Phenix Technologies 400P User manual

DCD 4120-10
USER’S MANUAL
DC DIELECTRIC TEST SET - 400P
MODEL NUMBER 4120-10
Version 3.2
Phenix Technologies Inc.
75 Speicher Drive
Accident, MD 21520
Copyright © Phenix Technologies, Inc.
Rev 8/30/2018 ARFII
Rev 8/9/2019

DCD 4120-10
TABLE OF CONTENTS
DESCRIPTION SECTION NUMBER
INTRODUCTION
DANGER / GENERAL SAFETY PRECAUTIONS
TECHNICAL SPECIFICATIONS 1
CONTROLS AND INDICATORS 2
ELECTRICAL SET-UP 3
OPERATING INSTRUCTIONS 4
RETURN-GROUND-GUARD CONNECTIONS 5
CALIBRATION 6
TROUBLESHOOTING 7
STORAGE OF EQUIPMENT 8
CIRCUIT DIAGRAM SYMBOLS 9
RECOMMENDED SPARE PARTS AND PARTS LIST 10
PARTS ORDERING INFORMATION 11
RETURNED MATERIAL 12
ELECTRICAL DIAGRAMS 13
CUSTOMER COMMENTS / SUGGESTIONS 14

DCD 4120-10
INTRODUCTION
The DC Hipot line offered by Phenix Technologies is ruggedly built and suitable for field or lab use. Designed
to test electrical switchgear, cables, motors, generators and protective equipment, DC testing is popular
because the equipment is more compact and lighter in weight than comparable AC equipment.
Design and Safety Features
Output voltage continuously adjustable to 120kV DC.
“Zero Start” voltage interlock and external safety interlock.
Leakage current measurements available from .01 to 10,000 microamps DC.
Removable line cord.
Rotary switch selection simplifies operation.
Integrated cable storage bin in controls.
Built in discharge circuit rated at 12 kilojoules.
Light weight, portable, with controls enclosed in rugged, high-density polyethylene case.
Adjustable overcurrent trip point from 10%-110% of each range.
Large, easy to read LCD meters
Input Circuit Breaker / Power Switch
Thermal resettable overload protecting high voltage transformer primary circuits.
Very low ripple, <2% RMS ripple at full output. (>40 Meg Resistive)
For detailed specifications, see Section 1-1.

DCD 4120-10
DANGER / WARNINGS
Complete Grounding of this unit is necessary for the
safe operation of this equipment. Disconnect inputs
before ungrounding this equipment
DANGER

DCD 4120-10
GENERAL SAFETY PRECAUTIONS
This equipment can produce POTENTIALLY LETHAL VOLTAGES!
Improper operation or test practices may result in injury or death to the operator or
surrounding personnel.
The operation of High Voltage test equipment should only be performed by personnel
familiar with HIGH VOLTAGE testing and safety procedures. The operator of this
equipment must be aware of all hazards associated with High Voltage testing. The
operator is responsible for himself and others in close proximity of the testing area.
Some General Safety Practices for working with High Voltage Test Equipment have
been listed below for your reference.
•Become familiar with your instrument before performing an actual test
•Know your work area, check that all circuits are de-energized and locked out.
•Never work alone; always work with another qualified worker.
•Mark off entire work area with barriers and warning tape.
•Make all personnel aware of your testing activities.
•Be aware of dangerous conditions that may arise from energizing a test
specimen.
•Never modify test equipment, modifications to equipment could introduce an
unknown hazard or hinder a designed-in safety feature.
•DO NOT operate damaged equipment. Remove power, and do not use the
equipment until safe operation can be verified by service-trained personnel.
Phenix Technologies, Inc. assumes no liability for unsafe or improper use of test equipment.

