Voltech AT5600 User manual

AT5600 User Manual 98-119 issue 14 Page 1
VOLTECH INSTRUMENTS
AT5600 Wound Component Tester
User Manual

AT5600 User Manual 98-119 issue 14 Page 2
Voltech AT5600 Wound Component Tester
AT5600 User Manual
Thank you for choosing the Voltech AT5600. This wound component tester
should 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.
Voltech Instruments Ltd
66 Innovation Drive
Milton Park
Abingdon
Oxfordshire
OX14 4RQ
UK
Phone [phone]
Voltech Instruments Inc.
12851 Banyan Creek Drive
Fort Myers
FL 33908
USA
Phone [phone]
[e-mail]
www.voltech.com
©Voltech Instruments All rights 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
Issue 14 –18 FEB 2019 / Firmware 1.001.026

AT5600 User Manual 98-119 issue 14 Page 3
Table of Contents
1. Introduction ................................................................................................... 11
1.1. AT5600 New Features............................................................................................................11
1.2. How to use this manual ..........................................................................................................12
1.2.1. How to Use this Manual –English...................................................................................12
1.2.2. Mode d'utilisation de ce manuel –Français ....................................................................12
1.2.3. Verwendung dieses Handbuchs –Deutsch ....................................................................13
1.2.4. Cómo Usar Este Manual –Español ................................................................................13
1.2.5. Come usare questo manuale –Italiano ..........................................................................14
1.2.6. Zo gebruikt u deze handleiding –Nederlands.................................................................14
1.2.7. Sådan bruger du denne manual –Dansk .......................................................................15
1.2.8. Så här använder du bruksanvisningen –Svenska..........................................................15
1.2.9. Tämän oppaan käyttöohjeet –Suomi .............................................................................16
1.2.10. Použití této příručky – Ceština.....................................................................................16
1.2.11. Hogy kell használni ezt a kézikönyvet –Magyar .........................................................17
1.2.12. Jak korzystać z niniejszej instrukcji – Polski................................................................17
1.2.13. Kılavuzun Kullanımı - Türkçe.......................................................................................18
1.3. General Safety Instructions ....................................................................................................19
1.3.1. General safety Instructions - English...............................................................................19
1.3.2. Consignes générales de sécurité –Français ..................................................................20
1.3.3. Allgemeine Sicherheitshinweise –Deutsch ....................................................................21
1.3.4. Instrucciones Generales de Seguridad –Español..........................................................22
1.3.5. Istruzioni generali di sicurezza –Italiano ........................................................................23
1.3.6. Algemene veiligheidsinstructies –Nederlands................................................................24
1.3.7. Generel sikkerhedsvejledning –Dansk...........................................................................25
1.3.8. Allmänna säkerhetsanvisningar –Svenska ....................................................................26
1.3.9. Yleiset turvallisuusohjeet –Suomi...................................................................................27
1.3.10. Obecné bezpečnostní pokyny – Ceština .....................................................................28
1.3.11. Általános biztonsági utasítások –Magyar ...................................................................29
1.3.12. Ogólne instrukcje bezpieczeństwa – Polski.................................................................30
1.3.13. Genel Güvenlik Talimatları - Türkçe ............................................................................31
1.4. Package Contents ..................................................................................................................32
2. System Overview........................................................................................... 33
2.1. What is the AT5600? ..............................................................................................................33
2.2. What is the AT5600 used for? ................................................................................................34
2.3. AT5600 Features Summary ...................................................................................................34
2.4. Front Panel Description ..........................................................................................................35
2.5. Rear Panel Description...........................................................................................................37
2.6. Air Circulation .........................................................................................................................41
2.7. Tilt Feet...................................................................................................................................42
2.8. Lifting Points ...........................................................................................................................42
2.9. A Typical Installation...............................................................................................................43
2.9.1. Server PC –results and test program management.......................................................43
2.9.2. Editor PC –test program development ...........................................................................43
2.9.3. Test Fixture......................................................................................................................44
2.9.4. Light Curtain (or another safety device) ..........................................................................44
3. Using the AT5600 .......................................................................................... 45

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3.1. Usage Overview .....................................................................................................................45
3.2. Test Fixtures ...........................................................................................................................46
3.3. Creating Test Programs - AT Editor .......................................................................................47
3.4. Utilizing Editor Test Programs ................................................................................................49
3.4.1. Storing programs on the Server ......................................................................................49
3.5. Results Printing.......................................................................................................................51
3.5.1. Report Format .................................................................................................................51
3.6. Recommended Configuration.................................................................................................53
3.7. Operating the AT5600 in Production Test ..............................................................................54
3.7.1. Manual Use .....................................................................................................................54
3.7.2. Robotic Operation ...........................................................................................................54
4. AT5600 Functional Description.................................................................... 55
4.1. Behind the Front Panel...........................................................................................................55
4.1.1. Test Nodes ......................................................................................................................55
4.1.2. Relay Switching Matrix ....................................................................................................56
