Schaffner NSG 438 User manual

NSG 438
601-241D
User Manual
NSG 438
ESD Simulator

NSG 438
Contents
1Explanationofthesymbolsused in thismanual.........................1
2Safety.............................................................................................2
3Introduction...................................................................................4
3.1.Electrostaticdischarge (ESD)..........................................................4
3.2.Simulation.......................................................................................4
3.3.Effectson the EUT...........................................................................7
4TheNSG438 system.....................................................................8
4.1.The generator..................................................................................9
4.1.1.Function modules............................................................................9
4.1.2.Blockdiagram................................................................................10
4.1.3.Operating elements.......................................................................12
4.2.Systemcomponents......................................................................14
4.2.1.Battery charger/ powersupplyunit................................................14
4.2.2.Options..........................................................................................15
4.2.3.Discharge networks.......................................................................15
4.2.4.Remotetriggering..........................................................................16
4.2.5.Interlock.........................................................................................18
4.2.6.Measurement adapters..................................................................22
5Commissioning............................................................................23
5.1.Function test..................................................................................23
6Operation.....................................................................................25
6.1.Switching on..................................................................................25
6.2.Battery monitoring..........................................................................26

NSG 438
6.3.Operation and settings...................................................................27
6.3.1.Displaymode.................................................................................28
6.3.2.Voltage..........................................................................................29
6.3.3.Polarity..........................................................................................30
6.3.4.Counter.........................................................................................30
6.3.5.Repetition......................................................................................31
6.3.6.Settings.........................................................................................32
6.3.7.Language......................................................................................32
6.3.8.Deviceinfo....................................................................................32
6.3.9.Discharge......................................................................................32
6.3.10.Threshold......................................................................................33
6.3.11.ISO-Selftest...................................................................................34
6.3.12.Level.............................................................................................35
6.3.13.Program........................................................................................35
6.3.14.Triggerbutton................................................................................36
6.3.15.Continuousoperation.....................................................................36
7Testprocedures...........................................................................37
7.1.Standard-compliant procedures.....................................................37
7.2.Othersituations.............................................................................32
8Verificationofthepulse data......................................................39
9Typicalpulse data........................................................................40
10 Maintenance.................................................................................41
10.1.Calibration.....................................................................................41
10.2.Exchanging the R-Cnetwork.........................................................42
10.2.1.Reduction of pulserepetition rateatincreased capacity.................43

NSG 438
10.3.Repairs..........................................................................................43
10.4.NSG 438 Systemerrormessages................................................. 44
10.5.Disposal........................................................................................ 45
11 Technical specifications..............................................................46
12 ESDstandards.............................................................................48
13 Warranty.......................................................................................49
14 Orderinginformation...................................................................50
15 Addresses....................................................................................51
Manufacturer
Schaffner EMV AG
Nordstrasse 11, 4542 Luterbach/Switzerland
www.schaffner.com

NSG 438
1
1Explanationofthesymbolsused in thismanual
Pleasetakenoteof the following explanationsof the symbolsused inorder
toachievethe optimumbenefitfromthismanual and toensuresafety
during operation of theequipment.
The following symboldrawsyourattention toacircumstancewherenon-
observation of the warning couldlead toinconvenienceorimpairmentin
the performance.
Example:
Thisconnection mustnotbeconfusedwiththemain
power input
The following symboldrawsyourattention toacircumstancewherenon-
observation of the warning couldlead tocomponent damage ordangerto
the operating personnel.
Example:
Never connectordisconnectthepistolwhilesystemis
performingatest

