Transmille 2100 Operation Manual
21002100
Electrical Test Equipment Calibrator
Operation Manual
Version 4.00
December 2004
All product names are trademarks of their respective companies
2100 Operation Manual
IMPORTANT NOTICE
THIS CALIBRATOR
WILL
REQUIRE AN
UNLOCK CODE
AFTER THE EVALUATION
PERIOD HAS EXPIRED.
( 60 Days after invoice date)
AFTER THE EVALUATION PERIOD HAS EXPIRED THE
OPERATION OF THE CALIBRATOR IS LOCKED AND THE
DISPLAY SHOWS A NUMBER WHICH MUST BE QUOTED TO
TRANSMILLE TO RECEIVE THE UNLOCK CODE
THE UNLOCK CODE IS
AVAILALBLE
FROM TRANSMILLE
ONLYAFTER PAYMENT
HAS BEEN RECEIVED.
(This code is only entered once in the life of the instrument.)
Please contact Transmille or use the form in the back
of the manual to obtain the code.
Transmille Ltd.
Staplehurst , Kent.
Tel: 44 (0)1580 890700 : Fax 44(0)1580 890711
email:- sales@transmille.com
Transmille Ltd. Issue 4.00 Page 2
2100 Operation Manual
DECLARATION OF CONFORMITY
Manufacturer’s Name: Transmille Ltd.
Manufacturer’s Address: Unit 4, Select Business Centre
Lodge Road
Staplehurst
TN12 0QW
Declares, that the product
Product Name: Electrical Test Calibrator
Model Number: 2100
Product Options: This declaration covers all options of the above
product(s)
Conforms with the following European Directives:
The product herewith complies with the requirements of the Low Voltage Directive
73/73EEC and the EMC Directive 89/336/EEC (including 93/68/EEC) and carries the
CE Marking accordingly
Conforms with the following product standards:
EMC
Standard Limit
IEC616326-1:1997+A1:1998 / EN 61326-1 :1997+A1:1998
EN55011:1991
IEC 61000-4-2:1995+A1:1998 / EN 61000-4-2:1995 Group 1Class A
IEC 61000-4-3:1995 / EN 61000-4-3:1995 4kV CD, 8kV AD
IEC 61000-4-4:1995 / EN 61000-4-4:1995 3 V/m, 80-1000 MHz
IEC 61000-4-5:1995 / EN 61000-4-5:1995 0.5kV signal lines, 1kV power lines
IEC 61000-4-6:1996 / EN 61000-4-6:1996 0.5kV line-line, 1kV line-ground
IEC 61000-4-11:1994 / EN 61000-4-11:1994 3V, 0.15-80 MHz I cycle, 100%
Dips: 30% 10ms; 60% 100ms
Interrupt > 95%@5000ms
SAFETY
IEC 61010-1:1990+A1:1992+A2:1995 / EN 61010-1:1993+A2:1995
12/12/2001
Revision No: 1.1 Managing Director
Date :12/12/2001
Transmille Ltd. Issue 4.00 Page 3
2100 Operation Manual
Table of Contents
2100 ELECTRICAL TEST EQUIPMENT CALIBRATOR INTRODUCTION..............................6
INSTALLATION & POWER REQUIREMENTS FOR THE 2100 ..................................................7
PREPARING THE CALIBRATOR FOR USE. ..................................................................................9
I
NITIAL INSPECTION. .............................................................................................................................9
S
HIPPING CHECKLIST ............................................................................................................................9
L
IFTING AND CARRYING THE CALIBRATOR ............................................................................................9
P
OSITIONING THE CALIBRATOR...........................................................................................................10
R
EAR PANEL CONNECTIONS AND CONTROLS ......................................................................................10
S
ETTING AND CHECKING THE LINE VOLTAGE......................................................................................11
C
ONNECTING TO A COMPUTER............................................................................................................11
P
OWERING UP THE CALIBRATOR..........................................................................................................12
O
UTPUT CONNECTIONS.......................................................................................................................12
OPERATION........................................................................................................................................13
I
NTRODUCTION TO OPERATION...........................................................................................................13
F
RONT PANEL CONTROLS AND INDICATORS .......................................................................................13
F
RONT PANEL KEYBOARD...................................................................................................................14
G
RAPHIC LCD DISPLAY .....................................................................................................................15
U
SING THE DIGITAL POTENTIOMETER.................................................................................................16
T
ERMINAL STATUS LEDS....................................................................................................................17
CALIBRATING INSTRUMENTS USING THE 2100......................................................................18
C
ALIBRATING INSULATION TESTERS...................................................................................................18
1. High Value Resistance for Insulation Testing...........................................................................18
2. Measuring Insulation Test Voltages & Current........................................................................19
3. Low Value Resistance for Continuity Testing ...........................................................................21
4. A.C. Voltage Output..................................................................................................................21
5. 5kV Insulation Tester Extension Adapter [OPTION] ...............................................................22
I
NTRODUCTION TO RCD TESTERS ......................................................................................................23
