolution: 5 V Tip Air or Contact Mode Normal or Tripod Repetition Rate [1pps, 20pps] Number of Pulses [1 . . . 999] Preprogrammed IEC Standard ESD Test Sequences Two preprogrammed test sequences are stored in the %'/#56'4for rapid testing to the IEC standards. There are two tests mandated by the specifications - a 4 kV contact discharge and an 8 kV air discharge. Repetition is set for 1 pps and polarity is set by the user to the most sensitive polarity. The user can select mode -- normal or tripod -- and the number of pulses. The table below shows these two tests: Tests Voltage, kV Contact 4 Air 8 CEMASTER System Number of Discharges 10 positive, 10 negative 10 positive, 10 negative Repetition, pps 1 1 39 Waveform Verification IEC 1000-4-2 requires that the ESD output be verified periodically. Verification requires an ESD target (Thermo KeyTek CTC-3), a target plane (Thermo KeyTek TP-1), and an oscilloscope of 1GHz minimum bandwidth. The ESD probe with contact-mode tip is placed on a tripod, the %'/#56'4set to TRIPOD mode, 1pps. The rise time, peak amplitude, and amplitude at 30 ns and 60 ns should be monitored and recorded and checked against the figure and table at the start of this section. Performing ESD calibration is not trivial. The high-speed oscilloscope is expensive; the extremely fast risetime and high-bandwidth required by specification can require that a dedicated test site be built, with Faraday-shields for the oscilloscope, and EMI damping materials on floors and walls to reduce reflections. Thermo KeyTek offers a calibration service for all equipment, including the ESD probe. Contact factory for details. CEMASTER System 40 IEC 1000-4-4 -- EFT Testing For safety reasons, the precautions taken during EFT testing should be the same as for Surge testing -- read and follow the guidelines of the Safety Concerns During Surge Testing section, Page 4. It is important that the Equipment Under Test be properly connected -- read and follow the guidelines of the Test Area Considerations and Site Preparation section and of the Special Considerations for EFT Testing section, Page 12, as well as the Testing Requirements per IEC 1000-4-4 section which follows. What is Electrical Fast Transients (Burst) Testing? The electrical fast transient test consists of a burst of fast transients, coupled into power supply, control and signal ports of electrical and electronic equipment. The significant characteristics of the test are very high amplitude, the short rise time, the high repetition rate, and the low energy of the transients. The test is intended to demonstrate the immunity of electrical and electronic equipment when subjected to types of transient disturbances such as those originating from switching transients (interruption of unsuppressed inductive loads, relay contact bounce, etc.). EFT Waveform CEMASTER System 41 General Guidelines for Testing The EFT test voltage is referenced to the chassis of the %'/#56'4 The EFT waveform is coupled into the EUT via the AC Mains and the mains coupler built into the %'/#56'4, or via signal lines (or both). An optional Capacitive Cable Clamp is available for coupling to signal lines or to power lines where the CEMASTER internal coupler cannot be used. When applied to the EUT Mains, the EFT voltage is applied between ground -- the Ground Reference Plane (GRP) -- and each of the power supply terminals and between the GRP and the protective earth of the EUT. Power-line -- Mains -- testing is performed by plugging the EUT into the %'/#56'4 EUT outlet, establishing the EUT in a normal operating mode, and applying the EFT waveform to, first the line (L1), then neutral (L2), then PE. Data-line testing starts with the EUT and auxiliary equipment plugged into the %'/#56'4 EUT outlet -- to prevent EFT waveforms from contaminating the AC Mains -- and couples the EFT waveform from the CLAMP outlet to a Capacitive Cable Clamp where the waveform is coupled into the signal lines. The Capacitive Cable Clamp should be adjusted to fit snugly about the cables to be tested. Testing Requirements per IEC 1000-4-4 Testing to IEC 1000-4-4 has the following requirements: • • • • • Testing takes place in climatic conditions as follows: Ambient temperature: 15 °C to 35 °C Relative Humidity: 25 % to 75 % Atmospheric Pressure: 86 kPa (860 mbar) to 106 kPa (1060 mbar) A ground reference plane (GRP) is required. The EUT shall be positioned at least 0.5 m from walls and any metallic structures. The EUT shall be connected to the grounding system, representative of good installation practice; no additional earthing connections are allowed. Positioning of power and signal cables shall be representative of good installation practice, EXCEPT: • The length of signal and power cables shall be 1 meter or less • If the length of signal or power cable exceeds 1 meter, the excess length shall be gathered into a flat coil with a diameter of 0.4 m and situated at a height of 0.1 m above the GRP. IEC 1000-4-4 requires the use of a ground plane which must be bonded to building Protective Earth (PE) ground. The minimum size of the ground plane is 1 m2, the exact size depending on the dimensions of the EUT and %'/#56'4; the ground plane shall extend beyond the EUT and %'/#56'4 by at least 0.1 m on all sides. The ground plane shall be sheet copper or CEMASTER System 42 aluminum of 0.25 mm minimum thickness, or 0.65 mm minimum thickness if another metal is used. The cabinet of the CEMASTER must be directly tied to the ground reference plane. Provision for a mounting bracket is made on the rear of the CEMASTER and the bracket and screws are provided. Location of Grounding Bracket For floor mounted equipment, the EUT shall be placed on the GRP and shall be insulated from the GRP by an insulating support 0.1 meter ± 0.01 meter thick. For table-top equipment, the EUT should be placed on a table of height 0.8 meter ± 0.08 meter above the GRP. EFT Connection to Equipment Under Test for Floor-standing EUT CEMASTER System 43 EFT Connection to Equipment Under Test for Table-top EUT Data and signal cables are tested using the EFT Capacitive Coupling Clamp (CM-CCL). When performing these tests, the EUT and any auxiliary equipment should be powered from the %'/#56'4EUT output, to provide isolation between the test setup and building power mains. The minimum spacing required between the clamp and the equipment in the test area is shown in the figure below (Note: if the Auxiliary equipment is not considered part of the EUT, the separation distance is 5 meters as shown. If the Auxiliary equipment is considered part of the EUT, the separation drops to 1 meter). Use of the Capacitive Cable Coupler for EFT Testing The voltage test levels to be applied vary with the test class, and are listed below: Test Level Class 1 Class 2 Class 3 Peak Voltage 500V 1.0kV 2.0kV Frequency 5kHz 5kHz 5kHz The level used in testing depends on the European Norm (EN) chosen to test against. As example, EN50082-1 (for Residential, commercial, and light industry) specifies a test level of 1000 volts. The EFT voltage is applied for one minute, for each test. CEMASTER System 44 User Defined EFT Test The user-defined test option allows individual control of all test parameters required in EFT testing; this allows testing at different levels, modes, and repetition rates. On being triggered by pressing the “start” key, a user defined test produces a series of output events with the parameters defined below: Parameter Voltage Burst Frequency Output Coupling Test Duration Range Resolution -250V ... -2500V, 250V ... 2500V 1V 2.5 ... 100kHz in 0.5kHz steps Clamp, Mains [Mains modes, L1, L2, PE, L1&L2, L2&PE, L1&PE, or L1&L2&PE All outputs with respect to Groundplane] 1...999 seconds 1 second Accuracy +/- 10% +/- 20% Preprogrammed EFT Test Sequences Three preprogrammed test sequences are stored in the %'/#56'4 for rapid testing to the IEC standards. These test sequences are designed to satisfy the requirements of EN50082-1 and EN50082-2. Test Sequence Peak Voltage Frequency Port Class 1 500V 5kHz Mains or Clamp Class 2 1.0kV 5kHz Mains or Clamp Class 3 2.0kV 5kHz Mains or Clamp Coupling Mode Mains only PE to groundplane. L1, L2, and PE in sequence L1, L2, and PE in sequence Number of Bursts 200 (1 polarity 200 (1 polarity mode 200 (1 polarity mode minute) per minute) per and coupling minute) per and coupling All tests are run twice: once in each polarity. CEMASTER System 45 Waveform Verification IEC 1000-4-4 requires that the EFT output be verified periodically. For verification, the output of the generator is connected to an oscilloscope through a 50-ohm, high-voltage coaxial attenuator. The rise time, duration, and repetition rate of the impulses within one burst should be monitored and recorded. The bandwidth of oscilloscope and attenuator must exceed 400MHz. For digital oscilloscopes a sampling rate exceeding 1GSa/s is recommended. The attenuator must have a voltage rating of 1250V minimum. The test setup shown below is usable for Waveform Verification. The BARTH Model 2237HFNFP attenuator4 has sufficient voltage and power rating to connect directly to the %'/#56'4 output. The Tektronix5 attenuators drop the voltage to within the range of typical oscilloscope inputs. The circuit below provides a total attenuation of 1000:1. Recommended Test Setup for Waveform Verification The circuit above is for measurement of the EFT waveform at the HN-coax connector; this circuit is not rated for use across the AC Mains outlet. Connecting this circuit across the AC Mains with Mains voltage present will result in damage of the attenuator. If measuring EFT waveform at the AC Mains outlet: Check that the EUT switch is off and no AC is applied to the EUT Mains Inlet before connecting the attenuator; make the measurement and remove the attenuator immediately. 4 5 Barth Electronics, Inc., 1300 Wyoming St., Boulder City, NV 89005 USA Tektronix, Inc., P.O. Box 1000, Wilsonville, OR 97070-1000 USA CEMASTER System 46 IEC 1000-4-5 -- SURGE Testing Surge testing is hazardous -- read and follow the guidelines of the Safety Concerns During Surge Testing section, Page 4. It is important that the Equipment Under Test be properly connected -- read and follow the guidelines of the Test Area Considerations and Site Preparation section and of the Special Considerations for Surge Testing section, Page 11. What is Surge Testing? Surge testing is the application of unidirectional surges to the Equipment Under Test to model those caused in the real world by overvoltages from switching and lightning transients. Surges occur on the AC power mains as a result of switching operations in the power grid and from nearby lightning strikes, either directly to the power distribution system or to nearby ground. Radiated coupling of surges into I/O lines can also occur. Electronic products are tested for Surge immunity to insure their continued reliable operation if subjected to realistic levels of surge voltages. The waveform used for IEC testing is the 1.2/50 µs open circuit voltage (8/20 µs short circuit current) combination wave. This waveform is separately characterized by the open circuit voltage and short circuit current. Open-Circuit Surge Voltage CEMASTER System 47 Short-Circuit Surge Current General Guidelines for Testing Surge testing is very useful to determine breakdown of components when subjected to a highvoltage impulse. Surge testing can be performed on AC or DC power Mains, communications lines, and components. The %'/#56'4 includes a built-in coupler which can place surges on AC or DC Mains for application to the EUT. The angle of application onto the AC Mains waveform can be precisely controlled; application at 90° and 270° cause the surge to add to the peak line voltage for worstcase