HT instruments FULLTEST3 User Manual
3
FULLTEST
User’s manual
Copyright HT ITALIA 2014 Release EN 1.01 - 24/01/2014
FULLTEST 3
Table of contents:
1. SAFETYPRECAUTIONSANDPROCEDURES.............................................................................................3
1.1. PRELIMINARYINSTRUCTIONS...................................................................................................... 4
1.2. DURINGUSE................................................................................................................................4
1.3. AFTERUSE...................................................................................................................................5
1.4. OVERVOLTAGECATEGORIES‐DEFINITIONS..................................................................................5
2. GENERALDESCRIPTION.........................................................................................................................6
2.1. WORKING....................................................................................................................................6
2.2. OPENINGTHEINSTRUMENT'SCOVER...........................................................................................8
3. PREPARATIONFORUSE........................................................................................................................9
3.1. PRELIMINARYCHECKS..................................................................................................................9
3.2. POWERSUPPLY...........................................................................................................................9
3.3. CALIBRATION...............................................................................................................................9
3.4. TRANSPORTANDSTORAGE..........................................................................................................9
4. OPERATINGINSTRUCTIONS................................................................................................................10
4.1. INSTRUMENT‐DESCRIPTION.....................................................................................................10
4.2. TURNINGONTHETESTER..........................................................................................................11
4.3. MEASUREMENTFUNCTIONSELECTION......................................................................................12
5. MEASUREMENTS................................................................................................................................13
5.1. CONTINUITY‐TWOWIREMETHOD(RPE‐2WIRE)........................................................................13
5.1.1. RPE‐2WIREDISPLAYEXPLANATION...............................................................................................13
5.1.2. CALIBRATIONOFTESTLEADS........................................................................................................14
5.1.3. LIMITVALUEADJUSTMENT...........................................................................................................15
5.1.4. RPE‐2WIREMEASUREMENT..........................................................................................................16
5.2. CONTINUITY‐FOURWIREMETHOD(RPE‐4WIRE).......................................................................18
5.2.1. RPE‐4WIREDISPLAYEXPLANATION...............................................................................................18
5.2.2. CALIBRATIONOFTESTLEADS........................................................................................................19
5.2.3. RPE‐4WIREMEASUREMENT..........................................................................................................20
5.3. INSULATIONRESISTANCE(M)..................................................................................................22
5.3.1. RISODISPLAYEXPLANATION.........................................................................................................22
5.3.2. RISOMEASUREMENT....................................................................................................................23
5.4. DIELECTRIC(DIELECTRIC)............................................................................................................25
5.4.1. WARNINGS....................................................................................................................................25
5.4.2. DIELECTRICDISPLAYEXPLANATION..............................................................................................26
5.4.3. DIELECTRICTEST............................................................................................................................27
5.5. RCD(RCD)..................................................................................................................................29
5.5.1. RCDDISPLAYEXPLANATION..........................................................................................................29
5.5.2. EXPLANATIONOFRCDTESTCURRENTS........................................................................................30
5.5.3. RCDMEASUREMENT.....................................................................................................................31
5.6. LOOPIMPEDANCE/SHORT‐CIRCUITCURRENT(LOOP)...............................................................33
5.6.1. LOOPDISPLAYEXPLANATION........................................................................................................33
5.6.2. LIMITVALUEEXPLANATION..........................................................................................................34
5.6.3. PROSPECTIVESHORT‐CIRCUITCURRENTCALCULATION...............................................................35
5.6.4. LOOPMEASUREMENT...................................................................................................................36
5.7. GLOBALEARTHRESISTANCE/CONTACTVOLTAGE(RA)..............................................................39
5.7.1. RALIMITVALUECALCULATION.....................................................................................................39
5.7.2. RADISPLAYEXPLANATION............................................................................................................39
5.7.3. RAMEASUREMENT.......................................................................................................................40
5.8. RESIDUALVOLTAGE(URES)........................................................................................................42
5.8.1. EXPLANATIONOFLINEARMODE..................................................................................................42
5.8.2. EXPLANATIONOFNONLINEAR MODE...........................................................................................43
5.8.3. URESDISPLAYEXPLANATION........................................................................................................44
5.8.4. TRIGGERCONDITIONS...................................................................................................................44
5.8.5. URESMEASUREMENT...................................................................................................................45
5.9. POWER(POWER).......................................................................................................................48
5.9.1. POWERDISPLAYEXPLANATION....................................................................................................48
5.9.2. POWERMEASUREMENT...............................................................................................................49
5.10. PHASESEQUENCE(PHASESEQ)...................................................................................................51
EN - 1
FULLTEST 3
5.10.1. PHASESEQUENCEDISPLAYEXPLANATION...............................................................................51
5.10.2. PHASESEQUENCEMEASUREMENT..........................................................................................52
5.11. CURRENTMEASUREMENTUSINGCURRENTCLAMP(ICLAMP)....................................................53
5.11.1. ICLAMPDISPLAYEXPLANATION...............................................................................................53
5.11.2. ICLAMPMEASUREMENT..........................................................................................................54
5.12. LEAKAGECURRENT(ILEAK)........................................................................................................55
5.12.1. LEAKAGEDISPLAYEXPLANATION.............................................................................................55
5.12.2. LEAKAGECURRENTMEASUREMENTUSINGCURRENTCLAMP................................................57
5.12.3. LEAKAGECURRENTMEASUREMENTONSCHUKOSOCKET......................................................58
6. MENUFUNCTIONS..............................................................................................................................60
6.1. MEMORYmenu.........................................................................................................................60
6.1.1. MEMORYINFOmenu....................................................................................................................60
6.1.2. CLEARmenu..................................................................................................................................61
6.1.3. USBmenu......................................................................................................................................61
6.2. SELECTOPERATORmenu...........................................................................................................61
6.3. LANGUAGEmenu...................................................................................................................... 62
6.4. TESTERINFOmenu....................................................................................................................62
6.5. SETUPmenu..............................................................................................................................63
6.5.1. LEVELNAMESmenu......................................................................................................................63
6.5.2. LIMITCONTACTVOLTAGEmenu...................................................................................................64
6.5.3. DATE/TIMEmenu..........................................................................................................................64
6.5.4. RESETmenu...................................................................................................................................64
6.5.5. NOMINALVOLTAGEmenu............................................................................................................69
6.5.6. SAFETYmenu.................................................................................................................................69
6.6. SOUNDmenu.............................................................................................................................70
7. MEMORYFEATURES...........................................................................................................................71
7.1. MEMORYSTRUCTURE................................................................................................................71
8. MEMORIZINGEXAMPLE.....................................................................................................................72
9. RECALLRESULTS.................................................................................................................................74
10. ENTRYOFDATABYUSINGANEXTERNALKEYBOARD..........................................................................76
11. ENTRYOFDATAUSINGABARCODEREADER....................................................................................... 76
12. FWUPDATEOFTHEFULLTEST3..........................................................................................................76
13. MAINTENANCE...................................................................................................................................76
13.1. CLEANING..................................................................................................................................76
13.2. FUSEREPLACEMENT..................................................................................................................76
14. TECHNICALSPECIFICATIONS................................................................................................................78
14.1. MEASUREMENTFUNCTIONS......................................................................................................78
14.2. GENERALSPECIFICATION...........................................................................................................89
14.3. ACCESSORIES.............................................................................................................................89
15. SERVICE..............................................................................................................................................90
15.1. WARRANTYCONDITIONS...........................................................................................................90
15.2. AFTER‐SALESERVICE..................................................................................................................90
EN - 2
FULLTEST 3
1. SAFETY PRECAUTIONS AND PROCEDURES
CAUTION
For your own safety and to avoid damaging the instrument follow the procedures
described in this instruction manual and read carefully all notes marked with this symbol.