4.1.3. Processors.......................................................................................................................56
4.1.4. Test Sources ...................................................................................................................56
4.1.5. Measurement Circuits .....................................................................................................57
4.1.6. Touch Screen & Buttons .................................................................................................58
4.1.7. Interfaces.........................................................................................................................58
4.2. How Does the AT5600 Tester Run a Test? ...........................................................................59
5. Getting Started .............................................................................................. 61
5.1. Installing the AT5600..............................................................................................................61
5.2. Installing the Windows Software.............................................................................................61
5.3. Install the Server Software .....................................................................................................61
5.4. Quick Start Tutorial.................................................................................................................62
5.4.1. Creating a Simple Schematic ..........................................................................................62
5.4.2. Creating the Test Program..............................................................................................64
5.4.3. Running the Program from the Editor .............................................................................71
5.4.4. Transferring the Program to the Server ..........................................................................72
5.5. USB Printer Setup ..................................................................................................................77
6. Safety Systems.............................................................................................. 81
6.1. Introduction .............................................................................................................................81
6.2. Recommended Safety Systems .............................................................................................82
6.2.1. Description of the OMRON Light Curtain System ...........................................................82
6.2.2. Description of the Banner Light Curtain system..............................................................82
6.2.3. Constructing your own Safety System ............................................................................83
6.3. Safety Notices.........................................................................................................................84
6.4. A Typical Installation of a Safety System ...............................................................................84
6.5. The AT5600 safety system user interface..............................................................................86
6.6. Constructing Safe Fixtures .....................................................................................................87
6.7. DC1000 DC Bias Current Source...........................................................................................87
6.8. AC Interface Fixture................................................................................................................87
7. Tests and Test Conditions............................................................................ 89
7.1. Available Tests .......................................................................................................................89
7.1.1. LOW VOLTAGE Tests ....................................................................................................90
7.1.2. HIGH VOLTAGE Tests....................................................................................................92
7.1.3. DC1000 Tests..................................................................................................................93
7.1.4. AC INTERFACE Tests ....................................................................................................93
7.2. Self-Resonant Frequency.......................................................................................................94
7.3. Explanation of Integration.......................................................................................................95
7.4. CTY - Continuity .....................................................................................................................97
7.5. R - Winding Resistance ..........................................................................................................98
7.6. RLS or RLP - Equivalent Series or Parallel Resistance .......................................................100
7.7. LS or LP - Inductance (Series or Parallel Circuit).................................................................101

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7.8. LSB or LPB-Inductance with Bias Current (Series or Parallel Circuit) .................................104
7.9. QL - Quality Factor ...............................................................................................................105
7.10. D –Dissipation Factor or Tan ...........................................................................................106
7.11. LL - Leakage Inductance ..................................................................................................107
7.12. C - Interwinding Capacitance............................................................................................109
7.13. TR - Turns Ratio................................................................................................................112
7.14. TRL - Turns Ratio by Inductance ......................................................................................117
7.15. Z, ZB –Impedance, Impedance with Bias ........................................................................119
7.16. R2 –DC Resistance Match...............................................................................................120
7.17. L2 –Inductance Match......................................................................................................121
7.18. C2 –Capacitance Match...................................................................................................124
7.19. GBAL –General Longitudinal Balance .............................................................................126
7.20. LBAL –Longitudinal Balance............................................................................................129
7.21. ILOS –Insertion Loss .......................................................................................................130
7.22. RESP –Frequency Response ..........................................................................................131
7.23. RLOS –Return Loss.........................................................................................................132
7.24. ANGL –Impedance Phase Angle.....................................................................................133
7.25. PHAS –Interwinding Phase Test......................................................................................134
7.26. OUT –Output to User Port ...............................................................................................135
7.27. IR - Insulation Resistance .................................................................................................136
7.28. HPDC - DC HI-POT (EHT)................................................................................................137
7.29. HPAC - AC HI-POT (EHT) ................................................................................................138
7.30. SURG - Surge Stress Test................................................................................................140
7.31. WATT - Wattage ...............................................................................................................144
7.32. WATX - Wattage (External Source) ..................................................................................145
7.33. STRW –Stress Watts .......................................................................................................147