voltage; application at other angles can be used to find sensitive components -- such as diodes, SCRs, or solid-state switches -- which are most sensitive at the time they turn on or off. The %'/#56'4 also has front panel, safety socket connections to apply surges to the magnetic field test coil (CM-HCOIL) or for component testing. The CM-I/OCD optional accessory provides convenient coupling of surges onto data and I/O lines. When surging a DC Mains or the EUT with no mains applied, the Line Coupling Phase Angle selection must be set to ‘RND’ -- random -- as the test will be unable to synchronize to a DC mains and will not run. CEMASTER System 48 Probing the EUT during Surge testing should be attempted only by experienced test engineers. When connecting probes to the EUT, follow these guidelines: • Use balanced, differential, high-voltage probes rated for the surge voltage (such as the Thermo KeyTek PK1001D probe set). Most oscilloscope probes are rate for 600Vac or less and should NOT be used in Surge testing. • Current should be measured with a non-contact, high-bandwidth current transformer (a Pearson6 model 110 current transformer, or equivalent). • Do not connect probe grounds to the EUT! This will create a path for Surge and fault currents which can endanger the operator and test equipment. • Do not defeat protective grounding or earthing of the oscilloscope or other test instrument. • If connecting a voltmeter or other high-impedance test equipment to the EUT, carefully check the common-mode voltage rating of the equipment. This is the voltage rating of both probes above the instrument ground. Surge testing will typically exceed the common-mode voltage rating of most Mains-powered equipment, and can exceed the rating of battery-powered equipment. Use of an instrument above its common-mode voltage rating may result in improper operation or damage. Connection of Probes to the EUT during Surge Testing 6 Pearson Electronics, Inc., 1860 Embarcadero Rd., Palo Alto, CA 94303 USA CEMASTER System 49 Testing Requirements per IEC 1000-4-5 The Basic EMC Standards for Surge define the methods of generating consistently reproducible surge voltages for test purposes. They specify generator and coupler/decoupler design and performance in sufficient detail to produce correlatable results between test sites. These are issues which are controlled by the design of the CEMASTER and need not be considered by the operator or user. While the Basic EMC Standard specifies how to perform Surge testing, the Generic, Product and Product Family Standards specify the test levels and pass/fail performance criteria. IEC 1000-4-5 also includes a climatic specification, as follows: • Testing takes place in climatic conditions as follows: Ambient temperature: 15 °C to 35 °C Relative Humidity: 10 % to 75 % Atmospheric Pressure: 86 kPa (860 mbar) to 106 kPa (1060 mbar) Note that other values may be specified in the test specification. The EUT should be operated within its intended climatic conditions. The test level, polarity, and source impedance are set by the European Norms (EN), as a function of use and exposure class (See the Class Definition Table and Test Levels Table, below). The %'/#56'4 is capable of testing to Classes 0, 1, 2, and 3 test levels. The general test requirements, per IEC 1000-4-5 are as follows: Output polarity Output (source) impedance Number of tests Repetition rate Mains Synchronization CEMASTER System Both positive and negative For power supply (AC or DC), line to line surges: 2 Ω For power supply (AC or DC), line to earth surges: 12 Ω For direct coupling to communication lines: 40 Ω (2 or 12 Ω selected from CEMASTER, and additional, external resistance added) At least five positive and five negative tests at each test level Maximum: 1 surge per minute 0° or 180°, 90°, and 270° 50 Class definitions Class 0 Class 1 Class 2 Class 3 Class 4 Well-protected electrical environment, often within a special room. Partly protected electrical environment. Electrical environment where the cables are well separated, even at short runs. Electrical environment where cables run in parallel. Electrical environment where the interconnections are running as outdoor cables along with power cables, and cables are used for both electronic and electric circuits. Electrical environment for electronic equipment connected to telecommunication cables and overhead power lines in a non-densely populated area. Special conditions specified in the product specification. Class 5 Class x Voltage Test Levels vs. Class Unbalanced datalines, LDB Coupling mode Line to line Line to earth Balanced datalines Coupling mode 0 Test levels (kV) Power supply Coupling Mode Line Line to line to earth NA NA NA NA NA NA NA NA 1 NA 0.5 NA 0.5 NA 0.5 NA NA 2 0.5 1.0 0.5 1.0 NA 1.0 Clas s 3 1.0 2.0 4 2.0 4.0 5 2) 2) Line to Line to Line to Line to line earth line earth NA 0.5 2.0 3) NA NA 3) NA NA NA NA 2.0 3) 2.0 4.0 3) NA 2.0 2.0 4.0 3) NA 4.0 3) 1.0 3) SDB, DB1) Coupling mode NA x 1) Limited distance, special configuration, special layout, 10 m to max. 30 m: no test is advised at interconnection cables up to 10 m, only class 2 is applicable. 2) Depends on the class of the local power supply system. 3) Normally tested with primary protection. Explanation: DB = data bus (data line) SDB = LDB = long-distance bus NA = CEMASTER System short-distance bus not applicable 51 User Defined Surge Test The User Defined menu allows individual control of all test parameters required in surge testing; this allows testing at different levels, modes, and repetition rates. A User defined Surge Test is controlled by a set of test parameters and results in a surge event, or number of surge events, whose parameters are defined in the table below. Surge Test Parameter Range/Units Waveform Auto, 2, 12 Ω Output Impedance (source impedance) For Waveform = “Auto”: If the Output is MAINS and the Line Coupling is PE, then the Output Impedance is 12Ω; otherwise the Output Impedance is 2Ω. Surge Voltage [-2500..+2500] V; resolution: 1 V Output Direct (safety sockets), MAINS (EUT output receptacle) Line Coupling For Output = Direct : [N/A] For Output = MAINS: (Surge HIGH/Surge LOW) = [L1/L2, L1/PE, L2/PE, (L1 and L2)/PE] Line Coupling Angle Phase For Output = Direct : [not applicable] For Output = MAINS: [Random, 0..360 °]; resolution: 1° Random is required when surging a DC Mains, or when surging the EUT outlet with no EUT power applied. Interval Between Tests [Min, (15..999) s]; resolution: 1 s For Interval Between Tests = “Min”: the interval between tests will be the minimum time required to charge the circuit to the required Surge Voltage. If a number is entered which is less than the minimum time required to charge the circuit to the required Surge Voltage, the time will be replaced with the minimum time. Number of Tests [1..999] When the operator presses the START key, the system will execute the specified number of Charge and Surge cycles; the surge will occur automatically every Interval Between Tests, preceded by an audible warning. Preprogrammed IEC Standard Surge Test Sequences Each of the preprogrammed tests is a set of sequentially executed tests where most parameter values are predefined. Preprogrammed tests are based on the IEC Installation Class definitions. There are eight pre-stored IEC Standard test sequences. “Pre-Qualification” test sequences offer test levels below the Class 1 test level. These tests are useful for tracking down problems in units which fail to meet the Class 1 test levels. “Fast” test sequences perform tests to one and only one Class level, while “Full” test sequences follow the directions of IEC 1000-4-5, testing to a Class test level and all Classes below that level. A “Full” test sequence is required to certify equipment. A “Fast” test sequence allow quickly tracking down problems; e.g. if a unit always passes Class 1 only to fail Class 2, the Fast test can test only the Class 2 level. CEMASTER System 52 After selecting a preprogrammed test you have the options of selecting Line Coupling, and Interval between tests. To meet the specifications of IEC 1000-4-5 the Interval between tests should be 60 seconds (the default) or greater. Use a larger interval, if needed, to verify operation of the EUT between pulses. While you can use a shorter interval to speed pre-qualification testing, note that the surge event can cause stress to the EUT; applying surges at too fast a rate may be overly stressful and could result in damage to the EUT. The time to complete column in the following table assumes the default Interval between tests is used. When Line Coupling is set to MAINS, the %'/#56'4 cycles through each line coupling mode: L1-to-L2, L1-to-PE , and L2-to-PE. When surging a DC Mains or the EUT with no mains applied, the Line Coupling Phase Angle selection must be set to ‘RND’ --random -- as the test will be unable to synchronize to a DC mains and will not run. Test Surge Voltage L1-to-L2 L1-to-PE & L2-to-PE Time to Complete (hrs:min) Direct Coupling Mains Coupling Pre-Qualification A NT 125 00:10 01:00 Pre-Qualification B 125 250 00:10 01:30 Class 1 Fast 250* 500 00:10 01:30 Class 2 Fast 500 1000 00:10 01:30 Class 3 Fast 1000 2000 00:10 01:30 no test 125 250 500 00:30 04:30 Class 2 Full Step 1 Step 2 Step 3 125 250 500 250 500 1000 00:30 04:30 Class 3 Full Step 1 Step 2 Step 3 250 500 1000 500 1000 2000 00:30 04:30 Class 1 Full Step 1 Step 2 Step 3 All tests perform 5 surges with negative polarity, 5 surges with positive polarity, at three line synchronizations (0°, 90°, and 270°). For Line Coupling = “DIRECT”, the Surge Voltage will be the same as for line to earth coupling (L1-to-PE & L2-to-PE) and no line synchronization is used. The 2-oh, waveform is used for Line-toline testing; the 12-ohm waveform is used for line-to-PE testing. * not required for Class 1 test (see Class 1 Full test) CEMASTER System 53 Waveform Verification IEC 1000-4-5 requires that the simulator output be verified periodically. High voltage differential surge probes are required for verifying the open-circuit voltage, and a suitable current transformer is required for verification of the short-circuit current. A digital or storage oscilloscope with 100MHz bandwidth is sufficient for measuring the surge voltage and current waveforms and peaks. The probes are connected across the lines to be verified (e.g. L1 and L2), the %'/#56'4 is programmed to apply a pulse to these lines, and the signal is captured by the oscilloscope. The peak value, rise, and duration is measured and calculated and compared to the waveforms at the beginning of this section. When measuring current at the EUT outlet, the EUT outlet must be switched off and the EUT Mains power cord should be removed from the inlet for safety. When measuring voltage across the EUT output, the AC Mains should be switched off and the line synchronization set to RANDOM; this simplifies measurements, as the Surge Voltage waveform will not be superimposed on the Mains waveform. CEMASTER System 54 IEC 1000-4-8 POWER-FREQUENCY MAGNETIC FIELD Testing What is Power Frequency Magnetic Field Testing? Electronic products are often subjected to magnetic fields at AC mains frequencies. These fields are frequently produced in the vicinity of power transformers and can cause problems with CRT’s, Hall effect sensors, and other electronic products having a sensitivity to magnetic fields. Electronic Products are tested for immunity to power frequency magnetic fields to insure their continued reliable operation when placed in service. General Guidelines for Testing The test magnetic field is applied by the immersion method to the EUT; in this method the EUT is placed in the center of an induction coil. The induction coil is characterized