This instrument complies with safety Standards EN61557 and EN61010-1 related to electronic
measuring instruments. When taking measurements:
Avoid doing this in humid or wet places - make sure that humidity is within the limits indicated in
section “Environmental conditions”.
Avoid doing this in rooms where explosive gas, combustible gas, steam or excessive dust is
present.
Keep you insulated from and do not touch the object under test, any exposed metal part such as
test lead ends, sockets, fixing objects, circuits etc.
Avoid doing this if you notice anomalous conditions such as breakages, deformations, fractures,
blind display etc.
The following symbols are used in this instruction manual:
Warning of a potential danger, comply with instruction manual.
☞
Reference, please pay utmost attention.
UUT Unit under test
Caution, dangerous voltage. Danger of electrical shock.
Symbol for marking of electrical and electronic equipment (WEEE Directive).
Conformity symbol, the instrument complies with the valid directives. It complies with the
EMC Directive and the Low Voltage Directive.
EN - 3
FULLTEST 3
1.1. PRELIMINARY INSTRUCTIONS
CAUTION
The instrument must be connected to a power socket with grounded PE terminal. If this
is not assured, the instrument will display PE DISCONNECTED, SWITCH OFF NOW
message and will perform no measurement.
The instruction manual contains information and references, necessary for safe operation and
maintenance of the instrument. Prior to using the instrument, the user is kindly requested to
thoroughly read the instruction manual and comply with it in all sections.
Failure to read the instruction manual or to comply with the warnings and references contained
herein can result in serious bodily injury or instrument damage.
In order to avoid electrical shock, the valid safety and national regulations regarding excessive
contact voltages must receive utmost attention when working with voltages exceeding 60 V DC or
50 V (25 V) RMS AC. The value in brackets is valid for limited ranges (as for example medicine).
The operator is recommended to respect the usual safety regulations aimed at protecting against
dangerous currents and protecting the instrument against improper use.
This instrument has been designed for use in environments of pollution degree 2.
It can be used for tests on electrical installations of overvoltage category III, 300V maximum
voltage to earth.
Do not effect measurements on circuit exceeding the specified voltage limits.
Only the original test leads supplied along with the instrument guarantee compliance with the
safety standards in force. They must be in good conditions and, if necessary, replaced with
identical ones.
Do not take measurements under environmental conditions exceeding the limits indicated in this
manual.
Before connecting the test probes to the installation make sure that the right function is selected.
The instrument may only be used in dry and clean environments. Dirt and humidity reduce
insulation resistance and may lead to electrical shocks, in particular for high voltages.
Never use the instrument in precipitation such as dew or rain. In case of condensation due to
temperature jumps, the instrument may not be used.
Start any test series by earth bond resistance measurement.
At earth bond resistance, insulation resistance and dielectric measurements unit under test must
be voltage-free. If necessary check the unit is voltage-free i.e. by using a voltage tester.
When modifying the instrument, the operational safety is no longer ensured.
1.2. DURING USE
CAUTION
An improper use may damage the instrument and/or its components or injure the
operator.
Only skilled technicians, who know the possible risks involved to the dangerous voltages use are
allowed to operate the instrument.
The instrument may only be connected to mains voltage as indicated on the type shield.
The instrument may only be used within the operating ranges as specified in the technical data
section.
Disconnect the test leads from the circuit under test before selecting any function.
Only touch test leads and test probes at handle surface provided. Never directly touch test probes.
Never touch any unused terminal when the instrument is connected to circuits.
EN - 4
FULLTEST 3
Do not measure resistance in presence of external voltages; although the instrument is protected,
an excessive voltage may cause malfunctioning.
Do not open the instrument! Dangerous voltages inside!
Connecting one terminal to the test object and working with one probe or holding both probes in
one hand is prohibited.
Use safety probes with protection against contact or with two-hand operation only. Always hold
only one probe in one hand.
It is prohibited to touch the unit under test during the test. If need be, additional measures must be
taken (e.g. cover made of insulating mats) to protect the person performing the test against
inadvertent contact with the unit under test.
1.3. AFTER USE
Disconnect all test leads from the circuit under test and switch off the instrument.
1.4. OVERVOLTAGE CATEGORIES - DEFINITIONS
Standard EN61010-1 (Safety requirements for electrical equipment for measurement, control and
laboratory use, Part 1: General requirements) defines what a measurement category (usually called as
Overvoltage Category) is. At paragraph 6.7.4: Measuring circuits it says:
(OMISSIS)
Circuits are divided into the following measurement categories:
Measurement category IV is for measurements performed at the source of the low-voltage
installation.
Examples are electricity meters and measurements on primary overcurrent protection devices
and ripple control units.
