Ametek 5000 User manual

Quick Start and Safety Guide V 1.00 1 / 27
Version:
1.00 08.04.2021
Replaces:
Filename:
Quick Start and Safety 5000-series V1.00 EN
Print date:
4.29.2021
QUICK-START GUIDE
AND SAFETY INSTRUCTIONS
Automotive Immunity
Test Generators
5000-series
NSG 5500x
PA 5840x
PA 5740x
NSG 5071x

AMETEK CTS Automotive Immunity Test Generators
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AMETEK CTS GmbH
Sternenhofstrasse 15
4153 Reinach BL1
Switzerland
Phone: [phone]
Fax: [phone]
URL : www.ametek-cts.com
Copyright © 2021 AMETEK CTS GmbH
. All right reserved.
Information in earlier versions. Specifications subject to change.

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Contents
1. Safety................................................................................................................................4
1.1. Safety Aspects....................................................................................................................................4
1.2. Safety and warning label on the device..............................................................................................4
1.3. Responsibility of the operator .............................................................................................................5
1.4. General hazard ...................................................................................................................................5
1.5. Qualification of personnel ...................................................................................................................6
1.6. Inspection before Use.........................................................................................................................6
1.6.1. Damage due to Shipment...................................................................................................................6
1.7. Power requirements ...........................................................................................................................6
1.8. 3-phase EUT power lines ...................................................................................................................7
1.9. Fuse for the EUT power supply ..........................................................................................................7
2. Safety functions ..............................................................................................................8
2.1. Earthing of devices .............................................................................................................................8
3. Testing and Precautions.................................................................................................9
3.1. Standard Testing and Trained Operators...........................................................................................9
3.2. Precautions to be taken......................................................................................................................9
3.3. Failures and Damage .........................................................................................................................9
3.4. Coupling Networks .............................................................................................................................9
3.5. Interference to the environment........................................................................................................10
3.6. Testing ..............................................................................................................................................10
3.6.1. Safety Precautions ...........................................................................................................................10
3.7. Danger from EUT .............................................................................................................................10
4. Operating elements, indications, connections 5000-series.......................................12
4.1. NSG 5500 front view ........................................................................................................................12
4.2. NSG 5500 rear view .........................................................................................................................14
4.3. PA 5840 front view ...........................................................................................................................17
4.4. PA 5840 rear view ............................................................................................................................19
4.5. PA 5740 front view ...........................................................................................................................20
4.6. PA 5740 rear view ............................................................................................................................21
4.7. NSG 5071 top / front view ................................................................................................................22
5. Operation .......................................................................................................................24
5.1. Test Setup ........................................................................................................................................24
5.2. Get started ........................................................................................................................................24
5.3. Software Operation...........................................................................................................................25
5.4. Tests with clamps and other couplers ..............................................................................................26
6. Maintenance, Adjustments, Replacement of Parts.....................................................27
6.1. Disposal of devices...........................................................................................................................27
6.2. Calibration and Verification...............................................................................................................27

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1. Safety
1.1. Safety Aspects
Observe all precautions to assure your personal safety. The generators comply with Installation Category II
(excess voltage section).
Pay special attention to safety and operation details!
1.2. Safety and warning label on the device
Take note of the following explanations of the symbols used in order to achieve the optimum benefit from this
manual and to ensure safety during operation of the equipment.
This symbol warns of a potential risk of shock hazard. The symbol on an instrument
shows that that it can source 1000 volt or more, including the combined effect of
normal and common mode voltages. Use standard safety precautions to avoid
personal contact with these voltages.
This symbol indicates where a caution is required. Refer to the operating instructions
located in the manual in order to protect against personal injury or damage the
equipment.
GROUND Indicates protective Ground Terminal
*CAUTION”
The “CAUTION” symbol indicates a potential hazard. It calls attention to a procedure,
practice or condition which, if not followed, could possibly cause damage to equipment.
Such damage may invalidate the warranty. If a “CAUTION” is indicated, do not proceed
until its conditions are fully understood and met.
“WARNING”
The “WARNING” symbol indicates a potential hazard. It calls attention to a procedure,
practice or condition which, if not followed, could possibly cause bodily injured or
death. If a “WARNING” is indicated, do not proceed until its conditions are fully
understood and met.
Power Supply
The equipment is intended to operate with a power supply not to exceed 250 volts between phase and neutral or
between phase and ground. A proper ground connection through the ground connector of the power cord is
essential for safe operation.
Grounding the Generators
The generators are grounded through the power cord. To avoid electric shock, plug the power cord into a
properly installed receptacle which was tested by a qualified electrician. Have the test performed before
connecting equipment.
Without the protective ground connection, all parts of the generators are potential electric shock hazards. This
may include components which appear to be insulated. The equipment must not be used if this protection is
altered.
Use the Proper Power Cord
Use only power cords and connector specified for your product. Use only power cords in good condition.
Use Proper Fuses
To avoid fire hazard, use only fuses as specified in the parts listing for your product - matching type, voltage and
current rating.

