Ground Bond Tester GCT-9040 USER MANUAL GW INSTEK PART NO. 82CT-90400E01. Test Equipment Depot Washington Street Melrose, MA 02176

Transcription

1 Ground Bond Tester GCT-9040 Test Equipment Depot Washington Street Melrose, MA USER MANUAL GW INSTEK PART NO. 82CT-90400E01 TestEquipmentDepot.com ISO-9001 CERTIFIED MANUFACTURER

2 This manual contains proprietary information, which is protected by copyright. All rights are reserved. No part of this manual may be photocopied, reproduced or translated to another language without prior written consent of Good Will company. The information in this manual was correct at the time of printing. However, Good Will continues to improve products and reserves the rights to change specification, equipment, and maintenance procedures at any time without notice.

3 Table of Contents Table of Contents SAFETY INSTRUCTIONS... 5 GETTING STARTED... 9 GCT-9040 Overview Appearance Set Up OPERATION Menu Tree Test Lead Connection GB Manual Testing Linked ACW/DCW/IR Tests Common Utility Settings EXTERNAL CONTROL External Control Overview REMOTE CONTROL Interface Configuration Command Syntax Command List for GCT Error Messages FAQ APPENDIX Fuse Replacement Error Messages GCT-9040 Specifications GCT-9040 Dimensions Declaration of Conformity

4 GCT-9040 User Manual INDEX Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com 4

5 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS This chapter contains important safety instructions that you must follow during operation and storage. Read the following before any operation to ensure your safety and to keep the instrument in the best possible condition. Safety Symbols These safety symbols may appear in this manual or on the instrument. WARNING CAUTION Warning: Identifies conditions or practices that could result in injury or loss of life. Caution: Identifies conditions or practices that could result in damage to the instrument or to other properties. Attention Refer to the Manual Protective Conductor Terminal Frame or Chassis Terminal Earth (ground) Terminal 5

6 GCT-9040 User Manual Do not dispose electronic equipment as unsorted municipal waste. Please use a separate collection facility or contact the supplier from which this instrument was purchased. Safety Guidelines General Guideline CAUTION Power Supply WARNING Do not place any heavy object on the instrument. Avoid severe impact or rough handling that leads to damaging the instrument. Do not discharge static electricity to the instrument. Use only mating connectors, not bare wires, for the terminals. Do not block the cooling fan opening. Do not disassemble the GCT-9040 unless you are qualified. (Measurement categories) EN :2010 specifies the measurement categories and their requirements as follows. The GCT-9040 does not fall under category II, III or IV. Measurement category IV is for measurement performed at the source of low-voltage installation. Measurement category III is for measurement performed in the building installation. Measurement category II is for measurement performed on the circuits directly connected to the low voltage installation. AC Input voltage range: 100/120/220/230VAC ±10% Frequency: 50Hz/60Hz To avoid electrical shock connect the protective grounding conductor of the AC power cord to an earth ground. 6

7 SAFETY INSTRUCTIONS Cleaning the GCT-9040 Disconnect the power cord before cleaning. Use a soft cloth dampened in a solution of mild detergent and water. Do not spray any liquid. Do not use chemicals containing harsh material such as benzene, toluene, xylene, and acetone. Operation Environment Storage environment Disposal Location: Indoor, no direct sunlight, dust free, almost non-conductive pollution (Note below) Relative Humidity: 70% (no condensation) Altitude: < 2000m Temperature: 0 C~40 C (Pollution Degree) EN :2010 specifies the pollution degrees and their requirements as follows. The GCT-9040 falls under degree 2. Pollution refers to addition of foreign matter, solid, liquid, or gaseous (ionized gases), that may produce a reduction of dielectric strength or surface resistivity. Pollution degree 1: No pollution or only dry, non-conductive pollution occurs. The pollution has no influence. Pollution degree 2: Normally only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation must be expected. Pollution degree 3: Conductive pollution occurs, or dry, nonconductive pollution occurs which becomes conductive due to condensation which is expected. In such conditions, equipment is normally protected against exposure to direct sunlight, precipitation, and full wind pressure, but neither temperature nor humidity is controlled. Location: Indoor Temperature: -10 C to 70 C Relative Humidity: 85% (no condensation) Do not dispose this instrument as unsorted municipal waste. Please use a separate collection facility or contact the supplier from which this instrument was purchased. Please make sure discarded electrical waste is properly recycled to reduce environmental impact. 7 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

8 GCT-9040 User Manual Power cord for the United Kingdom When using the tester in the United Kingdom, make sure the power cord meets the following safety instructions. NOTE: This lead/appliance must only be wired by competent persons WARNING: THIS APPLIANCE MUST BE EARTHED IMPORTANT: The wires in this lead are coloured in accordance with the following code: Green/ Yellow: Earth Blue: Neutral Brown: Live (Phase) As the colours of the wires in main leads may not correspond with the coloured marking identified in your plug/appliance, proceed as follows: The wire which is coloured Green & Yellow must be connected to the Earth terminal marked with either the letter E, the earth symbol or coloured Green/Green & Yellow. The wire which is coloured Blue must be connected to the terminal which is marked with the letter N or coloured Blue or Black. The wire which is coloured Brown must be connected to the terminal marked with the letter L or P or coloured Brown or Red. If in doubt, consult the instructions provided with the equipment or contact the supplier. This cable/appliance should be protected by a suitably rated and approved HBC mains fuse: refer to the rating information on the equipment and/or user instructions for details. As a guide, a cable of 0.75mm 2 should be protected by a 3A or 5A fuse. Larger conductors would normally require 13A types, depending on the connection method used. Any exposed wiring from a cable, plug or connection that is engaged in a live socket is extremely hazardous. If a cable or plug is deemed hazardous, turn off the mains power and remove the cable, any fuses and fuse assemblies. All hazardous wiring must be immediately destroyed and replaced in accordance to the above standard. 8