Measurement category III is for measurements performed in the building installation.
Examples are measurements on distribution boards, circuit breakers, wiring, including cables,
bus-bars, junction boxes, switches, socket-outlets in the fixed installation, and equipment for
industrial use and some other equipment, for example, stationary motors with permanent
connection to fixed installation.
Measurement category II is for measurements performed on circuits directly connected to the
low voltage installation.
Examples are measurements on household appliances, portable tools and similar equipment.
Measurement category I is for measurements performed on circuits not directly connected to
MAINS.
Examples are measurements on circuits not derived from MAINS, and specially protected
(internal) MAINS-derived circuits. In the latter case, transient stresses are variable; for that
reason, the norm requires that the transient withstand capability of the equipment is made
known to the user.
EN - 5
FULLTEST 3
2. GENERAL DESCRIPTION
Dear Customer, the instrument you have purchased, whether used according to the instructions given in
this manual, will grant you accurate and reliable measurements. Thanks to a development of newest
conception assuring overvoltage category III you will enjoy the highest safety.
The Machinery Tester FULLTEST 3 is a measurement instrument used for final inspection of electrical
equipment of machines, control cabinets, switchgears as well as other devices complying with
IEC/EN60204-1 and IEC/EN61439-1 standards.
2.1. WORKING
The instrument can carry out the following tests, further to the regulations listed below:
Continuity of protective conductor
- 2-wire or 4-wire measurement method.
- Compensation of test leads in case of 2-wire measurement.
- Open-circuit test voltage 6 V approx.
- Test current 200 mA and 25 A.
- Limit value adjustable, visual and acoustic warning in case of exceeded
value.
EN61557-4
EN61439-1-§10.5.2
EN60204-1-§18.2.2
EN60598-1
EN60335-1-§27.5
EN60335-1-§A.1
EN50106
EN60950
CEI 64-8/7-CEI64/13
Insulation resistance
- Test voltage 100 V, 250 V, 500 V and 1000 V DC.
- MAN (manual) mode.
- TIMER mode.
- AUTO mode.
- Limit value adjustable, visual and acoustic warning in case of exceeded
value.
Dielectric test
- Adjustable test voltage 250 V up to 5100 V AC.
- Trip out current adjustable 1 110 mA, visual and acoustic warning in
case of exceeded limit value.
- Display and trip out based on real or apparent current.
EN61557-2
CEI64-8
CEI23-51
CEI64-8/7-CEI64/13
EN61439-1-§11.9
EN60204-1
EN60598-1
EN61439-1-§9.1
EN60204-1-§18.4
EN60598-1
EN60335-1-§13.3
EN60335-1-§A.2
- MANUAL mode.
- RAMP mode (predefined automatic rising of test voltage).
- BURN mode.
- Protection against unauthorised use (safety measure).
- Red warning lamp connector (safety measure).
- Safety input connector (safety measure).
EN - 6
FULLTEST 3
RCD test
- AC, A and B type.
- General, selective and delayed characteristic.
- Voltage range 100 ... 265 V.
- Limit contact voltage 25 or 50 V.
- IN = 10, 30, 100, 300, 500, 650 or 1000 mA.
- Trip out time at IN/2 (AC, A and B type).
- Trip out time at IN (AC, A and B type).
- Trip out time at 2IN (AC and A type).
- Trip out time at 5IN (AC and A type) or at 4IN (B type).
- Ramp test (AC, A and B type).
- AUTO test (AC, A and B type).
- Visual and acoustic warning in case of exceeded limit value.
Loop impedance measurement
- ZL/N, ZL/L and ZL/PE measurement.
- Voltage range 100 460 V.
- IPSC calculation.
- Limit value adjustable, visual and acoustic warning in case of exceeded
value.
Global earth resistance
- Selectable test current with regard to involved RCD.
- IN = 10, 30, 100, 300, 500, 650 or 1000 mA.
- Measurement with IN/2 (without tripping out RCD)
- Voltage range 100 265 V.
- Contact voltage UC measured during the measurement.
- Limit value (RA) fixed to 25 or 50 V/IN, visual and acoustic warning in
case of exceeded value.
Residual voltage
- Measurement on power plug (2-wire method).
- Measurement on internal components (4-wire method).
- Limit discharge time 1 s or 5 s.
- LINEAR or NONLINEAR mode.
- Visual and acoustic warning in case of exceeded limit value.
Power (on schuko socket)
- Apparent power P
APP.
- Real power P.
- Mains voltage U
L/N.
- Load current IL.
- Power factor PF.
- Leakage current IPE (differential method).
- Internal phase position exchange.
- Limit value (apparent power) adjustable, visual and acoustic warning in
case of exceeded value.
Phase sequence
- Mains voltages UL1/2, UL2/3, UL3/1 simultaneously displayed.
EN61557-6
EN60204-1-§18.2
EN61557-3
EN60204-1-§18.5
EN61557-7
EN - 7
FULLTEST 3
Clamp current
- Measurement in combination with HT96U current clamp.
- Three ranges 1 A, 100 A and 1000 A.
- Limit value adjustable, visual and acoustic warning in case of exceeded
value.
Leakage current
- Measurement of IPE current on schuko socket (differential method).
- Measurement with current clamp type HT96U, three ranges 1 A, 100 A
and 1000 A.
- Limit value adjustable, visual and acoustic warning in case of exceeded
value.
GENERAL advantages
- Portable Machinery & Panel Tester constructed according to the
IEC/EN60204-1 and IEC/EN61439-1 standards.
- Operation system WINDOWS EMBEDDED COMPACT 7 supports all
measurements and operations.
- Easy and clear operation by using the touch screen and intuitive hard
keys.
- TRMS measurements.
- Data memory for 999 measurement results, three levels (e.g.
CUSTOMER, LOCATION, MACHINE) plus additional COMMENT.
- Real time clock included.
- Integrated interface (USB 2.0) for transfer of measurement results to PC.
- Separate interface (USB 2.0) for connection of USB barcode reader, USB
keyboard, USB memory stick, printer or IMP57-impedance tester.
- Graphic colour touch screen 102×60 mm, 480×272 dots.
- Compact housing with external accessory bag.