by a test volume, and an Induction Coil Factor; the coil factor is the ratio between the magnetic field strength generated by an induction coil and the current value required to obtain that field strength. For a standard coil, the coil factor is determined by the manufacturer of the coil, and can be verified by laboratory measurements before carrying out the tests. The %'/#56'4 operates as a current-controlled device -- it outputs a sinusoidal output current. The maximum Magnetic Field Strength available in a test is dependent upon the Induction Coil Factor of the Induction Coil, as the Magnetic Field Strength is the product of the Surge Current and the Induction Coil Factor. The %'/#56'4 can source 5 amperes; this is sufficient to drive a coil with a coil-factor of 0.8 to 4 A/m. With lesser coil factors, the current will increase, and this may cause distortion of the sinusoidal current. When the programmed magnetic field strength, divided by the coil factor, exceeds 5 amperes, the current should be checked for indications of distortion. The size and shape of the induction coil may vary, but one standard coil is the one-meter square coil available from Thermo KeyTek as CM-HCOIL. This coil is capable of providing a constant field-strength over a volume of 0.6 by 0.6 by 0.5 meter; for EUT larger than this, a larger coil will be required. The Coil Factor for this coil is 0.87. Since the Equipment Under Test may show sensitivity to the direction of magnetic field, the coil or EUT is typically rotated to apply the field in three orthogonal directions. The unit of magnetic field measurement is A/m. In free-space, 1 A/m is equivalent to 1.26 microTeslas or 0.0126 Gauss. CEMASTER System 55 Example of the three Orthogonal Axes for Magnetic Field Testing Testing Requirements per IEC 1000-4-8 Testing to IEC 1000-4-8 has the following requirements: • • • • • Testing takes place in climatic conditions as follows: Ambient temperature: 15 °C to 35 °C Relative Humidity: 25 % to 75 % Atmospheric Pressure: 86 kPa (860 mbar) to 106 kPa (1060 mbar) A ground reference plane (GRP) is required. The EUT shall be connected to the grounding system, representative of good installation practice. Positioning of power and signal cables shall be representative of good installation practice. A back-filter, to prevent possible interference with other equipment, is optional in IEC 10004-8, although required in the Pulsed Magnetic Field testing. The %'/#56'4EUT output may be used as a mains back-filter if desired. IEC 1000-4-8 requires the use of a ground plane which must be bonded to building Protective Earth (PE) ground. The minimum size of the ground plane is 1 m2, the exact size depending on the dimensions of the EUT; the ground plane shall extend beyond the EUT by at least 0.5 m on all sides. The ground plane shall be sheet copper or aluminum of 0.25 mm minimum thickness, or 0.65 mm minimum thickness if another metal is used. The EUT is placed on the ground reference plane, on an insulating support 0.1 meter thick. The EUT is operated normally and the magnetic field is applied. The coil is rotated twice and the test is repeated. IEC 1000-4-8 requires that one terminal of the test generator be attached to the ground reference plane; the %'/#56'4 does this internally. You should not make an external connection between coil and ground reference plane. User Defined Power Frequency Magnetic Field Test The User Defined menu allows individual control of all test parameters required in Power Frequency Magnetic Field Immunity Testing; this allows testing at different levels, frequencies, and durations. CEMASTER System 56 A User-defined test is controlled by a the parameters in the table below: Test Parameter Range/Units Coil Factor Field Strength Line Frequency Duration 0.65...1 0...4 A/m, in steps of 0.25 A/m 50Hz, 60Hz 1...9999 seconds Preprogrammed IEC Standard PFMF Immunity Test Sequences There are no preprogrammed tests for Power Frequency Magnetic Field Immunity Testing. Waveform Verification IEC 1000-4-8 requires that the simulator output be verified periodically. This is to ensure that the EUT is being tested at the proper test level. Waveform Verification takes place with the same setup as for EUT testing, but with the EUT removed. Verification requires a magnetic-field strength meter. Thermo KeyTek offers a magnetic-field strength meter , CM-HMON, for use in Verification. The %'/#56'4 is set for the desired field strength. The magnetic-field strength meter is placed in the center of the coil and oriented to achieve a maximum reading. The reading of the field meter is compared to the desired field-strength, and the coil factor adjusted accordingly: lower if the measured field strength is too low, higher if the measured field strength is too high. The measurement and adjustment may be repeated until the measured field strength is within acceptable tolerances of the desired field strength. CEMASTER System 57 IEC 1000-4-9 PULSED MAGNETIC FIELD Testing What is PULSED MAGNETIC FIELD Testing? Pulse Magnetic fields are produced as a result of a large current impulse through a conductor. An example is lightning current flowing through a grounding conductor at a power sub-station. Pulse magnetic fields can also occur in heavy industrial areas where very large current impulses are used in a manufacturing process. Electronic products are tested for immunity pulse magnetic fields to insure their continued reliable operation when placed in service in a very harsh environment. General Guidelines for Testing The test magnetic field is applied by the immersion method to the EUT; in this method the EUT is placed in the center of an induction coil. The induction coil is characterized by a test volume, and an Induction Coil Factor; the coil factor is the ratio between the magnetic field strength generated by an induction coil and the current value required to obtain that field strength. For standard dimension coil, the coil factor is determined by the manufacturer of the coil, and can be verified by laboratory measurements before carrying out the tests. The %'/#56'4 operates as a current-controlled device -- it outputs a current pulse. The maximum Magnetic Field Strength available in a test is dependent upon the Induction Coil Factor of the Induction Coil, as the Magnetic Field Strength is the product of the Surge Current and the Induction Coil Factor. The size and shape of the induction coil may vary, but one standard coil is the one-meter square coil available from Thermo KeyTek as CM-HCOIL. This coil is capable of providing a constant field-strength over a volume of 0.6 by 0.6 by 0.5 meter; for EUT larger than this, a larger coil will be required. The Coil Factor for this coil is 0.87. Since the Equipment Under Test may show sensitivity to the direction of magnetic field, the coil or EUT is typically rotated to apply the field in three orthogonal directions. The unit of magnetic field measurement is A/m. In free-space, 1 A/m is equivalent to 1.26 microTeslas or 0.0126 Gauss. CEMASTER System 58 Example of the three Orthogonal Axes for Magnetic Field Testing Testing Requirements per IEC 1000-4-9 Testing to IEC 1000-4-9 has the following requirements: • • • • • • Testing takes place in climatic conditions as follows: Ambient temperature: 15 °C to 35 °C Relative Humidity: 25 % to 75 % Atmospheric Pressure: 86 kPa (860 mbar) to 106 kPa (1060 mbar) A ground reference plane (GRP) is required. The EUT shall be connected to the grounding system, representative of good installation practice. The coil and EUT shall be positioned at least 1 meter from walls and metallic objects. A back-filter is required to prevent possible interference with other equipment. The CEMASTER EUT output may be used as a mains back-filter, or a Line-impedancestabilization-network (LISN) may be substituted. The user may have to provide additional backfilters for signal and communication lines (if any). Positioning of power and signal cables shall be representative of good installation practice, with the following notes: • Communication lines shall be maintained at a height of 0.1 meter above the GRP. • Backfilters on communication lines -- if used -- shall be at least one meter from the EUT. IEC 1000-4-9 requires the use of a ground plane which must be bonded to building Protective Earth (PE) ground. The minimum size of the ground plane is 1 m2, the exact size depending on the dimensions of the EUT; the ground plane shall extend beyond the EUT by at least 0.5 m on all sides. The ground plane shall be sheet copper or aluminum of 0.25 mm minimum thickness, or 0.65 mm minimum thickness if another metal is used. The EUT is placed on the ground reference plane, on an insulating support 0.1 meter thick. The EUT cabinet is connected to the ground plane via the EUT earth terminal (if any). The EUT is operated in a normal fashion and pulses are applied. The coil is rotated twice and the test is repeated. IEC 1000-4-9 requires that one terminal of the test generator be attached to the ground reference plane; the CEMASTER does this internally. You should not make an external connection between coil and ground reference plane. CEMASTER System 59 User Defined Pulsed Magnetic Field Immunity Test The User Defined menu allows individual control of all test parameters required in Pulsed Magnetic Field Immunity Testing; this allows testing at different levels, number of pulses, and time between tests. A User-defined test is controlled by a the parameters in the table below: PMF Test Parameter Range/Units Coil Factor [0.5..1.0]; resolution: 0.01 Magnetic Field Strength [-800..+800] A/m The Magnetic Field Strength is dependent upon the Coil Factor selected, as Magnetic Field Strength is the product of the Surge Current and the Coil Factor. The above range assumes a coil factor of 0.87; the actual Magnetic Field Strength will be less for lower coil factors. Time Between Tests [15..999 s]; resolution: 1 s The lower limit is dependent on Magnetic Field Strength; its value will be higher at higher Magnetic Field Strength, reaching a maximum of 30 s at 800 A/m. If a number is entered which is less than the minimum time required to charge the circuit to the required Surge Voltage, the time will be replaced with the minimum time. Number of Tests [1..999] When the operator presses the START key, the system will execute the specified number of Charge and Surge cycles; the surge will occur automatically every Interval Between Tests, preceded by an audible warning. Preprogrammed IEC Standard Pulsed Magnetic Field Immunity Test Sequences Each of the preprogrammed tests is a set of sequentially executed tests where most parameter values are predefined. Preprogrammed tests are based on the IEC Installation Class definitions. There are two pre-stored IEC Standard test sequences, which test to different magnetic field strengths. The only adjustment the user can make is to the time between tests. Class 3 Test: This test sets the magnetic field strength to 100 A/m and programs 5 pulses. Class 4 Test: This test sets the magnetic field strength to 300 A/m and programs 5 pulses. CEMASTER System 60 Waveform Verification IEC 1000-4-9 requires that the simulator output be verified periodically, to ensure that the EUT is being tested at the proper test level. Waveform Verification takes place with the same setup as for EUT testing, but with the EUT removed. Calibration requires a digital or storage oscilloscope with 100MHz bandwidth, a magnetic-field strength meter, and an inductive current probe and true-rms voltmeter capable of measuring 10 amperes peak with bandwidth exceeding 100Hz (the oscilloscope may be substituted for the voltmeter). Thermo KeyTek offers a magnetic-field strength meter , CM-HMON, for use in