Atec ROD-L M25 Operation And Service Manual
OPERATION AND SERVlCE
MANUAL
ROD-L
M25
25
AMP
GROUND CONTINUITY
TESTER
JULY,
1984
Advanced Test Equipment Rentals
www.atecorp.com 800-404-ATEC (2832)
®
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TABLE OF CONTENTS
-
SECTION
I
INTRODUCTION
1-1
General
1-6 General Description
1-11
Equipment Supplied
1-15 Identification
1-17 Specification
I1 INSTALLATION AND OPERATION
General 2-1
Unpacking and Inspection 2-1
Installation 2-1
Rack Mounting 2-1
Power Requirements 2-3
Power Cable 2-3
Initial Installation and Turn On
2-3
Storage 2-3
Repackaging for Shipment 2-3
Operating Controls 2-4
Operational Check 2-8
Test Time Adjustment Procedure
2-1 0
Automatic Test Procedures 2-1 0
25AMP Ground Tester with M488 Tester
Set
Up 2-10
ill
THEORY OF OPERATION
3-1 Theory of High Current Ground Testing 3-1
3-2 Ground Continuity 3-1
3-3 Instrument Functional Diagram 3-3
3-6 Instrument Assembly Diagram 3-4
3-7 Power Supply Circuit
(A101 3-4
3-9 A22 Control Logic Board 3-4
IV MAINTENANCE AND SERVICE
Introduction
Calibration
Set Up
Meter Mechanical Zero
Ammeter Calibration
Fail Pots Calibration
Test Time Calibration
Resistance Calibration
Troubleshooting
SECTION
TABLES, SPECIFICATION CHAR'TS
AND
DIAGRAMS
Table
1-1
Figure 2-1
Table 2-1
Figure 2-2
Figure 2-3
Figure 3-1
Figure 3-2
Figure 3-3
Table 4-1
Figure 4-1
V
PARTS LIST
Specifications
Rack Mounting Kit Installation
Control And Indicators
Control And Indicators
M25
Hipot Interface
Functional Diagram
Assembly Diagram
Detail Functional Diagram
Calibration Equipment
Test Set-Up
A10 Power Supply
A22 Control Logic
VI
SCHEMATICS
Wiring Diagram
Assembly Drawing, Mother Board
A10 Power Supply
A10 Power Supply Assembly
A22 Control Logic
A22 Control Logic Assembly
W
OPTIONS
PAGE
1-2
2-2
2-5
2-7
2-1
1
3-3
3-4
3-5
4-1
4-3
5-2
5-3
A8 Remote Control
Parts List
Schematics
lNTRODUCrI'lON
SECTION
I
1-1
GENERAL
1-2 This publication, which provides operating and servicing instructions for
the ROD-L Electronics 25 amp Ground Testers is divided into five sections.
sections I describes the Instrument and list its specifications. Section
II
contains Installation Instructions and Operating Procedures. Section 111
contains Theory of Operation. Section IV contains Service and Calibration
Instructions. Section
V
contains Replacement Parts Information, Parts
Location Diagrams and Schematics.
1-3 25amp Ground Testers are Low Voltage testers with ground continuity
test capability for performance of ground tests in accordance with
applicable B.S.I., V.D.E. and I.E.C. standards.
1-4 The 25 amp ground test is one of many tests required by certification
agencies
as
proof of an instrument's ability to withstand power line
spikes without becoming a hazard to itself or the user. For example,
lighting, drastic load changes or power line outages can place short
duration spikes on power lines of many times nominal line voltage. The
gnd should be able to divert any leakage to the chassis without getting
damaged.
1-5 GENERAL DESCRIPTION
1-6 The ROD-L Model
25amp Ground Testers apply low voltage to the device
under
test
for a duration of time preset from one second to
90
seconds.
The device under test is plugged into the front panel receptacle (or special
rear panel connector on some models). Test limits for total resistance
are preset by the user via a rear panel control. When the device under
test is defective, automatic circuitry turns off the low voltage and meter,
lights the FAIL lamp and activates an audible alarm. These audible and
visual alarms must be manually reset at front panel or can be reset by
remote control (see options).
1-7
All
Models incorporate a rapid, automatic electronic shutdown circuit to
turn off the low voltage within two milliseconds after a fault.
1-8 For operator use, the test cycle is
fully automatic; accidental test
initiation is prevented by use of a recessed start switch. If ground fails
during the test, the Tester automatically activates failure operation, i.e.,
voltage is shut down and there is a visual and audible alarm.