- Quick connection diagrams and limit values under the instrument cover.
- Fuse protection in case of overload.
- PC Software TOP VIEW available.
- Complete test accessories included.
- Blue tooth communication.
- Remote START/STOP and SAVE function.
- *HELP screens available.
- *20 programmable AUTO test procedures.
* Special FW version.
2.2. OPENING THE INSTRUMENT'S COVER
The instrument is built in a robust plastic case that allows comfortable transport.
We recommend the user to follow the next opening instructions:
1
Place the unit on to a hard horizontal surface.
2
Press on the case cover with your hands, see the
mark 1.
Unlock the fixing hooks of the cover, see the mark 2.
Open the cover into vertical position.
Figure 1: Opening the instrument’s cover
EN - 8
FULLTEST 3
3. PREPARATION FOR USE
3.1. PRELIMINARY CHECKS
This instrument was checked both mechanically and electrically prior to shipment. All possible cares and
precautions were taken to let you receive the instrument under perfect conditions. Notwithstanding we
suggest you to check it rapidly (possible damages may have occurred during transport – if so please
contact the local distributor from whom you purchased the item).
Make sure all standard accessories according to Packing List are included.
Should you have to return back the instrument for any reason please follow the instructions mentioned
in paragraph “TRANSPORT AND STORAGE”.
3.2. POWER SUPPLY
Earthed plugs must energize the instrument. To avoid any risk the instrument does not allow to effect
measurements when there is not such a connection (refer to paragraph “TURNING ON THE TESTER”
for details).
3.3. CALIBRATION
The instrument complies with the technical specifications contained in this manual and such a
compliance is guaranteed for 1 year. Annual recalibration is recommended.
3.4. TRANSPORT AND STORAGE
Please keep the original packaging for potential later transport, e.g. for calibration. Any transport
damage due to faulty packaging will be excluded from warranty claims.
Instruments must be stored in dry and closed areas. In case of an instrument being transported in
extreme temperatures, a recovery time of minimum 2 hours is required prior to instrument operation.
EN - 9
FULLTEST 3
4. OPERATING INSTRUCTIONS
4.1. INSTRUMENT - DESCRIPTION
Figure 2: Instrument description
LEGEND
1 Quick instruction label under the cover.
2 Fuse F3, type T12.5A/500V 6.3×32 mm which protects internal circuitry in LOOP, RA and RCD
measurements.
3 General tester fuse F2, type T16A/250V 5×20 mm which protects internal circuitry in POWER, RPE
and DIELECTRIC measurements.
4 General tester fuse F1, type T16A/250V 5×20 mm which protects internal circuitry in POWER, RPE
and DIELECTRIC measurements.
5 ON/OFF mains switch (with red pilot lamp).
EN - 10
FULLTEST 3
6 Connector for START/SAVE remote control adapter.
7 Connector SAFETY INPUT for connection of external safety switch (for example protection door). It
disables DIELECTRIC tests in case the switch is open.
8 IEC female connector for connection of red WARNING LAMP in DIELECTRIC test. The lamp is
active when the test is on (parallel operation to HV lamp on front panel, reference 35).
9 USB 1 connector for connection with PC.
10 USB 2 and USB 3 connectors for connection of USB stick, USB barcode reader, USB printer, USB
keyboard or IMP57 impedance meter.
11 Negative RISO terminal.
12 Positive RISO terminal.
13 RPE current generator terminal.
14 SENSE voltage terminal.
15 Fuse F4, type F20A/500V 6.3×32 mm which protects internal circuitry in RPE measurement.
16 SENSE voltage terminal.
17 RPE current generator terminal.
18 FUNC hard key to select appropriate measurement function.
19 SAVE hard key to save test result.
20 START/STOP button which starts or stops selected measurement.
21 RCL hard key to recall saved result.
22 MENU hard key to open MAIN MENU.
23 EXIT hard key to exit existing screen and return it one step back.
24 Colour LCD touch-screen display.
25 Mains test socket for POWER and LEAKAGE measurement.
26 CLAMP connector for HT96 current clamp.
27 URES measurement terminal.
28 URES measurement terminal.
29 L/TRIG/L1 terminal for LOOP, RA, RCD, PHASE SEQUENCE and URES measurements.
30 PE/L3 terminal for LOOP, RA, RCD and PHASE SEQUENCE measurements.
31 N/TRIG/L2 terminal for LOOP, RCD, PHASE SEQUENCE and URES measurements.
32 DIELECTRIC test terminal for test voltages 2.51 5.10 kV.
33 DIELECTRIC test terminal for test voltages 0.81 2.50 kV.
34 DIELECTRIC test terminal for test voltages 0.25 0.80 kV.
35 DIELECTRIC on lamp. It lights when DIELECTRIC test is running.
36 DIELECTRIC COM (common) test terminal.
4.2. TURNING ON THE TESTER
After switching on mains switch (5) the tester will upload WINDOWS first (it will take 30 s approx.), then
last used measurement screen will appear. A beep-beep sound signal will be given as soon as the
tester is ready for measurements.
CAUTION
In case energizing socket is not earthed properly PE DISCONNECTED message
will appear and the tester will not perform any further operation. In this case
switch off the tester immediately and check the energizing socket!
EN - 11
FULLTEST 3
4.3. MEASUREMENT FUNCTION SELECTION
Press the FUNC hard key (yellow), the function selection screen will appear.
R
PE-2WIRE
R
PE-4WIRE
M
DIELECT
RCD
LOOP
R
A
U
RES
POWER
PHASE
I
CLAMP
I
LEAK
SEQ
Figure 3: Function selection screen
Select wished function by pressing appropriate touch-screen key, basic measurement screen of
selected function will appear, see an example of RPE-2WIRE basic measurement screen below. Other
functions use adapted screens, but follow the same system.
Figure 4: Basic measurement screen in RPE-2WIRE function
1 ..... Selected function.
2 ..... Progress bar, it follows measurement time during the measurement (in TIMER mode only).
3 ..... Two lines reserved for sub-results (no value in basic screen yet).
4 ..... Measurement screen touch-screen key.
5 ..... Measurement parameters touch-screen keys.
6 ..... Test lead calibration status (LEADS CALIBATED or LEADS NOT CALIBRATED).