Verification. A Pearson7 model 110 current transformer (or equivalent) may be used as the current probe. The current probe is placed over one of the coil leads. The %'/#56'4 is set for Power Frequency Magnetic Field testing, and programmed for a field strength of three A/m. The magnetic-field strength meter is placed in the center of the coil and oriented to achieve a maximum. This reading is recorded. The rms-reading of the current is recorded. The ratio of magnetic field to current is calculated and recorded. The %'/#56'4 is set for Pulsed Magnetic Field testing, and programmed for the proper field strength specified by the test level. A pulse is programmed and the peak current recorded via the oscilloscope. The ratio of magnetic-field to current -- calculated in the prior step -- is multiplied by the peak current -- measured in this step -- to obtain the actual magnetic field applied during test. This result is compared to the test level, and the coil factor adjusted accordingly: lower if the measured field strength is too low, higher if the measured field strength is too high. The measurement and adjustment may be repeated until the measured field strength is within acceptable tolerances of the desired field strength. Alternatively, a peak reading magnetic field meter of bandwidth greater than 10MHz may be used. In this case the magnetic field may be measured directly (the current need not be measured). The current waveform obtained in Pulsed Magnetic Field Testing is identical to that obtained in Surge testing. IEC 1000-4-9 refers to the wave as a 6.4x16uS wave; this is the result of a difference in definition of risetimes and duration. Per IEC 1000-4-9, the risetime is simply the time from 10% to 90% with no multiplier. The duration is simply the time from 50% of rise to 50% of fall. 7 Pearson Electronics, Inc., 1860 Embarcadero Rd., Palo Alto, CA 94303 USA CEMASTER System 61 IEC 1000-4-11 POWER QUALITY FAILURE Testing What is Power Quality Failure Testing? Dips and interrupts can occur on the AC power mains as a result of a fault in the distribution system such as an open circuit breaker or a sudden large load being turned on in the immediate vicinity. A power distribution system fault can cause a switch in the distribution grid to open and close a number of times, resulting in multiple interrupts to electrical and electronic equipment. Electronic products are tested for immunity to dips and interrupts to insure their continued reliable operation if subjected to dips and/or interrupts on the AC power mains. General Guidelines for Testing The EUT is connected to the EUT outlet and powered. The EUT is allowed time to stabilize, and then a dip or interrupt is applied to the EUT. The duration and level of the dip is set by the test requirements. Testing Requirements per IEC 1000-4-11 Testing to IEC 1000-4-11 has the following requirements: • Testing takes place in climatic conditions as follows: Ambient temperature: 15 °C to 35 °C Relative Humidity: 25 % to 75 % Atmospheric Pressure: 86 kPa (860 mbar) to 106 kPa (1060 mbar) Or other values of climatic conditions as given in the product specifications. IEC 1000-4-11 requires the generator be capable of supplying peak inrush currents of 500A for 220V to 240V mains, and 250A for 100V to 120V mains. The %'/#56'4is designed to meet these levels, however -- due to building wiring capabilities -- the site where the %'/#56'4 is being used may not meet the requirement. The peak inrush current should be measured at the test site, using the circuit and method described in the Waveform Verification section. If the %'/#56'4plus test site meets the inrush current requirement (500A peak for 220V to 240V mains, or 250A for 100V to 120V mains), it is not necessary to measure the EUT peak inrush current. If the CEMASTER plus test site does not meet the inrush current requirement, the test can still be performed as long as the EUT peak inrush current is less than the peak inrush current of the %'/#56'4 plus test site. In this case, it is necessary to measure the EUT peak inrush current. CEMASTER System 62 The circuit and method for measuring EUT peak inrush current is described in the Waveform Verification section. User Defined PQF Test The User Defined menu allows individual control of all test parameters required in PQF Testing; this allows testing at different levels, phase angles, number of tests, and time between tests. A User-defined test is controlled by a the parameters in the table below: PQF Test Parameter Range/Units Test Level [0% (open circuit), 0% (short circuit), 40%, 70%] Test Level is the level of voltage during a test, as % of line voltage. The line voltage level before and after a test is the Default/Standby Test Level = 100% Starting Angle [0..360] ° of the line voltage waveform; resolution: 1° Starting Phase Angle is the phase angle at which the dip or interruption begins Test Duration Units [cyc, sec], cyc is periods (cycles) of the Mains and sec is time in seconds Test Duration If Test Duration Units = “cyc”: [0.1..3000.0] ; in the periods (cycles) of the line voltage waveform If Test Duration Units = “sec”: [0.01..60.00] s; where s is time in seconds Test Duration is the duration of the dip or interruption, in either waveform periods or seconds Time Between Tests [10..999] s; resolution: 1 s Number of Tests [1..999] Preprogrammed IEC Standard PQF Test Sequences Each is made up of a set of sequentially executed tests. The individual tests are similar to user defined PQF tests, except that all parameter values are predefined; none are changeable. There are five Preprogrammed IEC Standard test sequences: Test Sequence Name 0% Open / 5 s 0% Short / 5 s 40% / 0.10 s 70% / 0.01 s Combination CEMASTER System Test Level 0% (open circuit) 0% (short circuit) 40% 70% see right Test Duration 5.00 s 5.00 s 0.10 s 0.01 s • Perform one IEC Standard “70%/0.01 s” test sequence • Perform one IEC Standard “40%/0.10 s” test sequence • Perform one IEC Standard “0% Short/5 s” test sequence • Perform one IEC Standard “0% Open/5 s” test sequence 63 Each sequence has the following, common characteristics: • Default/Standby Test Level = 100% • Starting Phase Angle = 0° (and also 180° for Test Duration < 0.02 s) • Interval Between Tests = 10 s • Number of Tests = “N/A” Each of the IEC Standard test sequences, except “Combination”, is performed at the Test Level and using the Test Duration defined in the table above, as follows: • • • • • • • Start at the Default/Standby Test Level Switch to the Test Level at Starting Phase Angle = 0°, and maintain for Test Duration Switch to the Default/Standby Test Level, and maintain for Interval Between Tests Switch to the Test Level at Starting Phase Angle = 0°, and maintain for Test Duration Switch to the Default/Standby Test Level, and maintain for Interval Between Tests Switch to the Test Level at Starting Phase Angle = 0°and maintain for Test Duration Switch to the Default/Standby Test Level • If Test Duration is less than 0.02 s, then, in addition to the above: • Wait for Interval Between Tests • Switch to the Test Level at Starting Phase Angle = 180°, and maintain for Test Duration • Switch to the Default/Standby Test Level, and maintain for Interval Between Tests • Switch to the Test Level at Starting Phase Angle = 180°, and maintain for Test Duration • Switch to the Default/Standby Test Level, and maintain for Interval Between Tests • Switch to the Test Level at Starting Phase Angle = 180°, and maintain for Test Duration • Switch to the Default/Standby Test Level, and maintain for Interval Between Tests • Do not allow a new test sequence to start until Interval Between Tests has elapsed End of test sequence Other Preprogrammed Test Sequences -- Line Qualification See Waveform Verification Section CEMASTER System 64 Waveform Verification IEC 1000-4-11 requires that the simulator output be verified periodically. For Dip & Interrupt test simulators, it is necessary to verify the voltage transition levels, transition times to 100%, and the inrush current capability. Most modern oscilloscopes are capable of observing the voltage levels and transition times. Transition times are measured with a 100-ohm, 600-watt load. For verifying the inrush current, a bridge rectifier, suitably rated 1700uF capacitor, and appropriate current transformer (Pearson8 model 110 or equivalent) are required. The Line Qualify test sequences meet the IEC 1000-4-11: 1994 standard for qualifying the “Test generator peak inrush current drive capability". These test sequences require the use of a standard line qualification test load, “an uncharged capacitor whose value is 1700 µF in series with a suitable rectifier” (from IEC 1000-4-11: 1994, Clause 6.1.2). The two preprogrammed test sequences for verifying the peak inrush drive current capability of the test generator are: Line Qualify 90° Line Qualify 270° Common characteristics of the “Line Qualify” test sequences are: • Default/Standby Test Level = 0% (open circuit) • Test Level = 100% • Test Duration = 10 periods • Interval Between Tests = 120 s (user selectable) • Number of Tests = 1 (user selectable) And the “Line Qualify” test sequence consists of the following steps: Start at Default/Standby Test Level (open circuit) Switch to Test Level at the Starting Phase Angle defined by the test sequence name Maintain Test Level for Test Duration Switch to Default/Standby Test Level (open circuit) End test Warning! The Line Qualification Load will draw significant current; it should be plugged into the EUT outlet only when no voltage is present -- EUT switch OFF. DO NOT plug the Line Qualification Load into a live outlet as an arc may result which might damage the outlet. The charged capacitor requires a time to discharge after each test. The time allowed should exceed 7 time constants (seven times value-resistor {in ohms} times value-capacitor {in farads}). Failure to allow sufficient time to discharge may give invalid readings. Allow the Line Qualification Load to discharge -- EUT switch OFF -- before handling. 