Voltech dc1000 User manual

98-100 ISSUE 8 2
www.voltech.com
DC1000
PRECISION DC BIAS CURRENT SOURCE
USER MANUAL
Voltech Instruments, Inc. Voltech Instruments, Ltd.
12851 Banyan Creek Drive 66 Innovation Drive, Milton Park
Fort Myers, FL 33908-3083 Didcot, OX14 4RQ
U.S.A. U.K.
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
[email protected]m
Thank you for choosing the
Voltech DC1000. This quality
instrument will give you many years of reliable use. Should you
experience any difficulty during the set up or use of your Voltech
product, please do not hesitate to contact either your local supplier
or one of our main offices.

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CONTENTS
WARRANTY........................................................................................................................................5
HEALTH & SAFETY ..............................................................................................................................6
SAFETY PRECAUTIONS........................................................................................................................8
WHAT IS THE DC1000? .......................................................................................................................9
WHAT CAN THE DC1000 DO FOR YOU? ..............................................................................................9
PACKING LIST ...................................................................................................................................10
GETTING STARTED ...........................................................................................................................11
SAFETY INTERLOCK...........................................................................................................................13
USING THE DC1000 WITH A SAFETY SYSTEM ............................................................................................... 13
USING THE DC1000 AND A VOLTECH AT3600/AT5600 WITH A SAFETY SYSTEM ..............................................14
USING THE DC1000 WITH AN LCR METER.........................................................................................16
USING MULTIPLE DC1000S IN PARALLEL ..........................................................................................17
USING A PC TO CONTROL YOUR DC1000 (S).....................................................................................18
USING A PC TO CONTROL YOUR DC1000(S) WITH AN RS232 LCR METER (NOT A VOLTECH AT SERIES
PRODUCT)........................................................................................................................................ 19
USING A PC TO CONTROL YOUR DC1000(S) WITH AN IEEE-488 LCR METER (NOT A VOLTECH AT
SERIES PRODUCT).............................................................................................................................20
USING THE DC1000 WITH A VOLTECH AT3600 OR ATI(AND OPTIONAL PC) ......................................21
AT COMPENSATION WITH MULTIPLE DC1000S........................................................................................... 22
USING IR, ILK, HPDC, HPAC TESTS - (HIGH VOLTAGE TESTS).......................................................................23
USING SURG, MAGI, STRW, WATT, VOC TESTS..................................................................................... 23
 LSBX – INDUCTANCE WITH EXTERNAL BIAS (SERIES CIRCUIT)................................................................23
 LPBX – INDUCTANCE WITH EXTERNAL BIAS (PARALLEL CIRCUIT)............................................................25
 ZBX – IMPEDANCE WITH EXTERNAL BIAS...........................................................................................27
RS232 COMMUNICATION.................................................................................................................30
RS 232 CONNECTION.............................................................................................................................. 30
PINNING ............................................................................................................................................... 30
COMMANDS ..........................................................................................................................................31
 TURN THE OUTPUT ON OR OFF ...................................................................................................... 31
 SET DC1000 OUTPUT CURRENT......................................................................................................32
 GET THE STATUS OF THE UNIT .......................................................................................................... 32
 READ THE SERIAL NUMBER ............................................................................................................. 33
 GET THE NUMBER OF UNITS ATTACHED .............................................................................................. 33
STATUS NUMBERS ........................................................................................................................... 34
CALIBRATION ................................................................................................................................... 35
ACCESSORIES ................................................................................................................................... 35
PC SOFTWARE ..................................................................................................................................36
INSTALLING THE SOFTWARE ...................................................................................................................... 36

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CONNECTING THE EQUIPMENT .................................................................................................................. 36
USING THE SOFTWARE............................................................................................................................. 37
SPECIFICATIONS ............................................................................................................................... 43
EMC COMPLIANCE ...........................................................................................................................45