C
ALIBRATING RCD TESTERS USING THE 2100....................................................................................24
1. RCD Current Measurements.....................................................................................................25
2. RCD Trip Time Measurements..................................................................................................27
3. RCD Current Duration Measurements .....................................................................................29
C
ALIBRATING PORTABLE APPLIANCE TESTERS (PATS)......................................................................30
1. PAT : Earth Bond Resistance....................................................................................................30
2. PAT : Earth Bond Current........................................................................................................31
3. PAT : Insulation Testing ...........................................................................................................32
4. PAT : Load Testing...................................................................................................................33
5. PAT : Flash Testing [OPTION]................................................................................................34
6. PAT : Leakage [OPTION]........................................................................................................35
I
NTRODUCTION TO LOOP TESTERS....................................................................................................36
C
ALIBRATING LOOP TESTERS USING THE 2100 .................................................................................40
PSC (P
ROSPECTIVE SHORT CIRCUIT) TESTING ...................................................................................42
REMOTE PROGRAMMING.............................................................................................................43
T
HE RS232 INTERFACE.......................................................................................................................43
P
ROGRAMMING COMMANDS...............................................................................................................43
E
XAMPLE COMMAND SEQUENCES.......................................................................................................46
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2100 Operation Manual
TECHNICAL DESCRIPTION............................................................................................................47
G
ENERAL............................................................................................................................................47
C
ONSTRUCTION ..................................................................................................................................47
I
NTERNAL FUSES. ...............................................................................................................................48
O
PENING THE CASE ............................................................................................................................48
A
CCESS TO INTERNAL FUSES ..............................................................................................................48
PCB R
EMOVAL (NOT REQUIRED TO GAIN ACCESS TO INTERNAL FUSES). ............................................48
P
ROCESSOR BOARD............................................................................................................................49
CALIBRATION AND MAINTENANCE...........................................................................................50
G
ENERAL............................................................................................................................................50
E
LECTRICAL SAFETY TESTS................................................................................................................50
C
LEANING THE EXTERNAL CASE..........................................................................................................50
C
ALIBRATION OVERVIEW ...................................................................................................................50
GUARANTEE AND SERVICE...........................................................................................................52
APPENDIX A................................................................................................. 2100 SPECIFICATIONS
APPENDIX B..................................................................................................APPLICATION NOTES
Transmille Ltd. Issue 4.00 Page 5
2100 Operation Manual
2100 Electrical Test Equipment Calibrator Introduction
The 2100 Electrical Test Equipment Calibrator is a breakthrough in electrical test
equipment calibration providing a complete solution for testing :
§ Insulation Testers
§ RCD Testers
§ LOOP Testers
§ Portable Appliance Testers (PATs)
Extended Functionality
The 2100 Calibrator can be enhanced with options to provide high accuracy
resistance, auto loop measurement and two external resistance inputs to extend the
range of available resistors.
A complete electrical test equipment calibration solution from one instrument.
Designed to provide an accurate cost effective portable instrument for the calibration
of Insulation testers, RCD testers, LOOP testers and PATs the 2100 calibrator can be
combined with the
ProCal Calibration System to allow automated calibration.
IMPORTANT OPERATIONAL NOTE 1
DUE TO THE OPERATIONAL CHARACTERISTICS OF THE 2100
ELECTRICAL TEST EQUIPMENT CALIBRATOR, AN UNPROTECTED
SUPPLY (WITHOUT RCD TRIP) MUST BE USED *.