8 Pearson Electronics, Inc., 1860 Embarcadero Rd., Palo Alto, CA 94303 USA CEMASTER System 65 Line Qualification Test Setup -- Mains Peak Current Line Qualification Test Setup -- EUT Peak Current CEMASTER System 66 %'/#56'4 %'9CTG Overview of the software %'9CTG is the %'/#56'4ŏs PC control software. It provides full access to all the features and capabilities available from the %'/#56'4 front panel, including running a single test and running a pre-defined test sequence. In addition, %'9CTG adds a number of useful features. It allows a user to: • • • • • Create tests and easily edit them. Chain test sequences together. Multiple test sequences can then combine test types (e.g. do one or more Surge tests followed by one or more EFT tests, etc.). Store and recall tests and test sequences to disk. Log tests-- print or file a list of the tests which are executed. Develop tests off-line, and run in a simulation mode. A Help file for the %'/#56'4%'9CTG is provided with the software which can be opened by clicking Help|Contents on the menu bar. It provides complete operating instructions for the program; using the Help file while experimenting with the program is the recommended method for learning the software. These written instructions are largely duplicated in the Help file. The CM-SW option, available as a purchased %'/#56'4 option, includes the %'9CTG program. It may be used on a Personal Computer (PC) running either Windows 3.1 or Windows95. The computer must have at least 16MB of RAM and a 80486/66MHz or faster processor. Screen transitions are slower on 486 processors, thus Pentium computers are recommended. %'9CTG is designed for an 800x600 display driver. Some drivers require selection of ‘small fonts’ on the Windows 95 display settings. You should select such a driver (or one with greater resolution) in your Windows configuration. On a driver with a smaller display, scrolling is necessary to see the entire application screen. The CM-SW option includes an RS-232 to optical converter (the FC-11), a short RS-232 cable with a 9-pin D-shell connector, and a fiber optic cable with a duplex modular connector. The RS-232 connector connects to a Com port on your computer. The fiber optic cable connects to the %'/#56'4 front panel; this connector is polarized and can only be inserted in one orientation: with the small tab on the connector facing right. Do not force the connector. The FiberCom option derives power from the RS-232 port of the computer -- no external power source is required. %'9CTGversion 2.0 (and higher) also supports '/%2TQ and has some additional controls. References to EMCPro and hardware selection in this chapter apply to that %'9CTG version only. %'9CTGconfiguration for %'/#56'4or '/%2TQ is automatic when a tester is connected CEMASTER System 67 Basic Operations The following steps will take you through major operating modes of the program and will acquaint you with the screens. Refer to the next section for full description of all the controls and displays on the screens. These steps can be run in simulation mode or with a %'/#56'4 connected. If the %'/#56'4 is connected and powered on, the application will send commands to it by default. Starting the Program • Start the %'/#56'4 by powering it on and pressing a key to move beyond the warning screen. • Start the %'9CTG program by double-clicking on the ICON in the %'/#56'4 group on Windows 3.1, or running the program from the Start menu (PROGRAMS | %'/#56'4 Software | %'9CTG) on Windows95. Defining a Test • Click on one of the New Sequence buttons at the left of the Main Screen to create a new test. • Select "User-defined" from the box on the New Sequence Definition screen. The other items on that screen are defaults (the same ones as on the %'/#56'4 front panel) and can be left alone or changed, as you wish. • Click "OK" on the Custom Sequence Wizard screen to accept the Wizard defaults. This screen allows you to create several tests of the same type quickly. • Click "OK" on the Sequence Editor Screen to accept the test sequence. This screen allows you to manually edit the order of the tests or the test parameters. • Back on the Main Screen, you now have one sequence defined and shown in the grid. You can return to the Sequence Editor at any time by double-clicking on the row or row number of the sequence you wish to edit. • On the Menu bar at the top of the screen, select FILE | SAVE if you want to save your sample test. Running a Test • Click on the RUN button to start the test. The grids on the Run Screen, and the Status Block at the lower right, will show the status of the executing tests. CEMASTER System 68 • Hit the ABORT button to return to the Main Screen. After test completion, a notice is displayed, and return to the Main Screen is automatic on acknowledgment of the notice. • Exit the application by choosing FILE | EXIT from the main application menu. Additional Operating Notes • Remote mode. While the PC %'9CTG program controls the %'/#56'4, the normal idle screen contains a "Comm: Remote; Status: Idle" indication if no test is running. When a test is active, a Run Screen (the same as from front panel control) will be shown on the front panel display. If the EXIT button on the front panel is pressed when in "Remote Idle," the %'/#56'4 will no longer be controlled by the PC. This is not recommended. Termination of tests and remote control from the %'9CTG menu is preferable. (ESD test operation is a special case; see the next item.) • ESD operation. The ESD test function is designed for maximum control at the ESD head. %'/#56'4operation puts the unit in a "Test Run" state, where it will stay until the user hits EXIT on the front panel. The same front-panel control is in place when running from %'9CTG. Leave the ESD run state by hitting EXIT on the front panel when all ESD pulsing is done. You may also select ABORT from %'9CTG, but this will terminate the entire sequence. If your %'/CUVGT does not have a front panel, the ABORT from %'9CTG is the only mechanism for stopping an ESD test. For this reason, putting an ESD test in a sequence with other test types is not recommended in that configuration. During ESD tests, the user may perform more tests than are defined in the sequence definition; for this reason, the %'9CTG screen may show tests executed greater than the total tests, such as "140 of 100" pulses. • Mouse operations. If running Windows 3.1 with the "snap-to" option enabled on the mouse driver (see the Mouse driver selections on the Windows Control Panel), the mouse cursor may jump when the mouse button is pressed. Turn off "snap-to," if it is enabled. Not all mouse drivers support “snap-to.” • Editing pre-programmed surge tests. Some of the pre-programmed surge tests (prequalification and Level 1) include voltages which are below the normal limit for surge userdefined tests. These tests will run as pre-programmed tests, but not as user-defined tests. If you edit these pre-programmed tests and attempt to run without changing the voltages, %'9CTG will report errors at each voltage below the normal limit. If these low-voltage, pre-programmed tests are edited, be certain to remove or change all the voltages below the 200V limit. • Test timing counts. The test count displayed on the %'9CTG screen is a combination of values from %'9CTG timing and firmware timing. It may sometimes change quickly, faster than CEMASTER System 69 a normal clock, or lag the front panel count, due to communication delays. The test is being executed by the firmware, and the front panel has the most current information for each test. Only %'9CTG supports user-defined sequences and combinations of sequences; that timing information is summarized in the Sequence List Status block, as described in other sections of the manual. CEWare Support of '/%2TQ and CEMaster differences The standard test sequences supported on %'/CUVGT and '/%2TQ are not identical. This is largely due to the higher voltages and additional test types of the '/%2TQ. While CEWare version 2.0 supports both products, there are certain incompatibilities when using these standard sequences. Using CEMaster standard sequences with the EMCPro Most standard sequences created in CEWare for use on the %'/CUVGT can also be used on the '/%2TQ. The exceptions are those containing at least one of the following Surge (1.2/50) sequences: PreQual A PreQual B Class 1 Fast Class 1Full (formerly called Class 1 Complete) Class 2Full (formerly called Class 1 Complete) While neither of the %'/CUVGT prequalification sequences are available on the '/%2TQ, the Class 1 Fast sequence is the same as the '/%2TQ sequence Class 1 Complete, and therefore a direct substitution can be made. Note, however, that the new suite will not run on a %'/CUVGT. Also note that the %'/CUVGT Class 1 Complete and Class 2 Complete sequences are not the same as those sequences with the same names on the '/%2TQ. Using EMCPro standard sequences with the CEMaster Many standard sequences created in CEWare for use on the '/%2TQ can also be used on the %'/CUVGT. The exceptions are those containing at least one of the following sequences: EFT Class 4 HPulse Class 5 Surge (1.2/50) Class 1 Full Surge (1.2/50) Class 2 Full Surge (1.2/50) Class 4 Fast Surge (1.2/50) Class 4 Full Surge (10/700), all sequences Surge (Ring), all sequences Note that the '/%2TQ Class 1 Full and Class 2 Full sequences are not the same as those sequences with the same names on the %'/CUVGT. However the '/%2TQ Surge(1.2/50) CEMASTER System 70 Class 1 Full sequence is the same as the %'/CUVGT sequence Surge (1.2/50) Class 1 Fast, and therefore a direct substitution can be made. Note, though, that the new suite will not run on an '/%2TQ. Changing Program Settings Program settings - defaults - affecting communications, data logging, and user-defined messages, may be changed from the menu bar; the setup option. See the `Menu, Toolbar, and Status Bar’ section for more detail. • Viewing, editing, and printing test reports outside %'9CTG. Test logs may also be viewed, edited, and printed using a word processor. The following document format controls are appropriate for MicroSoft Word. Equivalent margin and font selections are likely to be necessary from other word processors. 1. Start MS Word and select the text log file you wish to print from FILE • OPEN. 2. Select all of the text in the document 3. Select FORMAT - FONT • Select Font = Courier New, MS LineDraw, or Lucida Console • Select Font Style = Regular • Select Size = 10 • Select OK 4. Select FILE - PAGE SETUP • Set Margins Left = 0.9" • Right = 0.9" • Top = 1.0" • Bottom = 1.0" • Select OK 5. If you wish to Print, select FILE - PRINT CEMASTER System 71 %'9CTGin Detail Screens and Organization %'9CTG uses five screens to create, edit, and run tests. The material on the screens is described in the following sections. This information is also contained in the Help file. Main Screen -- The overview screen; used to create and run tests. New Sequence Definition Screen -- Used to define a test sequence, selecting pre-programmed or custom (user-defined) tests. New Custom Sequence Wizard Screen -- If a User Defined test sequence is selected, the Custom Sequence Wizard will help define the sequence of tests. Sequence Editor Screen -- Used to modify a test sequence. Run Screen -- Shows Test Status information while tests are running. Main Screen CEMASTER System 72 Main Screen The Main Screen is the screen you use to create tests, load or save tests, and run tests. To create a new test, click on one of the seven test buttons, left-center on the screen. To load an existing test, click on the Toolbar or Menubar at the top of the screen. To Run a test click on the RUN button at the bottom left of the screen. The following sections describe the information and the controls on the Main Screen. Toolbar The toolbar at the top of the screen supports some system-level operations. It is described in detail in the section on Menu, Toolbar, and Status Bar, which appear on several screens. Test Status Block When on the Run Screen, the Test Status Block shows which test is currently executing, and shows duration and elapsed times. While displayed on the Main Screen, this block is updated when a test sequence is selected or deselected on the Sequence List grid. It is described in detail in the section on the Run Screen. Test Control Block The test control block has control buttons to start, stop, and control tests. • RUN Button -- The Run button starts the Test. Once the test is running, the Run button becomes the Pause button. • PAUSE Button (Only enabled on Run Screen) -- Click the Pause button to temporarily halt the test. • RESUME Button (Only on Run Screen, when in Paused state) -- Click to resume a paused test. • ABORT Button -- The Abort button Halts the test. • BREAK Button -- The Break button 'breaks' out of loops. When you click the Break button, if the Present Sequence Status has a repeat count greater than one, it drops to one. Any test presently executing continues to completion, but at completion the present test ends. If the Sequence List Status has a repeat count greater than one, it drops to one. Any test presently executing continues to completion, but at completion the present test ends; at completion of all tests in the present sequence, the present sequence ends. CEMASTER System 73 • COMMENT Button -- The Comment button allows definition of a user comment while tests are running. The comment can then be inserted