9 S S SS Y S S V Y S S 0 S S GETTING STARTED GETTING STARTED This chapter describes the safety tester in a nutshell, including its main features and front / rear panel introduction. After going through the overview, please read the safety considerations in the Set Up chapter. GCT-9040 B CAUT ON POWER GB Rx GCT-9040 Overview Introduction to the GCT Main Features Accessories Package Contents Appearance Front Panel Rear Panel Set Up Line Voltage Connection and Power Up Installing the Optional GPIB Card Workplace Precautions Operating Precautions

10 GCT-9040 User Manual GCT-9040 Overview Introduction to the GCT-9040 GCT-9040 is a ground bond tester that can operate as a standalone unit or in conjunction with a GPT-9000 Series safety tester to perform additional ACW/DCW/IR tests before, after or simultaneously(acw/dcw only) with GB tests. When the GCT-9040 operates with a GPT-9000 Series safety tester, it uses a dedicated LINK port and remote commands to communicate in a master-slave fashion. The GCT-9040 operates as the master and the GPT-9000 Series unit operates as a slave. The GCT-9040 can store up to 100 manual tests allowing the safety testers to accommodate any number of safety standards, including IEC, EN, UL, CSA, GB, JIS and others. Note: Throughout this user manual, the terms ACW, DCW, IR and GB refer to AC Withstanding, DC Withstanding, Insulation Resistance and Ground Bond testing, respectively. GPT-9000 refers to any of the GPT-98XX or GPT-99XX models, GPT-9000A refers to any of the GPT-99XXA models. For information specific to the GPT- 9000, please see the GW Instek website, Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

11 GETTING STARTED Main Features Performance GB: 3A~40A ac Features 100 test conditions (MANU mode) Over temperature, voltage and current protection Pass, Fail, Test, Caution and Ready indicators PWM output (90% efficiency, increased reliability) Interlock (configurable). Interface Remote control start/stop interface terminal USB interface for programming Optional GPIB interface for programming Signal I/O port for pass/fail/test monitoring and start/stop control/interlock LINK port to control slave units for ACW, DCW and IR tests. Accessories Standard Accessories Part number Region dependent GTL-215 x1 N/A N/A GTL-247 GTL-132 Description Power cord GB Test leads Remote terminal male plug Interlock key Type A-A USB cable Link cable 11

12 Optional Accessories Part number GTL-248 GTL-251 Description GPIB cable GCT-9040 User Manual GPIB-USB-HS (high speed) GRA-417 Rack Adapter Panel (19, 4U) Options Part number Description Opt.01 GPIB Interface GPIB card 12

13 GETTING STARTED Package Contents Check the contents before using the GCT Opening the box Contents (single unit) GCT-9040 unit Quick Start guide User manual CD CTC (Calibration Traceable Certificate) Type A-A USB cable Power cord x1 (region dependent) GTL-215 test leads x1 GTL-132 LINK cable Remote terminal male plug Interlock key Note Keep the packaging, including the box, polystyrene foam and plastic envelopes should the need arise to return the unit to GW Instek. 13 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

14 PASS FA L READY TEST S MANU ED T/SAVE UT L TY SENSE H SOURCE H 40A MAX SENSE L SOURCE L GCT-9040 User Manual Appearance Front Panel Display PASS/FAIL indicators Function keys Directional keys READY indicator TEST indicator GCT-9040 Ground Bond Tes er CAUTION CAUTION indicator POWER button POWER START STOP REMOTE GB Rx Sense H and L terminals Source H and L terminals START button REMOTE terminal Scroll wheel STOP button Configuration keys Display Function keys 240 X 64 dot matrix display (LCD) The function keys correspond to the soft-keys directly above on the main display. Pass/Fail indicators PASS FAIL The PASS and FAIL indicators light up upon a PASS or FAIL test result at the end of a manual test or automatic test. ESC key ESC The ESC key is used to exit out of a menu or cancel a setting. PAGE key PAGE The PAGE key is used in the EDIT status to toggle the HI/LO setting between mω & V. Directional arrow keys The directional arrow keys are used to navigate menus and parameter settings. 14

15 GETTING STARTED READY indicator TEST indicator READY TEST The READY indicator is lit when the tester is ready to begin testing. The STOP button is used to put the tester into READY status. The TEST indicator is lit when a test is on. The START button is used to put the tester into TEST status. CAUTION indicator CAUTION 40A MAX. The CAUTION indicator will light up when the output terminals are active. Only after the test has finished or stopped will the indicator turn off. SENSE and SOURCE terminals SENSE H GB Rx SENSE L SOURCE H SOURCE L The SOURCE H, SOURCE L, SENSE H and SENSE L terminals are used for GB testing. Scroll wheel The scroll wheel is used to edit parameter values. UTILITY key UTILITY Used to enter the Common Utility menu. EDIT/SAVE key EDIT/SAVE Used to start editing MANU tests as well as save settings and parameters. MANU key MANU The MANU key is used to select manual tests. 15