7 ..... Measurement result field (result in green colour - OK, result in red colour - not OK, result in white
colour – not judged).
8 ..... Real time clock (hh.mm.ss).
9 ..... Unit of the measurement result.
10 ... Set measurement time (in TIMER mode only).
EN - 12
FULLTEST 3
5. MEASUREMENTS
5.1. CONTINUITY - TWO WIRE METHOD (RPE-2WIRE)
Complying with EN 60204-1, continuity of protective bonding circuit between PE terminal and
relevant points of the protective conductor system must be checked by injecting a measurement
current of 0.2 A up to 10 A approx.
5.1.1. RPE-2WIRE DISPLAY EXPLANATION
Adjustable/selectable parameters:
Im NOM - nominal measurement current 200 mA or 25 A AC
LIMIT (meas. current 200 mA) - continuity limit value 0.01 19.99, 20.0 200.0
LIMIT (meas. current 25 A) - continuity limit mode STANDARD, 60204 SET Z or 60204 SET L
LIMIT (test current 25 A, STANDARD mode) -
continuity limit value 0.01 20.00
MODE - measurement mode MANUAL or TIMER
CAL (meas. current 200 mA) - calibration of test leads 0.00 5.00
CAL (meas. current 25 A) - calibration of test leads 0.000 1.999, 2.00 5.00
TIMER - measurement time 00:01 60:00 (1 s 60 min), resolution 1 s
LENGTH - wire length 0.1 999.9 m, resolution 0.1 m
SECTION - wire section 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50 or 70 mm2
MATERIAL - wire material Cu (Cupper) or Al (Aluminium)
ZLINE - input line impedance 0.001 2.000 , resolution 0.001
PROTECTION - over-current protection device MCB B, MCB C, MCB D, MCB K, FUSE gG or
FUSE aM
In - nominal current of protection device Depends on selected protection device, see the
chapter 5.1.3. LIMIT VALUE ADJUSTMENT
Figure 5: Display with RPE-2WIRE test result
1 ..... Selected function.
2 ..... Progress bar, it follows measurement time during the measurement (in TIMER mode only).
3 ..... Sub-result - measurement current Im that was flowing through UUT during the measurement.
4 ..... Measurement screen touch-screen key.
5 ..... Im NOM touch-screen key to select nominal test current (200 mA or 25 A). Currently selected value
is displayed on the bottom of the key.
EN - 13
FULLTEST 3
6 ..... LIMIT touch-screen key to select limit value (200 mA measurement) or limit mode (25 A
measurement). Currently selected value or CALC is displayed on the bottom of the key. CALC
message means the value is calculated.
7 ..... MODE touch-screen key to select operation mode (MANUAL or TIMER). Currently selected mode
is displayed on the bottom of the key. TIMER mode is available in 200 mA measurement and in 25
A measurement if STANDARD limit mode is selected.
8 ..... CAL touch-screen key to carry out calibration of test leads. Currently calibrated value is displayed
on the bottom of the key. In case of no calibration, the value 0.00 is displayed in red colour.
9 ..... Test lead calibration status (LEADS CALIBATED or LEADS NOT CALIBRATED).
10 ... Measurement value (in green colour - result OK, in red colour - result not OK).
11 ... Real time clock (hh.mm.ss).
12 ... Unit of measurement result ().
13 ... Set measurement time (in TIMER mode only).
14 ... Measurement result status (symbol in green colour - result OK, symbol in red colour - result
not OK or symbol in yellow colour – result OK, but measurement current too low).
5.1.2. CALIBRATION OF TEST LEADS
In order test leads not to influence the test results, resistance of the leads must be calibrated (zeroed).
Follow the next steps to calibrate test lead’s resistance:
1) Select test current that will be used for later measurement (200 mA or 25 A) by pressing the
Im NOM touch-screen key (5) first.
2) Press the CAL touch-screen key (8), the message “SHORTCIRCUIT TEST LEADS AND PRESS
START TO CALIBRATE” will appear.
3) Connect test leads according to the figure below, make sure two crocodiles are connected as close
as possible to each other to a piece of unisolated wire.
Short unisolated wire
2
Red test leads 2,5 mm
Figure 6: Connection of test leads for calibration purpose
4) Press the START button. The measurement will be done and value without calibration will be
displayed for a moment, then the value will be set to zero (0.00). Test leads are thus calibrated,
measurements can follow.
CAUTION
The calibration must be done separately for each test current (200 mA and 25
A)!
The calibration must be repeated when test leads are changed (replaced,
shortened or extended)!
Max resistance that can be calibrated is 5 !
Existing calibration can be annulled if test leads are opened when calibration
is carried out!
Calibration is not needed in R
PE-4WIRE function!
EN - 14
FULLTEST 3
The following specific information may be shown on the display during calibration:
Information displayed Description
SHORTCIRCUIT TEST LEADS
AND PRESS START KEY TO
CALIBRATE
OPEN TEST LEADS,
CALIBRATION ANNULED
Calibration has been started (CAL touch-screen key has
been pressed).
Shortcircuit test leads and press the START button!
Test leads are opened after pressing the START button.
Press YES key … existing calibration will be annulled!
Press NO key … existing calibration will stay untouched!
Connected resistance is higher than 5 and lower than
RPE > 5
CALIBRATION FAILED
measurement range, calibration can not be carried out.
Existing calibration will stay untouched.
Reduce external resistance and repeat the calibration!
5.1.3. LIMIT VALUE ADJUSTMENT
Test current 200 mA is selected:
Limit value can be selected within the range from 0.01 up to 99.99 in steps of 0.01 .
Test current 25 A is selected:
There are three possibilities to select the limit value.
- STANDARD selection.
Limit value can be selected within the range from 0.01 up to 20.00 in steps of 0.01 .
- EN60204 SET L selection.
Limit value is calculated on bases of wire length (L), wire section (SECTION) and wire material
(MATERIAL), where the parameters can be selected/adjusted within the following ranges:
- L (length) 0.1 up to 999.9 m in steps of 0.1 m
- SECTION (wire section) 1, 2.5, 4, 6, 10, 16, 25, 35, 50 or 70 mm
2
- MATERIAL (wire material) Cu (Copper) or Al (Aluminium)
- EN60204 SET Z selection.
