Ametek Ripple NX600-1000-5 User manual

Version:
1.0, 15-May 2023
Replaces:
--
Filename:
Quick Start and Safetyl-Ripple NX-E-V1.0 en
Print date:
15 June 2023
Safety and Quick Start
Manual
Ripple NX
Ripple NX600-1000-5
Ripple NX1000-1000-5
Ripple NX1000-1000-10
RippleSource NX5
RippleSource NX10

AMETEK CTS Ripple NX
Safety and Quick Start Manual V 1.0 2 / 57
AMETEK CTS GmbH
Sternenhofstrasse 15
4153 Reinach BL1
Switzerland
Phone: [phone]
Fax: [phone]
URL : www.ametek-cts.com
Copyright © 2023 AMETEK CTS GmbH
All rights reserved.
Specifications subject to change.

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1Introduction and intended use ................................................................................................................5
2Technical Specifications..........................................................................................................................6
2.1 Models and Options ....................................................................................................................................................7
2.2 Scope of supply...........................................................................................................................................................8
2.2.1 Ripple NX system........................................................................................................................................................8
2.2.2 Connection Box Power CBP 1000-1000-2 ..................................................................................................................9
2.3 RippleSource NX.......................................................................................................................................................10
2.3.1 Front Side..................................................................................................................................................................10
2.3.2 Rear Side ..................................................................................................................................................................11
2.4 RippleCoupler NX .....................................................................................................................................................14
2.4.1 Front Side..................................................................................................................................................................14
2.4.2 Rear Side ..................................................................................................................................................................17
2.5 Connection Box Power.............................................................................................................................................. 19
3Equipment installation recommendation .............................................................................................20
3.1 Unpacking .................................................................................................................................................................20
3.2 Installation .................................................................................................................................................................21
3.2.1 Location and mounting requirement..........................................................................................................................21
3.2.2 Heat dissipation and cooling requirements ...............................................................................................................21
3.2.3 Airflow ....................................................................................................................................................................... 22
3.2.4 Tightening Torque .....................................................................................................................................................22
3.2.5 Grounding .................................................................................................................................................................22
3.2.6 Power Requirements................................................................................................................................................. 24
3.2.7 Cabling of racks ........................................................................................................................................................26
3.2.8 Overview of connections to source and EUT ............................................................................................................27
3.2.9 Cabling connection box............................................................................................................................................. 27
3.2.10 Cabling of external source.........................................................................................................................................28
3.2.11 Cabling of EUT.......................................................................................................................................................... 29
4Equipment operation indication............................................................................................................30
4.1 Identification, description and use from operating controls in all mode .....................................................................30
4.2 Instruction for interconnection to accessories and other equipment..........................................................................30
4.2.1 Safety circuits............................................................................................................................................................ 30
4.2.2 Warning Lamp...........................................................................................................................................................32
4.3 Safety circuit with Safety Circuit Adapter SCC AD ....................................................................................................32
4.4 Safety and warning label on the device.....................................................................................................................33
5Safety .......................................................................................................................................................35
5.1 Safety Aspects ..........................................................................................................................................................35
5.2 Responsibility of the operator.................................................................................................................................... 35
5.3 General hazard .........................................................................................................................................................35
5.4 Qualification of personnel.......................................................................................................................................... 36
5.5 Safety functions.........................................................................................................................................................36
5.6 Standard safety procedure........................................................................................................................................37
6Maintenance, Adjustments, Replacement of Parts .............................................................................38
6.1 General .....................................................................................................................................................................38
6.2 Disposal of devices ................................................................................................................................................... 38
6.3 Consumable material ................................................................................................................................................39
6.3.1 Fuses ........................................................................................................................................................................ 39
6.3.2 Protective covers.......................................................................................................................................................44
6.4 Cleaning....................................................................................................................................................................44
6.5 Calibration and Verification ....................................................................................................................................... 45
6.6 Firmware Update.......................................................................................................................................................46
6.7 Periodical check ........................................................................................................................................................47
6.7.1 Check of emergency stop circuit ...............................................................................................................................47
6.7.2 Check of Interlock .....................................................................................................................................................47
6.7.3 Check of voltage indicator, decoupling capacitor switch and discharge circuits........................................................47
6.8 Support and Service..................................................................................................................................................48
7Risk Mitigation ........................................................................................................................................49
8Quick Start Guide....................................................................................................................................50
8.1.1 Switch on procedure .................................................................................................................................................50
8.1.2 Switch-off procedure .................................................................................................................................................50
8.1.3 Testing ......................................................................................................................................................................50
8.1.4 Front panel control .................................................................................................................................................... 51
8.1.5 Operation by the web access....................................................................................................................................52
9Front Panel Control ................................................................................................................................53
9.1 Main Ripple Settings .................................................................................................................................................53
9.2 Measurement channel selection................................................................................................................................ 53
9.3 Disturbance limiter settings .......................................................................................................................................54

