STS 1652 User guide

OPERATION AND SETUP MANUAL
MODEL 1652
SLAUGHTER TEST SYSTEMS
801 HAILEY STREET SW
ARDMORE, OKLAHOMA 73401 U.S.A.
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FAX: [phone]
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http://www.slaughtertest.com
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1652 Manual Rev 1.0 - 031101

2
Introduction ___________________________________________________________ 3
Controls and Indicators __________________________________________________ 4
Input Power Adjustment _________________________________________________ 5
Theory of Operation_____________________________________________________ 6
Installation and Safety___________________________________________________ 7
Setup and Operation____________________________________________________ 11
Maintenance__________________________________________________________ 13
Repairs ______________________________________________________________ 14

3
Introduction
This description applies to the Model 1652 Surge Type Testers designed to test the
dielectric strength of separators in storage battery cells. These units will give a good
resolution of defective separators without false rejects due to moisture in damp process
plates.
Output voltage is adjustable to 3000 volts peak and is indicated on a digital peak reading
voltmeter. This output voltage is not of a sinusoidal waveform. The Model 1652
instrument produces high voltage, high-current pulses of very short time duration. These
pulses repeat at the rate of 60 pulses per second on a 60 Hz power source or 50 pulses per
second on a 50 Hz power source. Duration of each pulse is approximately 10
microseconds. Though the instantaneous energy in each pulse is high, the short duration
of the pulses results in a low average energy level. Therefore, the high voltage stress
required to obtain a good test is produced without the problem of providing a high-
powered tester and the problem of producing excessive heat within the test object.
The digital quality metering circuit provided essentially monitors the loading of the tester
by the workpiece cell, which is being tested. This meter indicates quality in arbitrary
units, on a scale of 0 to ±1000. It reads downscale (increasingly larger negative number)
with increasing current through the workpiece.
A dual range front panel sensitivity switch allows the testing of battery cells with
minimum impedance of 250 ohms or 100 ohms. When properly calibrated, the associated
circuitry allows switching between impedance ranges without re-balancing.
The Model 1652 Battery Element Tester (BET) is equipped with a Modular Line Cord
Assembly and isolation transformer that allows the tester to be configured to operate on a
nominal 130 volt input or a nominal 230 volt input at 50 or 60 Hz. The letter “S” in the
model number identifies units set for 230 volt input at the factory. Refer to Input Power
Adjustment section.

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Controls and Indicators
Functions of the various Controls and Indicators are shown in fig. 1 on the next page and
described as follows:
1. Power Switch – The rocker power switch is used to turn the unit On and Off.
2. Pilot Light – Contained within the Power switch is a Pilot Lamp, which lights
when the unit is turned On.
3. Voltmeter – The digital Voltmeter provided on this unit monitors the actual test
voltage at the output terminals of the unit at all times. This is a true peak reading
meter and indicates the actual peak voltage appearing at the output terminals of
the unit. Note that when a load is placed on the output terminals, the voltmeter
indication may change, depending on the type of load involved. In the case of a
short circuit, this voltage may fall practically to zero. However, the tester will still
be On, producing test voltage, which is absorbed within the unit. NOTE. The
testing voltage is a NEGATIVE voltage and the voltmeter will display a negative
sign (-).
4. Voltage control – Voltage control provided on this unit is used to adjust the
actual test voltage. Clockwise rotation increases test voltage.
5. Quality Meter – The digital Quality Meter monitors loading produced by the
workpiece. It is calibrated in arbitrary units on a scale of 0 to ±1000. As loading
increases, due to defects or moisture, the indication on this meter will read down-
scale as an increasingly larger negative number.
6. Balance Control – This control is used to balance quality meter circuitry to
correspond to the actual operating conditions. Normally, it is adjusted under no-
load conditions to provide a 000 reading on the leakage meter.
7. Check Button – The Check Button is used to verify that the leakage meter
circuitry is operating normally. After the voltmeter has been properly balanced at
2.00KV, operation of the check button under no-load conditions should produce a
leakage meter reading of approximately –600. When the button is released, the
leakage meter reading should return to the 000 balance condition.
8. Trip Level – This control is used to set the desired reject level.
9. Sensitivity Select Switch – This rocker switch allows the selection of two levels
of sensitivity to match the minimum impedance characteristics of different battery
element testing requirements.
10. Modular Line Cord Assembly – The Modular Line Cord Assembly is located on
the rear of the tester. It consists of the Socket/Filter section, which is black and
permanently mounted to the tester, the removable Line Cord, and the removable
Fuse Drawer, which is tan.
11. Reject Indicator(s) – The Model 1652 has three (3) Reject Indicators; on the
front panel, a Red illuminated button, on the rear panel, an Audible Tone and a 9-
pin D-sub connector provides a Dry Contact Closure when a reject occurs.
12. High Voltage Connectors – Two (2) High Voltage connectors are provided on
the front panel. Polarity should be observed when connecting the leads. The
black socket is referenced to ground.