NSG 438
2
2Safety
Thisitemofequipment,together withitsaccessories,
works athighvoltages ofup to 30kV.Anycareless
handlingornon-observance oftheoperating
instructionscanhave dangerousconsequences.
The NSG438 generatorisnot atoy!It isaprofessionaltool and belongs
onlyinthehandsofspecialistsand appropriatelytrainedpersonnel.
Whenpowered byitsownbatteriesthe generatorcan beactiveeven
without anypowercablebeing connected.
The instrument must not be switched on unless acorrectlyconnected
earthorearthcable(pulsecurrent returnpath)isinplace. The original
earthcablesuppliedwiththe instrumentistobe used.Anyreplacement
cablesmust be fabricated insuchawaythat theycannot be accidentally
connected toamainsoutletsocket. Donot touchthe test finger!Thereisa
dangerofan unpleasant electricshock if the instrumentisswitched on
(LC-displayactive).
Onlytrainedpersonnelmay operatetheinstrument.
Personnel fittedwithaheart-pacemaker must notoperate
the instrument norapproachthe test rigwhileitisin
operation.
Theseoperating instructionsforman integralpartoftheinstrument and
must be availabletothe operating personnelat alltimes.
The instrument must not be used foranypurposeotherthan testing the
ESDimmunityofelectronicequipment.
The construction ofthe generatorisnotdesigned foruseinan explosive
environment.

NSG 438
3
Each electrostaticdischargeproduces powerful
electromagneticinterference.
Nearbyelectronicequipment can be seriouslydisrupted
unless the appropriatecounter-measuresaretaken.
PerformESDtestspreferablyinashielded room.
Ifanetwork needsto beexchanged, thetesthas tobe
stoppedfirst,followedbyawaitingtime ofatleast5s
to ensure thevoltagebeinginternallydischarged.
The rechargeablebatteriesinthe basestation must notbe short-circuited
underanycircumstances. Theymust onlybe recharged withthe original
charging unitsupplied withthe generator.Shouldtheyhavetobe
replaced, kindlyobservethe relevantrecommendationsfortheircorrect
disposal.
The instrument must not be opened. Repairs,maintenancework and
internal adjustmentsareonlytobecarried out byaqualifiedservice
engineer. Usethe instrument onlyindrysurroundings. Anycondensation
that occursmust be allowed toevaporatebeforeputtingthe generatorinto
operation. Long periodsofexposuretosunlightand excessivewarmingby
externalenergysourcesaretobe avoided.
Do not continue tousethe instrument shouldanymechanical damage
occur.The instrument'shousing and the cablehavebothan insulating and
ascreening function, whichcan onlybe assured whilethe housing is
intact. Returnadamaged generatortoaSchaffnerservicecentre
immediatelyforrepair.
SchaffnerEMV AG Luterbach, Switzerland and theassociated sales
organization accept no responsibilityforpersonalormaterialdamage nor
foranyconsequentialdamage that resultsfromirresponsibleoperation of
thisinstrument.

NSG 438
4
3Introduction
Underappropriateambientconditions, bothmaterial objectsand even the
human bodyitself can becomecharged withelectrical energy. Thiseffect
isdue to"electrostatics", aphenomenon that hasbeen knownsincethe
earliesttimes.Thalesvon Milet(600 BC)noticed howamberattracted very
light particleswhen it wasrubbed. Touching acharged itemagainst a
conductiveobjectleadstoacharge equalization through aspark
discharge, whichproducesabrief but powerfulelectro-magneticfield.
3.1.Electrostaticdischarge (ESD*)
Thiseffect canbe explained asfollows: Twoinsulating substanceswith
differing dielectricconstantsbecomecharged when rubbed together,i.e.
one materialgiveselectronstothe otherone.Thiseffectisknownas
electrostaticcharging.The samecan happen toaperson.When
somebodywalksaround inadry atmosphereon carpetwhilewearing
shoeswithgood insulating properties, acharge ofseveralthousand volts
can be built up.If,now, that person comesclosetoaconductivesurface,
the charge that heorshe iscarrying flowsawaythroughaheftyspark
discharge.
The high equalizing currentthat flows, and the associated large
electromagneticfieldthat henceresults,can causeelectronicdevices
(computers, terminals, process controllers,vehicleelectronics, solidstate
devices, credit ormemorycards, etc.)tomalfunction orevenbe destroyed.
*ESD= electrostaticdischarge
3.2.Simulation
Asystematicinvestigation of electronicequipmentand installationsto
determine theirelectromagneticcompatibility(EMC)is,today, anecessity
if one isnot prepared tosufferthe economicdisadvantagesthat could
otherwiseensue. Asalogical consequence, appropriatetesting isnowa
legalrequirement forthe saleof electronicproductswithinthe EU.
The ESD-test playsan importantroleinthe range ofinterference
sensitivitytests. It simulatesfrequentlyoccurring effectsand guidesthe
developmentengineertoanyweakspotsinan instrument oritemof
equipmentthrough acombination of high voltage and high frequency
properties.