* Use of an isolation transformer can be employed in conjunction with a protected supply
(with RCD Trip), however this will degrade performance of the calibrator.
Please contact Transmille for further details.
IMPORTANT OPERATIONAL NOTE 2
It is also necessary that for correct operation the Phase (Live) and
Phase (Neutral) MUST be connected round the correct way (some plugs
used in non-UK countries can be connected either way round, therefore
this check is necessary). There should only be a small voltage between
Phase (Neutral) and Phase (Earth).
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2100 Operation Manual
Installation & Power Requirements for the 2100
For correct operation of the 2100 it must be powered from an unprotected (ie. no RCD
trip) supply. This is because the 2100 will pass current down the Earth conductor
when performing tests and therefore trip any protection device present - FOR THIS
REASON IT IS ESSENTIAL THAT THE 2100 IS PROPERLY EARTHED.
It is also necessary that for correct operation the Phase (Live) and Phase (Neutral)
MUST be connected round the correct way (some plugs used in non-UK countries can
be connected either way round, therefore this check is necessary). There should only
be a small voltage between Phase (Neutral) and Phase (Earth).
To keep the LOOP impedance value to a minimum, the mains input to the 2100 is of a
direct cable type. This avoids any introduction of unnecessary impedance.
It is desirable that the 2100 is connected to a supply point with low LOOP impedance
as this will limit the lowest value available LOOP impedance from the 2100 using as
good a quality outlet (contact wise) as possible.
If an unprotected supply is not available, use of an Isolation Transformer can be
employed, however this will increase the lowest LOOP impedance available.
Connection of the isolation transformer should be as detailed below :
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2100 Operation Manual
Designed for on use in the laboratory or portable on site calibration.
The 2100 calibrator is equally suitable for use in the standards laboratory or for on site
calibration work. The Small footprint and low weight makes the 2100 calibrator ideal
for on site calibration. The serial interface allows direct connection to a portable PC.
Retro fit options allows extra functions to be added as required.
Several internal retro fit options including auto loop, high accuracy resistance and
external resistance input allow the user to select the most cost effective solution for
the calibration work required at the time with the ability to add extra functions as
required.
Serial Line RS232 Interface as standard.
All functions and outputs of the 2100 calibrator are fully programmable over the
RS232 interface fitted as standard. The use of the RS232 interface saves the cost of
fitting IEEE cards to the PC, and also allows easy connection to portable PC’s,
reducing the set up time for on site calibration.
Input / Output Connection
The input and output terminal configuration is designed to enable simple connection
to a full range of instrumentation using the supplied adapter lead. Use of a dedicated
input adapter lead allows resistance measurement functions such as LOOP testing to
be calibrated to include residual values right up to the socket into which test
equipment is plugged.
All outputs are isolated when not in use, with an LED indicator showing the active
input / output terminal(s).
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2100 Operation Manual
Preparing the calibrator for use.
Initial Inspection.
After shipment the calibrator should be inspected for any signs of external damage.
Should external damage be found contact the carrier immediately. Do not connect a
damaged instrument to the line power as this may result in internal damage. Please
keep the original box which can be used when returning the calibrator for service and
re-calibration.
Shipping Checklist
1 x Serial Communication lead (9 Way ‘D’ female to 9 Way ‘D’ male connectors)
1 x Operation manual (this document)
1 x Input Adapter lead
Input Adapter Lead
Lifting and carrying the calibrator
The calibrator can be carried easily by one person in any position by either holding the
front handles or by supporting from underneath (note : observe all normal practices for
health and safety when carrying). A custom carry case with shoulder strap is available
if the calibrator is to be regularly transported - see options list. The calibrator should
always be placed down on a firm flat surface on its base feet. Standing the calibrator
down on its back may cause damage. Avoid knocking or banging the calibrator and
always place down smoothly.
Warning
DO NOT DROP THE CALIBRATOR as this may cause internal damage.
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2100 Operation Manual
Minimum 2” (5cm) Clearance
LOOP N
Positioning the Calibrator.