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9.4 Regulation parameters and frequency selective measurement.................................................................................54
10 Error Code ...............................................................................................................................................55
10.1 Type of errors............................................................................................................................................................55
10.2 Error Codes............................................................................................................................................................... 55
10.3 Info codes and text.................................................................................................................................................... 56

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1 Introduction and intended use
The Ripple NX is used to perform a ripple test on devices e.g., high voltage components for electric vehicles (battery, inverter,
DC-DC converter, on-board charger, etc.), high power devices for airplanes and others.
The Ripple NX generates a disturbance signal (ripple) that is superimposed on the supply lines to the test object. An external
source (AC or DC) delivers the supply voltage to the EUT.
The Ripple NX is a system and consists of:
- RippleSource NX (signal generator and amplifier)
- RippleCoupler NX (coupling transformer, shunt capacitors, control, and measurement unit)
- Connection box CBP with cables
The Ripple NX can be controlled by the touch screen interface on the RippleSource NX front panel or remotely controlled
through the CAN, Ethernet, OptoLink or GPIB/IEEE interfaces by using programming commands. It can also be controlled by
the
Compliance Test Studio software that includes a library of pre-programmed tests.

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2 Technical Specifications

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2.1 Models and Options
Model
Description
Ripple NX600-1000-5-208 Fully integrated ripple generator consisting of: RippleSource NX5(5kVA, dual range, 160 Vp / 63 Ap
and 80 Vp / 126 Ap), RippleCoupler NX600-1000 (600 A, 1000 VDC, incl. coupling transformers, 10
mF shunt capacitor with pre-/discharge circuit, measuring unit), connection box CBP-1000-1000 (1000
A, 1000 VDC) and connection cables (RippleCoupler NX to CBP, 3 meter); built-in control and meas-
uring unit with touch display and Ethernet / CAN / Optolink / GPIB remote control interfaces; incl.
Compliance Test Studio 23 software with standards library; built into two 19" racks 34 HU 3 x 208 V
input voltage
Ripple NX600-1000-5-400 Fully integrated ripple generator consisting of: RippleSource NX5(5kVA, dual range, 160 Vp / 63 Ap
and 80 Vp / 126 Ap), RippleCoupler NX600-1000 (600 A, 1000 VDC, incl. coupling transformers, 10
mF shunt capacitor with pre-/discharge circuit, measuring unit), connection box CBP-1000-1000 (1000
A, 1000 VDC) and connection cables (RippleCoupler NX to CBP, 3 meter); built-in control and meas-
uring unit with touch display and Ethernet / CAN / Optolink / GPIB remote control interfaces; incl.
Compliance Test Studio 23 software with standards library; built into two 19" racks 34 HU 3 x 400 V
input voltage
Ripple NX1000-1000-5-208 Fully integrated ripple generator consisting of:
RippleSource NX5
(5kVA, dual range, 160 Vp / 63 Ap
and 80 Vp / 126 Ap), RippleCoupler NX1000-1000 (1000 A, 1000 VDC, incl. coupling transformers,
10 mF shunt capacitor with pre-/discharge circuit, measuring unit), connection box CBP-1000-1000
(1000 A, 1000 VDC) and connection cables (RippleCoupler NX to CBP, 3 meter); built-in control and
measuring unit with touch display and Ethernet / CAN / Optolink / GPIB remote control interfaces; incl.
Compliance Test Studio 23 software with standards library; built into two 19" racks 34 HU; 3 x 208 V
input voltage
Ripple NX1000-1000-5-400 Fully integrated ripple generator consisting of: RippleSource NX5(5kVA, dual range, 160 Vp / 63 Ap
and 80 Vp / 126 Ap), RippleCoupler NX1000-1000 (1000 A, 1000 VDC, incl. coupling transformers,
10 mF shunt capacitor with pre-/discharge circuit, measuring unit), connection box CBP-1000-1000
(1000 A, 1000 VDC) and connection cables (RippleCoupler NX to CBP, 3 meter); built-in control and
measuring unit with touch display and Ethernet / CAN / Optolink / GPIB remote control interfaces; ;
incl. Compliance Test Studio 23 software with standards library; built into two 19" racks 34 HU; 3 x
400 V input voltage
Ripple NX1000-1000-10-
208
Fully integrated ripple generator consisting of: RippleSource NX10 (10 kVA, 160 Vp / 126 Ap), Rip-
pleCoupler NX1000-1000 (1000 A, 1000 VDC, incl. coupling transformers, 10 mF shunt capacitor
with pre-/discharge circuit, measuring unit), connection box CBP-1000-1000 (1000 A, 1000 VDC) and
connection cables (RippleCoupler NX to CBP, 3 meter); built-in control and measuring unit with touch
display and Ethernet / CAN / Optolink / GPIB remote control interfaces; incl. Compliance Test Studio
23 software with standards library; built into two 19" racks 34 HU; 3 x 208 V input voltage
Ripple NX1000-1000-10-
400
Fully integrated ripple generator consisting of: RippleSource NX10 (10 kVA, 160 Vp / 126 Ap), Rip-
pleCoupler NX1000-1000 (1000 A, 1000 VDC, incl. coupling transformers, 10 mF shunt capacitor
with pre-/discharge circuit, measuring unit), connection box CBP-1000-1000 (1000 A, 1000 VDC) and
connection cables (RippleCoupler NX to CBP, 3 meter); built-in control and measuring unit with touch
display and Ethernet / CAN / Optolink / GPIB remote control interfaces; incl. Compliance Test Studio
23 software with standards library; built into two 19" racks 34 HU; 3 x 400 V input voltage

