Fluke i410, i1010 Service Manual

i410/i1010

®

AC/DC Current Clamp

Service Information

WWarning

To avoid electric shock:

• Do not service this Current Clamp unless you are qualified to do so.

The service information provided in this document is f or use by qual i ­fied personnel only.

• Always remove input signals from the Current Cl amp before opening

the case.

• Be careful when working with vol t ages t hat exceed 30V ac rms, 42.4V

pk, or 60V dc.

• The Current Clamp is protected throughout by double insul ation. When

servicing the Current Clamp, use only specified replacement parts.

• If the Current Clamp is to be Calibrat ed, you must have a replacement

decal. See the Replacement Parts section for further det ai l s.

• This Current Clamp contains parts that can be damaged by stat i c dis-

charge. Follow the standard practices for handling static sensitive de­vices.

Introduction

Service Information covers the following service-related areas for the i410/i1010 AC/DC Current
Clamps:

• Product specifications

• Required equipment

• Performance test procedure and test values

• Preparing for calibration

• Calibration procedure

• Reassembly procedure

• Replacement parts

Usually, service information in this document applies to both models (i410 and i1010). Information ap­plicable to only one model is so noted. For operating information, refer to the Instruction Sheet that came
with the Current Clamp.

Caution

PN 642733 December, 1996 1996 Fluke Corporation. All rights reserved. Printed in U.S.A. Product names are trademarks of their respective companies.

i410/i1010

AC/DC Current Clamp

Service Under Warranty

The Current Clamp is warranted to be free from defects in material and workmanship for one year.
The warranty does not cover abuse, batteries, or damage caused by using the Current Clamp outside its

rated specifications or operating environment. The complete warranty statement appears in the Current
Clamp Instruction Sheet.

For repairs:

• In the USA or Canada, call 1-800-323-5700

• Outside the USA, contact your nearest Fluke Distributor or Service Center.

Service, repairs, and replacement parts are warranted for 90 days.

Specifications

General specifications are shown in Table 1. Range and accuracy specifications are shown in Table 2.

The accuracy of the Current Clamp is specified for one year after calibration, at 18°C to 28°C (64°F to
82°F), with relative humidity to 90%.

Table 1. General Specifications

Operating Temperature -10 to 50°C (14 to 122°F) Current x Hz Product ≤ 240,000
Storage Temperature -20 to 60°C (-4 to 140°F) Output Signal 1 mV per amp dc or ac
Relative Humidity 0 to 95% (0 to 30°C)

0 to 75% (30 to 40°C)
0 to 45% (40 to 50°C)

Altitude
Operating
Non-operating

Battery Type 9V (alkaline) Load Impedance ≥1 MΩ, ≤100 pF
Battery Life 60 hrs typical (continuous

Safety

Specified Current Range 1 - 400A ac rms *

Usable Current Range 0.5 - 400A 0.5 - 1000A
DC Accuracy (zero adjusted,
conductor centered)
AC Accuracy 3.5% + 0.5A, 45 - 400 Hz, Crest

Bandwidth 3 kHz 10 kHz

*

With a true-rms DMM, the minimum ac current is limited to the low end of the specified mV ac range.

0 - 2000m
0 - 12000m

with alkaline)

s Double Insulation, 600V,

CAT. III

Table 2. Range and Accuracy Specifications

i410 i1010

1 - 400A dc

3.5% + 0.5A (0 - 400A) 2.0% + 0.5A (0-1000A)

Factor ≤ 3.
(1 - 400A)

Working Voltage 600V CAT. III

maximum at input

Maximum Conductor
Size

Temperature
Coefficient
Size 209 x 78 x 48 mm (3.09 x

Weight 0.5 kg (17.6 oz.)

1 - 600A ac rms *
1 - 1000A dc

2.0% + 0.5A, 45 - 400 Hz, Crest Factor ≤ 3.

3.0% + 0.5A, 400 Hz - 2 kHz sine wave.
(1 - 600A)

1 ea. 30 mm (1.18 in.)
diameter
2 ea. 25 mm (0.98 in.)
diameter

+/-(0.05 x accuracy per °C
(0 -18°C, 28-50°C)

8.21 x 1.87 in.)