The calibrator can be used free standing on a bench or mounted in a standard 19” rack
enclosure. The calibrator can be operated at any angle, the two front feet have tilt legs
for bench operation. For all installations care must be taken not to cover the
ventilation slots underneath. A 2” (5cm) space behind the instrument is also required
for line and interface connections (See diagram) :
Rear Panel Connections and controls
Connections on the rear panel consist of a 9Pin Serial interface connector for the
computer interface, this is optically isolated from the calibrator outputs.
Fuse holders for individual instrument types are accessible from the back of the
calibrator. These are bayonet type fuse holders which allow a screwdriver to be used
to turn the fuse carrier until it ‘pops’ out of the fuse holder body .The fuse carrier can
then be withdrawn from the fuse holder body for inspection / replacement.
FUSES
LOOP L
RS232 9 Way
‘D’ Type
Connector
(Serial Port)
On / Off Switch
MAINS
RCD
ACV
PAT
Mains Lead
Insulation Resistance
FLASH
CONNECTOR
EXTERNAL
RESISTOR
INPUT
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2100 Operation Manual
P.C. Rear Panel
2100 Rear Panel
Setting and checking the Line Voltage.
Warning
The line power cord must have an earth conductor to avoid
risk of shock. This instrument must be correctly earthed.
The calibrator has been designed to work from either 100-120 Volt line supply or 200
- 240 Volt line supply. Check Supply voltage as marked on the rear panel before
connecting to power line. Connecting the calibrator to the wrong supply will cause
internal damage to the instrument. To Change the line voltage it is necessary to
remove the rear panel and rewire the transformer. The calibrator will have been
shipped wired for 110V operation for USA, 240V for Europe.
Connecting to a computer
If required a standard serial 9 pin cable may be used to connect the calibrator to a
Comm port on a PC. A Null modem cable is not needed.
Keyboard Socket
Serial (RS232) Port
Parallel
(Printer)
Port
Mains Lead
Serial (RS232)
Cable
Transmille Ltd. Issue 4.00 Page 11
2100 Operation Manual
Powering up the calibrator
After connecting line power the calibrator can be switched on with the line power
switch above the mains inlet socket on the rear panel.
The front panel display will illuminate indicating power. The display will show
program version number and after a short delay, during which time the processor
performs a self test of the instrument, the display will show the default start-up display
:
2100 CALIBRATOR Ver x.x
TRANSMILLE LTD.
The calibrator has been designed to be powered up continuously, automatically
switching the display to power save mode after a pre-set period of time from the last
command. In power save mode the display back light will turn off.
Output Connections
Warning - Risk of shock.
High voltages may be present on the output sockets.
Output sockets comprise of the following types :
IEC 3-Pin Socket : For use directly with the lead of a PAT tester or in
conjunction with the supplied adapter lead.
IEC 3-Pin Plug : For use directly with the lead of a LOOP or RCD tester
or in conjunction with the supplied adapter lead.
4mm Safety Sockets: For connection to Insulation Testers
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2100 Operation Manual
Button
Function Keys
Operation
SAFETY WARNINGS
This instrument is capable of generating high voltages.
WARNING : The information in this section is intended only for qualified
personnel. The user must at all times be adequately protected from electric shock.
Qualified personnel must ensure that operators of the equipment are adequately
insulated from connection points.
A carry-case is available for regular transportation of the calibrator.
Introduction to Operation
All functions of the 2100 Calibrator can be controlled from the front panel or
controlled remotely by a computer over the RS232 interface.
Front Panel Controls and Indicators
LCD
Active
Terminal /
Socket LED
Display with
integral
Backlight
Menu buttons
(SoftKeys)
Numeric
Stand-By
Output On
Button
Transmille Ltd. Issue 4.00 Page 13
Keypad
Digital
Potentiometer
2100 Operation Manual
Front panel Keyboard
The front panel of the 2100 Calibrator utilises a high quality membrane switch panel
with tactile feel buttons and integral display window. The front panel is therefore
sealed against the ingress of moisture and dirt enabling the calibrator to be used in
working environments without risk of dirt causing early failure of the operating
buttons. The front panel can easily be wiped clean with a soft cloth. Care should be
taken not scratch the display window. All graphics are ‘under printed’ so that they will
not wear off with use.