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Option Description
CBP 2-1000-1000-10m Connection box power for Ripple NX, max. 1000 VDC and 1000 A, robust aluminum hous-
ing, temperature range -20 to + 80°C, measuring voltage connection with fuse, 10m cable
length
CBP 2-1000-1000-3m Connection box power for Ripple NX, max. 1000 VDC and 1000 A, robust aluminum hous-
ing, temperature range -20 to + 80°C, measuring voltage connection with fuse, 3m cable
length
CBM 2-1000-1000 Connection box measure for Ripple NX, max. 1000 VDC, robust aluminum housing, tem-
perature range -10 to + 80 °C, measuring connection protected by fuse
2.2 Scope of supply
2.2.1 Ripple NX system
Part
Part No.
Picture
RippleSource NX
RippleCoupler NX
Connection Box Power with cables
EMERGENCY STOP SWITCH 101224
Emergency stop master-slave cable 1007608
CBLA STR 2Pol 1500mm GY 2CON MM I 1:1
SysLink Cable, 2000mm 112390 SLC 2000 SYSTEM LINK CONNECTION CABLE
SWL AD safety warning lamp adapter 111241
SCC AD short circuit connector adapter 111240
Plug for interlock connection
105495 Industrial Connector ST-Serie Stakei 2

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Part
Part No.
Picture
RJ45 cable (CBLA TPC 8xAWG27 5m
300V GY 2CON MM RJ I 1:1)
1004402
Cleaning tissue 111268
USB Stick
111563
Connector CEE 5P 32A or
Connector CEE 5P 63A 105796
105797
Power mains cable (country specific)
2.2.2 Connection Box Power CBP 1000-1000-2
Part
Part No.
Picture
Connection box
Complete with cables and accessories
Box only
1007526
1007522
Shielded power connection cable 1005995
Measuring cable, 4 meters 1006108
Short circuit bridge 1007623
Silicon stopper to close the cable fit-
tings if not used
1007730
Rubber reductions for the cable
fittings

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2.3 RippleSource NX
2.3.1 Front Side
Figure 1 Front view of RippleSource NX
1 RippleSource NX control unit with touch panel (see below for details)
2 Main switch
3 Wheels with brakes
1
3 3
2