DCD 4120-10
1-1
SECTION 1: TECHNICAL SPECIFICATIONS
Input
120 VAC 10 Amps or 220 VAC 5 Amps, 50/60 Hz, single phase (refer to Unit Data Tag)
Output Rating (maximum)
120 kilovolts DC, 10 milliamperes
Internal Discharge Capability: 12 kilojoules
Duty Cycle
Continuous –Capacitive Charging
Type of Cooling: Natural convection
Ripple: Less than 2 percent, at 120kV, (> 40 Meg Resistive)
Output
Negative output, positive ground standard. Positive output available by special order. Filtered voltage doubler
circuit, equivalent to full wave rectification.
Operating Ambient Temperature
0 to 40 degrees Celsius
Output Termination
High voltage cable, shield grounded
Metering
Output Voltmeter: 3 ½ DIGIT LCD, accuracy 0.5% of full scale.
Ranges: 0 to 19.99kV, 0-120.0kV
Output Currentmeter: 3 ½ DIGIT LCD, accuracy 0.5% of full scale.
Ranges of 0 to 19.99a, 199.9A, 1.999mA, 10.00mA
Size and Weight
Controls: 21.25" W x 16.75" D x 13.75" H; 25* lbs.
(540 mm W x 426 mm D x 350 mm H; 11.4* kg)
HV Unit: 17.25" W x 12" D x 22" H; 110 lbs.
(438 mm W x 305 mm D x 559 mm H; 49.9 kg)
Cables: 9.5 lbs. (4.3kg); *For 220 V units: add 10 lbs. (4.5 kg)

DCD 4120-10
2-1
SECTION 2: CONTROLS AND INDICATORS
Control Unit (Refer to Figure 2-1)
1. AC Power Input. Connect to a suitable grounded receptacle. See specifications tag on unit for voltage
and current requirements.
2. Voltmeter. Displays output voltage of test set.
3. Currentmeter. Displays current out of high voltage lead or into RTN terminal depending upon mode of
measurement.
4. Currentmeter Range Selector. Rotate to desired range.
5. J5. Interconnect cable between controls and HV unit connects here.
6. ANALOG CURRENT INDICATOR. Meter displays current from 0-100% of range to give visual
indications of capacitive charging conditions or to show changing current conditions that are not easily
determined from digital meters.
7. Output Voltage Control. Turn clockwise to increase output of test set. This control must be in the full
counterclockwise position (zero start) in order to turn High Voltage On. Under normal circumstances,
Voltage Control should always be returned to zero and voltage displayed on the voltmeter allowed to
decay to zero before pressing High Voltage Off.
8. High Voltage Off/Ready. Press to turn off high voltage output. Under normal circumstances the voltage
control should be returned to zero, and the high voltage allowed to decay near zero before switching
High Voltage OFF. CAUTION: Capacitive loads may retain voltage for a short time after high
voltage is turned off while the internal circuitry bleeds their charge to ground.
High Voltage Off/Ready lamp must be illuminated before High Voltage ON can be activated.
Conditions required for illumination are:
•External Interlock loop must be closed.
•Overcurrent Trip/Reset circuit must not be tripped. (Push Reset if circuit is tripped)
9. High Voltage On. Press to turn on high voltage.
Conditions required before high voltage will activate are:
•Voltage control at Zero Start
•External Interlock loop closed.
10. Current Trip Adjust. Dial adjusts from 1 to 11 corresponding to approximately 10% to 110% of selected
output current range. Current Trip/Reset lamp illuminates and high voltage turns off when output
current exceeds setting, causing circuit to trip. Circuit also acts as short circuit and overload protection
on high voltage output. To reactivate high voltage, Voltage Control must be returned to zero, and
Reset switch must be pressed to clear Current Trip circuit.

DCD 4120-10
2-2
CONTROLS AND INDICATORS
Control Unit (Cont’d)
11. Reset. Reset lamp illuminates to show that current trip circuit has tripped. High voltage circuits are
deactivated. Momentary Reset switch must be pressed to extinguish Reset lamp to allow high voltage
to be reapplied after returning Voltage Control to zero.
12. VOLTMETER RANGE SELECTOR. Rotate to appropriate setting for test voltage.
13. MAIN POWER INDICATOR. Lights to indicate that power is available for testing.
14. MAIN POWER CIRCUIT BREAKER. Press I to connect power, Press O to disconnect power.
15. F1. Control Power Fuse
16. THERMAL OVERLOAD. Circuit breaker protects primary of high voltage transformer. If circuit breaker
trips, turn High Voltage Off and return Voltage Control knob to zero before resetting.
17. External Interlock. If desired, remove jumper from connector and replace with cable connected to
contact(s) that must be maintained closed during testing. Some examples include footswitch, dead man
switch, gate interlock, panic button, etc. Only non-energized contact devices may be used. This is a
series 120 VAC circuit that must be maintained closed for high voltage to be activated or maintained.

