Phenix Technologies 4160-5 User manual

DCD 4160-5
USER’S MANUAL
DC DIELECTRIC TEST SET - 400P
MODEL NUMBER 4160-5
Version 2.1
Phenix Technologies Inc.
75 Speicher Drive
Accident, Maryland 21520
Copyright © Phenix Technologies, Inc
Rev 5/28/2015
nab

DCD 4160-5
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, the DC test set 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 160kV DC.
“Zero Start” voltage interlock and external safety interlock.
Leakage current measurements available from .01 to 5,000 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. (>80 Meg Resistive)
For full detailed specifications see Section 1-1.

DCD 4160-5
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

DCD 4160-5
DANGER
GENERAL SAFETY PRECAUTIONS


HIGH VOLTAGE
This equipment is capable of providing 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 4160-5
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)
160 kilovolts DC, 5 milliamperes
Internal Discharge Capability 12 kilojoules
Duty Cycle
Continuous –Capacitive Charging
Type of Cooling
Natural convection
Ripple
Less than 2 percent, at 160kV, (> 80 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 35 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, 0-160.0kV
Output Currentmeter: 3 ½ DIGIT LCD, accuracy 0.5% of full scale.
Ranges of 0 to 19.99a, 199.9A, 1.999mA, 5.00mA
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: 18" W x 12.75" D x 27.75" H; 150 lbs.
(457 mm W x 324 mm D x 705 mm H; 68 kg)
Cables: 10 lbs. (4.5kg)
*For 220 V units: add 10 lbs. (4.5 kg)

DCD 4160-5
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
counter-clockwise 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.
Ready light Illuminated
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 4160-5
2-2
CONTROLS AND INDICATORS
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 4160-5
2-3
CONTROLS AND INDICATORS
FIGURE 2-1







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
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





PHENIX

TECHNOLOGIES
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
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



PHENIX












TECHNOLOGIES

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
















DCD 4160-5
2-4
CONTROLS AND INDICATORS
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 is in Return-Ground-Guard Section 5.
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 4160-5
2-5
CONTROLS AND INDICATORS
FIGURE 2-2












DCD 4160-5
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 5 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 J5 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 4160-5
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 4160-5
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 4160-5
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.
NOTE: 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
(Figures 5-1 and 5-2).

DCD 4160-5
5-2
RETURN-GROUND-GUARD CONNECTIONS
FIGURE 5-1
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








 
 
HIGH VOLTAGE
DANGER


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



 



HIGH VOLTAGE
DANGER







DCD 4160-5
5-3
RETURN-GROUND-GUARD CONNECTIONS
FIGURE 5-2


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DCD 4160-5
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 low range. Raise the output to
approximately 80% of range. Adjust the reading on the panel meter (M1) by means of potentiometer R1
to a corresponding reading. Check Linearity and calibration at various other main points of the range
such as 20%, 40%, 60%, 100%. Repeat for High range, adjusting R2.
R101
10%
Ovld
R103
110%
Ovld
R235
Range
Ovld
R201
20mA
CM
R202
2mA
CM
R203
200uA
CM
R204
20uA
CM
R2
160kV
VM
R1
20kV
VM
WARNING:
Calibration should only be done by persons familiar with High Voltage testing and safety
procedures.

DCD 4160-5
6-2
CALIBRATION
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 Guard and
Ground posts.)
Connect a precision ammeter between the low potential side of the appropriate high voltage load and the
Return post. Select the low current meter range (20uA). Raise the output to approximately 80% of
range (16uA). Adjust the reading on the panel meter (M1) by means of potentiometer R204 to the
corresponding reading of the standard meter. Repeat for 200uA, 2mA, and 5mA ranges; adjusting R203,
R202, and R201 respectively. (High Voltage load will need to change when changing range).
An optional method is to use DC current injection between “RTN” and “GND” (Guard Mode). If using
this method, do not turn High Voltage ON!
3. Overcurrent
This calibration should not need adjustment (factory adjusted). If the overcurrent circuit is out of
calibration, perform the following steps.
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 (.5mA) is displayed
on the currentmeter.
d. Adjust potentiometer R101 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 (22mA) is displayed
on meter.
g. Adjust potentiometer R103 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. R235 sets an overcurrent for the ranges and should be set to trip at approximately
112% of 2mA range.

DCD 4160-5
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 U101 (LM311N)
Faulty HV On switch, faulty HV Off switch.
Relay K1 dislodged or faulty.
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 U101 (LM311N).
Faulty DC Power Supply circuit.
Defective over current relay K101.
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.
Faulty U201 or U202 (LM348).
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 K1 relay or Thermal Overload.
High Voltage Cable shorted to shield of cable.
Faulty High Voltage Unit.

DCD 4160-5
8-1
SECTION 8: STORAGE OF EQUIPMENT
If the equipment will be stored for a prolonged period, the following precautions are recommended.
1. The equipment should be covered and kept in a warm, dry environment (95% maximum humidity, 5 to 30
Celsius).
2. In no case should the test unit be stored outdoors (unless previously specified in the original purchase
agreement).