Limit value is calculated on bases of entered line impedance (Z
LINE), type of protection (TYPE),
nominal current (IN) and wire section (SECTION), where the parameters can be selected within the
following ranges:
- Zline (line impedance) 0.001 up to 2.000 in steps of 0.001
- TYPE (type of protection) MCB B, MCB C, MCB D, MCB K, FUSE gG or FUSE aM
- In (nominal current) - 6, 10, 13, 16, 20, 25, 32, 40, 50 or 63 A (MCB B)
- 0.5, 1, 1.6, 2, 4, 6, 10, 13, 16, 20, 25, 32, 40, 50 or 63 A (MCB C)
- 0.5, 1, 1.6, 2, 4, 6, 10, 13, 16, 20, 25 or 32 A (MCB D, MCB K)
- 2, 4, 6, 8, 10, 12, 16, 20, 25, 32, 40, 50, 63, 80, 100, 125, 160,
200, 250, 315, 400, 500, 630, 800, 1000 or 1250 A (FUSE gG)
- 2, 4, 6, 8, 10, 12, 16, 20, 25, 32, 40, 50, 63, 80, 100, 125, 160,
200, 250, 315, 400, 500 or 630 A (FUSE aM)
- SECTION (wire section) 1, 2.5, 4, 6, 10, 16, 25, 35, 50 or 70 mm
2
EN - 15
FULLTEST 3
5.1.4. RPE-2WIRE MEASUREMENT
Measured quantities and display ranges:
Resistance RPE 0 200 (nominal test current 200 mA)
0 20 (nominal test current 25 A)
Measurement current Im 10 255 mA (nominal test current 200 mA)
0.2 30.0 A (nominal test current 25 A)
1) Select the RPE-2WIRE measurement by pressing the FUNC hard key first.
2) Check selected test current (200 mA or 25 A) and modify it if needed by pressing the Im
NOM (5)
touch-screen key first.
3) Check selected limit value and modify it if needed by pressing the LIMIT (6) touch-screen key first.
Four independent preset limit values are available in STANDARD limit mode selection for quicker
operations. Select the one closest to wished value and modify it by using the + and ― touch screen
keys if needed.
4) Check selected mode (MANUAL or TIMER) and modify it if needed by pressing the MODE (7)
touch-screen key first. In MANUAL mode the measurement will start after pressing the
START/STOP button and will stop after pressing the START/STOP button again. In TIMER mode
the measurement will start after pressing the START/STOP button and will stop after elapsing set
measurement time or after pressing the START/STOP button again.
5) Check the status of test lead calibration and carry out the calibration if needed, see the instructions
in chapter “CALIBRATION OF TEST LEADS” above.
6) Select measurement screen by pressing the
(4) touch-screen key and check all settings again.
7) Connect the test leads according to the figure below.
CAUTION
Before connecting test leads to UUT obligatory assure there is no external voltage
higher than 10 V between the test points where test leads will be connected to,
otherwise fuse F4 may blow!
Figure 7: Connection of test leads in RPE-2WIRE function
8) Carry out the measurement by pressing the START/STOP button. Test result will currently be
displayed in green (result lower than or equal to set limit value) or in red colour (result higher than
set limit value). Final result will be equipped with green
(result OK) or with red
symbol and with longer beep sound (result not OK) or with yellow
symbol and with beep-beep sound
symbol and with beep-beep sound (result OK, but measurement current was too low). See the
display outlook with test result on figure 5.
9) Save the test result by pressing the SAVE hard key twice, for further instructions see the
“MEMORIZING EXAMPLE” section.
EN - 16
FULLTEST 3
CAUTION
Max external voltage between two RPE or between two SENSE test terminals
is 10 VAC, no DC external voltage is allowed! In case of higher external
voltage fuse F4 (T20A/500V, 6.3×32 mm) may blow!
Measurement time in MANUAL mode is limited to 60 min!
The following specific information can be shown on the display during measurement:
Information displayed Description
Measurement result is negative probably because of
shorter test leads than calibrated (negative value is higher
CHECK CALIBRATION
than 5 digits).
Calibrate test leads again!
External voltage higher than 3 V is applied between two
RPE or between two SENSE test terminals
(measurement is not running) or higher than 10 V
EXTERNAL VOLTAGE
(measurement is running).
External voltage higher than 5 30 V is applied between
any RPE or SENSE test terminal and GND.
Remove external voltage!
LIMIT OUT OF RANGE
FUSE F4!
Calculated limit value is < 1 (EN60204 SET Z limit mode)
Fuse F4 is blown.
Internal fuse may be blown!
ERROR 1!
The fuse is not customer replaceable, send the tester into
a service department.
EN - 17
FULLTEST 3
5.2. CONTINUITY - FOUR WIRE METHOD (RPE-4WIRE)
Complying with EN 60204-1, continuity of protective bonding circuit between PE terminal and
relevant points of the protective conductor system must be checked by injecting a measurement
current of 0.2 A up to 10 A approx.
Limit values are the values which correspond to the length, cross section and material of measured
conductor.
5.2.1. RPE-4WIRE DISPLAY EXPLANATION
Adjustable/selectable parameters:
LIMIT - continuity limit mode STANDARD, 60204 SET Z or 60204 SET L
MODE - measurement mode MANUAL or TIMER
TIMER – measurement time 00:01 60:00, resolution 1 s
LENGTH - wire length 0.1 999.9 m, resolution 0.1 m
SECTION - wire section 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50 or 70 mm2
WIRE - wire material Cu (Cupper) or Al (Aluminium)
ZLINE - input line impedance 0.001 2.000 , resolution 0.001
PROTECTION - over-current protection device MCB B, MCB C, MCB D, MCB K, FUSE gG or
FUSE aM
In - nominal current of protection device Depends on selected protection device, see the
chapter 5.1.3. LIMIT VALUE ADJUSTMENT
Figure 8: Display with RPE-4WIRE test result
1 ..... Selected function.
2 ..... Progress bar, it follows measurement time during the measurement (in TIMER mode only).
3 ..... Measurement current flowing through UUT during the measurement.
4 ..... Measurement screen touch-screen key.