16 GCT-9040 User Manual REMOTE terminal REMOTE The REMOTE terminal is used to connect to a remote controller. STOP button STOP The STOP button is used to stop/cancel tests. The STOP button will also put the tester in the READY status to begin testing. START button START The START button is used to start tests. The START button can be used to start tests when the tester is in the READY status. Pressing the START button will put the tester in the TEST status. POWER switch POWER Turns the power on. The tester will always start up with the last test setting from when the instrument was last powered down. Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

17 S GNAL I / O GPIB LINK SER NO LB AC POWER MAX 700VA TO AVOD EL CTRC SHOCK T E POWER CORD PRO ECTVE GROUN ING C ND CTOR MUST BE CONNE TED TO GROUND FOR CON IN ED RE PR TEC ON RE LACE ONLY WTH SPE I I D Y E AND RA ED FUSE NO OPERA OR ERV E BLE COMPON NTS NSD DO NOT REMOVE C V RS R FER SER I ING TO QUA I ED ERSO N L GND V 0 V V S 0V 0V GETTING STARTED Rear Panel SIGNAL I/O USB A port LINK port Fan GND WARNING S S V S B S Optional GPIB port Line voltage Fuse selector SIGNAL I/O port USB A port SIGNAL I / O The SIGNAL I/O port is used to monitor the tester status (PASS, FAIL, TEST) and input (START/ STOP signals). It is also used with the Interlock key. Used for remote control and firmware updates. LINK port Fan/Fan Vents LINK With the GCT-9040 acting as the master unit, the LINK port is used to control a GPT-9XXX slave unit to perform additional ACW, DCW or IR tests. Exhaust fan. Allow enough room for the fan to vent. Do not block the fan openings. GND GND Connect the GND (ground) terminal to the earth ground. 17

18 GCT-9040 User Manual Line voltage input Line voltage input: 100/120/220/230VAC ±10% Line voltage fuse Line voltage selector and fuse: 100V/120V T7A 250V 220V/230V T4A 250V Optional GPIB port GP B Optional GPIB interface for remote control. 18

19 GETTING STARTED Set Up Line Voltage Connection and Power Up Background Before powering up the GCT-9040 ensure the correct voltage has been selected on the rear panel. The GCT-9040 supports line voltages of 100V/120V/220V and 230V. Steps 1. Check the line voltage and the fuse in the fuse holder. Page 127 The desired line voltage should line up with the arrow on the fuse holder Connect the power cord to the AC voltage input If the power cord does not have an earth ground, ensure the ground terminal is connected to an earth ground. GND Warning Ensure the power cord is connected to an earth ground. Failure could be harmful to the operator and instrument. 4. Press the Power button. POWER 19 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

20 GCT-9040 User Manual 5. When the unit is powering up, all the LED indicators will light. Check to make sure all 5 LED indicators are working. 6. Check to make sure the System Self Test passes without errors. S Y S T EM S E L F T E S T S y s t e m C h e c k i n g... H a r d w a r e C h F i r m w a r e C h e c k i n g... e c k i n g... After the System Self Test completes, the tester will go into VIEW status and be ready to operate. VIEW status M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B WARNING See the Appendix on page 128 for details if a selftest error is detected. 20

21 GETTING STARTED Installing the Optional GPIB Card Background Steps WARNING The optional GPIB is a user-installable option. Follow the instructions below to install the GPIB card. Before installing the optional GPIB card ensure the GCT-9040 is turned off and disconnected from power. 1. Remove the screws from the rear panel cover plate. 2. Insert the GPIB card into the two slots on either side of the opening. Push the card gently until it is fully inserted. 21

22 GCT-9040 User Manual Workplace Precautions Background WARNING The GCT-9040 is a high current instrument that is capable of delivering up to 40A. The following section describes precautions and procedures that must be followed to ensure a safe work environment. The GCT-9040 generates high current in excess of 40A. Follow all safety precautions, warnings and directions given in the following section when using the instrument. 1. Only technically qualified personnel should be allowed to operate the tester. 2. The operating workplace must be fully isolated, especially when the instrument is in operation. The instrument should be clearly labeled with appropriate warning signage. 3. The operator should not wear any conductive materials, jewelry, badges, or other items, such wrist watches. 4. The operator should wear insulation gloves for electrical protection. 5. Ensure the earth ground of the line voltage is properly grounded. 6. When high current flows through the test leads a strong magnetic field is produced. Ensure any devices that are adversely affected by magnetic fields are not placed near the tester. 22 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