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Do Not Remove Covers or Panels
To avoid personal injury, do not operate the generators without panels and covers.
Do Not Operate in an Explosive Environment
Never apply power to a connector which is not specified for that particular voltage/current.
1.3. Responsibility of the operator
These operating instructions form an essential part of the equipment and must be available to the operator at all
times. The user must obey all safety instructions and warnings.
CAUTION
CAUTION: The purpose of this instrument is the generation of defined interferences signals
for EMI immunity testing. Depending on the arrangement of the test rig, the configuration,
the cabling and the properties of the EUT itself, a significant amount of electromagnetic
radiation may result that could also affect other equipment and systems.
The equipment is designed to operate in industrial environment. For operating in other or
sensitive environment, such as light industry, airport area…, the user may use a shielded
room for operate.
The user himself or herself is ultimately responsible for the correct and controlled operation
of the rig. In case of doubt, the tests should be carried out in a Faraday cage.
1.4. General hazard
Before applying power to the system, verify that your product is configured properly for your particular application.
WARNING
WARNING: The generators and their accessories operate at high voltages.
Hazardous voltages may be present when covers are removed. Qualified personnel must
use extreme caution when servicing this equipment.
Circuit boards, test points, and output voltages also may be floating above (below) chassis
ground.
The design of external insulation must be such that it exceeds the maximum impulse
voltages of the generator.
Only qualified personnel who deal with attendant hazards in impulse generators, are allowed to perform
installation and servicing.
Ensure that the AC power line ground is connected properly to the Unit or Power Rack input connector or
chassis. Similarly, other power ground lines including those to application and maintenance equipment must be
grounded properly for both personnel and equipment safety.
Always ensure that facility AC input power is de-energized prior to connecting or disconnecting any cable.
The user must ensure that the output power lines are labeled properly as to the safety hazards and that any
inadvertent contact with hazardous voltages is eliminated.
Guard against risks of electrical shock during open cover checks by not touching any portion of the electrical
circuits. Even when power is off, capacitors may retain an electrical charge. Use safety glasses during open
cover checks to avoid personal injury by any sudden component failure.
Neither AMETEK CTS GmbH, nor any of the subsidiary sales organizations can accept any responsibility for
personnel, material or inconsequential injury, loss or damage that results from improper use of the equipment
and accessories.
CAUTION
CAUTION: Personnel fitted with a heart pacemaker must neither operate the
instrument nor approach the test setup while a test is being executed.

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Only approved accessories, connectors, adapters, etc. are to be used to ensure safe operation.
1.5. Qualification of personnel
The generator must be operated only by authorized and trained specialists with detailed knowledge of the
international, national or manufacturer’s test standard.
1.6. Inspection before Use
1.6.1. Damage due to Shipment
The instrument was tested before shipment and was packed carefully on a transport palette. Each box is marked
with a detailed list of the contents.
Figure 1 - Rack shipment Figure 2 - System shipment
Figure 3 - Single equipment shipment
1.7. Power requirements
Prior to turning the equipment on, check that the selected voltage corresponds to the supply voltage.
The position of the voltage selector must correspond with the
mains. If you change the mains voltage, replace the fuses
according the recommended value on the number plate.
Figure 4 - Power Requirements

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First check the 115 V / 230 V voltage selector where applicable!
Do not connect 230 VAC into the 115 VAC units.
The result could be a severely damaged unit.
Figure 5 - Voltage Selection
If power to the equipment of Class I is supplied by an auto-transformer which is connected to a higher supply
voltage, the base of the auto-transformer must be connected to the neutral of the power supply.
Equipment of Class I, which is supplied with a 3-phase power cord, must only be connected to a grounded
receptacle. The protective ground connection must not be disconnected or otherwise interrupted.
Each interruption or disconnection of the protective ground connection inside or outside the equipment may
cause electric shock.
Connecting different units with each other or to a personal computer for remote control may be performed only
with cables recommended and/or supplied by the manufacturer.
1.8. 3-phase EUT power lines
The connectors for 3-phase EUT power lines on the devices is realized with CEE connectors.
Take care to connect carefully the correct plugs during installation.
Important is a direct connection between neutral and PE from the power supply. Otherwise you get problems with
the floating neutral star point and inconvenience or malfunctions during the test.
The figures show the correct mapping of the plugs of the CEE connectors.
Figure 6 - Female Connector Figure 7 - Male Connector
1.9. Fuse for the EUT power supply
The pulse generators have no built in fuse for the EUT power supply. It is in the scope of responsibility of the user
to protect the EUT external for the rated current.
CAUTION
CAUTION: The design of the external fuse must be matching the following rules:
- fuse dimension must be equal or smaller than the rated EUT current of the connected test
generator
- fuse must be designed for protect the connected EUT device under test in malfunction

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2. Safety functions
The test area must be organized so that only those involved in the test may enter it. In the case that the safety
circuit is used to control the complete area, an additional interlock contact must be used to directly protect the
operator from contact with the DUT.
Neither the DUT nor any cables or accessories must be touched during the test. During work on the DUT, the test
procedure must be stopped and the DUT disconnected from the power mains supply.
Coupling devices have no safety functions built in, because these functions are integrated in the generators.
2.1. Earthing of devices
Earth bolt, when equipped
Generators must be grounded to the reference ground plane. Generally, the generators are equipped with a
metal earth bolt at the rear side of the device.