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fig. 1
Input Power Adjustment
The input power setting is visible in a small window in the fuse drawer.
To change the input voltage setting, proceed as outlined below.
1. Switch tester off and unplug the line cord from the utility mains and remove it
from the socket-filter.
2. Remove the fuse drawer.
3. One half of the fuse drawer contains a voltage selector insert with 110 and 220
written on the bottom. Remove, rotate and re-install the voltage selector insert so
that the desired input voltage is visible in the window of the fuse drawer.
4. Re-install the fuse drawer.
5. Re-install the line cord with the appropriate plug properly installed.

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Theory of Operation
Pulses produced at the output terminals of the unit result from the discharge of capacitors
that have been charged to a high voltage. Discharge capacitors are charged by means of a
half-wave rectifier power supply operating from a high voltage transformer that is
controlled on the primary side by means of the front panel voltage control.
The discharge capacitors are charged on the negative half cycles of the 60-cycle input.
On the alternate half cycles, the SCR is triggered so that the capacitor is discharged into
the load while the main charging circuit is in a non-conducting condition. The voltmeter
is a peak reading type connected across the output terminals of the unit.
A bleed load-switching coil is connected across the output terminals of the unit to
produce a fixed load condition while the unit is operating under standby conditions.
Under normal conditions, discharge of the capacitors into the bleed load creates a strong
magnetic field in the core of the bleed load. When the forward pulse dies off, this
magnetic field collapses producing a back EMF which is applied to the quality meter
circuits where it is compared with a reference voltage which is proportional to the
original forward pulse. By means of the balance control, conditions are established, so a
000 reading appears on the quality meter under normal operating conditions.
Any external load, such as a workpiece under test, is effectively in shunt with the bleed
load and therefore, will reduce the back EMF signal, resulting in a down-scale reading on
the quality meter. The amount of the down-scale reading will, of course, depend on the
amount of reduction existing.
Warning: To allow for sufficient voltage levels to be available for tests, a certain
amount of over-voltage is to be expected during idle conditions (no load). It is not
recommended, that this unit be adjusted to Maximum voltage output (full CW voltage
adjust) during idle conditions for extended periods of time such as breaks, lunch hour, or
etc. The high over-voltage levels may damage the switching coil or the SCR.

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Installation and Safety
Caution: This unit is equipped with a three-prong grounding type line plug. It is
essential that it be utilized only with a mating three-terminal receptacle, properly
grounded in accordance with electrical codes.
When first received, unpack the equipment carefully and inspect for any hidden damage.
If damage is evident, keep the carton and file a claim with the carrier.
Packed with all Slaughter equipment is a certificate of conformance, operator’s manual,
test leads and any required interface connectors.
To check the unit quickly, set the trip level knob to 10.0, the balance control at 5.0, the
voltage control to full counter clockwise and plug the unit into the appropriate single
phase voltage source. With the test leads removed from their connectors, turn unit ON
and slowly rotate the voltage control clockwise. A reading should appear on the digital
voltmeter, which will increase, as voltage control is turned further clockwise. Continue
to rotate voltage control until voltage is approximately 1.00KV.
Depending on the setting of the balance control, a reading may appear on the leakage
meter, and this reading may be positive or negative. Rotate balance control, as necessary,
to obtain a 000 reading on the leakage meter.
Increase voltage control setting to obtain a 2.00KV-voltmeter reading. When necessary
re-adjust balance control to obtain a reading of 000 on the leakage meter. Operate the
check button. The Leakage meter indication should be approximately –600. Release
button. The leakage meter reading should return to 000.
Repeat the above, and while holding the Check Button In, adjust the trip level until the
tester registers a rejection. this will be an intermittent type signal and will automatically
clear when the check button is released.
Again, rotate voltage control full CCW. Wait until the voltmeter returns to zero. Then,
insert test leads into connectors provided.
After inserting test leads, return voltage control to a voltmeter indication of
approximately 1.00KV. With unit operating at this voltage, short circuit test leads. A
rejection should be indicated.
If the unit does not operate, contact the factory for instructions.
No special installation requirements are necessary. However, any electrical power
receptacle utilized to operate this equipment must be a properly grounded three-wire
receptacle that has been checked for proper polarity. Avoid locations with extremes of
temperature, humidity, or vibration. As a matter of safety, avoid metal-topped benches,
and metal operator stools.