DCD 4120-10
CONTROLS AND INDICATORS 2-3
FIGURE 2-1



































PHENIX

TECHNOLOGIES









PHENIX












TECHNOLOGIES



DCD 4120-10
2-4
CONTROLS AND INDICATORS
CONTROLS (Cont’d)
High Voltage Unit (Refer to Figure 2-2)
1. J5. Interconnect cable from controls connects here.
2. Guard Terminal (GRD). Connect to Ground (GND) terminal (#3) for guard mode operation. Connect
currents that need to bypass the currentmeter to this point. Low potential side of specimen must be
isolated from ground to use this mode.
3. Ground Terminal (GND). Connects to Facility Ground. See (#2 and #4).
4. Return Terminal (RTN). Connect to Ground (GND) terminal (#3) for normal operation. Always connect
low side of test specimen to this point. This is the metered connection point for current.
Note: Further explanation of terminals occurs later under Return-Ground-Guard Section.
5. Grounding Clip-The grounding clip must always be connected from the Ground (GND) post to either the
Return (RTN) post or the Guard (GRD) post. Do not operate the unit with the clip removed or
disconnected.
6. High Voltage Bushing Well. High voltage output cable connects here. Opposite end attaches to the
high potential side of the test specimen.

DCD 4120-10
2-4
CONTROLS AND INDICATORS
FIGURE 2-2









HIGH VOLTAGE
DANGER

DCD 4120-10
3-1
SECTION 3: ELECTRICAL SET-UP
1. Locate the desired location for the test set. Prepare the main power input cable for plugging into the
proper facility power (i.e., 120 volts AC or 220 volts AC). Leave plug unconnected at this time.
High Voltage Connection
1. Place currentmeter in desired mode of operation by connecting the jumper clip between Return (RTN) and
Ground (GND) or Guard (GRD) and Ground (GND) binding posts. The normal connection is between
Ground and Return. See Section on Return-Ground-Guard for more information on this connection.
2. Connect the Ground (GND)” connection to facility ground using the ground test lead provided.
3. Connect the low potential side of test specimen to terminal labeled Return (RTN). Use red test lead
provided.
4. Connect the high voltage output cable to HV unit re-entrant bushing and to high potential side of test
specimen. Keep shielded part of high voltage cable away from test specimen high voltage points.
5. Connect cable from controls to High Voltage unit
6. Connect the input main power cable to appropriate power source. Check Technical Specifications tag on
unit, for proper input voltage.
7. Read and understand entire operating instructions before applying power.
WARNING:
Main Power switch on front panel must be in the OFF (O) position before proceeding. Make sure
Test object is de-energized and discharged.
WARNING
Improper contact with the test leads on this equipment can cause harmful or fatal electrical shock.
Do not touch test leads while a test is in process. This equipment should only be operated by
someone familiar with high voltage testing and safety procedures.

DCD 4120-10
4-1
SECTION 4: OPERATING INSTRUCTIONS
1. Ensure proper electrical set-up has been performed.
2. Check that the Voltage Control dial is set to "0" (Zero Start position).
3. Select the proper voltmeter range and currentmeter range.
High Voltage Applied
4. Turn on the Control Main Power switch. The Power On lamp will illuminate.
5. Momentarily press the HV On pushbutton. The high voltage will be applied to the cable and the HV On
switch lamp will illuminate. (Zero Start and External Interlock Loop conditions must be met.)
6. With HV On, rotate the Voltage Control dial and watch the Output Voltmeter and Output Currentmeter
until desired levels are reached.
Note: When testing samples that are largely capacitive in nature, it may be necessary to place
currentmeter range switch in the X1K position. Operator must then slowly raise output watching the
currentmeter and allowing the test sample to "charge up".
7. Record data, if desired, and lower the Voltage Control to Zero after testing is completed. Use Discharge
or Grounding stick to discharge specimen or allow voltage to return to zero. Press HV Off button; high
voltage will be shut off and the HV On switch lamp will extinguish and the High Voltage Off/Ready lamp
will illuminate.
Overcurrent Failure
8. If an overcurrent situation occurs (output current exceeds Overcurrent Trip set point), the overcurrent
relay will activate, deenergizing the test set (High Voltage Off). To regain high voltage the Reset button
must be depressed and, the Voltage Control dial must be returned to zero. Press the HV On button
momentarily to turn High Voltage back on.
9. After all testing is completed; turn off the front panel Main Power switch. Remove the input power cable
from the facility power input.
10. CAUTION: Make certain that the test specimen is totally discharged and grounded before
removing test cables.
WARNING:
This equipment should only be operated by personnel familiar with high voltage testing and safety
procedures. Improper operation may result in injury or death and can cause damage to the unit or
test object.