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WARRANTY
This product is warranted against defect in materials and workmanship for a period of
one year from the date of shipment. During the warranty period, Voltech will, at its
option, either repair or replace products that prove to be defective.
For repair services under warranty, the instrument must be returned to a Voltech
designated service center. Please contact your local supplier for details.
LIMITATION OF WARRANTY
The foregoing warranty shall not apply to defects resulting from unauthorized
modification, misuse, or operation outside the specification of the instrument. No
other warranty is either expressed or implied.
Whilst every care has been taken in compiling the information in this publication,
Voltech cannot accept legal liability for any inaccuracies contained herein. Voltech
has an intensive program of design and development that may alter product
specification, and reserve the right to alter specification without notice and whenever
necessary to ensure optimum performance from its product range.
Because software is inherently complex, and may not be completely free of errors,
you are advised to verify your work. In no event will Voltech be liable for direct,
indirect, special, incidental or consequential damages arising out of the use of or
inability to use software or documentation, even if advised of the possibility of such
damage.
All right reserved.
No part of this publication may be produced, stored in a retrieval system, or
transmitted in any form, or by means, electronic, mechanical photocopying, recording
or otherwise without prior written permission of Voltech.
© Voltech Instruments, Inc 2016.
Voltech Part Number 98-100 revision 8. 01 JUN 2016

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HEALTH & SAFETY
Electrical devices can constitute a safety hazard. It is the responsibility of the user to
ensure the compliance of the installation with any local acts or bylaws in force. Only
qualified personnel should install this equipment, after reading and understanding this
users manual. These operating instructions should be adhered to. If in any doubt,
please contact your supplier.
DANGER!
Electric Shock Risk
Please Note:
This equipment is supplied under warranty conditions in force at the time of purchase
from your supplier. Contact your supplier for details. Any attempt to disable or
modify the unit will render any warranty agreement invalid.
The contents of this user manual are believed to be accurate at the time of printing.
The manufacturer, however, reserves the right to change the content, product
specification, and performance criteria without notice. No liability is accepted for the
inappropriate, negligent, or incorrect set-up of the instrument by the user, either by
manual or automated means.

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CHECK YOUR LINE INPUT VOLTAGE SETTING BEFORE CONNECTING TO SUPPLY!
Fig.1
Use a flat-headed screwdriver to pull the fuse drawer out.
Rotate the gray voltage selector to select the correct voltage for your location.

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SAFETY PRECAUTIONS
 There are no user serviceable parts inside the DC1000. Please return the unit
to a Voltech approved service center for any repairs that may be required.
 Use fuses only of the type and rating – 4.00A 5X20 T-LAG HI-BREAK (VPN
66-052)
 The DC1000 has been constructed in compliance with the requirements of
EN61010-1, Pollution Degree 2, Installation Category II: FOR INDOOR USE
ONLY. This ensures the safety of the instrument and the user when normal
precautions are followed.

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WHAT IS THE DC1000?
The DC1000 is a DC Bias current source that can generate between 0 and 25A. Up to
ten DC1000’s can simply be joined together in parallel to produce up to 250A.
The DC1000 can be used with almost any LCR meter – making it unique amongst all
DC Bias Current Sources. It can also be used with either the Voltech ‘ATi’ or the
‘AT3600’ transformer testers – these products have specific programs for testing
using the DC1000 (LPBX, LSBX, and ZBX).
WHAT CAN THE DC1000 DO FOR YOU?
The DC1000 is used to characterize wound components that are intended for use in
high current DC power supplies and DC-to-DC converters.
It is used to apply a DC current through the component to be tested, allowing an LCR
meter or Voltech AT-series product to measure the inductance of the component at
that DC current.
Unlike a regular DC power supply; the DC1000 minimizes the load on an LCR meter.
Regular loading would cause gross errors in the measurement of inductors.
Additionally, unlike DC Bias sources from other manufacturers, the Voltech DC1000
can be used with almost any LCR meter.

