Phenix 4100-10 User manual

DCD 4100-10
USER’S MANUAL
DC DIELECTRIC TEST SET - 400P
MODEL 4100-10
VERSION 5.2
Phenix Technologies Inc.
75 Speicher Drive
Accident, MD 21520
Copyright © Phenix Technologies, Inc
Rev 5/28/2015 nab

INTRODUCTION
The DC Hipot line offered by Phenix Technologies is ruggedly built and suitable for field or
lab use. It is 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 100kV DC.
“Zero Start” voltage interlock and external safety interlock.
Leakage current measurements available from .01 to 20,000 microamps DC.
Removable line cord.
Rotary switch selection simplifies operation.
Integrated cable storage bin.
Built in discharge circuit rated at 6 kilojoules.
Light weight, portable, and enclosed in rugged, high-density polyethylene carrying 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 at normal hi-pot test impedances.
For full detailed specifications, see Section 1-1.

DCD 4100-10
TABLE OF CONTENTS
DESCRIPTION SECTION
INTRODUTION
DANGER / GENERAL SAFETY PRECAUTIONS
TECHNICAL SPECIFICATIONS 1
CONTROLS AND INDICATORS 2
ELECTRICAL SET-UP 3
OPERATING INSTRUCTIONS 4
RETURN-GROUND-GUARD FRONT PANEL CONNECTIONS 5
CALIBRATION 6
TROUBLESHOOTING 7
STORAGE OF EQUIPMENT 8
CIRCUIT DIAGRAM SYMBOLS 9
RECOMMENDED SPARE PARTS / PARTS LIST 10
PARTS ORDERING INFORMATION 11
RETURNED MATERIAL 12
ELECTRICAL DIAGRAMS 13

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 4100-10
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)
0-100 kilovolts dc
0-5 milliamperes continuous resistive leakage
0-20 milliamperes short term capacitive charging
Internal Discharge Capability 6 kilojoules
Duty Cycle
Continuous –Capacitive Charging
Type of Cooling Natural convection.
Ripple Less than 2 percent RMS at loads of 30 Megohms and higher from 10kV-100KV and
capacitive loads.
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 guarded.
Metering
Output Voltmeter: 3 ½ DIGIT LCD, accuracy .5% of full scale.
Ranges: 0 to 19.99kV, 0-100.0kV
Output Currentmeter: 3 ½ DIGIT LCD, accuracy .5% of full scale.
Ranges of 0 to 19.99a, 199.9A, 1.999mA, 19.99mA
Analog Output 1.5” ANALOG
Charging Indicator: 0-100% of selected range indication.
Size and Weight
22.5" W x 21" D x 16.5" H; 98* lbs. (572 mm W x 533 mm D x 419 mm H; 44.5* kg)
*For 220 V units: add 10 lbs. (4.5 kg)

2-1
SECTION 2: CONTROLS AND INDICATORS
CONTROL PANEL
(Refer to Figure 2-1).
1. AC POWER INPUT. Plug into a suitable grounded receptacle. See specifications tag on unit for voltage
and current requirements.
2. EXTERNAL INTERLOCK. If desired, remove jumper from connector and replace with contact(s) that must
be maintained closed during testing. Some examples include footswitch, deadman switch, gate interlock,
panic button, etc.
3. 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.
4. F1. Control Power Fuse.
5. MAIN POWER CIRCUIT BREAKER. Press Ito connect power, Press Oto disconnect power.
6. MAIN POWER INDICATOR. Lights to indicate that power is available for testing.
7. 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.
8. 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.
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.
Current Trip circuit Reset.
10. High Voltage Off. 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 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)

DCD 4100-10
2-2
CONTROLS AND INDICATORS
CONTROL PANEL (Cont’d)
11. 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.
12. 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.
13. CURRENTMETER. Displays current out of High Voltage Lead (#16) or into Return terminal depending
upon mode of measurement
14. VOLTMETER. Displays voltage output of test set in kilovolts.
15. VOLTMETER RANGE SELECTOR. Rotate to appropriate setting for test voltage.
16. CURRENTMETER RANGE SELECTOR. Rotate to desired range. With capacitive loads, selector will
normally be placed in highest current range and then ranged lower as appropriate.
17. GUARD TERMINAL. Connect to Ground terminal (#13) with Grounding Clip 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, and will be connected to Return post. See section on
Return –Ground –Guard for more information.
18. GROUND (GND) TERMINAL. Connects to facility ground. See (#12), (#14) and (#15) for more
information.
19. GROUNDING CLIP. The Grounding Clip must always be connected from the Ground post to either the
Return post or the Guard post. Do not operate the unit with the clip disconnected.
See Section 5 on Return –Ground –Guard for more information.
20. RETURN (RTN) TERMINAL. Connect to Ground terminal (#13) with grounding clip for normal operation.
Always connect low potential side of test specimen to this point. This is the metered connection point for
measuring current. This mode must be used if low potential side of test object is grounded or has a ground
reference. See section on Return –Ground –Guard for more
information.
21. HV OUTPUT LEAD. This lead is always attached to the high potential side of the specimen under test.

2-3
CONTROLS AND INDICATORS
FIGURE 2-1
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
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
PHENIX
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TECHNO LOGIES
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 




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 
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




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TECHNOLOGIES
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PHENIX
















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
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
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


DCD 4100-10
3-1
SECTION 3: ELECTRICAL SET-UP
High Voltage Connection
1. Locate the desired placement 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.
2. 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.
3. Connect the Ground (GND)” connection to facility ground using the ground test lead provided.
4. Connect the low potential side of test specimen to terminal labeled Return (RTN). Use red test lead
provided.
5. Connect the high voltage output cable to the high potential side of test specimen. CAUTION: Keep
shielded part of high voltage cable away from test specimen high voltage points.
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.

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, currentmeter range, and current trip setting.
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, and Reset
lamp must be extinguished.
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 20mA 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 setpoint), the over-current
relay will activate, de-energizing 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.