DCD 4120-10
4-2
OPERATING INSTRUCTIONS
Calculating Meg-Ohms The Impedance of a test object can be determined by the formula:
V/I=R where voltage in Volts divided by current in Amps equals Resistance in Ohms.
Resistance divided by 1,000,000 then equals Meg-Ohms: R/1,000,000=Meg-Ohms
When voltages are in Kilovolts and currents are in Milliamps, a more direct method is to directly divide
Kilovolts by Milliamps to obtain the result directly in Meg-Ohms.
KV/mA=Meg-Ohms
Example: 10kv divided by 2mA equals 5Meg-Ohms
Many times, though, the current will be in micro amps. In this case, micro amps must first be converted to
milliamps, or the formula must be changed to accommodate micro amps.
Micro amps can be converted to milliamps by dividing by 1,000.
uA/1,000=mA Example: 50 uA/1,000=0.05mA. The result can now be used directly in the above
formula. 10kV divided by .05mA equals 200Meg-Ohms
An alternate method is to use the formula; Kilovolts divided by Microamps multiplied by 1,000 equals Meg-
Ohms.
KV/uA x 1,000=Meg-Ohms
Example: 10kV divided by 50uA times 1,000 equals 200Meg-Ohms

DCD 4120-10
5-1
SECTION 5: RETURN-GROUND-GUARD CONNECTIONS
The unit contains a currentmeter feature useful in measurement of different current sources.
1. Return Mode (RTN) (Grounded Return Mode)
This is the standard measurement configuration. The Ground jumper is installed between the Ground
(GND) post and the Return (RTN) post. The low potential side of the test specimen is connected to
Return. It can initially be isolated from ground or tied to ground. When it is connected to Return in this
mode, it will be grounded through the Ground jumper if it was initially isolated from ground.
If the low potential side of the test specimen will not or cannot be isolated from ground, this hookup mode
must be used. Any connections made to Guard must be isolated from ground in this mode and will bypass
the currentmeter. All currents to Ground and Return will be measured in this mode.
2. Guard Mode
In this mode, the Ground jumper is connected to the Guard post and Ground post. The low potential side
of the test specimen must be isolated from ground and connected to the Return post. Only current to the
Return post will be measured by the currentmeter. Any stray leakage currents to ground or from sources
connected to Guard will bypass the currentmeter and not be measured such as stray leakage currents to
ground, stray currents to shields or housings tied to Ground or Guard, etc. In this mode, the low potential
side of the specimen must be isolated from ground. If the low side of the specimen can not or will not be
isolated from ground, this mode cannot be used to accurately measure current flow.
CAUTION: Do not operate unit with the ground jumper removed or not connected to either Return or
Guard. Make sure the Ground post is connected to a good earth ground. See connection diagrams on
next pages.

DCD 4120-10
5-2
RETURN-GROUND-GUARD CONNECTIONS











 
 
HIGH VOLTAGE
DANGER









 



HIGH VOLTAGE
DANGER







DCD 4120-10
5-3
RETURN-GROUND-GUARD CONNECTIONS
































DCD 4120-10
6-1
SECTION 6: CALIBRATION
All calibrations have been done at the factory. Periodic calibration of the output voltmeter and output
currentmeter should be done annually.
NOTE: Refer to Electrical Diagram Section for schematics pertaining to the model number of your test set.
Locating the Calibration Adjustments
The calibration points are shown in the following diagram.
1. Output Voltmeter
Connect a precision high voltage voltmeter across the output to ground on 20 kV output, with the
Voltage Range switch set to 20 kV. Raise the output to approximately 80% of the output rating. Adjust
the reading on the panel meter (M2) by means of potentiometer R17 to a corresponding reading.
Repeat procedure with precision high voltage voltmeter connected between the 120 kV output and
ground with the Voltage Range switch set to 120 kV. Adjust R19 to match precision voltmeter at 80% of
output rating.
2. Output Currentmeter
It is necessary to connect adequately rated High Voltage loads (isolated from ground) to the high voltage
unit that will allow each full range current to be drawn at approximately 15% or higher output voltage.
This allows sufficient resolution to adjust current levels.
Place Binding Post Configuration in GUARD MODE. (Jumper clip is installed between “GRD” and
“GND” posts.)
Connect a precision ammeter between the low potential side of the appropriate high voltage load and
the “RTN” post. Select the 20 uA meter range. Raise the output to approximately 80% of the range
rating. Adjust the reading on the panel meter (M1) by means of potentiometer R78 to a corresponding
reading. Repeat for 200 uA, 2 mA and 10 mA ranges adjusting R80, R82 and R84, respectively. (High
Voltage load will need to change when changing range).
An optional method is to use current injection between RTN and GND (Guard Mode).
Do not turn High Voltage on for this method!
R19
120 kV
VM
R17
20 kV
VM
R113
VOLT
OFFSET
R84
10mA
CM
R82
2mA
CM
R80
200µA
CM
R78
20µA
CM
R77
CURRENT
OFFSET
R87
RANGE
OVLD
R72
110%
OVLD
R69
10%
OVLD
CAUTION:
Calibration should only be done by persons familiar with High Voltage testing and safety
procedures.