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Of prime consideration and importance in the layout and installation of a test station is to
insure the safety both of the operator and any visitors or casual bystanders, invited or
otherwise. As a general rule it is suggested that each test area be in a location with
minimum distractions and not subject to extremes of temperature and moisture.
One of the more important ways to promote safety is through operator training. Benefits
of training are twofold. First, thorough training promotes safety, which may significantly
reduce injuries on the job. Second, it ensures adequate testing of the product which helps
increase product reliability. Both of these can have a positive impact on profits.
An additional consideration in any test station is operator comfort. This is affected by the
operator’s position, which includes the chair, table, test equipment, the object under test
and the test procedure itself. The chair and work bench or table should be nonconductive
and the table as large as possible to allow sufficient room for the test equipment and the
object under test. Studies should be made of the test requirements and work habits and
steps taken to ensure that any unusual or unnatural motion is not required and to eliminate
any repetitive motions that may produce injuries such as carpel tunnel syndrome.
After the equipment has been installed, a careful study should be made of the test station
to determine what, if any, safeguards are needed. It is suggested that any electrical test
station involving voltages in excess of 42.4 volts peak (approximately 30 volts RMS)
should be equipped with safeguards. These should operate both for the protection of the
operating personnel and for the protection of casual bystanders. At the minimum,
safeguards should prevent the operating personnel or casual bystanders from coming into
contact with the test circuit. In the event electrical interlocks of any sort are required,
either to insure that guards are in place, or to insure that the operator’s hands are in a safe
location, we will be happy to provide suggestions and schematics for safety interlocking
our test equipment.
The test procedure should be well thought out to ensure that it adequately tests the
product to the desired criteria but that the procedure does not require the operator to
perform tasks that are unsafe. The product should never be touched during a test.
Good safety practice dictates labeling of hazards properly. Since high voltage testing can
be hazardous, the work station should be labeled. Naturally, the location of the label
should be carefully selected so that it can be placed in a location that will do the most
good.
In some cases, this may be on the test instrument itself, and in others, it may be in a
location directly in front of the operator, somewhat removed from the instrument.
In addition to instrument labeling, we are supplying labels that you should apply in
accordance with the above suggestions. If you need a couple more, please let us know…
we will gladly supply them. If you need a large quantity, these are available at a nominal
price.

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A final word about high voltage testers. Generally, commercial high voltage test
equipment is not in itself hazardous. The hazards come about when the equipment is
improperly used. These testers, when used properly and in a safe manner, can be a check
on the quality and reliability of your product. If used incorrectly and without proper
consideration for safety, they represent a hazard for both operating personnel and casual
bystanders. We strongly recommend proper training for all personnel involved in testing.
Technical Notes
1. This unit is solid state High-Voltage Pulse type leakage and breakdown Tester
with digital meters. Essentially, it subjects the battery elements to a high peak
voltage that appears between all plates and across all separators.
2. If everything is normal – if there are no defects in the separators, no runs, trees, et
cetera, the battery element will withstand the test voltage, and the instrument will
register a “normal” quality meter reading.
3. This normal quality meter reading is due to the electrostatic capacity between the
plates, and should not vary except in relation to the moisture content of the
separators.
4. If separators are defective, or if for any reason opposite polarity spacing within the
battery element are abnormally close, the high voltage applied will jump this gap,
and a rejection will be indicated.
5. The user best establishes exact test voltage for any particular battery element. It is
suggested that a representative group be checked at successively higher voltages
until the voltage that will reject good assemblies is established. The voltage
should then be “backed off” 200 to 500 volts for routine testing of high quality
assemblies, and somewhat more for lower grade elements.
When a capacitive load (the battery) is coupled to an inductor (internal load of the
tester) the voltage developed across the inductor and the capacitor will be higher
at resonance. The outgoing voltage pulse of the battery tester is composed of an
extremely wide range of frequencies so resonance can occur. The battery’s
capacitance will determine the resonance frequency for a particular battery line.
The difference in firing characteristics of the Thryratron tube and the SCR
produce different output wave shapes that affect the frequency of the output and
consequently resonance.
6. The most difficult defects to detect are pinholes and splits or tears in separators.
With present day separators a voltage in the 2000 to 2500 volt range may be
required. If some defects are acceptable, the test voltage can be dropped as low as
1500, and practically all defects except pinholes, hairline splits, and tears will be
detected. Holes in the insulation are normally detected by arcing. The suggested
procedure is to use sufficient voltage to initiate an arc if the insulation has a hole
or is missing. The insulation will prevent arcing. If there is a hole or the
insulation is missing, the tester will arc across and find the fault (no insulation).

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7. These units have dual sensitivity ranges and may be operated with the limits set to
accept external loads having effective impedance in excess of 250 ohms or in
excess of 100 ohms. With the 250 ohm sensitivity selected, these units are
normally operated with the limit set to accept external loads having an effective
resistance in excess of 260 ohms. If the effective resistance of the load is less than
240 ohms, the workpiece will be rejected. Effective resistances between 240 and
280 ohms are marginal and may or may not be rejected. Switching to the 100
ohm sensitivity setting, the workpiece will be rejected if the effective resistance is
less than 90 ohms. Effective resistances between 90 and 110 ohms are marginal
and may or may not be rejected.
8. Battery elements are sometimes tested in a “formed” (the paste in the lattice is
conductive) or an “un-formed” (the past in the lattice is non-conductive)
condition. If the battery element is un-formed when the test is conducted, faults
are much, much harder to detect because a fault must be located in an area
between the conductive lead lattices of the positive and negative plates. If the
fault is located in a non-conductive area, an arc will generally not occur and the
fault will be un-detected.
9. The tester does not determine that an element is reversed in a cell. The tester sees
only the potential between the positive and the negative plate.
10. Users may construct a STANDARD BATTERY. This is a .002 microfarad
capacitor in parallel with two ½ inch steel balls separated by gap of .013 inch.
This ‘standard’ can be constructed by anyone and allows a repeatable comparison
of testers.