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PACKING LIST
When you receive your DC1000, the following accessories will also be in the packing
box with your new instrument. Also given are the Voltech part numbers (VPN), in
case you’d like to order spares.
 1 x DC1000 CD – Which contains the demo DC1000 PC software and an
electronic version of the user manual. (VPN 88-297)
 1 x 30A Test Lead set – One yellow and one black, with clips. Each lead is 1.5
meters long. (VPN 78-114)
 2 x 9-Way Male-Female straight through RS232 Lead – This is for connection
between your DC1000 and an AT Tester or between your DC1000 and another
DC1000. (VPN 77-046). Also can be used for chaining the interlock system
between DC1000s
 1 x Handle Assembly – This includes two handles, and the fixing hardware
needed to attach them to your DC1000 (VPN 74-027)
 1 x Safety Interlock Override Plug – This can be used in place of a safety
system where there is no risk of dangerous voltages. This is only for use when not
testing with high currents or voltages. We recommend using an approved Safety
System at all times. Please consult your safety officer. (VPN 91-265)
 1 x Product Registration Card – Please fill this out and return it to Voltech to
help us serve you better. (VPN 86-203)
 1 x Power Cord (VPN 91-019L)
If there is anything missing from this list when you first unpack your new DC1000,
then please contact your supplier for an immediate replacement.

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GETTING STARTED
The DC1000 is designed with ease of use and speed of testing in mind. Following is a
description of the functions on both the front and rear panels of the DC1000, to help
you familiarize yourself with the basic operation of the instrument.
FRONT PANEL DESCRIPTION
Fig.2
1) Power Switch – Used to turn power to the instrument ON or OFF.
2) Output Terminals – 4mm safety sockets, for connection of the supplied 30A
test leads.
3) Display – 4-character display to indicate the output current in Amps.
4) Compliance LED – Lights up to indicate an error. The display will indicate
the error number. See the “Status Numbers” section in this manual for details.
5) Rotary Dial – Rotates to set the output current
6) Output Enable Button/LED – Momentary button used to enable or disable
the output current. A green LED indicates the status of the output. The LED
lights to indicate that the output is turned on.
7) Remote Button – Momentary button used to put the instrument into ‘Remote’
mode – in which another DC1000 or a PC can control it. A yellow LED
indicates that ‘Remote’ mode is turned on.

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REAR PANEL DESCRIPTION
Fig.3
1) RS232 IN – Connects either to a PC or to the RS232 OUT port of the
DC1000 closest to the controlling DC1000 or a Voltech AT instrument.
2) RS232 OUT – Connects to the RS232 IN port of another DC1000, in order to
control its functionality, or connects to another DC1000, or any LCR meter
other that a Voltech AT series product.
3) Fan Outlet – When outputting high currents from the DC1000 for an
extended period of time, high temperatures can be produced. Please keep this
air outlet clear of obstruction to allow the instrument to automatically regulate
its internal temperature.
4) Safety Interlock IN – Connects to a safety device, such as a light curtain.
When the connection is broken the DC1000 ceases to produce any current.
5) Safety Interlock OUT – Connects to another DC1000’s Safety Interlock IN
port. If you are using more than one DC1000 in parallel, then a single safety
device can control each of the units in the chain.
6) Power Entry Module – Connect the power outlet to this socket. Contained
within the module are two fuses, which should always be replaced when
necessary with the same type and rating (4.00A 5X20 T-LAG HI-BREAK).
There is also a voltage selector, which should always be checked, and set, if
necessary, to the correct voltage for your location.

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SAFETY INTERLOCK
For the DC1000 to produce any current, a safety system is required.
The DC1000 can be used with and produces high currents; therefore, Voltech
recommends that your always use a safety system when using your DC1000.
Consult with your company’s safety officer prior to using the DC1000.
Your safety system should not allow the operator or near-by workers to touch any
dangerous part during testing.
A single safety device can control all the DC1000s in your chain. Fig. 24 indicates the
required connections to connect either a single DC1000 or multiple instruments to
your safety device.
Using the DC1000 with a safety system
Fig.24
Please take care not to insert the safety interlock cable into the RS232 port on the rear
of the DC1000. Doing so could damage your instrument.