NSG 438
5
Asimulationdevicemust be constructed suchthatitreproducespractical
conditionsrealistically.Furthermore,the resultsobtained (interference
sensitivitythreshold)must be reproducible.
The interferenceimmunityof an instrumentisnot onlydependent on its
construction,it isalsolargelydependent on the qualityorthe consistency
of the mass production techniquesused. Knowing thishasled tothe
demand forindividualtesting oratleast randomsample testing.
Furtherweakspots, whichcouldaffectthe overallinterferenceimmunity,
can arisethrough the assemblyofinstrumentsintocompletesystems
becauseof the installation method used, the cabling and the earthing. An
ESDcheck on systemsisthereforealsoprescribed. Suchtestsprovide
valuableinformationabout the immunityof the systemtoeffectsthatoccur
onlysporadicallyunderoperating conditionsand hencerepresent difficult
todetectsourcesofdisruption.

NSG 438
6
The ESDgeneratorNSG438 fulfilstherequirementsof numerous
applicationsinan ideal manner,thus:
Ergonomicshape Fornon-tiring use
OperationOperating elementsand displayalwaysin
viewof the user. Constant check on the test
values.
Battery-poweredIndependencefromamainspowerfeed.
Carrying caseGeneratorand itsaccessoriescan be readily
packed and convenientlytransported.
Microprocessor-controlAllthe functionsare"on-board",including a
pre-settablecounter, pre-programmed test
values, discharge voltage measurement, etc.
PrecisionThe test parametersaremaintained precisely
forreliablyreproducibletests.
FlexibilityThe specificationsprescribed inthe standards
aremorethan fulfilled inevery respect.The
instrument alsooffersmanyadditional handy
features.
SafetyThe high voltage generatorisautomatically
deactivated if the instrumentremainsunused
foraperiod oftime.
Long-term operationAutomaticlong-termoperation forstationary
applicationswiththe generatormounted on a
tripod.
Application fieldDevelopment optimization,type-approval,
EMCcertification, batchtesting (individually),
testing offullyinstalled systems.

NSG 438
7
3.3.Effectson the EUT
The most significantinterferencecomponentsof an electrostaticdischarge are
of ahigh frequency nature.The interferencepathsand effectshavetobe
assessed inthe range fromabout 30MHztomulti-GHz.
The extremelyrapidrisetimeof adischarge affectsan object undertest
mostlythrough:
§magneticHF-coupling between electricalconductorsinthe
electronicsand the discharge current path.
§electricalcoupling between the discharge current and signal
lines. Adischarge currenttotheEUT flowsproportionallythrough
allthe associated conductors(earth,mains, datalines,
screening, etc.)according totheirrelativeimpedance.
Malfunctionsininsufficientlyimmune electronicequipment and systems
makethemselvesapparent through:
§programcrashes
§blockingofcommand sequences
§incorrectcommands, statusesordatabeing furtherprocessed
§partialsystemresets(e.g. onlyinperipheral modules,whichlead
toerrorsthatthe systemdoesnot recognize)
§disturbanceordestruction of interfacemodules
§destruction ofinsufficientlyprotectedMOScomponents.
ESD(electrostaticdischarge)testing usuallyshowsup allthe weakspots
intheHF-range of apieceofequipment simultaneously. The usestowhich
the NSG438 ESDsimulatorcan be puthencego waybeyond thosecalled
forinstandard-conformapplications.
Thisinstrumentprovidesthe engineerwithameanstodetect sourcesof
errorcaused byunsuitableearthing,poorground connections,insulation
problems,etc.
The generatoralsoservesasareliableaidforlocalizinghidden wiring
faultsduring acceptancetrialson installations.
Usecan alsobe made of the instrument asan insulationtesterto
determine the breakdownvoltage of switches, relaycontacts, insulators,
etc.