IMPORTANT NOTE
The front panel key buttons are for use with fingers only - do not press the key with
hard or sharp objects e.g. Ball-point pens, pencils, screwdrivers etc. Repeated actions
like this will almost certainly cause the keyboard to fail. (This will not be covered
under warranty). Care should also be taken when transporting the instrument - do not
leave test leads plugged in which may get squashed into the display area or keys
which can also cause damage.
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2100 Operation Manual
SoftKey Menu items
The Keyboard is divided into sections to allow rapid operation.
The Numeric section allowing values to be entered,
Functions keys for RCD, LOOP, PAT, Insulation Resistance, Continuity Resistance
and ACV Output
Range up and range down keys allows range changing for the currently selected
function
Left/right arrow keys select the digit to be controlled by the rotary control knob.
Output on / Standby keys allow the calibrator output to be disconnected from the
terminals. Led indicators are incorporated in these switches to clearly show the output
status.
Graphic LCD Display
A back lit graphic LCD display shows the present setting and instrument status. The
bottom line of the display is used to assign the function of the four ‘ soft (menu) keys’
immediately under the display. The display utilises a back light which automatically
turns off if no activity takes place. The back light turns on as soon as a key is pressed
or a command is received.
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2100 Operation Manual
Using the Digital Potentiometer
A digital potentiometer allows selected digits on the display to be incremented
(turning clockwise) or decrement (turning anti-clockwise).
Selected digit
marker.
Cursor Keys can be used
to move the position of the
digit marker, and increment
/ decrement the digit.
Clockwise Rotation Anti-Clockwise Rotation
(Increment Digit) (Decrement Digit)
Transmille Ltd. Issue 4.00 Page 16
Terminal status LEDs
LED’s above the terminals indicate the active terminal.
2100 Operation Manual
Active terminals
indicated by
illuminated LED
PAT Test IEC Socket
WARNING
Dangerous voltage may be present on these terminals.
LOOP & RCD TEST IEC Plug
WARNING
Dangerous voltage may be present on these terminals.
INSULATION TEST 4mm terminals
WARNING
Dangerous voltage may be present on these terminals.
PAT GND 4mm Terminal (Blue)
Transmille Ltd. Issue 4.00 Page 17
2100 Operation Manual
Calibrating Instruments Using the 2100
Calibrating Insulation Testers
The 2100 has five functions for calibrating insulation testers :
1. High value resistance output for insulation testing (0MΩ to 2,000MΩ)
2. Measurement of the insulation test voltage
3. Low value resistance for continuity testing
(0.1Ω to 20.0Ω Variable, 100R & 1kΩ Fixed Ranges)
4. Insulation test current measurement
5. A.C. voltage output at 100V, 200V, 240V, 300V and 400V
Use the 4mm sockets
labelled INSULATION
TESTERS for all
insulation meter tests.
1. High Value Resistance for Insulation Testing
Step 1 Select ‘INS RES’ from the function key section of the 2100 front panel
Step 2 Connect the insulation tester to the Black & Red 4mm terminals.
Step 3 Enter the required resistance in MΩ from 10kΩ to 10,000MΩ
on the keyboard followed by Enter. An alternative way to select the
required resistance is to use the digital potentiometer to increment /
decrement the digit indicated by the cursor. The Left and Right
arrow keys allow the selected digit to be changed
Transmille Ltd. Issue 4.00 Page 18
2100 Operation Manual
100.00 MΩ
2. Measuring Insulation Test Voltages & Current
Step 1 From the Insulation Resistance menu displayed on the 2100, select the
Voltage function using the ‘SoftKey’.
INSULATION RESISTANCE
VOLTAGE
Step 2 Select the required voltage range using either the digital potentiometer or the
up / down arrow keys. Ranges include 50V, 100V, 250V, 500V and 1000V.
The impedance of each range is automatically set to give the correct
load 1mA / 0.5mA (see test current below) at the applied nominal
voltage range.
RANGE INPUT IMPEDANCE
1mA 0.5mA
50V 50kOhm 100kOhm
100V 100kOhm 200kOhm
250V 250kOhm 500kOhm
500V 500kOhm 1Mohm
1000V 1Mohm 2MOhm
Step 3 Select the required measurement current using the SoftKeys.