5 ..... LIMIT touch-screen key to select limit mode (STANDARD, 60204 SET Z or 60204 SET L).
Currently selected value (STANDARD mode) or CALC (60204 SET Z or 60204 SET L mode) is
displayed on the bottom of the key. CALC message means the value is calculated.
6 ..... MODE touch-screen key to select operation mode (MANUAL or TIMER). Currently selected mode
is displayed on the bottom of the key. TIMER mode is available only if STANDARD limit mode is
selected.
7 ..... Measurement value (in green colour - result lower than or equal to set limit value, in red colour -
result is higher than set limit value).
8 ..... Real time clock (hh.mm.ss).
9 ..... Unit of measurement result ().
EN - 18
FULLTEST 3
10 ... Set measurement time (in TIMER mode only).
11 ... Measurement result status (symbol in green colour - result OK, symbol in red colour –
result not OK).
5.2.2. CALIBRATION OF TEST LEADS
The calibration is not needed because of 4-wire method.
EN - 19
FULLTEST 3
5.2.3. RPE-4WIRE MEASUREMENT
Measured quantities and display ranges:
Continuity RPE 0 20
Test current 0.2 30 A
1) Select the RPE-4WIRE function by pressing the FUNC hard key first.
2) Check selected limit value and modify it if needed by pressing the LIMIT (6) touch-screen key first.
Four independent preset limit values are available in STANDARD limit mode selection for quicker
operations. Select the one closest to wished value and modify it by using the + and ― touch screen
keys if needed.
3) Check selected mode and modify it if needed by pressing the MODE (7) touch-screen key first.
4) Select measurement screen by pressing the (4) touch-screen key and check all settings again.
5) Connect the test leads according to the figure below.
CAUTION
Before connecting test leads to UUT obligatory assure there is no external voltage
higher than 10 V between the test points where test leads will be connected to,
otherwise fuse F4 may blow!
Figure 9: Connection of standard test leads
Figure 10: Connection of optional Kelvin test leads
6) Carry out the measurement by pressing the START/STOP button. The measurement will start to
run and will be stopped after pressing the START/STOP button again (MANUAL mode) or after
elapsing set measurement time (TIMER mode).
Test result will currently be displayed in green (result lower than or equal to set limit value) or in red
colour (result is higher than set limit value). Final result will be equipped with green symbol and
EN - 20
FULLTEST 3
with beep-beep sound (result OK) or with red symbol and with longer beep sound (result not
OK). See the display outlook with test result on Figure 8.
7) Save the test result by pressing the SAVE hard key twice, for further instructions see the
“MEMORIZING EXAMPLE” section.
CAUTION
Max external voltage between two RPE or between two SENSE test terminals
is 10 VAC, no DC external voltage is allowed! In case of higher external
voltage fuse F4 (T20A/500V, 6.3×32 mm) may blow!
If SENSE test leads are not connected, then measurement result will include
also the resistance of current test leads.
Measurement time in MANUAL mode is limited to 60 min!
The following specific information can be shown on the display during measurement:
Information displayed Description
External voltage higher than 3 VAC is applied between
two RPE or between two SENSE test terminals
(measurement is not running) or higher than 10 VAC
EXTERNAL VOLTAGE
(measurement is running).
External voltage higher than 5 30 V is applied between
any RPE or SENSE test terminal and GND.
Remove external voltage!
FUSE F4!
Fuse F4 is blown.
Internal fuse may be blown!
EROR1!
The fuse is not customer replaceable, send the tester into
a service department.
EN - 21
FULLTEST 3
5.3. INSULATION RESISTANCE (M)
• According to EN 60204-1, the insulation resistance between shorted active conductors of power
circuit and the earth bonding system must be checked by applying a test voltage of 500 V DC. The
limit value is 1 M.
• Ensure that all switches on the unit under test are closed in order to test all it’s components. For
purpose of the measurement, all active conductors (L1, L2, L3 and N) must be shortcircuited.
5.3.1. RISO DISPLAY EXPLANATION
Adjustable/selectable parameters:
Utest - nominal test voltage 100, 250, 500 or 1000 V DC
MODE - operation mode MANUAL, TIMER or AUTO
LIMIT - insulation resistance limit 0.01 100.0 M
Figure 11: Display with RISO test result
1 ..... Selected function.
2 ..... Progress bar, it follows measurement time during the measurement (in TIMER mode only).
3 ..... Test voltage applied during the measurement.
4 ..... Measurement screen touch-screen key.
5 ..... Utest touch-screen key to select nominal test voltage (100, 250, 500 or 1000 V). Currently selected
value is displayed on the bottom of the key.
6 ..... MODE touch-screen key to select operation mode (MANUAL, TIMER or AUTO). Currently selected
mode is displayed on the bottom of the key.
7 ..... LIMIT touch-screen key to select limit insulation resistance. Currently selected value is displayed
on the bottom of the key.
8 ..... Measurement value (in green colour - result OK, in red colour - result not OK).
9 ..... Real time clock (hh.mm.ss).
10 ... Unit of the measurement result M).
11 ... Set measurement time (in TIMER mode only).
12 ... Measurement result status (symbol in green colour - result OK, symbol in red colour - result
not OK).
EN - 22
FULLTEST 3
5.3.2. RISO MEASUREMENT
Measured quantities and display ranges:
Insulation resistance RINS 0 100 M (test voltage 100 V)
0 250 M (test voltage 250 V)
0 500 M (test voltage 500 V)
0 1000 M (test voltage 1000 V)
Test voltage Utest 0 1100 V
1) Select M function by pressing the FUNC hard key first.
2) Check selected test voltage (100, 250, 500 or 1000V) and modify it if needed by pressing the Utest
(5) touch-screen key first.
3) Check selected mode and modify it if needed by pressing the MODE (6) touch-screen key first.
MANUAL, TIMER or AUTO mode can be selected.
4) Check selected limit value and modify it if needed by pressing the LIMIT (7) touch-screen key first.
Four independent preset limit values are available for quicker operations. Select the one closest to
wished value and modify it by using the + and ― touch screen keys if needed.
5) Select measurement screen by pressing the (4) touch-screen key and check all settings again.
6) Connect the test leads according to the figure below.