23 GETTING STARTED Operating Precautions Background WARNING The GCT-9040 is a high current instrument. The following section describes precautions and procedures that must be followed to ensure that the tester is operated in a safe manner. The GCT-9040 generates outputs up to 40A ac. Follow all safety precautions, warnings and directions given in the following section when using the instrument. 1. Never touch the tester, lead wires, terminals, probes and other connected equipment when the tester is testing. 2. After testing, any probes, terminals or ports may become extremely hot due to the high test current. Do not touch these points to avoid burns. 3. Do not turn the tester on and off quickly or repeatedly. When turning the power off, please allow a few moments before turning the power back on. This will allow the protection circuits to properly initialize. Do not turn the power off when a test is running, unless in an emergency. 4. Only use those test leads supplied with the instrument. Leads with inappropriate gauges can be dangerous to both the operator and the instrument. Never use the Sense leads on the SOURCE terminals. 23

24 GCT-9040 User Manual 5. Ensure the earth ground of the line voltage is properly grounded. 6. Only connect the test leads to the SOURCE H/SENSE H terminals before the start of a test. Keep the test leads disconnected at all other times. 7. Always press the STOP button when pausing testing. 8. Do not leave the tester unattended. Always turn the power off when leaving the testing area. 9. When remotely controlling the tester, ensure adequate safety measures are in place to prevent: Inadvertent output of the test current. Accidental contact with the instrument during testing. Ensure that the instrument and DUT are fully isolated when the instrument is remotely controlled. 24

25 OPERATION OPERATION Menu Tree Menu Tree Overview Test Lead Connection GB Connection Grounding Mode Note GB Manual Testing Choose/Recall a Manual Test Number Edit Manual Test Settings Setting the GB Test Current Setting the Test Frequency Setting the Upper and Lower Limits Setting a Reference Value Setting the Test Time (Timer) Creating a MANU Test File Name Saving and Exiting EDIT Status Running a MANU Test PASS / FAIL MANU Test Zeroing of the Test Leads Linked ACW/DCW/IR Tests LINK Connection LINK Test Configuration Run LINK Test Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com 25

26 GCT-9040 User Manual Menu Tree This section describes the overall structure of the operation statuses and modes for the GCT-9040 ground bond safety tester. The tester has one testing mode (MANU mode) and 5 main operation statuses (VIEW, EDIT, READY, TEST and STOP). P A S S status F A I L status Press START Z E RO status T E S T status Press STOP S T O P status Press START Press STOP Press START Press STOP Short test leads Press ZERO soft-key R E A D Y status Press STOP X2 Press MANU V I EW status Press STOP Press UTILITY Common Utility Settings 1 Press EDIT/ SAVE Press ESC Toggle between ref/hi/lo V and ref/hi/lo Ω Press PAGE E D I T status Press EDIT/ SAVE Save the MANU test 1 Press EDIT/SAVE to save settings, or ESC to cancel and return to the previous screen. 26

27 OPERATION Menu Tree Overview VIEW status VIEW status is used to view the parameters of the selected manual test. The VIEW status is also used to select the MANU test number. VIEW status is the default state of the unit. VIEW status M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B EDIT status EDIT status is used to edit the manual test parameters. Pressing the EDIT/SAVE key will save any changes. Pressing the ESC key will cancel any changes. EDIT status M A N U = * * * F R E Q = 6 0 H z M A N U _ N A M E H I = V R E F # = V L O = V E D I A V G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M E R T READY status When the tester is in READY status, it is ready to begin testing. Pressing the START button will begin testing and put the tester into TEST status. Pressing the MANU key will return the tester to VIEW status. READY status M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V R E A D Y V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B Z E R O 27

28 GCT-9040 User Manual TEST status TEST status is active when a MANU test is running. Pressing STOP will cancel the test. TEST status M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N T L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V T E S T T I M E R = S Z E R O STOP status STOP status is shown when a manual test did not finish running and has been stopped by the operator. Pressing STOP will return the tester to READY status. STOP status M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N T L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V S T O P T I M E R = S ZERO status ZERO status is shown when performing a zeroing test for the test leads. Performing a zeroing test will automatically set the REF# value for the selected test. ZERO status M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N T L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V Z E RO T I M E R = S Z E R O MANU test number When in the VIEW mode, you can select a MANU test number with the scroll wheel. MANU test number M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

29 OPERATION Common Utility Settings This utility controls the LCD, buzzer, interface, control and time settings. These settings are system wide. COMMON U T I L I T Y L C D C o n t r a s t 8 L C D B r i g h t n e s s : B R I G H T L C D B U Z Z I N T E R C T R L T I M E 29

30 GCT-9040 User Manual Test Lead Connection This section describes how to connect the GCT-9040 to a DUT for ground bond testing. The DUT should be floating with respect to ground and should be powered off. GB Connection Background GB tests use the SENSE H/L and SOURCE H/L terminals with the GTL-215 test leads. Single GB Connection GPT-9000 Source H Sense H Source L Sense L DUT FLOATING Ground bond tests are usually connected between the ground pin (conductor terminal) of the DUT s power cord or power socket and a conductive point on the DUT chassis. ACW/DCW/IR and GB Connection GPT-9XXX (ACW/DCW) High Voltage terminal DUT FLOATING GCT-9XXX (GB tests) Source H Sense H Return terminal Sense L Source L ACW, DCW and IR withstanding tests are usually performed by testing the withstanding potential (ACW/DCW) or resistance (IR) from the neutral or live pin and the ground pin (conductor terminal) of the DUT. 30