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3. Testing and Precautions
All tests produced EMC generators are immunity tests on electronic equipment or devices. These tests are
potentially dangerous to the operator. It is the responsibility of the user to avoid critical failures and risks to the
environment and the operator.
National and International regulations regarding human safety must be followed.
Individuals with certain health conditions (e.g. with a heart pacemakers or similar devices), should not participate
in testing.
Long power supply lines to the EUT may radiate energy which may interfere with other instruments unrelated to
the generator. It is the responsibility of the user to determine whether to conduct immunity tests in a given area.
Generator and coupling/decoupling voltage power supplies must be grounded and connected to reference plane.
3.1. Standard Testing and Trained Operators
Operators must have read and understood the manufacturer or international standard to be applied.
This document does not replace an intimate understanding of the standard and the DUT which is required for
correct, compliant testing. The equipment is to be used by trained operators only.
3.2. Precautions to be taken
EMC and High Voltage test areas must always be supplied by a decoupled and well-known power supply.
The decoupling can be realized either by
- filtering
- or the use of an isolating transformer
When using isolating transformers, the fault current safety devices normally don’t trip.
EMC and High Voltage test areas must always have a clear grounding strategy. All coupling/decoupling high
power voltages and all LISN’s must be strictly and securely connected to the ground reference plane of the test
setup.
Ensure the correct current back flow to the generator. Missing connections can cause extremely high voltages
and may become a health hazard. Therefore, it is absolutely necessary to use ground reference planes which are
connected to a protective ground.
3.3. Failures and Damage
If it is determined that a safe operation of the equipment due to failure or heavy strain is no longer possible, the
supply voltage must be disconnected, and the equipment protected from unintentional use.
Unsafe operation is determined as follows:
•the equipment shows visible damage
•the equipment is not working
•the equipment has experienced severe stress during transport
•the equipment was stored in an unsuitable environment for an extended period of time.
Always exercise good judgement in determining whether a device is unsafe for operation.
3.4. Coupling Networks
•The coupling network has mostly no On / Off switch and no internal fuse for the EUT power supply. This is
caused the different regulation in each country. The device under test must be protected by the user in an
adequate safe solution. As an option special adapters and switches can be built in, but the user must specify
this special solutions.
•Generators and coupling devices must be grounded and connected to the reference ground.
•For coupling pulses to the lines, the coupling path must be setted.
•If a line has not to be coupled, it is necessary to disconnect or switch off this coupling path.
•Special safety adapter cables are part of the delivery.

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3.5. Interference to the environment
CAUTION
CAUTION: The AMETEK CTS interferences generators are instruments with a functionally
emission of electromagnetic interference during the test (e.g., ESD, EFT, conducted RF, etc.).
Therefore, a disturbance of the environment cannot be excluded.
The user has an obligation to use a suitable test environment in order to minimize influences to
the environment. This may require a suitable screening or to test in a shielded room.
Next should be considered during the test, that nearby are no disturbers such as (switching
relays or drives with frequency converters etc.) that can influence through their emission the test.
3.6. Testing
The generator can be operated locally from the front panel or remotely from the computer.
When it is necessary to observe the EUT during the test, it can be more comfortable to operate locally. The tester
is nearer to the EUT and therefore faster to switch off the test generator in EUT fail condition.
When the computer fails, the Test On button on the generator front or the Fail 1 input must be used for switching
off the test.
3.6.1. Safety Precautions
The test area must be secured that only authorized test personnel may enter it.
Working alone with high voltages is dangerous.
The high voltages must be switched off when nobody is present.
Neither the EUT nor cables or accessories must be touched during the test.
Make sure all high voltage connections are adequately insulated to prevent accidental contact by you or
neighboring colleagues.
Keep one hand in your pocket when probing high voltage circuits or discharging capacitors. This reduces the peril
to touch the high voltage with both hands.
While working on the EUT, the test procedure should be stopped and the EUT disconnected from the voltage
power supply.
The EUT must be tested within a safety container or within a protected area. In extreme circumstances the EUT
may ignite or explode as a result of internal damage.
3.7. Danger from EUT
WARNING
WARNING: The device being tested may become defective an
d ignite due to the influence of
the applied test signal.
The stored energy inside the test simulator must be considerred. This energy can destroy or
damage the EUT even when the EUT operates under normal conditions.
WARNING
WARNING: Moving parts
may move in an unexpected way due to the interference of the
applied signal.
Never approach a test setup that uses actuators or electric motors during the test run!
Therefore, the operator shall take the following precautions:
As soon as the EUT ceases to operate as intended, the test shall be stopped immediately.
In case of internal damage, the operator may be exposed to high frequency signals of high power (up to 75 Watts
and more) anywhere on the EUT.