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USING THE DC1000 AND A VOLTECH AT3600/AT5600 WITH A SAFETY SYSTEM
When using your DC1000(s) with a Voltech AT a bespoke “Y” lead should be used
for the interlock system
Fig. 25 shows this connection.
Fig. 25
INTERLOCK
A) Use the Safety Device “Y” lead (250-031).
The end labeled “SD” connects to the Safety Light Curtain Interface cable (250-030)
from the Control Box (1).
The end labeled “AT” is connected to the AT Safety Interlock (2).
The end labeled “DC” is connected to Safety Interlock IN (3) of DC1000A #1.
B. If using more than one DC1000, then use a 9way-9way M-F straight through lead
(77-046) to connect Safety Interlock OUT (4) of DC1000A #1 to the Safety Interlock
IN (5) of DC1000A #2. This can be repeated for up to 20 DC1000s in a chain.
COMMUNICATIONS
C. Use a 9way-9way M-F straight-through lead (77-046) to connect AT Aux (Port 6)
to RS232 In (7) of DC1000A #1.
D. Use a 9way-9way M-F straight-through lead (77-046) to connect RS232 OUT (8)
of DC1000A #1 to RS232 IN (9) DC1000A #2. This can be repeated for up to 20
DC1000s in a chain.
E. Use 9way-9way F-F RS232 lead (77-015 AT Editor Cable) to connect RS232 OUT
(10) of DC1000A #2 to PC RS232 (11).

98-100 ISSUE 8 15
For optimum safety, ease of use and test speed, Voltech recommends the use of a
safety light curtain.
This provides a ‘light curtain’ of infrared beams positioned in front of the test
environment. Once the operator has removed his hand, the light curtain can signal that
the situation is safe within a few tens of milliseconds. However, if the operator breaks
the light curtain during testing, the safety system will open the safety interlocks (also
within a few tens of milliseconds), so that the DC1000 output will cease.
Voltech can provide a cable for connection between a light curtain and the DC1000 or
AT transformer tester. The cable has been optimized for use with the ‘Banner’ safety
light curtain described below, but safety light curtains from other manufacturers may
also be suitable. (out part number 250-030)
To construct a complete safety system you will need:
 Voltech Safety Interlock Y lead (250-031).
 Voltech Safety Interlock Cable (250-030)
 Banner ‘Micro-Screen’ safety light curtain
 1 x USCD-1T2 Metal Box Controller
 1 x USE2424YI Yellow Emitter 610mm high with 150mm to 9m range.
 1 xUSR2424YI Yellow Receiver 610mm high with 150mm to 9m range.
Source: http://www.banner.com/
 Methods to restrict access to the back of the working area
NOTE: The Banner part numbers were correct in 2005. You are strongly advised to
consult with your safety system supplier before making purchase decisions. Similar
safety systems are available from many other manufacturers and may be suitable.
Your DC1000 shipped with a Safety Interlock Override Plug, which can be inserted
into the Safety Interlock IN port in the place of a safety device.
DO NOT USE THIS DEVICE WITH DANGEROUS CURRENTS OR
VOLTAGES!

98-100 ISSUE 8 16
USING THE DC1000 WITH AN LCR METER
The powerful design of the DC1000 allows it to be used with almost any
manufacturer’s LCR meter. Using the test leads that were supplied with your DC1000
and with your LCR meter, it is fast and easy to setup your environment for testing an
inductor.
A) Be sure that the power is off to your Voltech DC1000.
B) Make all the connections indicated in fig.4.
C) Power up your DC1000, and turn the output on, making sure that the current
output is set to zero.
D) Perform compensation on your LCR meter.
E) Turn the DC1000 output off.
F) Using the rotary encoder set your DC1000 output to the desired current.
G) Turn the DC1000 output on.
H) Adjustments can be made to the DC1000 current while the output is enabled,
using the rotary encoder.
Fig. 4
Be sure to connect the HI side of your LCR meter to the same side of the inductor to
which the HI side of your DC1000 is attached, and use the opposite side of the
inductor to connect the LO sides of both the DC1000 and the LCR meter.
LCR COMPENSATION WITH A SINGLE DC1000
When compensating your LCR meter for use with the DC1000, always set the current
to ‘0.00’ and turn the output ON.