into the log file at any instance the user chooses by selecting the OK button on the comment entry window. • AUTO PAUSE/REPEATS Checkboxes -- Enable steps and defined sequence repeats. When checked, Auto Pause will enable any pauses defined in the Sequence Editor. At each pause the operator must click the OK button on a Windows prompt box to continue the test. When un-checked, any pauses defined in the Sequence Editor are ignored. When checked, Repeats will allow any repeats defined in the Sequence Editor and in the main menu. When un-checked, any repeats are ignored; each test and sequence will execute exactly one time. (This is the mechanism for single-stepping, used in coordination with the Pause column on the Sequence Editing screen.) • EUT POWER STATUS Button -- The EUT Power status button shows the EUT status. The EUT power may be turned off from the computer by clicking this button. When off, the EUT Power can only be turned on from the %'/#56'4, by turning the EUT switch ON, or toggling OFF and ON. Sequence List Grid The Sequence List Grid shows which test sequences have been defined (or loaded with the current file). The grid allows editing the sequence during the definition and editing phases. A yellow highlight bar identifies the test to be edited when using CUT, COPY, and PASTE. • To Edit a Test Sequence: Double-click on the gray, numbered, row-header cell to the left of the test you want to edit, or anwhere in the row of that test. The Sequence editor will open. • To Add a Test Sequence to the end of the sequence list: Deselect any selected Test Sequences by clicking the button in the upper-left corner of the grid. Then, click a test type button. • To Insert a Test Sequence: Click the gray numbered cell to the left of the test you want to insert the new sequence in front of. Then select a test type by clicking a test type button. • To Delete a Test Sequence: Click the gray numbered cell to the left of the test you want to delete. Then click the Cut button from the toolbar. • To Move a Test Sequence: Click the gray numbered cell to the left of the test you want to move. Click the Cut button from the toolbar to remove this test. Click the gray numbered cell to the left of the test you want to insert the cut sequence in front of. Then click the paste button from the toolbar to insert the test. CEMASTER System 74 Test Type Controls These 6 buttons at the left of the Main Screen select a test type to create. There are 8 different immunity tests available, in accordance with European Norm requirements and the controlling, basic EMC immunity standards of: IEC 1000-4-2 ESD IEC 1000-4-4 EFT IEC 1000-4-5 Combination and Telcom Wave Surge IEC 1000-4-8 Power Frequency Magnetic Field IEC 1000-4-9 Pulse Magnetic Field IEC 1000-4-11 Dip and Interrupt The tests available on your system will depend on the options installed in your %'/#56'4. If a test is not available, the corresponding test button will be grayed out, and cannot be selected. The legend on the last button will depend on the surge option installed in the system. Repeat Control The repeat control sets how many times the sequence shown in the Sequence List grid is executed. Click this control and enter a number. Test Description If a test is loaded from a file, the description box will contain the text description filed with the test. If a new test is created, enter a description of the test in the description box for inclusion in reports and logfiles, and to be saved with the test. Tool Bar The toolbar holds icons for common tasks, allowing you to select that task with a single mouseclick. See the section below on the Menu, Toolbar, and Status Bar. • File Icons -- The file icons create a new test sequence, load an existing test sequence, or save the current test sequence. If you attempt to create a new sequence or load an existing sequence, you will be prompted to save any existing work. • Edit Icons -- The CUT, COPY, and PASTE icons allow you to edit the test sequence grid. These icons are also found in the Sequence Editor. • The Printer icon will print the test sequence. Starting a Run CEMASTER System 75 When you wish to execute the presently defined sequence list, select the Run button in the Test Control area. A Windows message box will appear to inform you if you are doing a Local/Simulation run. If you are about to do a Remote run (connected to a %'/#56'4) no warning is given. If Logging is enabled, a Run-Time Logging Information screen will appear where you will see the header information that will appear in the log report(s) and can edit this information/ You may edit the 60 character log report header line or the 40 character operator name. There is a 60 character field for a description of the equipment under test and a text entry field where you can make any comments regarding the run before you begin. The comment will appear after the header on the first page of the log text report. Enter up to 8 characters for the file name for either or both of the log report types selected. This must be a valid 8 character DOS filename. The file paths and extensions are shown for reference only and are not editable in this window. Run-Time Logging Information Screen CEMASTER System 76 New Sequence Definition Screen New Sequence Definition Screen The New Sequence Definition Screen is opened when you create a new test by clicking on one of the test type buttons from the Main screen. The list box to the left of the screen shows sequences that you can choose. The User Defined sequence gives you the most control of the test, allowing you to define all of the Sequence Defaults shown on the right side of the screen. The other options shown -- which vary by test type -- are test sequences which the %'/#56'4 has stored and available. These sequences speed set-up and execution of commonly performed IEC test sequences by setting and locking many of the defaults -- the locked defaults will be grayed, and cannot be selected. The standard test sequences for each test type are described in the %'/#56'4 manual. To continue, click one of the sequences shown. If the Sequence Defaults to the right of the screen are enabled, you can select one or more of the Defaults. Finally, click OK. CEMASTER System 77 New Custom Sequence Wizard Screen New Custom Sequence Wizard Screen The New Custom Sequence Wizard screen quickly creates test sequences. The Wizard is run automatically whenever you select a User Defined Sequence in the New Sequence Definition Screen. The Wizard allows you to create lists of one or more parameters, then forms all combinations of these parameters to quickly create a large number of tests. When you click OK, the Wizard closes and the Sequence Editor opens for fine editing of test parameters. To use the Wizard, select one of the radio button options at the bottom left of the screen, or click within any parameter definition box to the right of the screen. The defaults in the combo boxes are those you selected from the New Sequence Definition Screen. Make a parameter selection, then click the Insert button (to the left of the parameter definition boxes) to copy the selection into the list box. You can change list boxes using the radio buttons below the list box, and edit the list box using the CUT, COPY, and PASTE buttons above the list box. CEMASTER System 78 As example, if you click Voltages, and insert 250V, 500V, and 1000V, then click Output and select L1-L2 and L1-PE, when you exit the Wizard, the Wizard will create six tests: L1-L2 at 250V L1-L2 at 500V L1-L2 at 1000V L1-PE at 250V L1-PE at 500V L1-PE at 1000V If you want to create a User-Defined test sequence with a single test, simply click the OK button to exit the Wizard and open the Sequence Editor. Sequence Editor The Sequence Editor is opened after selecting a test sequence from the New Sequence Definition Screen, or by double-clicking an existing test from the test grid of the Main Screen. The sequence editor gives you fine control over what tests are performed and all options. If you wish to execute a predefined test with no changes, you should simply click on the OK button. If you make any changes in a predefined test, the test will be re-defined as a User Defined test. Sequence Editor Screen CEMASTER System 79 Sequence Description Grid The Sequence Description Grid shows which tests have been defined in a sequence.. It supports the editing process on the Sequence Editing Screen as well as allowing the data to be changed in any individual cell. Basic test editing is allowed on any test in the grid. Text cells can be changed by selecting a cell, deleting the current entry, and typing the new one. Cells that support a list of legal values have a standard Windows drop-down list controlled by the drop-down button at the right of the cell. Open the list and select a new valve to change it. Additional editing controls that affect more than one cell are also supported and are described in more detail below. • PAUSE or PAUSE AND DISPLAY MESSAGE Control The PAUSE column of this grid allows single-stepping or automatic stopping at any test in the sequence. Check the box in the row of the test where you wish to pause. (The pause will occur before the test executes.) Make sure that the Auto Pause box is checked, on the Main Screen, before the test starts. The PAUSE box for all tests in a sequence may be set with the technique described in this section for changing an entire column. To set or reset the PAUSE box, use a single left button click of the mouse to select the PAUSE cell then use single left button clicks to set or reset the check-box in the cell. A message can be displayed during a PAUSE - see the Message Selection section. A yellow highlight bar identifies the test to be edited when using CUT, COPY, and PASTE, which act on entire test rows. • To Delete a Test Sequence Click the gray, numbered cell to the left of the test you want to delete. The entire row will highlight. Then click the CUT button from the toolbar. • To Move a Test Sequence Click the gray, numbered cell to the left of the test you want to move. Click the CUT button above the grid to remove this test. Click the gray numbered cell to the left of the test that will follow the moved test. Then click the PASTE button from the toolbar to insert the test. • To Copy a Test Step Click the gray, numbered box to the left of the test you want to copy; the entire row will highlight. Click the COPY button. • To Paste a Test Step CEMASTER System 80 After a Cut or Copy operation, click the gray, numbered box to the left of the test you want to insert in front of; the entire row will highlight. Click the PASTE button. NOTE: To select a block of rows, hold [Shift] key when left-clicking; to select multiple single rows, hold [Cntrl] key when left-clicking. The Sequence Editor allows several special editing operations in addition to the normal Cut and Paste Operations. These operations take place over all or part of a column. This can change many tests with a single editing step. • To change an entire column Click one cell within the column you want to change. Then, click the gray column header at the top of the grid. All cells in the column will be highlighted. Press ENTER. The cell you highlighted will open for editing. Select a new value and press ENTER (if this is a numeric cell, type in a new value and press ENTER; if this is a check box, press ENTER to toggle). All cells in the column -- and thus all tests within this sequence -- will take on the new value you entered. • To change all entries in a range within a column Click the first cell in the range within the column you want to change. Then, hold down the shift key and click the last cell in the range you want to change. All cells between the first and last cells will be