31 OPERATION Steps for GB Connection (GCT-9040) 1. Turn the power off on the safety tester. 2. Using the GTL-215 GB test lead, a. Connect the Sense H lead to the SENSE H terminal. b. Connect the Sense L lead to the SENSE L terminal. c. Connect the Source H lead to the SOURCE H terminal. d. Connect the Source L lead to the SOURCE L terminal. Sense H lead Sense L lead Source H lead SENSE H GB Rx SENSE L SOURCE H SOURCE L Source L lead e. Connect the H clip of the GB test lead to a conductive point on the DUT chassis. f. Connect L clip of the GB test lead to the ground (conductor terminal) pin of the DUT power cord or power socket. DUT Ground pin from power cord or power socket G Conductive point on the chassis H clip N L L clip 31 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

32 GCT-9040 User Manual Steps for ACW/DCW/IR Connection (GPT-9XXX) 1. Turn the power off on the GPT-9XXX safety tester. 2. Using the GHT-114 test leads, a. Connect the high voltage test lead(red) to the HIGH VOLTAGE terminal and screw firmly into place. b. Connect the return test lead(white) into the RETURN terminal and screw the protector bar into place, as shown below. HIGH VOLTAGE Terminal RETURN Terminal c. Connect the high potential clip to neutral or live pin of the power cord or socket of the DUT that you want to test. d. Connect the return clip to the ground pin (conductor terminal) of the power cord or socket. 32

33 OPERATION DUT Ground pin from power cord or power socket G L clip H clip N L Live or neutral pin from power cord or socket. Grounding Mode Note Background The GCT-9040 operates with the SOURCE L terminal floating with respect to the earth ground. For the GCT-9040 and GPT-9XXX Series, this is referred to as having the GROUND MODE is set to OFF. On the GCT this mode is fixed. When performing additional ACW or DCW tests, a slave GPT-9XXX Series unit can operate with the GROUND MODE set to ON or OFF. 33

34 GCT-9040 User Manual Overview GROUND MODE = OFF This mode is for DUTs that are floating and not directly connected to an earth ground. When GROUND MODE is set to OFF any stray capacitance/resistance that leaks to the earth ground from the DUT side of the testing circuit are not measured. GB and IR tests must operate with GROUND MODE = OFF. GROUND MODE = ON When GROUND MODE is set to ON, the GPT- 9XXX grounds the return terminal to the ground. This mode measures the potential of the HIGH VOLTAGE terminal with respect to earth ground. This means that any stray capacitance/resistance that leaks to earth ground will also be measured. For further details about the grounding mode for the ACW, DCW and IR tests, please see the GPT-9XXX user manual. Ground Mode Icons The ground mode icons represent the ground mode settings. _ N A M E = m A m A = S G B R E F # = E D T I M E R H I / L _ N A M E = m A m A = S G B R E F # = E D T I M E R H I / L GROUND MODE = OFF GROUND MODE = ON Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

35 OPERATION Warning The GCT-9040 is a floating device. The DUT ground mode setup depends on the GPT-9XXX ground mode setting. GPT-9XXX (ACW/DCW) High Voltage terminal Return terminal DUT GCT-9040 (GB tests) Source H Sense H Sense L 1 Source L 2 GROUND MODE = ON or OFF GROUNDED DUT GROUND MODE = OFF GPT-9XXX (ACW/DCW) High Voltage terminal Return terminal 1 GROUND MODE = ON or OFF DUT DUT FLOATING GCT-9040 (GB tests) Source H Sense H Sense L Source L 2 GROUND MODE = OFF 35

36 GCT-9040 User Manual GB Manual Testing This section describes how to create, edit and run a single GB safety test. Each Manual setting described in this chapter only applies to the selected manual test no other manual tests are affected. Each manual test can be created/stored/recalled to/from one of 100 memory locations. Choose/Recall a Manual Test number from page 37. Edit Manual Test Settings from page 38. Setting the GB Test Current from page 39. Setting the Test Frequency from page 39. Setting the Upper and Lower Limits from page 40. Setting a Reference Value from page 42. Setting the Test Time (Timer) from page 43. Creating a MANU Test File Name from page 44. Saving and Exiting EDIT Status from page 45. Running a MANU Test from page 47. PASS / FAIL MANU Test from page 51. Zeroing of the Test Leads from page 54 Before operating the GCT-9040 please read the safety precautions as outlined in the Set Up chapter on page

37 OPERATION Choose/Recall a Manual Test Number Background Steps Up to 100 different manual tests can be saved/recalled. MANU tests are selected in the VIEW status. 1. Ensure that the tester is in VIEW status. See the menu tree on page 26 for details on how to enter the VIEW status. VIEW status M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B 2. Use the scroll wheel to choose the MANU number. MANU # 001~100 MANU test number M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B Note The MANU number can only be chosen in VIEW status. If in the EDIT status, switch to the VIEW status by pressing the EDIT/SAVE or ESC key. Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com 37