The default setting for current load is 1mA nominal which is the correctly
load/test current for the 16th Edition equipment - e.g. must be able to supply
1mA at the test voltage. Older insulation testers (15th Edition Reg.) only had
to produce 0.5mA current at the test voltage. The 2100 should be set to
0.5mA current for these instruments. Very old tester’s may only produce a
very small current and the voltage will collapse under any load - these cannot
be tested with the 2100.
Transmille Ltd. Issue 4.00 Page 19
2100 Operation Manual
The correct polarity must be applied to obtain a reading
TEST VOLTAGE - 1000V / 1mA
UNDER-RANGE/POLARITY
TEST CURRENT : 1.00mA
CURRENT BACK
Step 4 Press the test button on the insulation tester to apply the insulation test voltage
and read the voltage and current on the 2100 display.
To return from the Voltage measurement screen to the insulation
resistance select the Back menu item using the Softkey.
If the voltage applied by the tester is less than 30% of the range or
the polarity is incorrect, the display will show
UNDER-RANGE / POLARITY (note some tester’s ‘positive’ red
terminals are supplying negative voltage and need to have test leads
reversed.
NOTE:- NEGATIVE INPUT OF 2100 (BLACK) IS CONNECTED
TO SUPPLY EARTH.
Warning : The maximum input voltage is 1100 volts
Transmille Ltd. Issue 4.00 Page 20
2100 Operation Manual
1.00 Ω
3. Low Value Resistance for Continuity Testing
Step 1 Connect the insulation tester to the Black & Red 4mm sockets.
Step 2 Select ‘CONT RES’ from the function key section of the 2100 front panel
CONTINUITY RESISTANCE
CURRENT
0.0mA
20mOHMS 0.1-20R 100 OHMS 1kOHMS
Fixed values
Step 3 Select the required resistance in Ω from 20mΩ to 1kΩ
on the 2100 keyboard followed by Enter, or by using the softkeys.
An alternative way to select the required resistance is to use the digital
potentiometer to increment / decrement the digit indicated by the cursor.
The Left and Right arrow keys allow the selected digit to be changed.
NOTE : 20mΩ, 100Ω and 1kΩ are fixed values. 0.1Ω to 20Ω is a variable range
The measured current is also displayed when a resistance of 1Ω is set..
4. A.C. Voltage Output
Notes on ACV Output
To provide the power necessary for some insulation testers, the AC output
from the 2100 is derived from transformer tappings. The output is
unregulated and will vary with line voltage and loading. The actual output
voltage at any time is measured and displayed by the 2100 which can be
compared to the displayed value on the UUT.
234.1V
234.1V
2100
UUT
Example
2100 set to 230V range, measures mains
and displays a measured value of 234.1V.
The UUT is compared to check its accuracy
at this value.
Step 1 Connect the insulation tester to the Black & Red 4mm sockets.
Step 2 Select ‘ACV O/P’ from the function key section of the 2100 front panel
Step 3 Select the required voltage using either the range up / range down buttons
Step 4 Read the voltage displayed on the insulation tester meter.
Transmille Ltd. Issue 4.00 Page 21
or by incrementing / decrementing the range using the digital potentiometer.
and compare it with the value displayed on the 2100
Use the Output Standby and Output On buttons to control the output.
2100 Operation Manual
5. 5kV Insulation Tester Extension Adapter [OPTION]
This option allows the testing of Insulation Testers with test voltages up to 5kV and
Insulation range up to 200GΩ.
The insulation tester must have a guard terminal for this adapter to function
correctly
Step 1 Select ‘INS RES’ from the function key section of the 2100 front panel
Step 2 Connect the 5kV Adapter flying leads to the 2100 Insulation tester terminals
(observing correct polarity)
Step 3 Connect the Insulation tester to the adapter box
Step 4 Calculate the value needed to be entered in order to give the required resistance
(this will be 100th of the actual required resistance less the input
impedance of the tester - typically 10MΩ, example to simulate
100GΩ select 990MΩ on the 2100)
In most cases it is not necessary to allow for the input impedance of the tester.
This value can be entered on the keyboard followed by Enter. An
alternative way to select the required resistance is to use the digital
potentiometer to increment / decrement the digit indicated by the
cursor. The Left and Right arrow keys allow the selected digit to be
changed
Transmille Ltd. Issue 4.00 Page 22
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