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RippleSource NX control unit details
Figure 2 Front view of control unit RippleSource NX
1 Touch panel for local control and status information for remote control.
2 TEST ON button and indicator
WHITE TEST ON button is inactive, no test can be
performed
YELLOW TEST ON button is activated and a test can
be performed
The TEST ON button can be enabled locally by pushing the button. Or remotely by software/web interface/re-
mote control.
3
Measurement inputs (optional, active if measurement option for RippleSource NX is installed)
4 ACTIVE indicator
Off RippleSource NX switched off
constant RippleSource NX is powered up
blinking Test is running
2.3.2 Rear Side
Figure 3 Rear view of RippleSource NX connection panel
1 Grounding connector
2 System power, mains connector (see chapter 3.2.6 for details)
RippleSource NX5-400 RippleSource NX10-400
Connector CEE 32A socket CEE 63A socket
Configuration
Polarization
3P+N+PE
6H
3P+N+PE
6H
Matching plug CEE 32A plug CEE 125A plug

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3 Output (+) and (-)
Connector Stäubli 14.0048C1
Matching plug Stäubli 15.0645C1
Do not connect output (+) or (-) to ground or earth. Otherwise, the amplifier output would be
short circuited. The outputs are differential and not potential free.
4 Auxiliary outputs (+) red and (-) black, protected by fuse
Connector 4mm safety lab plug
Stäubli 23.3020-22
Matching plug 4mm safety banana
Output Max. 30 A
Do not connect auxiliary output (+) or (-) to ground or earth. Otherwise, the amplifier output
would be short circuited. The outputs are differential and not potential free.
5 Fuse for auxiliary outputs
Fuse type 30 A slow blow, 230 VAC
6 and 7 Analog input 1 and 2, allows to use external signal generators as input to the amplifier
Max. +/- 10V, 100 kΩinput impedance
8 Analog output of the internal signal generator, delivers a control signal with +/- 10 V (max. 8 mA), allows to
control external devices (e.g., amplifiers, sources)
9 and 10 EUT status input to control the behavior of the Ripple NX (i.e., start, stop etc. of test depend on the EUT
status), used to connect EUT monitoring outputs (i.e., digital status output)
Connector BNC
Signal 0 V to max. +15 V, 1 MΩinput impedance
Negative slope
Function Programmable:
Stop: stops the test
Notify: adds a “notify” remark
11 Trigger input, allows to control defined functions of the Ripple NX by an external trigger signal
Connector BNC
Signal 0 – max. +15 V, 1 MΩinput impedance
Positive slope
Function Start, next test point
12 SYS.LINK input, communication interface to connect the RippleCoupler NX to a SYS.LINK controller (i.e.,
RippleSource NX)
Note: the first SYS.LINK instrument must have a SCT or SCC terminator
13 SYS.LINK output, connection of additional instruments with SYS.LINK interface
Note: the last SYS.LINK instrument needs to be terminated at its SYS.LINK output connector with a SYS.LINK
terminator.
14 OptoLink remote control interface
15 Ethernet remote control interface
16 GPIB/IEEE 488 remote control interface

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17 Emergency switch, MASTER, control input for the emergency circuit (see chapter Emergency Stop Cir-
cuit4.2.1.1). Operates the input circuit breaker and disconnects the instrument from mains when open.
The RippleCoupler NX is usually connected to the RippleSource NX emergency switch SLAVE connector.
Connector Hirschmann STAKEI 2
Pinout
Pin 1
Pin 2
Output +24 VDC, max. 0.4 A, fuse protected
Input (to relay coil)
Matching plug Hirschmann STAS 2
18 Emergency switch, SLAVE, auxiliar contact that operates in parallel to the MASTER and allows to control the
emergency circuit of additional instruments (i.e., power sources NetWave/PowerWave) or used as feedback
for external safety circuits.
Connector Hirschmann STAKEI 2
Pinout
Pin 1
Pin 2
Relay contact 1
Relay contact 2
Rating AC: 50 V / 8 A, DC: 60 V / 1 A
Matching plug Hirschmann STAS 2
19 CAN remote control interface
Connector Sub-D 9 pole
20 USB host interface, connection to an external drive (save and load test files, firmware update etc.)
This interface cannot be used to remotely control the Ripple NX