NSG 438
8
4TheNSG438 system
By using the latestmaterials, construction methodsand manufacturing
techniquesforthe robust housing shell,togetherwithhighlyinsulated
modules, the newest high voltage technology,the touch-sensitive
operating paneland acontrol unit built using the SMD-technique, it has
been possibletointegrateallthefunctionsthat acomprehensivesimulator
systemshouldofferintoone compactinstrument.
Professionalindustrial designershaveensured an optimized ergonomic
concept. Theinstrument, withitswell-balanced handgrip, sitscomfortably
intheuser'shandand guaranteesnon-tiring operation. Boththe operating
elementsand the displaywindowremaininviewof the userwhilework is
inprogress.
The NSG438 offersoptimalfreedomofmovement around the work-place
and isan ideal testinstrument notjustforthe development engineerbut
alsoforqualitycontrolpurposes, systemtestsand forinvestigationsinthe
field.
Assupplied inthebasicset, thesystemisequipped witha150pF /330
discharge network forthe IEC/ EN61000-4-2(2001)standard.
The discharge voltage ofup to30kV forbothAir-Dischargesand Contact-
Dischargesensureacomfortabletestmarginoverand abovethe levels
calledforinthe standards.
The instrumentiswellequipped tocope withother(andfuture)standards.
The accessoriesinclude variousnetworksand test fingersthat can be
attached bytheuserhimself.
The basicset containseverything necessary forgeneraluse. Arich
assortment of accessoriesforspecialtasksisavailablesuchasaremote
triggering unit, furtherdischarge networks, an ergonomicallyshaped
carrying case, atripod adapter,testfingers, etc.

NSG 438
9
4.1.The generator
The NSG438 generatorismodularlyconstructed fromanumberof
discretefunction units.
4.1.1.Function modules
The basestation containsthe battery supply,the high voltage generator
and regulatoraswell asseveral safetyfeatures.
The pistol housesthe interchangeablepulsenetwork, high voltage relay,
the exchangeabletestfinger,measuring electronicsand the touch-
sensitiveinput/ displaypanel.
Pistol Displayand
touch-panel
Network
(exchangeable)
Pistolstand
On/Off button and
emergency off switch
Basestation

NSG 438
10
4.1.2.Blockdiagram
The variousfunction unitsareshown inthe blockdiagram:
Blockdiagramofthe basestation:
µPControlUnit Buzzer
High Voltage
active
Communication to
Discharge Pistol
Meas.
Circuit
High Voltage to
Discharge Pistol
High Voltage
Generator
+/ -
Interlock Unit
Communication to
the PC (Opto Link)
ExternalTrigger
EUTFail
Interlock IN
Interlock OUT
24 VDC PSU and Battery
PowerOnPowerBatt. Status
Interlock Interlock
Reset

NSG 438
11
Blockdiagramofthe pistol:
The microprocessorcontrolsand monitorsallthe generatorfunctions:
§Touch-panelentriesarechecked forplausibility. Unacceptable
entriesarerejected and an acousticwarning notifiestheuserof
the error.
§Valuesentered areclearlyshownon the large displayscreen.
Furtherinformation showsthe operating statusand the counter
settings.
§The batterycharge stateiscontinuouslymonitored.Thedisplay
warnsif thereisatendency towardslowvoltage.The
instrument'sfunctionsareinhibited oncethe batteryvoltage is
insufficienttoguarantee thepulseparameters.
§High voltage generation isdynamicallycontrolled bythe
processor. Varying load conditions, supplyvoltages, etc. can
thusbe taken intoaccount and haveno effecton the pulse
parameters.
High Voltage
ManualTrigger
Communication to
the BaseStation
Discharge Network
Displaywith
Touch -Panel
µPControlUnit
High Voltage
Relay
Test Finger
Buzzer
TipIdent.
NetworkIdent.