7.34. STRX –Stress Watts (External Source)...........................................................................148
7.35. MAGI - Magnetizing Current .............................................................................................150
7.36. MAGX - Magnetizing Current (External Source)...............................................................152
7.37. VOC - Open Circuit Voltage..............................................................................................154
7.38. VOCX - O/C Voltage (External Source)............................................................................156
7.39. LVOC –Low Voltage Open Circuit ...................................................................................158
7.40. ILK –Leakage Current Test..............................................................................................160
7.41. LSBX –Inductance with External Bias (Series Circuit).....................................................161
7.42. LPBX –Inductance with External Bias (Parallel Circuit)...................................................162
7.43. ZBX - Impedance with External Bias ................................................................................163
7.44. ACRT - AC HI-POT Ramp ................................................................................................164
7.45. DCRT - DC HI-POT Ramp................................................................................................165
7.46. ACVB - AC Voltage Break Down ......................................................................................166
7.47. DCVB - DC Voltage Break Down......................................................................................167
8. Front Panel Operation................................................................................. 169
8.1. Introduction ...........................................................................................................................169
8.1.1. The Touch Screen Display ............................................................................................169
8.1.2. RUN and STOP buttons ................................................................................................170
8.1.3. User Input ......................................................................................................................170
8.1.4. Splash Screen ...............................................................................................................171
8.1.5. Power On.......................................................................................................................171
8.1.6. PART LIST ....................................................................................................................172
Entering a Part Number............................................................................................................173
Serial Number ..........................................................................................................................175
Batch ........................................................................................................................................176
Operator ...................................................................................................................................177
Compensation ..........................................................................................................................178
Run Screen ..............................................................................................................................182
Results .....................................................................................................................................183
8.1.7. SELF-TEST ...................................................................................................................184
8.1.8. SET UP..........................................................................................................................186
8.1.9. SOUND..........................................................................................................................187
8.1.10. CLOCK.......................................................................................................................188

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8.1.11. SERVER ....................................................................................................................189
8.1.12. NETWORK.................................................................................................................190
8.1.13. UNIT INFO.................................................................................................................191
8.1.14. STATUS BAR ICONS................................................................................................192
8.2. Testing Wound Components ................................................................................................193
8.2.1. A Typical Workflow........................................................................................................193
8.2.2. Traceability ....................................................................................................................194
8.2.3. STOP ON FAIL function ................................................................................................195
8.2.4. Getting the Results........................................................................................................196
9. Troubleshooting.......................................................................................... 199
9.1. Measurement Error Codes ...................................................................................................199
9.1.1. Self-test error codes ......................................................................................................199
9.1.2. Editor Error Codes.........................................................................................................200
9.1.3. Status Code Example....................................................................................................200
9.2. Correcting Errors ..................................................................................................................202
9.2.1. Safety Interlock error .....................................................................................................202
9.2.2. Temperature error .........................................................................................................202
9.2.3. Voltage Present Error....................................................................................................203
10. Specifications.............................................................................................. 205
10.1. Specification Summary .....................................................................................................205
10.2. Accuracy Specifications –Available Tests .......................................................................209
10.2.1. R Test ........................................................................................................................209
10.2.2. LS, LP, RLS, RLP, LL and C Tests............................................................................210
10.2.3. QL and D Tests..........................................................................................................211
10.2.4. TR Test ......................................................................................................................212
10.2.5. TRL Test ....................................................................................................................213
10.2.6. MAGI Test..................................................................................................................214
10.2.7. MAGX Test (External Source) ...................................................................................215
10.2.8. VOC Test ...................................................................................................................216
10.2.9. VOCX Test (External Source)....................................................................................217
10.2.10. LVOC Test .................................................................................................................218
10.2.11. IR Test .......................................................................................................................219