DCD 4120-10
6-2
CALIBRATION
3. Overcurrent
This calibration should not need adjustment (factory adjusted). If the Overcurrent Circuit is out of
calibration, perform the following steps.
a. a. With unit off, short the output terminal to ground through an appropriate currentmeter. (A
High Voltage Load will give better resolution and make calibration easier and more accurate.
Minimum recommended resistance: 100K ohm, 100 watt.).
b. Set the Current Trip potentiometer on the front panel to "1” and the current range switch to 5mA.
c. Turn on HV On and adjust the output current slowly until 10% of rated current (1mA) is displayed
on the currentmeter.
d. Adjust potentiometer R69 until the Reset lamp illuminates and high voltage is shut off.
e. Set the Current Trip potentiometer on front panel to "11."
f. Turn on HV On and adjust the output current slowly until 110% of rated current (11mA) is displayed
on meter.
g. Adjust potentiometer R72 until the Overload lamp illuminates and high voltage is shut off.
h. Repeat steps "b" through "g" as necessary until both settings are calibrated.
4. Range Overcurrent. R87 sets an overcurrent for the ranges and should be set to trip at approximately
112% of full range current on medium range setting (2mA) with current trip potentiometer set at “11.”.
5. Voltage offset adjustment (R113):
The voltage offset should be done with the voltage output lead connected to board ground. This typically
can be done by connecting the output to the guard terminal. Once connected the offset should be
adjusted till the output meter reads nearest to zero. This offset adjustment should be done before
adjustments to the voltage ranges are made. Test point T10 may also be used to make this adjustment.
6. Current offset adjustment (R77):
The current offset should be done with the current input connected to board ground. This typically can be
done by placing a jumper from the guard to the return terminal. Once jumped the offset should be
adjusted till the output meter reads nearest to zero. This offset adjustment should be done before
adjustments to the current ranges are made. Test point T37 may also be used to make this adjustment.

DCD 4120-10
7-1
SECTION 7: TROUBLESHOOTING
General
If the controls do not operate properly after having been used according to the instructions, the following hints
may help.
•Check main facility input power to the test set.
•Check indicating lamps. (Spare lamps are available through Phenix Technologies.)
•Check fuse-F1.
•Check all external plug connections on the test set.
Specific Problems Refer to appropriate electrical diagrams.
1. High Voltage cannot be turned on?
•Voltage Control dial is not in Zero Start position.
•External interlock circuit open.
•Current Trip setting too low or needs reset.
•Current trip circuit damaged, won’t reset, try replacing U13.
•Faulty HV On switch, faulty HV Off switch.
•Faulty relay contacts.
2. Voltage control inoperable?
•Tripped or faulty Thermal Overload.
•High voltage is not on (see number 1 above).
•Faulty Variable transformer T1.
•Faulty High Voltage tank assembly.
3. Over current inoperable?
•Faulty U13.
•Faulty DC Power Supply circuit.
•Faulty relay contacts.
•Faulty R7 over current trip potentiometer.
4. Currentmeter inoperable?
•Improper connection of GUARD/GND/RETURN jumper (J1) for mode of operation.
•Improper connection of test specimen.
•Meter damaged.
•Faulty currentmeter range switch SW5.
•Faulty connection in currentmeter circuit.
•Faulty DC Power Supply Circuit.
5. Voltmeter inoperable?
•Meter damaged.
•No high voltage present at output.
•Faulty connection in voltmeter circuit.
6. No output voltage from high voltage section?
•Defective metering circuit.
•No input to voltage regulator section, possible problems with K8 relay or Thermal Overload.
•High Voltage Cable shorted to shield of cable.
•Faulty High Voltage Unit.