38 GCT-9040 User Manual Edit Manual Test Settings Background To edit any of the manual test settings, the tester must be in EDIT status. Any settings or parameters that are edited only apply to the currently selected MANU number. Steps 1. Press the EDIT/SAVE key when in VIEW status to enter the EDIT status. This will enter the EDIT status for the currently chosen test number. EDIT/SAVE Currently selected MANU test number V I EW M A N U = * * * F R E Q = 6 0 H z M A N U _ N A M E H I = V R E F # = V L O = V E D I A V G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M E R T 2. The Status changes from VIEW to EDIT. Note Pressing the EDIT/SAVE key again will save the settings for the current test and return back to VIEW status. 38

39 OPERATION Setting the GB Test Current Background The GB test current can be set from 3A to 40A ac. Steps 1. Ensure the tester is in EDIT status. Page Press the UP / DOWN arrow keys to bring the cursor to the current setting. M A N U = * * * F R E Q = 6 0 H z G B V = V G - W F C O N L I N K M A N U _ N A M E H I = V G B R E F # = V L O = V E D I A V cursor 3. Use the scroll wheel to set the current level. T T I M E R = S H I / L O T I M E R GB 3.00A ~ 40.00A ac Note The ground bond voltage (GBV) is calculated as the HI limit voltage + REF voltage (or (HI limit Ω + REFΩ) X test current). Setting the Test Frequency Background A test frequency of 60Hz or 50Hz can be set, regardless of the input line voltage. Steps 1. Ensure the tester is in EDIT status. Page 38 39

40 GCT-9040 User Manual 2. Press the UP / DOWN arrow keys to bring the cursor to the FREQ setting. M A N U = * * * F R E Q = 6 0 H z M A N U _ N A M E H I = V R E F # = V L O = V E D I A V G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M E R cursor 3. Use the scroll wheel to set the test frequency. T Frequency 50Hz, 60Hz Setting the Upper and Lower Limits Background There is both a LO and HI judgment setting. When the measured value is below the LO SET setting, the test will be judged as FAIL. When the value exceeds the HI SET setting the test will be judged as FAIL. Any measurement between the LO SET and HI SET setting is judged as PASS. The LO SET limit cannot be made greater than the HI SET limit. Steps 1. Ensure the tester is in EDIT status. Page Press the PAGE to choose the HI and LO value units (voltage or resistance). PAGE Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com 40

41 OPERATION Note Toggling the HI/LO units will also toggle the REF# units as well (REF# mω, REF# V). The REF# units and the HI/LO units are the same. If the units are changed, the REF# value will need to be set again. See page 42 for setting the REF# value. 3. Press the HI/LO soft-key or use the UP / DOWN arrow keys to bring the cursor to the HI limit setting. H I / L O OR 4. Use the scroll wheel to set the HI limit. HI 000.1mΩ ~ 650.0mΩ 0.001V ~ 7.200V 5. Repeat steps 2 and 3 for the LO limit setting. LO 000.0mΩ ~ 649.9mΩ 0.000V ~ 7.199V Example: V units M A N U = * * * F R E Q = 6 0 H z M A N U _ N A M E H I = V R E F # = V L O = V E D I A V G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M E R T HI limit LO limit Example: Ω units M A N U = * * * F R E Q = 6 0 H z A M A N U _ N A M E H I = m Ω R E F # = m Ω L O = m Ω E D I T m Ω G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M E R HI limit LO limit Note The LO SET setting is limited by the HI SET setting. The LO SET limit cannot be greater than the HI SET limit. 41

42 GCT-9040 User Manual Setting a Reference Value Background The REF# acts as an offset. The REF# value is subtracted from the measured current (ACW, DCW) or measured resistance (IR, GB). Steps 1. Ensure the tester is in EDIT status. Page Press the PAGE soft-key to choose the REF# value unit (voltage or resistance). PAGE Note Toggling the REF# units will also toggle the HI/LO units (HI/LO mω, HI/LO V). The REF# units and the HI/LO units are the same. If the units are changed, the HI/LO settings will need to be set again. See page 40 for setting the HI/LO values. 3. Press the UP / DOWN arrow keys to bring the cursor to the REF# setting. 4. Use the scroll wheel to set the REF# value. REF# (Ω) REF# (V) 000.0mΩ ~ 650.0mΩ 0.000V ~ 7.200V Example: V units REF# M A N U = * * * F R E Q = 6 0 H z M A N U _ N A M E H I = V R E F # = V L O = V E D I A V G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M E R T 42

43 OPERATION Example: Ω units REF# M A N U = * * * F R E Q = 6 0 H z A M A N U _ N A M E H I = m Ω R E F # = m Ω L O = m Ω E D I T m Ω G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M E R Note Note Limitations: ((REF# (Ω) + HI Set (Ω) ) x I Set) < 7.2V. ((REF# (V) + HI Set (V)) < 7.2V. A reference offset can be automatically created using the zeroing function. See page 54 for details. Setting the Test Time (Timer) Background The TIMER setting is used to set the test time for the current test. The test time determines how long the test current is applied to the DUT. The test time can be set from 0.5 to seconds, with a resolution of 0.1 seconds. Test I Start I TEST TIME Initial time (Approximately 100ms) time Note Each test has an initial test time of approximately 100ms. This time cannot be edited. Steps 1. Ensure the tester is in EDIT status. Page 38 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com 43