2

Required Equipment

Equipment required for the performance test and calibration procedure is shown in Table 3.

Equipment Recommended Model

Calibrator Fluke 5700A, 5720A, or 5500A
Transconductance Amplifier Fluke 5220A
Digital Multimeter (DMM) Fluke 45 or equivalent
Current Coil Fluke 5500A/Coil (50-Turn)
Calibration tool (slotted, as required)
Decal (replace to calibrate) PN 642584 (i410) or 642592 (i1010)

Performance Test

To avoid electric shock, do not execute the performance t est s unless the
Current Clamp is fully assembled.

Service Information

Required Equipment

Table 3. Required Equipment

WWarning

The Battery LED and Measurement Accuracy tests verify that the Current Clamp is working properly
and performs to specification.

Battery LED Test

Complete the following procedure to verify that the Battery LED threshold is set correctly:

1. Turn on the Calibrator and allow it to warm up and stabilize for 30 minutes.

2. Place the Current Clamp face down.

3. Remove the screw securing the battery cover to the back of the Current Clamp.

4. Remove the battery cover.

5. Connect the Calibrator to the Current Clamp battery snap connectors.

6. Set the Calibrator to 6.70V dc. Check that the Current Clamp LED is off.

7. Set the Calibrator to 7.30V dc. Check that the LED is on.

8. Replace the battery cover and securing screw.

Measurement Accuracy Tests

Connect the Current Clamp and test equipment as shown in Figure 1. Then perform the appropriate steps
shown in Table 4. Most tests apply to both the i410 and the i1010, with resulting DMM readings listed
separately for each model. Some tests apply to only one model; the model not being tested is then

marked with “NA”.

3

i410/i1010

AC/DC Current Clamp

5700A/5720A 5500A

HI

LO

1V PK

MAX

A, -SENSE,

AUX V

20V PK

SCOPE

200V PK

MAX

20V
RMS
MAX

TRIG
OUT

MAX

Calibrator

NORMAL AUX

V, ,

RTD

1000V

RMS
MAX

20V PK

MAX

TC

V

1000V

MAX

750V

COM

ALL INPUTS

10A

FUSED

!

100
mA

500mA
F 250V

1kV MAX

Conductor

45

DUAL DISPLAY MULTIMETER

45

AUTO

REL

SMF MAX

REMOTE

MINdBHOLD

EXT TRG

V

V

mA

DC AC

mV

mA

mVDCAC

UNCAL

CAL

Hz

Mk

Hz

Mk

A

AUTO

A

FREQ

COMP

HI

REL

REF# LOCAL

HOLD

LO

THRESH ADDR BAUD

POWER

ENABLE

2ND

dB

REF

RATE

MN MX

50-Turn Current Coil

5220A

Preparing for Calibration

Before calibrating the Current Clamp, do the following:

1. Calibration necessitates removal of the decal on the case top. Plan to install a new decal when cali-

bration is complete. See “Replacement Parts” for decal ordering information.

2. Turn on the Calibrator and allow it to warm up and stabilize for 30 minutes.

3. Place the Current Clamp face down.

4. Remove the screw securing the battery cover to the back of the Current Clamp.

5. Remove the battery cover.

6. Connect the DMM to the Current Clamp battery terminals.

Figure 1. Equipment Connections

el001f.eps

7. Press the green power button on and verify that the battery voltage is at least 7V. If the battery volt-

age is too low, replace the battery before proceeding.

8. Carefully remove the Current Clamp decal to uncover a set of five holes in the case top. These holes

allow direct access to calibration potentiometers.