10.2.12. HPDC Test.................................................................................................................220
10.2.13. HPAC Test .................................................................................................................221
10.2.14. LSB AND LPB Tests..................................................................................................222
10.2.15. WATT and STRW Tests ............................................................................................223
10.2.16. WATX and STRX Tests (External Source)................................................................224
10.2.17. SURG Test.................................................................................................................225
10.2.18. L2, C2 and R2 Tests..................................................................................................226
10.2.19. GBAL Test .................................................................................................................227
10.2.20. LBAL and ILOS Tests ................................................................................................228
10.2.21. RESP Test .................................................................................................................229
10.2.22. RLOS Test .................................................................................................................230
10.2.23. Z and ZB Test ............................................................................................................231
10.2.24. ANGL Test .................................................................................................................232
10.2.25. PHAS Test .................................................................................................................233
10.2.26. ILK Test......................................................................................................................234
10.2.27. LSBX and LPBX Tests...............................................................................................235
10.2.28. ZBX Test....................................................................................................................236
10.2.29. ACRT Test .................................................................................................................237
10.2.30. DCRT Test.................................................................................................................238
10.2.31. ACVB Test .................................................................................................................239
10.2.32. DCVB Test .................................................................................................................240
10.3. Interface Specifications.....................................................................................................241
10.3.1. Server Port.................................................................................................................241
10.3.2. Auxiliary Port..............................................................................................................241
10.3.3. Remote Port...............................................................................................................242

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10.3.4. Peripheral Interface ...................................................................................................244
10.3.5. Safety Interlock ..........................................................................................................245
10.3.6. User Port....................................................................................................................246
10.3.7. Ethernet Port..............................................................................................................248
10.3.8. Front and Rear USB ‘A’ Ports....................................................................................248
10.3.9. USB ‘B’ Port ...............................................................................................................248
10.4. Environmental Conditions .................................................................................................249
10.5. Mechanical ........................................................................................................................250
10.6. EMC Compliance ..............................................................................................................251
10.6.1. Declaration of Conformity ..........................................................................................251
11. Maintenance................................................................................................. 253
11.1. Air Filters ...........................................................................................................................253
11.1.1. Removing the right-hand side panel..........................................................................253
11.1.2. Removing the air filters ..............................................................................................254
11.2. Test Probes.......................................................................................................................254
11.3. Power Cords .....................................................................................................................254
11.4. Cleaning ............................................................................................................................254
12. Warranty and Service.................................................................................. 255
12.1. Warranty Information ........................................................................................................255
12.1.1. Post-sale Warranty Agreement..................................................................................255
12.2. Service and Calibration.....................................................................................................256
12.3. Accessories.......................................................................................................................257
13. Test Fixtures................................................................................................ 259
13.1. Introduction .......................................................................................................................259
13.2. The Voltech Fixture System..............................................................................................260
13.2.1. Description of the Fixture System..............................................................................260
13.2.2. Compatible connection types.....................................................................................261
13.3. The Voltech 40 Socket Fixture..........................................................................................261
13.4. Making Fixture Connections –Kelvin Connections ..........................................................262
13.5. Compensation ...................................................................................................................264
13.5.1. Compensation Summary –Available Tests...............................................................265
13.5.2. Equipment Required ..................................................................................................266
13.6. General Notes...................................................................................................................268
13.6.1. Beware of High Voltages ...........................................................................................268
13.6.2. Kelvin Connections ....................................................................................................269
13.6.3. Mechanical Problems ................................................................................................269
13.6.4. Cleaning Test Pins.....................................................................................................269
14. AT Series Editor Software .......................................................................... 271
14.1. Introduction .......................................................................................................................271
14.2. Installing the Editor Software ............................................................................................272