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2.4 RippleCoupler NX
2.4.1 Front Side
Figure 4 Front view RippleCoupler NX
1 RippleCoupler NX control unit with indicators (see below for details)
2 Lockable front door with access to connection panel (see below for details)
Note: the door is monitored by a door contact. If the door is opened, the TEST ON is deactivated
3 Wheels with brakes
RippleCoupler NX control unit details
Figure 5 Front view control unit RippleCoupler NX
1 Indicator for the presence of DC voltage, measured at the DC source inputs
ON DC voltage present, voltage > 35 V
OFF DC voltage < 35 V
2 Indicator for the state of charge of the internal capacitor
CHARGED Constant capacitor is charged and connected to the DC line
Blinking capacitor is being charged via the integrated pre-charge circuit
DISCHARGED Constant capacitor is discharged and disconnected from the DC line
Blinking capacitor is being discharged via the integrated discharge circuit

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3 Indicator for the interlock circuit (see chapter 4.2.1.2 for details)
CLOSED Interlock circuit is closed, and ripple generator
can be used
OPEN Interlock circuit is open, and the ripple gener-
ator is in safety mode (coupling capacitor dis-
charged, transformers short-circuited and ext.
relay control open)
4 ACTIVE indicator
Off RippleCoupler NX not in use
constant RippleCoupler NX is powered up
blinking Test is running
5 Indicator for overtemperature, lights up in case the internal temperature is above a critical level
6 TEST ON button and indicator
WHITE TEST ON button is inactive, no test can be
performed
YELLOW TEST ON button is activated and a test can
be performed
The TEST ON button can be enabled locally by pushing the button. Or remotely by software/web interface/re-
mote control.
7 VCAP measuring outputs can be used to check the voltage of the internal capacitor with a voltmeter.
Voltage divider ratio: 1:1 with a protection resistor of 50 kΩin series for each line (+ and -)
8 VDC measuring outputs can be used to check the voltage at the DC source inputs with a voltmeter.
Voltage divider ratio: 1:1 with a protection resistor of 50 kΩin series for each line (+ and -)

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RippleCoupler NX connection panel details
Figure 6 Overview RippleCoupler NX connection panel and protective cover
Voltage test points, used to check the presence of voltage at the DC IN and OUT1 / OUT 2 terminals.
A voltage tester with a rated voltage of 1000VDC or more must be used to check the voltage.
1 Voltage measurement inputs (channel 1 and channel 2), used to measure the ripple voltage at the measure-
ment point. For normal operation, the voltage measurement inputs are connected to the CBP (connection
box power).
Connector 4mm safety lab plug
Stäubli 23.3020-22
Matching plug 4mm safety banana
Max. voltages
V+ to V-
V+ / V- to GND
1000 V, 80 MΩ
1000 V, 40 MΩ
External fuses must be installed if the voltage input is used.
Fuses are included in the CBP (connection box power).
2
Safety cover made of acrylic glass, prevents the user from touching the parts under voltage
Before removing the safety cover, the user must make sure:
- To check the presence of voltage using a voltage tester
- That the connected DC source (DC IN terminal) and the test object (OUT 1 and
OUT 2 terminals) are switched off
- That no residual voltage (i.e., charged capacitors or batteries) is present coming
from the DC source and/or the test object
3 + 4 DC IN (HV+ and HV-) connection terminals, used to connect the external DC source
Connector M10 screw connection for cable lug

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5 Cap rail with clamps as strain-relief for the DC source cables
6 Fuses holders for OUT 1 and OUT 2 outputs, used to protect the EUT from overcurrent. Fuses are not part
of the standard scope of delivery.
The voltage and current ratings of the fuse must match the maximum voltage and current of
the test object (EUT) and/or the maximum voltage and current rating of the RippleCoupler
NX (whichever is smaller).
Carefull: the fuses can be hot.
The lower part of the fuse holder can be adjusted to fit the fuse size.
7 + 8 OUT 1 (HV+) and OUT 2 (HV+) connection terminals, outputs towards the EUT
Connector M10 screw connection for cable lug
9 OUT (HV-) connection terminal, common for OUT 1 and OUT 2
10 GND ground connection points, can be used to terminate the shield of the HV cables
11 Cap rail with clamps used as strain-relief for the connection cables towards the EUT
12 Earth connection point
2.4.2 Rear Side
Figure 7 Rear view RippleCoupler NX connection panel
1 Input (from RippleSource NX), the black and red connection cables (not shown) are hard-wired to the Rip-
pleCoupler NX and cannot be removed
In case of damage to the black or red connection cables, do not replace or repair the cables
on your own. Contact AMETEK CTS service center for support.
2 System power, mains connector and switch (see chapter 3.2.6 for details)
3 SYS.LINK input, communication interface to connect the RippleCoupler NX to a SYS.LINK controller (i.e.,
RippleSource NX)
4 SYS.LINK output, connection of additional instruments with SYS.LINK interface
Note: the last SYS.LINK instrument needs to be terminated at its SYS.LINK output connector with a SYS.LINK
terminator.