highlighted. Press ENTER. The last cell you highlighted will open for editing. Select a new value and press ENTER (if this is a numeric cell, type in a new value and press ENTER; if this is a check box, press ENTER to toggle). All cells in the range will take on the new value you entered. When you change a column, other columns may change as a result. These changes will always be 'legal' -- that is, the test will run with the resulting change, and you will not get an error. But the changes may not be uniform. Check the other columns to be sure the tests will run the way you want them to. Keyboard Editing The grid can be edited using the keyboard cursor keys, Tab, and ENTER. Press Tab until the grid is selected -- the highlighted cell within the grid will have a dotted selection-box drawn inside it. Use the cursor keys to select a cell to edit. Press ENTER to open the cell. If the cell is CEMASTER System 81 a drop-down box, use the cursors to select an option. If the cell is numeric, type in a new value. Press ENTER to accept the change. Message Selection Grid To assign a message to be displayed during a run-time pause, double-click the left mouse button on the desired PAUSE cell. This will bring up the Message Selection window where a single 80character message may be selected from 200 available messages. Message Selection Screen Use the right scroll bar to scroll through the 200 messages or enter a specific message number in the Go To… edit box then click the Go To… button. Select the desired message by clicking on the message number button to the right of the message, then click OK. Message Selection Screen, with message selected CEMASTER System 82 When OK is selected, the Message Selection Window closes, and the message number is pasted in the PAUSE cell of the Sequence Editor Grid. ESD: Sequence Editor Screen To remove a message from being displayed during pause, double-click the left mouse button on the desired PAUSE cell. This will bring up the Message Selection window where the selected message will be displayed highlighted. Deselect the message by clicking on the upper left corner button on the Message Selection grid, then click OK. NOTE: The Message Selection grid does allow editing of message text but does not allow Cut, Copy and Paste operations. CEMASTER System 83 The Run Screen The Run Screen The Run Screen is displayed while tests are executing. A Present Sequence grid control is added to the screen, along with the Sequence List grid control. Together they describe the current set of tests being run. Sequence List Grid This list of sequences is the same as shown on the Main Screen, and shows the presently defined set of test sequences. A yellow highlight bar indicates the test sequence that is presently executing. Present Sequence Grid The Present Sequence Grid is displayed when running tests. The grid shows all the parameters of the present test sequence, which consists of one or more tests. It is essentially the same information presented on the Sequence Edit screen. A horizontal highlight bar across the grid identifies which test of the sequence is running. Test Status Block CEMASTER System 84 The Test Status Block at the lower right of the Run Screen shows which test is currently executing, test duration, and elapsed times. It contains two display areas: one for the Sequence List, and one for Present Sequence -- the one that is currently executing. The two sets of data are similar: the Sequence List Status summarizes statistics for the entire set of sequences, and the current sequence within that list; the Present Sequence summarizes information about the current test within the present sequence. • Sequence List Status Sequence -- The sequence that is running, out of the total number of sequences. Duration -- The duration shown is the estimated time required to complete the entire sequence, excluding time for pauses. The time format is hours:minutes:seconds. Elapsed Time -- The elapsed time is the total time from the start of the test to the present time. Repeat Count -- These fields show the present loop count, and the total list count for the sequence. The total reflects the value from the List Repeats field on the Main Screen. • Present Sequence Status Test -- These fields identify which test is running out of the total number of tests in the present sequence. Duration -- The duration shown is the estimated time required to complete the Present Test Sequence. The time format is hours:minutes:seconds. Elapsed Time -- The elapsed time is the total time from the start of the present sequence to the present time. Repeat Count -- These fields show the present loop count, and the total list count for the sequence. The total reflects the value from the Sequence Editor, Sequence Repeats field. Test Control Block This set of buttons is the same as on the Main Screen and is described in that section. Buttons may be enabled or not, depending on the state of the system and the software. Menu, Toolbar, and Status Bar These areas appear on both the Main and Run Screens. Menubar The menu bar performs actions, sets options and preferences, and accesses the help file. The menu options are described below. CEMASTER System 85 Menubar Selections File Menu The File menu supports loading and saving of test files, and exit from the application. The default extension used for test sequence files is .SEQ. • File | New Delete any present tests and prepare for creating a new test. If you have tests defined and have not saved them you will be prompted to save the tests before continuing. • File | Open Load an existing test file. The File Common-Dialog box will open, allowing you to click on a file to load. If you have tests defined and have not saved them you will be prompted to save the tests before continuing. • File | Save, Save As The Save command will save the present test to a disk file. If the test was loaded from disk, the test will be written to the same file. If the test is a new test, you will be prompted for a path and filename to use in saving the test. The Save As command will prompt you for a path and filename to use in saving the test. Use this command to create file copies of tests, or new tests based on the old ones that you have edited. • File | Print Sequence, Print Log, Print Setup The Print Sequence command will print the present Sequence List. The Print Setup command controls the printer, selecting which printer is used, which font is used, and paper orientation. Print Log will allow the user to select and print a Log file. • File | File Select This section holds the last four files you opened / saved. You can quickly load a prior file by clicking one of these selections or typing the corresponding number • File | Exit CEMASTER System 86 This selection exits from the application. Edit The Edit menu allows keyboard selection of the CUT, COPY, and PASTE selections that are also accessible from the Toolbar. In addition, there is a DELETE selection which does a destructive cut of selected data. Setup The Setup menu is where the user may select and set parameters for run time operation or report generation. The items on the setup menu are: Setup menu • Communications The user may select the COM port to set up communications with a C'/CUVGT. %'9CTG allows selections (COM1 - COM4) and automatically detects which ports are available on the system. The default selection is COM1. Other communication parameters, although shown, are fixed. CEMASTER System 87 Communication Parameters Screen • Log Reports Log Reports allows the user to select the type of logging reports they which to produce: Text Reports or Export Reports. For each type of report, you may define your own file extension and path or you may accept the defaults (you will be asked to enter a log report file name at run time). The file extension must be a (up to) 3 character valid DOS file extension. The path must be a valid DOS path of up to 60 characters in length. You may also define your own header line that will appear as the first line in the header of all Log reports. A default report header is supplied. You may enter a new report header of up to 60 characters. A 40 character field is supplied where you may enter an operator name that will also appear on the Log reports. CEMASTER System 88 Log Reports Screen • Sequence Reports Sequence Reports allows the user to define his own header line that will appear as the first line in the header of all Sequence List reports. All other data for the Sequence List report is fixed. A default report header is supplied. You may enter a new report header of up to 60 characters. Sequence list Reports Screen CEMASTER System 89 • Message Editor The Message Editor allows you to define up to 200 messages that may later be attached to Auto-Pause controls on the test edit screens for display to an operator at run time. Use the scroll bar control on the right side of the message grid to scroll through the 200 messages. Each message may be up to 80 characters (maximum) in length. A set of default messages is supplied for use with several optional components available for use with the %'/#56'4. These default messages may be redefined if you desire. To define a message, click within a message cell to highlight it (green highlight), then click a second time to enter “edit mode” for the cell. Enter the desired message text then press Enter. To select messages for CUT, COPY, and PASTE operations, click the message number cells on the left side of the message grid. This will highlight the message in yellow. Multiple messages may be selected by holding the Ctrl key while clicking, or a block of messages may be selected by holding the Shift key while clicking after the first message in the block has been selected. To deselect all messages, click the button in the upper left corner of the message grid. Message Editor Screen • Show Versions CEMASTER System 90 Show Versions is a display of the version number of the %'9CTG application, plus the version of all major software components the %'9CTG application uses. When communicating remotely with a %'/#56'4, the firmware version plus the version of all major firmware components of the %'/#56'4 is also shown. Versions Display Screen • HW Selection This selection is necessary only when running %'9CTG in local mode (with simulated hardware). The menu supports selection of test hardware type (%'/CUVGT or '/%2TQ) and also of a second surge type (10/700 Telecom wave or Ring wave) if '/%2TQis selected. Selection of this configuration information is automatic in ‘Remote’ mode, with hardware connected. HW Selection Screen CEMASTER System 91 Enable There are two selections under Enable: Remote Communications and Logging. Both of these selections are ON/OFF selections that are indicated by a check mark when they are ON and no check mark when they are OFF. • Remote Communications This selection turns ON or OFF the remote (PC-based) control of the %'/CUVGT by the %'9CTG application. The selection is disabled if the communications cannot be established with a %'/CUVGT: (communications cable not connected or %'/CUVGT power is OFF). When communication with a %'/CUVGT is established, this selection is enabled and %'9CTG will automatically try to turn remote control ON. The status of communications is shown on the Status Bar at the bottom of the %'9CTG screen. When communication is not established the first item next to the “Communication:” label says DISCONNECTED. When communication is established, the label says CONNECTED. When remote control to a %'/#56'4 is enabled successfully (Remote Communications ON), the second item next to the “Communication:” label says REMOTE. When remote control is disabled (Remote Communications OFF), the item says LOCAL. • Logging This selection turns ON