14.2.1. Computer Requirements............................................................................................272
14.2.2. Installing the USB Drivers..........................................................................................272
14.2.3. Installing the main application....................................................................................273
14.3. Starting for the first time....................................................................................................273
14.3.1. Running the software.................................................................................................273
14.3.2. Language Configuration ............................................................................................273
14.3.3. Communications Configuration..................................................................................273
14.4. Schematic Editing .............................................................................................................274
14.4.1. Adding a Transformer Winding ..................................................................................274
14.4.2. Connecting the Winding Terminals to Nodes ............................................................276
14.4.3. Deleting a Winding.....................................................................................................276
14.4.4. Renaming a Terminal ................................................................................................277
14.4.5. Adding a Terminal to an Existing Winding.................................................................277
14.4.6. Deleting a Terminal from an Existing Winding...........................................................278
14.4.7. Adding a Core Connection.........................................................................................278

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14.4.8. Deleting a Core Connection.......................................................................................279
14.4.9. Adding a Screen Connection .....................................................................................279
14.4.10. Deleting a Screen Connection ...................................................................................279
14.5. Creating the Program........................................................................................................280
14.5.1. Setting the Program Options .....................................................................................280
Results Printing ........................................................................................................................281
Kelvin Pre-Check......................................................................................................................282
Operator Numbering.................................................................................................................285
Batch Numbering......................................................................................................................285
Serial Numbering......................................................................................................................285
Send Results to Server ............................................................................................................285
Send Retry Results to Server...................................................................................................285
Stop on Fail ..............................................................................................................................286
Date and Time on Reports .......................................................................................................287
Disable test failures due to ALC error ......................................................................................287
AQL (Acceptable Quality Level) ...............................................................................................288
Run audit test every [X] parts tested........................................................................................288
Fixture ID..................................................................................................................................289
External AC Source..................................................................................................................289
Custom Text .............................................................................................................................289
14.5.2. Program Edit..............................................................................................................290
14.5.3. Adding Tests ..............................................................................................................291
14.5.4. Inserting Tests ...........................................................................................................292
14.5.5. Modifying Tests..........................................................................................................294
14.5.6. Deleting Tests ............................................................................................................295
14.5.7. Test Parameters ........................................................................................................296
14.5.8. Test Limits..................................................................................................................297
14.5.9. Using the Measure Button .........................................................................................299
14.5.10. Verifying Your Program .............................................................................................303
14.5.11. Compensation............................................................................................................305
14.5.12. Hints and Tips ............................................................................................................307
14.5.12.1 Schematic.................................................................................................................307
14.5.12.2 Test Order ................................................................................................................307
14.5.12.3 Test Grouping ..........................................................................................................309
14.6. Programming Tests...........................................................................................................311
14.6.1. CTY - Continuity.........................................................................................................312
14.6.2. R - Winding Resistance .............................................................................................313
14.6.3. RLS or RLP - Equivalent Series or Parallel Resistance ...........................................314
14.6.4. LS or LP –Winding Inductance (Series or Parallel Circuit).......................................316
14.6.5. LSB or LPB - Inductance with Bias (Series or Parallel Circuit) .................................318
14.6.6. QL - Quality Factor ....................................................................................................320
14.6.7. D –Dissipation Factor or Tan..................................................................................322
14.6.8. LL - Leakage Inductance ...........................................................................................323
14.6.9. C - Interwinding Capacitance.....................................................................................325
14.6.10. TR - Turns Ratio ........................................................................................................326
14.6.11. TRL - Turns Ratio (by Inductance) ............................................................................330
14.6.12. Z, ZB –Impedance ....................................................................................................332
14.6.13. L2 - Inductance Match ...............................................................................................334
14.6.14. C2 –Capacitance Match ...........................................................................................335
14.6.15. GBAL –General Longitudinal Balance......................................................................337
14.6.16. LBAL –Longitudinal Balance.....................................................................................339