1-9
The ROD-L 25 amp Ground Testers are completely self contained
rugged instruments designed for laboratory and production testing
environments.
1-1
0
EQUIPMENT SUPPLIED
1-11
The ROD-L Ground Tester is comprised of the following:
a.
Ground Tester, ROD-L Model 25amp Ground.
b. Six foot power cord, three pronged.
c.
18 inch Ground Cable
d. This Manual
e.
Extra fuses
f. HV Interface Cable
1-1
3
The ROD-L 25amp Ground Testers are identified by a part number
and
a
serial number (see Figure 2-2).
Table
1-1
lists the most important electrical, environmental and
physical specifications of the Ground Testers.
TABLE
1-1
SPECIFICATIONS
Test Voltage and Current
Voltage Shutdown
Automatic Test Cycle
Initial Turn
-
On Period
3
VAC RMS, 25 ARMS,
33/60
Hz
at
0.1 ohms load
.
No Load boltage, YVACRMS.
Within 2ms after a fault
(electronic shutdown circuits).
One second to 90 seconds
Allow
5
minutes warm-up
Ohm Meter
Ammeter
SPECIFICATIONS (CONTINUED)
0-0.1 5 ohms Accurate to
+5%
F.S.
Up
to 30amps accuracy
to
+5%
F.S.
Input Power
lZOVAC, 50160
Hz,
280 W max
Environmental Operating Condition O"to 50% (32Oto 122*~)
Physical Color Mint greyIOlive grey
Weight 35
ibs Net (13.5 Kg)
Dimensions
SAFETY FEATURES
16 3/4x54x13i inches
(43
x
13 x 34 cm)
Sequenced design of operation. Loss of ground terminates
test
cycle.
Recessed
START
button. Visual and audible alarm
at
failure. Voltage
lockout requiring manual reset.
INSTALLATJON AND OPERATJON
SECTION
I1
2-1 GENERAL
2-2
This section contains
the
recommended procedure for unpacking and
inspection, installation, operation, storage and reshipment.
2-3 UNPACKING AND INSPECTION
2-4
Any shipping carton that appears damaged should be unpacked with
carrier's agent present. Inspect the instrument for damage (scratches,
dents, broken knobs or meters, etc). If the instrument is damaged
or
fails to meet specifications (see Performance Test, Section IV), notify
ROD-L Electronics immediately, retain the shipping carton and the
padding material for the carrier's inspection.
2-5 LNSTALLATION
2-6
The ROD-L Model
25amp Ground Testers
are
suitable for either bench
or rack mounting. To rack mount the instrument, use Rack Mounting
Kit, part #M100-5001.
Rack Mounting Kits may be ordered from factory.
2-7
RACK
MOUNTING
2-8
The procedure for installing Rack Mounting Kit, M100-5001 on the
Tester
is
as
follows:
a.
Place the instrument on edge of bench
as
shown in Figure
2-1
b.
Remove Trim Strip (#2) from both sides of instrument
c.
Place L-Bracket
(#3)
and secure to chassis with two machine
screws
(#4)
furnished with Mounting Kit.
d.
Rotate Instrument on work bench and repeat steps "b" and
nC~~
.
Check that screws and brackets are firmly secure
Figure
2-1
-
Rack
Mounting Kit Installation
-
2-9 POWER REQUIREMENTS
2-10
The Model 25amp Ground Tester requires a power source of 120 or 240
volts AC, single phase, 50 to 60
Hz.
Insure that the power socket to
which the instrument connects has a functioning safety ground.
2-11 POWER CABLE
2-12
To protect operating personnel, the National Electrical
Nanufacturers
Association (NEMA) recommends that the instrument panel and cabinet
be grounded. This instrument is equipped with a three-conductor Dower
cable which when plugged into an appropriate.rcceptacle grounds the
instrument. The offset pin on the three-prong connector is the ground
pin.
2-13
INITIAL INSTALLATION AND TURNqN
2-14 CAUTION
Prior to applying power to the instrument perform the following:
a.
Turn-Off Power Switch on ROD-L Tester,
set
the rear panel
AC Line 115/230V voltage switch to indicate the number that
corresponds to the line voltage range being used. The number
visible on the slide switch indicates the line voltage range for
which the primary circuit is connected.