or OFF the logging feature for producing run time log reports. At least one of the two Log report types must have been enabled in Setup | Log Reports to enable logging or an error message will appear when you try to enable it. Logging may only be set ON or OFF when the Main Screen is visible: Logging may not be turned ON or OFF once a run is started. The status of Logging is also shown on the Status Bar at the bottom of the %'9CTG screen. When Logging is not enabled the item next to the “Logging:” label says OFF. When Logging is enabled, the item says ON. System These are debugging and field service functions that do not need to be accessed by the user for any normal operation. CEMASTER System 92 Help The Help menu brings up the Help file and shows the About box. Toolbar Toolbar The toolbar holds icons for common tasks, allowing you to select that task with a single mouseclick. • File Icons -- The file icons create a new test sequence, load an existing test sequence, or save the current test sequence. If you attempt to create a new sequence or load an existing sequence, you will be prompted to save any existing work. • Edit Icons -- The CUT, COPY, and PASTE icons allow you to edit the test sequence grid. These icons are also found in the Sequence Editor. • The Printer icon will print the present sequence list, i.e. it is the same as the File Print Sequence selection on the menu bar. Status Bar The status bar at the bottom of the screen gives a quick synopsis of the CEMASTER and test status. In some cases, the status bar will be replaced with help prompts. It contains the following information. System Status Bar CEMASTER System 93 Communication • DISCONNECTED/CONNECTED Indicates if a %'/#56'4 (DISCONNECTED). has been detected (CONNECTED) or not • LOCAL/REMOTE When communications with the %'/#56'4 are established, this indicates whether control is from the front panel (LOCAL) or from the PC (REMOTE). The program will automatically go Remote; select from the menu bar (EnableRemote Communications) to change to simulation mode when a %'/#56'4 is connected and powered on. Run State Shows the operating state of the %'/#56'4 • CHARGING - generating high voltage. • WAITING - between active test states, waiting for the next. • FIRING - generating an output • IDLE - no tests are running. • RUNNING - generating a continuous test state (EFT, ESD, or PFMF). Logging Indicates if run time test information is being written to disk (ON) or not (OFF). CEMASTER System 94 Maintenance Service and Maintenance Issues There are no user serviceable parts within the %'/#56'4. Service is solely by Thermo KeyTek-trained, authorized technicians. Annual Calibration Periodic calibration of the %'/#56'4 is required. The recommended calibration interval is dependent on use. If periodic waveform verification is performed, calibration need be performed only if the waveform verification fails; if periodic waveform verification is not performed the recommended calibration interval is one year. Factory calibration is available; consult factory for terms and conditions. Factory Inspection and Refurbishment Factory Inspection and Refurbishment is available. Consult factory for terms and conditions. Updating Firmware There may be periodic updates of the %'/#56'4firmware or application software. Each update is provided with instructions for installation and use. An update of the %'/#56'4 firmware requires the CM-SW option be installed. If this option is not installed a Thermo KeyTek authorized service representative is required to upgrade the firmware in the field. If you have questions about what is the latest versions of firmware, contact Customer Service. The latest firmware revisions are also listed on the Thermo Voltek web page, at: http://www.thermovoltek.com Upgrading Hardware Options Most hardware options can be added in the field by a Thermo KeyTek authorized service representative. Consult factory for terms and conditions. Decommission Issues There are no special issues in decommissioning %'/#56'4 equipment. CEMASTER System 95 Troubleshooting This section aids in finding and solving any problems you may experience. As a first step, the %'/#56'4 includes diagnostic tools, accessed through the System Menu, and described below. System Menu The System Menu gives access to several useful functions to aid in troubleshooting. SYSTEM SETUP 1. Parameters 2. Access Code 3. Diagnostics 4. Versions EUT OFF ↑ ↓ The System menu selects special system operations; move the highlight bar using the arrow function keys and press ENTER, or press the number key associated with the sub-menu. EXIT The Parameters Menu offers control of a number of system parameters, allowing customization of the %'/#56'4 system. Check the menu for options available in your system; possible options are: control of the beeper; default coil factor to use; etc. The Access Code Menu is not available at this time. In the future, this menu will allow locking features of the %'/#56'4system -- preventing unauthorized use. The Versions Menu shows internal revisions for the code and databases used by the %'/#56'4. This information is important and should be checked whenever contacting Customer Service. VERSIONS Firmware ...... Kernel ...... Sequence Database .... Rule Database .... String Database .... Option Code .... EUT Vx.xx Vx.xx Vx.xx Vx.xx Vx.xx AA OFF Sep 24, 96 16:15 The Version Menu shows a Build date and time, five arguments with revisions, and a code indicating the installed options. EXIT CEMASTER System 96 The Diagnostics Menu performs a quick check of basic %'/#56'4 functions, and can often localize a problem and allow a field service repair rather than a factory repair. DIAGNOSTICS:TESTS 1. Line Sync 1 2. Line Sync 2 3. High Volt 4. Coil EUT OFF 5. ESD 6. RELAY ↑ ↓ EXIT The DIAGNOSTICS: TESTS menu selects special system operations; move the highlight bar using the arrow function keys and press ENTER, or press the number key associated with the test. Before running any diagnostic, remove all connections from the front panel EUT connector, the coaxial connector, and the safety socket connectors. To use the diagnostic tests, follow the requirements from the list below, choose a test, and follow any on-screen directions. If the test halts, record any message displayed and report the message to Customer Service. The basic functions tested are listed below: 1. Line Sync 1 -- General Purpose check of Mains circuitry. Checks that Mains contactor is operational, thermal breaker is operational, basic wiring OK, and line sync is operational. Requires: EUT Mains present, EUT Switch ON, no EUT connected, no interlock fault. 2. Line Sync 2 -- Checks PQF circuitry. Checks PQF transformer and contactors are operational, PQF switches are operational, and Aux line sync circuit is operational. Requires: EUT Mains present, EUT Switch ON, no EUT connected, no interlock fault. 3. High Volt -- Checks high-voltage supply, energy storage capacitors, and discharge circuitry 4. Coil -- Checks power frequency magnetic field circuitry. Requires: no front-panel connections, no EUT AC present, no interlock fault. 5. ESD -- Checks ESD head interface circuitry. Requires: an ESD head, no interlock fault. 6. RELAY -- Checks all internal relays and switching circuits. Requires: EUT Mains present, EUT switch ON, no EUT connected, no interlock fault. CEMASTER System 97 Troubleshooting Guide In the event of a problem with the %'/#56'4, please follow the following procedure. • Verify that you have properly selected all test parameters. • • • • Check that the %'/#56'4 is properly connected to the AC Mains. Check that the EUT is properly connected to the %'/#56'4. Check all interconnections for loose connections. Try cycling power to the EUT and the %'/#56'4. • Run Diagnostics tests from the System Menu. • Contact Customer Service for guidance. CEMASTER System 98 Error Messages The following are possible error messages, their causes, and possible solutions. The Surge parameters specify line sync, and no No AC Phase Reference Detected Check EUT Power switch and EUT AC mains was detected for synchronization. power To surge without AC mains present: Change the line sync setting from “L1” to “RND” random. To surge with AC mains: Check that EUT power cord is plugged in, EUT power is present, and the %'/#56'4 EUT switch is on; check that EUT ON is shown on the front panel display. During a PQF test, AC was not present (PQF AC Required At Mains Output Check EUT Power switch and EUT requires AC to be present). power Check that EUT power cord is plugged in, EUT power is present, and the %'/#56'4 EUT switch is on; check that EUT ON is shown on the front panel display. ESD Simulator Not Connected An ESD test is selected, and no ESD simulator head was attached. Attach an ESD head; check that the cable is properly connected (remove ground-return cable; if the ground-return indicator does not light on the head, there is a poor connection). Interlock Open Fault EFT Interlock This fault indicates a problem in the EFT subsystem and requires factory service. Consult the factory for further information. Interlock Open Fault Power PCB Interlock This fault indicates a problem with an internal subsystem and requires factory service. Consult the factory for further information. Interlock Open Fault External Interlock The external interlock is open, forcing the %'/#56'4 into a safe state. If a cable is in the interlock connector, remove it and check that the fault goes away. Repair any break in the external interlock circuit. CEMASTER System 99 Mains Fault: Disconnect and check EUT During a PQF test a high-current was detected, If fault recurs contact Thermo KeyTek possibly due to a short in the EUT. Service Disconnect the EUT and check it for possible shorts line-to-line or line-to-chassis. Retest. Test with a second EUT if possible. If this message persists factory service is required. Consult Customer Service for detail. Unspecified Fault # Record the fault number and retry the failed test. If this fault persists, report it to Customer Service. Timeout on Remote Control: Check PC The %'/#56'4 while running under control Application and Connection of a PC, lost communications with the PC. For safety, a loss of communications halts all tests. Check connections between the %'/#56'4 and the PC, and check that the PC application is running. CEMASTER System 100 Filing a Problem Report When reporting a problem to Thermo KeyTek Customer Service, please include the serial number and model number from the rear panel of the %'/#56'4 (and serial number of the ESD probe or other accessories, if applicable). If your CEMASTER is operational, access the SYSTEM menu, VERSIONS screen and copy all the information shown to include in your trouble report. VERSIONS Firmware ...... Kernel ...... Sequence Database .... Rule Database .... String Database .... Option Code .... EUT OFF Vx.xx Vx.xx Vx.xx Vx.xx Vx.xx AA Sep 24, 96 16:15 The Version Menu shows a Build date and time, five arguments with revisions, and a code indicating the installed options. EXIT Mail, Fax, or phone your problem report to: Customer Service Thermo KeyTek One Lowell Research Center Lowell, MA 01852-4345 USA Voice: 978-275-0800 FAX: 978-275-0850 http://www.thermokeytek.com or your local, authorized service representative. CEMASTER System 101 Appendix A Multi-Contacts Accessories To our customers using the ECAT System with 6mm socket jumpers, adapters, patch cords and for all others ECAT, EMCPro and CEMASTER Systems using 4mm safety jacks: To obtain parts please refer to the Multi-Contact electronic catalog at MC USA U.S Headquarters 5560 Skylane Blvd. Santa Rosa, CA 95403 http://www.multi-contact-usa.com CEMASTER System A-1
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