44 GCT-9040 User Manual 2. Press the TIMER soft-key or use the UP/DOWN arrow keys to bring the cursor to the TIMER setting. T I M E R OR M A N U = * * * F R E Q = 6 0 H z M A N U _ N A M E H I = V R E F # = V L O = V E D I A V G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M R T cursor 3. Use the scroll wheel to set the TIMER value. GB 000.5s~999.9s Creating a MANU Test File Name Background Each MANU test can have a user-defined test file name (default: MANU_NAME) up to 10 characters long. See the character list below for the allowed characters. Character List: A B C D E F G H I J K L M N O P Q R S T U V W X Y Z a b c d e f g h i j k l m n o p q r s t u v w x y z + - * / _ = : Ω? ( ) < > [ ] Steps 1. Ensure the tester is in EDIT status. Page 38 44

45 OPERATION 2. Use the UP/DOWN arrow keys to bring the cursor to the MANU test file name at the top of the screen. The test file name is initially set as MANU_NAME. cursor M A N U = * * * F R E Q = 6 0 H z M A N U _ N A M E H I = V R E F # = V L O = V E D I A V G B V = V T I M E R = S G - W F C O N T L I N K G B H I / L O T I M E R T 3. Use the scroll wheel to scroll through the available characters. 4. Press the Left/Right arrow keys to go the next character. 5. The MANU test file name is set when the current test setting is saved or when the cursor is moved to another setting. Saving and Exiting EDIT Status Background After all test parameters have been set, the test can be saved. Steps 1. When in EDIT status, press the EDIT/SAVE key to save the current test. This will enter the VIEW status for the chosen test number. EDIT/SAVE 45

46 GCT-9040 User Manual E D I T M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B 2. The Status changes from EDIT to VIEW. Note Pressing the EDIT/SAVE key again will return the tester back to EDIT status for the current test. Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

47 OPERATION Running a MANU Test Background Note A test can be run when the tester is in READY status. The tester cannot start to run a test under the following conditions: A protection setting has been tripped; when a protection setting has been tripped the corresponding error message is displayed on the screen. See page 129 for a comprehensive list of the all the setting errors. The INTERLOCK function is ON and the Interlock key is not inserted in the signal I/O port (page 70). The STOP signal has been received remotely. If Double Action is ON, ensure the START button is pressed immediately after the STOP button (<0.5s). Note When a test is running the current output cannot be changed. Steps 1. Ensure the tester is in VIEW status for the current test. Save the current test if necessary. Page 45 VIEW status M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B 47

48 GCT-9040 User Manual 2. Press the STOP button to put the tester into the READY status. STOP READY status M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V R E A D Y V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B Z E R O 3. The READY indicator will be lit blue when in the READY status. READY 4. Press the START button when the tester is in the READY status. The manual test starts automatically and the tester goes into the TEST status. START 5. The TEST indicator will be lit orange when in the TEST status. TEST TEST status M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N T L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V T E S T T I M E R = S Z E R O 6. The test will start by showing the remaining test time. The test will continue until the test is finished or the test is stopped. 48

49 OPERATION Measured Ω/V Test Current TEST status M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V T E S T T I M E R = S Z R O Measured Ω/V Remaining test time Stop the Test 1. To stop the test at any time when it is running, press the STOP button. The test will stop immediately. When the STOP button is pressed, a judgment is not made on the test. All panel keys except the STOP button are locked when the tester is in STOP status. STOP STOP status M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N T L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V S T O P T I M E R = S 2. To put the tester back into READY status, press the STOP button again. STOP Exit TEST Status To exit testing, press the MANU key when the tester is in the READY status. The tester will revert to the VIEW status for the current test. MANU 49 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

50 GCT-9040 User Manual M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B Note Do not touch any terminals, test leads or any other connections when the test is on. 50

51 OPERATION PASS / FAIL MANU Test Background Note If the test is allowed to run to completion (the test is not stopped or a protection setting is not tripped) then the tester will judge the test as either PASS or FAIL. The test will be judged PASS when: The HI and LO limits have not been tripped during the test time. The test will be judged FAIL when: Either the HI or LO limit has been tripped during the test time. A protection setting has been tripped during the test time. See page 129 for a list of error messages. PASS Judgment 1. When the test is judged as PASS, PASS will be displayed, the buzzer will sound and the PASS indicator will be lit green. PASS M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N T L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V P A S S T I M E R = S Z E R O 2. The PASS judgment will be held on the display until the STOP or START button is pressed. Pressing the STOP button will return the tester to the READY status. STOP 51

52 GCT-9040 User Manual Pressing the START button will restart the test. START Note The buzzer will only sound if the Pass Sound is set to ON. See page 67 for buzzer details. The START button is disabled when the buzzer is beeping. PASS Timing Diagrams GB PASS Timing The timing diagrams below show the GB timing for the START status, TEST status and PASS judgment. All the test lines are active low. START TEST PASS Output I 0.5s Total Test Time Initial time (Approximately 100ms) Signal IO Time Cut = ON Signal IO Time Cut = OFF time FAIL Judgment 1. When the test is judged as FAIL, FAIL will be displayed, the buzzer will sound and the FAIL indicator will be lit red. As soon as a test is judged FAIL, power is cut from the terminals. FAIL Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