14.6.17. ILOS –Insertion Loss ................................................................................................340
14.6.18. RESP –Frequency Response...................................................................................341
14.6.19. RLOS –Return Loss..................................................................................................342
14.6.20. ANGL –Impedance Phase Angle..............................................................................343
14.6.21. PHAS –Interwinding Phase Test ..............................................................................345
14.6.22. OUT –Output to User Port ........................................................................................347
14.6.23. IR - Insulation Resistance..........................................................................................348
14.6.24. HPDC - DC Hi-Pot (EHT)...........................................................................................349
14.6.25. HPAC - AC Hi-Pot (EHT)...........................................................................................350

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14.6.26. SURG - Surge Stress Test ........................................................................................351
14.6.27. WATT - Wattage ........................................................................................................353
14.6.28. WATX –Wattage (External Source)..........................................................................354
14.6.29. STRW –Stress Wattage............................................................................................355
14.6.30. STRX - Stress Watts (External Source) ....................................................................356
14.6.31. MAGI - Magnetizing Current ......................................................................................357
14.6.32. MAGX - Mag. Current (External Source)...................................................................358
14.6.33. VOC - Open Circuit Voltage.......................................................................................359
14.6.34. VOCX –O/C Voltage (External Source)....................................................................361
14.6.35. LVOC –Low Voltage Open Circuit ............................................................................363
14.6.36. ILK –Leakage Current Test.......................................................................................364
14.6.37. LSBX –Inductance with External Bias (Series Circuit) .............................................365
14.6.38. LPBX –Inductance with External Bias (Parallel Circuit) ...........................................367
14.6.39. ZBX - Impedance with External Bias .........................................................................369
14.6.40. ACRT - AC Hi-Pot Ramp ...........................................................................................371
14.6.41. DCRT - DC Hi-Pot Ramp...........................................................................................372
14.6.42. ACVB - AC Voltage Break Down...............................................................................373
14.6.43. DCVB - DC Voltage Break Down...............................................................................374
14.7. Firmware Upgrades ..........................................................................................................375
14.8. Self-Test............................................................................................................................376
14.9. Customize Tester..............................................................................................................378
15. AT Series Server Software ......................................................................... 379
15.1. Introduction .......................................................................................................................379
15.2. Installing the Server Software ...........................................................................................380
15.2.1. Computer Requirements............................................................................................380
15.2.2. Installation Instructions ..............................................................................................380
15.3. Starting for the first time....................................................................................................381
15.3.1. Running the software.................................................................................................381
15.3.2. Initial Configuration ....................................................................................................381
15.4. Setting up the Options ......................................................................................................382
15.4.1. Communications ........................................................................................................382
15.4.2. Directories..................................................................................................................386
15.4.3. Groups .......................................................................................................................387
15.4.4. Password ...................................................................................................................387
15.4.5. Results .......................................................................................................................388
15.4.6. Language ...................................................................................................................388
15.4.7. Storing Test Programs...............................................................................................389
15.4.8. Viewing a Test Program ............................................................................................390
15.4.9. Deleting a Test Program............................................................................................391
15.5. Test Results Handling.......................................................................................................392
15.5.1. Receiving Test Results ..............................................................................................392
15.5.2. Result Display and Analysis ......................................................................................393
15.5.3. On-Line Monitoring ....................................................................................................394
15.5.4. Batch Statistics On-line Analysis ...............................................................................395
15.5.5. On-Line Analysis via a Database...............................................................................397
Introduction...............................................................................................................................397
Setting Up Database Results Storage .....................................................................................397
Database Tables ......................................................................................................................402
Charting and Analysis Using SPC/SQC Software ...................................................................406
15.5.6. On-Line Analysis via OLE..........................................................................................408
15.5.6.1 Transferring Server Results from Microsoft Access Database (.mdb) to Microsoft Excel
2016 (.xlsx)...............................................................................................................................418
15.5.7. Off-line Analysis.........................................................................................................421
16. Manual, Firmware and Software Change Log........................................... 425
16.1. AT5600 User Manual ........................................................................................................426
16.2. AT5600 Firmware..............................................................................................................428
16.3. AT Series Editor Software.................................................................................................436

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16.4. AT Series Server Software ...............................................................................................437