Set the OHMS TRIP control to full clockwise position.
With and AC voltmeter, check the primary power line for normal
line voltage conditions.
Set VOLTAGE ADJ switch on rear panel to appropriate position
ke.
if input low line conditions exist, set to normal,8% low line,
or 16% low line as appropriate).
e.
With power switch off, check to be sure that the proper fuses are
installed in accordance with markings on rear panel and in accorance with 115/230V line switch.
f.
Connect the six foot power cord between instrument and power
source. Operational Check procedure per paragraph 2-23.
2-15 STORAGE
2-16 It is strongly recommended that the equipment be packed as if for
reshipment. Environmental conditions during storage and reshipment
should be as follows:
a.
Maximum temperature
167 degrees F(75 degrees
C)
b. Minimum temperature
-40
degrees F
(-40
degrees
C)
2-17 REPACKAGING FOR SHIPMENT
2-18
If possible, use the original shipping container and packing materials,
or:
a. Wrap the instrument in heavy paper or plastic before placing
it
in the shipping container.
b. Use plenty of packing material around the instrument and
protect the front panel with cardboard or plastic bubble
packing. Protect the instrument with two inch rubberized
foam pads placed along
all
surfaces of instruments, or with
a
layer of excelsior about six inches thick packed firmly against
all
surfaces of instrument.
c.
Use a strong, well-sealed shipping container (350 lb/sq in.
bursting test).
d.
Mark the container "FRAGILE
-
DELICATE INSTRUMENT!'
2-19
Attach
a
tag to the instrument giving the following information:
a.
Type of service required.
b.
'
Return address
c.
Instrument Model number
d. Full Serial Number
In any correspondence refer to the instrument by Model number and
full serial number.
2-20 OPERATING CONTROLS
2-21
Figure 2-2 illustrates the front and rear panel controls for the
Model
25amp Ground Testers Table 2-1 describes the functions of all the controls
and indicators.
FIG. 2-2
INDEX
NO
TABLE 2-1 CONTROLS AND INDICATORS
CONTROL
LlNE POWER ON (Sl)
ON LAMP (1
1)
START Pushbutton (S2)
RESET Pushbutton (S3)
FUNCTION Select Switch
64)
CHASSIS GROUND
Voltage Connector (52)
~-
-
FUNCTION
This switch applies or
removes, power from the
instrument.
When lit, indicates power
is applied to the
instrument
When depressed,
the
test
sequence begins
if the instrument is
grounded properly and
not already indicating a
grounded test failure.
Resets
a
failure
indication when depressed; also terrninates
a
test early.
Selects Ground Test
only or ground
test
and Hipot Test
sequence.
Connect the chassis
of the device under
test
to this terminal.
The lead used should
be of low resistance
and preferably
as
short as possible.
An
instrument to be
tested for ground
resistance is to be
plugged into this
outlet. Only three
pronged AC line
plugs for three-wire
cords are to be
inserted (unless
adapter is required).
TABLE 2-1 CONTROLS AND INDICATORS (continued)
FIG.
2-2
INDEX NO CONTROL FUNCTION
Ohms Meter (RMeter)
Total Current Meter
(
I
METER)
FAIL Indicator
(14)
TESTING Indicator (I
3)
READY Indicator (I 2)
Audible Warning (SP1)
AC Line Voltage (A71
AC Line power receptable (J1)
Line Fuse (F2)
Line Supply Fuse (El)
Ohms Trip Pot (R5)
Low Line Switch (S5)
Serial/Model Code Label
Remote Control Connector(J3)
Hipot Interface Connector (54)
2-6
Provides
a
direct reading of
the Resistance of
the
tested
instruments ground loop.
Indicates amount of AC
current in (AMPS) flow
during a test.
Displays a visual warning
that
test
was a failure.
Indicates
a
test
in progress.
Comes on a power up.
Emits
a
warning sound
when a test results in
a
failure.
Slide switch to select
either 115 VAC or
230
VAC.
The exposed number
indicates the Line Voltage
range
selected.
Connects to power cable
supplied with instrument.
Provide primary circuit
protection from overcurrent conditions.
SAME AS ABOVE
Calibrates Ohms Trip setting.
Compensate for input Low
Line Voltage conditionnormal,
-8%,
and -16%.
Identifies Serial Number and
Model number of
tester.
Allows Remote signal
input and output.
Allows interface with ROD-L
~ii'pot tester.
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