53 OPERATION M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N T L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V F A I L T I M E R = S Z E R O 2. The FAIL judgment will be held on the display until the STOP button is pressed. Pressing the STOP button twice will return the tester to the READY status. 3. The READY indicator will be lit blue in the READY status. X2 READY STOP READY status M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V R E A D Y V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B Z E R O Note FAIL Timing Diagrams GB FAIL Timing The buzzer will only sound if Fail Sound is set to ON. See page 67 for details. The timing diagrams below show the GB timing for the START status, TEST status and FAIL judgment. All test lines are active low. START TEST FAIL Output I 0.5s Total Test Time Initial time (Approximately 100ms) Signal IO Time Cut = ON Signal IO Time Cut = OFF time 53

54 GCT-9040 User Manual Zeroing of the Test Leads Background The Zeroing function is used to determine the resistance of the test leads for GB tests. When a zero check is performed, the reference is automatically set to the measured resistance of the test leads. Steps 1. Ensure the tester is in VIEW status for the current GB test. Save the current test if necessary. Page 45 M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B 2. Short the positive and negative alligator clips as shown below. 3. Press the STOP button to put the tester into the READY status. STOP 54

55 OPERATION 4. The ZERO function can be activated by pressing the corresponding soft-key in the READY status. The ZERO soft-key will be highlighted. 5. Press the START button to perform the zero check. The tester will go into the ZERO status. Z E R O START 6. The TEST indicator will be lit orange when in the ZERO status. TEST Measured Ω/V ZERO status M A N U = * * * F R E Q = 6 0 H z A G B R = m Ω G - W F C O N T L I N K M A N U _ N A M E H I = V V G B R E F # = V L O = V Z E RO T I M E R = S Z E R O 7. When the zero check has finished, the tester will return back to the VIEW status. The resistance of the test leads will be automatically set as the Reference value. Reference value M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V R E A D Y V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B Z E R O Note Remember to replace the test leads to the proper position on the DUT before testing. 55 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

56 GCT-9040 User Manual I<SET If SOURCE H/L terminals are open or poorly connected, then an I<SET error will appear on the screen. Stop the test and re-check the connection again and try again. I<SET error message FAIL status M A N U = * * * M A N U _ N A M E R E F # = V F R E Q = 6 0 H z H I = V L O = V I < S E T G B R = m Ω G - W F C O N T L I N K G B F A I L T I M E R = S R = 0 Stop the test and perform the zero check again. R = 0 error message FAIL status M A N U = * * * M A N U _ N A M E R E F # = V F R E Q = 6 0 H z H I = V L O = V R = 0 G B R = m Ω G - W F C O N T L I N K G B F A I L T I M E R = S 56

57 OPERATION Linked ACW/DCW/IR Tests This section describes how to perform additional ACW, DCW or IR tests with a slave GPT-9XXX unit using the GCT-9040 as the master unit. ACW and DCW tests can be performed before, after or simultaneously with a GB test. IR tests can only be performed before or after a GB test. The LINK port on the GCT-9040 is used to control the linked slave unit. The slave unit can be used in MANU or AUTO mode, depending on the setup. In addition, remote commands can also be issued to slave units via the GCT LINK Connection from page 58 LINK Test Configuration from page 60 Run LINK Test from page 63 Before operating the GCT-9040 please read the safety precautions as outlined in the Set Up chapter on page 19 as well as the safety information in the user manuals of the GPT-9XXX units that function as the slave units when using the link connection. 57

58 GCT-9040 User Manual LINK Connection Background Any GPT-98XX or GPT-99XX unit can be used in conjunction with the GCT-9040 to perform additional ACW, DCW or IR tests. The LINK port on the GCT-9040 and the RS-232 port on the slave unit is used to connect both devices. The GPT-9XXX interface should be configured to the RS-232, with a baud of Steps 1. Ensure the power is off on both the GCT-9040 and the GPT-9XXX slave unit. 2. Connect the LINK cable (GTL-132) to the LINK port on the GCT-9040 and to the RS-232 port on the GPT-9XXX unit. 3. Connect the DUT as shown on page 30. Note: Stack the units vertically to use the cable. GCT-9040 master unit LINK port LINK cable RS-232 port GPT-9XXX slave unit 58 Test Equipment Depot Washington Street Melrose, MA TestEquipmentDepot.com

59 OPERATION Note No more than 2 units should be stacked vertically. 59

60 GCT-9040 User Manual LINK Test Configuration Steps Note First ensure the GPT-9XXX interface s set to RS- 232 and that the baud rate is set to See the Remote Control chapter of the corresponding user manual for configuration details. Not setting the interface correctly will result in failure of the LINK mode connection. 1. Turn on both units after the link cable has been connected*. 2. The GCT-9040 will be in VIEW mode upon startup. Note Load GB Test *The GCT-9040 will perform a search to see if a slave unit is connected with the LINK cable upon startup. If the slave GPT-9XXX is found then the LINK connection will automatically be activated at startup. Note, however, that the GPT-9XXX unit will need to have been fully powered on before the GCT-9040 is powered on for the search to succeed. 3. Use the scroll wheel on the GCT to select a MANU test number. This will be the GB test used. M A N U = * * * M A N U _ N A M E F R E Q = 6 0 H z H I = V A R E F # = V L O = V V I EW V G B R = m Ω T I M E R = S G - W F C O N T L I N K G B 60