Figure 12: Connection of test leads
7) Carry out the measurement by pressing the START/STOP button. The measurement will start to
run and will be stopped after pressing the START/STOP button again (MANUAL mode) or after
elapsing set measurement time (TIMER mode) or after reaching stabile result (AUTO mode).
Test result will currently be displayed in green colour (result higher than or equal to set limit value)
or in red colour (result lower than set limit value). Final result will be equipped with green
symbol and with beep-beep sound (result OK) or with red
symbol and with longer beep sound
(result not OK). See the display outlook with test result on Figure 11.
8) Save the test result by pressing the SAVE hard key twice, for further instructions see the
“MEMORIZING EXAMPLE” section.
EN - 23
FULLTEST 3
CAUTION
Connect COM test lead to chassis if the UUT is grounded. In case of reversed
test leads measurement result may be affected by instrument’s internal
resistance of 10 M!
Due to the measurement of insulation resistance, capacitive UUT will be
charged with test voltage. The UUT will be discharged after finishing the
measurement via internal resistance of approx. 2 M. The UUT can retain
dangerous voltage in case of premature removal of test leads. Ensure that the
UUT is discharged through the measurement instrument (not through short
circuit)!
Measurement time in MANUAL mode is limited to 60 min!
The following specific information can be shown on the display during the measurement:
Information displayed Description
External voltage higher than 10 VAC approx. is applied
between positive and negative test terminals
(measurement is not running) or higher than 50 VAC
approx. (measurement is running).
EXTERNAL VOLTAGE
Negative external voltage higher than 10 VDC approx. is
applied between positive and negative test terminals
(measurement is running).
Remove external voltage!
External capacitor (or internal) that was charged during the
DISCHARGING!
measurement is discharging.
Wait until the message disappears! Do not disconnect test
leads until the message is present!
EN - 24
FULLTEST 3
5.4. DIELECTRIC (DIELECTRIC)
According to EN 60204-1, electric equipment must withstand a voltage test between shorcircuited
active conductors of power circuit and the earth bonding system for approx. 1 s.
The test shall be carried out at twice the rated supply (or 1000 V whichever is greater) 50 Hz.
Components not rated for this test voltage may be disconnected before carrying out the test.
5.4.1. WARNINGS
WARNING, DANGER OF ELECTRICAL SHOCK
The Machine Tester FULLTEST 3 supplies high voltage of a dangerous power. According to EN 50191
the following precautionary measures must be taken prior to a test:
• Block access to danger area.
• Put up warning signs (Attention! High voltage, danger to life).
• Install warning lamps (red, green) to be easily visible.
• Install EMERGENCY-OFF switch into the mains installation outside the dangerous area.
• Electrical trained personnel may only do the tests under supervision of specialist staff and have to be
trained regularly.
• Use safety probes with protection against contact or with two-hand operation only. Always hold only
one probe in one hand.
• Connecting one test terminal to the UUT and working with one probe or holding both probes in one
hand is prohibited.
• It is prohibited to touch the unit under test during the test. If need be, additional measures must be
taken (e.g. cover made of insulating mats) to protect the person performing the test against
inadvertent contact with the test object.
Testing may commence only after all safety measures were taken.
Ensure that all switches on the UUT are closed in order to test all it’s components. For the purpose of
measurement all active conductors (L1, L2, L3 and N) must be shortcircuited.
EN - 25
FULLTEST 3
5.4.2. DIELECTRIC DISPLAY EXPLANATION
Adjustable/selectable parameters:
MODE - operation mode MANUAL, RAMP or BURN
UTEST NOM - nominal test voltage 250 5100 V AC
LIMIT - current limit 1 110 mA
CHAR - current character IAPP or IREAL
Figure 13: Display with DIELECTRIC test result
1 ..... Selected function.
2 ..... Progress bar, it follows test time during the measurement (in RAMP mode only).
3 ..... Test voltage applied during the measurement.
4 ..... Measurement screen touch-screen key.
5 ..... MODE touch-screen key to select operation mode (MANUAL, RAMP or BURN). Currently selected
mode is displayed on the bottom of the key.
6 ..... UTEST NOM touch-screen key to select nominal test voltage (250 up to 5100 V). Currently
selected value is displayed on the bottom of the key.
7 ..... LIMIT touch-screen key. Currently selected limit leakage current (trip out current) is displayed on
the bottom of the key.
8 ..... CHAR (character) touch-screen key to select the character of displayed leakage current (IAPP or
REAL). Currently selected character is displayed on the bottom of the key.
I
9 ..... Leakage current in green colour if the result is lower than or equal to set limit value. If break-
through occurred during the test then limit value will be displayed in red colour.
10 ... Real time clock (hh.mm.ss).
11 ... Unit of the test result (mA).
12 ... Set measurement time (in RAMP mode only).
13 ... Measurement result status (symbol
in green colour - result lower than or equal to set limit
value, symbol in red colour - break through occurred during the test or result higher than set
limit value).
EN - 26
FULLTEST 3
5.4.3. DIELECTRIC TEST
Measured quantities and display ranges:
Apparent leakage current IAPP 0 200 mA
Real leakage current IREAL 0 200 mA
Test voltage 250 5.100 V
Explanation of measurement modes:
MANUAL or BURN mode:
Figure 14: Presence of test voltage with regard to pressed START button in MANUAL or BURN mode
RAMP mode:
Figure 15: Presence of test voltage with regard to pressed START button and set time in RAMP mode
1) Select DIELECTRIC measurement by pressing the FUNC hard key first.
2) Check selected mode and correct it if needed by pressing the MODE (5) touch-screen key first.
MANUAL, RAMP or BURN mode can be selected.
3) Check selected test voltage (250 up to 5100V) and correct it if needed by pressing the UTES NOM
(6) touch-screen key first.
4) Check selected limit current and correct it if needed by pressing the LIMIT (7) touch-screen key
first. Four independent preset limit currents are available for quicker operations. Select the one
closest to wished value and modify it by using the + and ― touch screen keys if needed.
5) Check selected character of displayed current (IAPP or IREAL) and correct it if needed by pressing
the CHAR (8) touch-screen key first.
6) Select measurement screen by pressing the (4) touch-screen key and check all settings again.
7) Connect the test leads according to the figure below.
EN - 27
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