NSG 438
12
§The instrumentswitchesitselfoff automaticallyifitisnot used for
awhile.The pulseparametersand operating mode remain
stored and readyforre-use.
§The charge voltage tothe network iskeptconstant aslong asthe
triggerisactive.The high voltage isdischarged internallywhen
the triggerisreset.
§Ifno discharge occurswhen set foran Air-Discharge and the
triggerisactive,the processorwaitsforabout 15sthen auto-
nomouslyresetsthe triggerand dischargesthe networkinternally
withsimultaneousacousticwarning.
§Ameasurementfacilitydetectsan actualvaliddischarge and
showsit on thedisplay.
§Pulsetriggering ismonitored.Oncean arc hasoccurredthe
network isdischarged internallysothatno furtherarcing is
possible.
4.1.3.Operating elements
Apartfromthe triggerbutton itself(pulsetriggering), allthe operating
elements, test-relevant setting and userinformation arepresented on the
touch-sensitivedisplaypanel facing theoperator.
The NSG438 isswitched on and offwiththe mainpowerswitch.The
significanceofthe elementsinthe displayfieldcan be seen inthe
following picture.Furtherinformation can be found insection “Operation”.

NSG 438
13
Alloperationsareperformed via the touch-panel.
The following displayisshownon the panelwhen the pistolisswitched on.
The function of the triggerbutton on the handgripdependson the
operating mode currentlyselected:
§Asapulsebutton insingledischarge mode (1pulseeachtimeit
ispressed).
§Asan on/off switchinrepetitivemode (dischargeswhilebutton is
pressed).
§Asapausing on/off switchinrepetitivemode withthe preset
counterinoperation (startthe dischargesbypressing the
button/stop the dischargesbypressing the button again).
The remotecontrol facilityreplicatesthe action of thetriggerbutton by
meansofappropriatecontrolsignals.

NSG 438
14
4.2.Systemcomponents
The basicset ispackaged inapracticalcarryingcaseand comprises:
§Carrying case
§ESDgeneratorNSG 438 consisting of apistoland abasestation
withabatterypowersupply
§Discharge network 150pF / 330Ω
IEC/EN61000-4-2(2001)
§1testfingereachforairand contactdischarges
§Battery charger/ mainspowerpack
§Pistol stand
§Operating instructions
Thisset containsall the itemsnecessary undernormalconditionsto
conduct testsconforming tothe
IEC/EN61000-4-2(2001)standard.
4.2.1.Battery charger/ powersupplyunit
Powertothe instrumentisprovided through auniversal mainsunit suitable
forinputvoltagesbetween 80 and 240Vac. Thissameunit alsoservesas
achargerforthe integral batterypack.
Charging ofthebatterytakesabout three hours. Atthispointatimer
switchesthe chargertoareduced charging currentand the indicatorlamp
changesfromred togreen.
The batterywillalsocharge up when the instrumentisswitched off.
Afullbatterycharge willsufficeforseveraldaysof normaltest operation.
Battery lifeexpectancy:
§Ambienttemperaturesover50°Ccanlead todegradation of the
battery.If treated carefully,morethan 300 charge /discharge
cyclescan be expected withoutanoticeablereduction in
capacity.
§The chargerand battery-packformamatched entity.The battery
must notbe charged fromanyotherunitand the chargeristobe
used exclusivelyforthe intended purpose.