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5 Emergency switch, MASTER, control input for the emergency circuit (see chapter Emergency Stop Cir-
cuit4.2.1.1). Operates the input circuit breaker and disconnects the instrument from mains when open.
The RippleCoupler NX is usually connected to the RippleSource NX emergency switch SLAVE connector.
Connector Hirschmann STAKEI 2
Pinout
Pin 1
Pin 2
Output +24 VDC, max. 0.4 A, fuse protected
Input (to relay coil)
Matching plug Hirschmann STAS 2
6 Emergency switch, SLAVE, auxiliar contact that operates in parallel to the MASTER and allows to control the
emergency circuit of additional instruments (i.e., power sources NetWave/PowerWave) or used as feedback
for external safety circuits.
Connector Hirschmann STAKEI 2
Pinout
Pin 1
Pin 2
Relay contact 1
Relay contact 2
Rating AC: 50 V / 8 A, DC: 60 V / 1 A
Matching plug Hirschmann STAS 2
7 External relay control,
Connector Hirschmann STAKEI 2
Pinout
Pin 1 relay contact 1
Pin 2 relay contact 2
Rating AC: 277 V, 5 A
DC 30 V, 3 A
Matching plug Hirschmann STAS 2

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2.5 Connection Box Power
Figure 8 Connection Box Power CBP, protective cover and accessories
Voltage test points, used to check the presence of voltage at the DC IN and OUT1 / OUT 2 terminals.
A voltage tester with a rated voltage of 1000VDC or more must be used to check the
voltage.
1 Connection to RippleCoupler NX
Cable fitting Hummel HSK-M-PVDF 1.699.4000.31
2 Connection to EUT
Cable fitting Hummel HSK-M-PVDF 1.699.4000.31
3 Grounding point
Bolt M10
4 Screws to ground the cable shield
Screw M6
5 Channel 1 – HV (+) connection point
Bolt M10
6 Channel 1 and channel 2 – HV (-) connection point
Bolt M10
7 Channel 2 – HV (+) connection point
Bolt M10
8 Fuse holders with fuses to protect the voltage measuring inputs
Fuse LittleFuse SPXV 001
9 Cable fitting for the measurement cable
10 Ground plate with fixation notch
11 Protective cover with test points
12 Copper bar bridge for parallel configuration of channel 1 and channel 2
13 Silicon stoppers to seal the cable fittings
14 Rubber reduction rings for the cable fittings

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3 Equipment installation recommendation
3.1 Unpacking
Inspect the packaging and the units for any possible shipping damage immediately upon receipt. If damage is evident, notify
the carrier. DO NOT return an instrument to the factory without prior approval. Do not destroy the packing container until the
unit has been inspected for damage in shipment.
WARNING
Obtain adequate help when moving the unit. Make sure the location (floor) in which the unit(s) will be
installed can support the weight of the unit(s).
To open the box user needs the following tools:
Lifter: Forklift, or crane with suitable capacity
Other useful items: Blade, pinch bar, hammer, crane ropes
Unpack the box:
1. Remove the bands
2. Remove the cardboard
3. Remove the plastic foil
4. Remove the wooden strip
Figure 9 Packing
Unloading
By crane:
1. Allocate two crane ropes around the rack and attach
to crane.
Make sure that the two ropes are positioned that
there is a maximum space in between to prevent the
rack from tilting when it is lifted.
2. Unload the rack from the wooden platform
Figure 10 Lifting by crane