98-100 ISSUE 8 17
USING MULTIPLE DC1000S IN PARALLEL
You can generate up to 250A as a maximum by connecting up to ten DC1000s
together in parallel. Either the first DC1000, or a PC or a Voltech AT3600 or ATi
can be used to control all the other DC1000s in the chain – automatically adjusting
their output current to allow you to easily achieve the results you require.
Everything you need to hookup multiple DC1000s is provided with the units
themselves. Fig.5 illustrates the connections required.
Fig.5
Be sure to connect the HI side of your LCR meter to the same side of the inductor to
which the HI sides of your DC1000s are attached, and use the opposite side of the
inductor to connect the LO sides of both the DC1000s and the LCR meter.
Connect the 9-Way RS232 cable between the RS232 OUT of the first DC1000 in
your chain and the RS232 IN of the second DC1000, using the cable provided with
your DC1000. Then, if you have more than two DC1000’s, connect the RS232 OUT
of the second DC1000 in your chain to the RS232 IN of the third. Follow the same
pattern for any remaining DC1000’s you wish to connect together in parallel.
Always connect directly from EACH DC1000 in your chain to the inductor. NEVER
daisy chain the outputs of multiple DC1000’s. The accumulated current could exceed
the rating for the supplied cable, and cause fire and injury.
LCR COMPENSATION WITH MULTIPLE DC1000S
When compensating your LCR meter for use with the DC1000s, always set each
DC1000’s current to ‘0.00’ and turn the output ON at each unit.

98-100 ISSUE 8 18
USING A PC TO CONTROL YOUR DC1000 (S)
To use a PC to just control your DC1000s, but not controlling an LCR meter at the
same time, follow the setup in Fig.6.
Fig. 6
Connect your computer’s RS232 port to the RS232 IN port of the first DC1000 in
your chain (‘DC1000 # 1’), using a 9-way male to 9-way female null modem cable
(see ‘Accessories’ section of this user manual).
Connect the RS232 IN port of the next DC1000 in your chain to the previous
DC1000’s RS232 OUT.
NOTE: See the RS232 communications section for information on USB to RS232
converters.

98-100 ISSUE 8 19
USING A PC TO CONTROL YOUR DC1000(S) WITH
AN RS232 LCR METER (NOT A VOLTECH AT
SERIES PRODUCT)
To use your PC to control your DC1000s, and an LCR meter with RS232
communications capability, follow the setup in Fig.7.
Fig.7
Connect your computer’s RS232 port to the RS232 IN port of the first DC1000 in
your chain (‘DC1000 # 1’), using a 9-way male to 9-way female null modem cable
(see ‘Accessories’ section of this user manual).
When using an LCR meter with RS232 communications capability, connect the
RS232 port of the LCR meter to the RS232 OUT port of the last DC1000 ‘(DC1000 #
2’ in the Fig. 7) in your chain, using a null modem cable (see the Accessories section
of this user manual for details on a null modem cable available from Voltech, but
please note, that the type of cable required will depend on the type of RS232
connector on your LCR meter. See the RS232 Communications - Pinning section of
this user manual for details if a custom cable is required).
NOTE: See the RS232 communications section for information on USB to RS232
converters.

98-100 ISSUE 8 20
USING A PC TO CONTROL YOUR DC1000(S) WITH
AN IEEE-488 LCR METER (NOT A VOLTECH AT
SERIES PRODUCT)
To use your PC to control your DC1000s, and an LCR meter with IEEE-488
communications capability, follow the setup in Fig.8.
Fig.8
Connect your computer’s RS232 port to the RS232 IN port of the first DC1000 in
your chain (‘DC1000 # 1’), using a 9-way male to 9-way female null modem cable
(see ‘Accessories’ section of this user manual).
When using an LCR meter without RS232 communications capability, the PC you are
using must have both an RS232 port (to control the DC1000s) and an IEEE-488 port
(to control the LCR meter directly). Connect the PC directly to the IEEE port of the
LCR meter, as illustrated in Fig. 8.
NOTE: See the RS232 communications section for information on USB to RS232
converters.