9. Continue with the calibration procedure that follows.

4

Table 4. Performance Test Values

Service Information

Preparing for Calibration

Step Calibrator

Setting

DC Amps Zero Test

10.0 (ZERO knob CW) NA Pos. span 3.0 15.0 3.0 15.0

20.0 (ZERO knob CCW) NA Neg. span −15.0 −3.0 −15.0 −3.0

DC Amps Test

3 0.04A dc 2.0A dc 2.00 mV 1.43 2.57 1.46 2.54
4 0.4A dc 20.0A dc 20.0 mV 18.8 21.2 19.1 20.9
5 -0.4A dc -20.0A dc -20.0 mV -21.2 -18.8 -20.9 -19.1
6 1.2A dc 60.0A dc 60.0 mV 57.4 62.6 58.3 61.7

AC Amps Test

7 0.40A, 45 Hz, 400 Hz 20.0A ac 20.0 mV 18.8 21.2 19.1 20.9
8 0.40A, 2 kHz 20.0A ac 20.0 mV NA NA 18.9 21.1
9 1.0A 45 Hz, 400 Hz 50.0A ac 50.0 mV 47.7 52.3 48.5 51.5
10 1.0A 2 kHz 50.0A ac 50.0 mV NA NA 48.0 52.0
11 2.0A, 45 Hz, 400 Hz 100.0A ac 100.0 mV 96.0 104.0 97.5 102.5

1

50T Coil
Current

Measure i410

Lo mV

i410
Hi mV

i1010
Lo mV

i1010
Hi mV

12 2.0A, 1 kHz 100.0A ac 100.0 mV NA NA 96.5 103.5

DC Amps Balance Test

13 4.0A dc 200.0A dc 200.0 mV

DC Amps Test

14 4.0A dc 200.0A dc 200.0 mV 192.5 207.5 195.5 204.5
15 8.0A dc 400.0A dc 0.4000V 0.3855V 0.4145V 0.3915V 0.4085V
16 -8.0A dc -400.0A dc -0.4000V -0.4145V -0.3855V
17 -12.0A dc -600.0A dc -0.6000V NA NA
18 20.0A dc 1000.0A dc 1.0000V NA NA
19 -20.0A dc -1000.0A dc -1.0000V NA NA

AC Amps Test

20 2.4A, 45 Hz, 400 Hz 120.0A ac 120.0 mV 115.3 124.7 117.1 122.9
21 2.4A, 800 Hz 120.0A ac 120.0 mV NA NA 115.9 124.1
22 5.0A, 45 Hz, 400 Hz 250.0A ac 250.0 mV 240.7 259.3 244.5 255.5
23 8.0A, 45 Hz, 400 Hz 400.0A ac 0.4000V 0.3855V 0.4145V NA NA
24 12.0A, 45 Hz, 65 Hz 600.0A ac 0.6000V NA NA 0.5875V 0.6125V

1.0A maximum change from Center of Jaw
Reading to Top or Bottom of Jaw Readings.

NA NA

-0.6125V -0.5875V

0.9795V 1.0205V

-1.0205V -0.9795V

Notes:

1. Prior to performing DC Amp tests, adjust ZERO so that the DMM reads 00.0 +/- 00.1 mV without current applied.

5

i410/i1010

AC/DC Current Clamp

Calibration and Adjustment

Always complete the Performance Test prior to Calibration. If Performance Test results are satisfactory,
calibration is not necessary. Otherwise, to ensure that the Current Clamp performs to specification, cali­brate the Battery Indicator, DC Zero, and DC Amps and check the AC Amps function on a yearly basis.

When it is needed, be sure to complete the full calibration procedure (Battery Indicator, DC Zero, DC
Amps Calibration and AC Amps Check.) Partial completion of this procedure will not ensure that the
Current Clamp performs to specification.

Adjustment points are shown in Figure 2.

Decal

AC/DC CURRENT CLAMP

i1010

OUTPUT 1mV/A

600V

Figure 2. Calibration Adjustment Points

Calibrating the Battery Indicator

Use the following procedure to calibrate the low battery indicator:

1. Set the DC voltage generator to 9.0V dc.

CAT III

CAT III

600V
600A

1000A

~

Power On Indicator
Power On/Off Button

ZERO Knob

VR4

A

ZERO

VR5
VR1

VR6

VR3

el004f.eps

2. On the Current Clamp, disconnect the battery from the battery clip.

3. Connect the DC voltage generator to the battery snap.

4. Connect the Current Clamp output cable to a DMM. Check that the DMM reads 9.0V dc.

5. On the Current Clamp, press the green power button on and check that the LED is on.

6. Set the DC voltage generator to 7.0V dc. (The LED may be on or off at this point.)

7. Adjust VR4 on the Current Clamp to the point where the LED cycles from on to off.

6

Calibrating DC Zero

Use the following procedure to calibrate the ZERO control:

1. Set the DMM to measure 3V dc to four decimal places.

2. Rotate the ZERO knob to mid-range (ZERO knob bar vertical.)

3. Adjust VR3 so that the DMM reads 0.0000.

4. Turn ZERO (VR2) fully CCW. Check that the DMM reads 0.0050 or higher.

5. Turn ZERO (VR2) full CW. Check that the DMM reads -0.0050 or lower.

Calibrating the DC Amps Function

Use the following procedure to calibrate the DC Amps function:

1. Clamp and center the Current Clamp onto the current coil.

2. Set the DMM to 300 mV dc range at medium speed.

3. Rotate the ZERO knob so that the DMM reads 000.0.

4. Apply 4A dc (200 ampere-turns) to the current coil. Check that the DMM reads 200 mV.

Service Information

Calibration and Adjustment

5. Move the coil conductor within the Current Clamp jaws as you observe reading differences on the

DMM.

6. Adjust VR5 so that multimeter readings vary by no more than 0.2% (199.6 to 200.4 mV).

7. Remove the Current Clamp jaws from the current coil and check that the DMM reads 000.0. If nec-

essary, adjust the ZERO knob to obtain 000.0.

8. Apply 4A dc (200 ampere-turns) to the current coil.

9. Clamp the Current Clamp jaws onto the current coil.

10. With the coil conductor centered in the jaws, adjust VR6 to its mid-range. Then adjust VR1 so that

the DMM reads 199.9 to 200.1. If necessary, adjust VR6 to fine tune this reading.

Checking the AC Amps Function

To check the AC Amps function, do the following:

1. Make sure that the Calibrator, Transconductance Amplifier, DMM, and Current Coil are connected

as shown in Figure 1.

2. Set the DMM to the 300 mV ac range.

3. Clamp the Current Clamp around the Current Coil, taking care to align the conductor with the align-

ment marks on the jaws of the Current Clamp.

4. Apply 5A ac (250 ampere-turns) at 50 or 60 Hz to the Current Coil.

For the i410, the DMM should read between 240.7 and 259.3 mV ac. For the i1010, the DMM should

read between 244.50 and 255.50 mV ac.

5. If you do not obtain readings within the limits of step 4, repeat "Calibrating the DC Amps Function."

7

i410/i1010

AC/DC Current Clamp

Reassembling the Current Clamp

After you have completed the last calibration step and checked the AC Amps function, do the following:

1. Replace the decal over the potentiometer access holes.

2. Replace the battery cover and its securing screw.
The Current Clamp is now ready for normal operation.

Replacement Parts

Replacement parts are listed in Table 5 and shown in Figure 3. To obtain replacement parts, call Fluke
Corporation at 1-800-526-4731.

Table 5. Replacement Parts

Part Description Part No.

i410 Case Top Decal 642584
i1010 Case Top Decal 642592
Battery Door 642600
Top Case and Zero Knob 642618
PCB Assembly 642626
Case Screw 642634
Jaw Spring 642642
Bottom Case 642645
Brass Cable Clamp 642659
Power On/Off Button (green) 642675
Output Cable Assembly 642683
Jaw Assembly 603602
Poron Ring 642535

8

Zero Knob

Service Information

Replacement Parts

Jaw Assembly

Battery Door

CAT

Decal

i1010

CAT III

OUTPUT 1mV/A

ZERO

AC/DC CURRENT CLAMP

600V

Top Case

600V

600A

1000A

A

Power ON/OFF Button

Poron Ring

Jaw Spring

Case Bottom Screw

(1 of 2)

Figure 3. Replacement Parts

Case Bottom

Brass Cable Clamp

Cable Output Assembly

el002f.eps

9

i410/i1010

AC/DC Current Clamp

10