ELABO G7-1G Bedienungsanleitung

TestSystems

Service

Calibration at ELABO

Calibration at customer premises

Test units on loan

ELABO GmbH, Hotline ++49 7951/307-202

www.elabo-testsysteme.com

Operating Manual

AC Combi-Tester

G7-1G/-1T

G7-1H/-1U

Full-electronic

combi-tester HV,IS,PE

1. INTRODUCTION

Combi-tester G7-1G/-1H/-1T/-1U

Contents

A OPERATING ELEMENTS ........................................................................ 6

Info about device versions and options.................................................................... 7

1 INTRODUCTION....................................................................................... 9

1.1 GENERAL INFORMATION ...................................................................... 9

1.2 ABBREVIATIONS AND SYMBOLS ....................................................... 10

1.3 SHORT DESCRIPTION OF THE TESTERS .......................................... 10

1.4 Standards supported............................................................................ 12

1.5 NAME PLATE......................................................................................... 12

2 SAFETY INSTRUCTIONS...................................................................... 13

2.1 MARKINGS FOR SAFETY INSTRUCTIONS AND WARNINGS ........... 13

2.2 WARRANTY ........................................................................................... 13

2.3 USE AS PER SPECIFICATIONS AND EXCLUSION OF LIABILITY..... 14

2.4 GENERAL RULES OF CONDUCT AND SAFETY INSTRUCTIONS .... 14

2.5 PROTECTIVE FACILITIES / EMERGENCY OFF .................................. 15

2.6 OPERATOR QUALIFICATIONS............................................................. 15

2.7 WORKING CLOTHES (PERSONAL PROTECTION EQUIPMENT) AND

PROTECTION AT WORK....................................................................... 15

2.8 MAINTENANCE...................................................................................... 16

2.9 MOISTURE AND HUMIDITY .................................................................. 16

2.10 COMPLIANCE WITH THE TECHNICAL DATA ..................................... 16

2.11 PHYSICAL/DESIGN CHANGES TO THE SYSTEM/DEVICE................ 16

2.12 OTHER INFORMATION ......................................................................... 16

2.13 INFORMATION ON THE HIGH VOLTAGE............................................. 17

2.14 DISCHARGING TEST OBJECTS WITH INTERNAL CAPACITANCE .. 17

3 PUTTING INTO OPERATION................................................................. 19

3.1 TRANSPORT AND INSTALLATION ...................................................... 19

3.2 AMBIENT CONDITIONS ........................................................................ 19

3.3 INSTALLATION IN HOUSING OR RACK .............................................. 19

3.4 CONNECTION TO THE CONNECTION BOX / CONNECTION PANEL /

TEST SYSTEM............................................................................. 20

3.4.1 Requirements for connecting lines to the test object............. 22

3.4.2 Cable length ............................................................................... 22

3.5 MAINS CONNECTION ........................................................................... 23

3.6 USING AND CONTROLLING ................................................................ 23

3.7 CONNECTION TO THE COMPUTER .................................................... 23

3.8. OPERATING TOUCH DISPLAY............................................................. 24

3.8.1 Entering arbitrary numerical values.......................................... 24

3.8.2 Entering arbitrary text ................................................................ 25

3.9 PASSWORD PROTECTION.................................................................. 26

3.9.1 Password level 1......................................................................... 26

3.9.2 Password level 2......................................................................... 26

3.9.3 Password level 3......................................................................... 26

3.10 SWITCHING ON ..................................................................................... 28

3.11 CHANGING LANGUAGE....................................................................... 29

3.12 STATE PAST SWITCH ON HV/IS........................................................... 30

3.12.1 SWITCH ON HV/IS ................................................................................. 31

3.12.2 STATES ISO ................................................................................. 32

3.12.3 STATES PE ................................................................................. 33

3.13 CONTACT MONITORING ...................................................................... 34

3.14 SAFETY CIRCUITS SK1 and SK2......................................................... 35

3.14.1 Fault in the device‘s safety circuit ............................................ 35

1. INTRODUCTION

Combi-tester G7-1G/-1H/-1T/-1U

3.15 INDICATION AT THE DISCHARGE OF TEST OBJECTS..................... 35

4 OPERATING MODES............................................................................. 36

4.1 FAST-START-MODE OR NORMAL-MODE .......................................... 37

4.2 NORMAL-MODE TEST SEQUENCE.................................................... 38

4.2.1 HV/IS-test normal mode ............................................................. 39

4.2.2 PE-test normal mode.................................................................. 40

4.2.3 Normal mode input step............................................................ 41

4.2.4 Normal mode output step ......................................................... 42

4.4 Current tripping modes.............................................................. 42

4.2.4 Normal mode time step ............................................................. 43

4.3 FAST-START-MODE TEST SEQUENCE .............................................. 44

4.3.1 Fast-Start-Mode PE-HV-ISO-Test .............................................. 45

5 ERROR MESSAGES.............................................................................. 46

6 CONNECTIONS / INTERFACES............................................................ 47

6.1 POWER CONNECTIONS....................................................................... 47

6.1.1 High Voltage ................................................................................ 47

6.1.2 PE-Conductor Test (Rx)............................................................. 47

6.1.3 X6 Warning lamp set 94-2C connection................................... 48

6.2 INTERFACES ......................................................................................... 49

6.2.1 Ethernet-INTERFACE X9 .......................................................... 49

6.2.2 USB-NTERFACE X9 ................................................................... 49

6.2.3 RS232 INTERFACE X9 ................................................................ 49

6.2.4 Service-INTERFACE X9a (RS232)............................................. 49

6.2.5 DIGITAL INTERFACE X7 ............................................................. 50

6.2.5.1 OUTPUTS................................................................................ 50

6.2.5.2 INPUTS.................................................................................... 52

6.2.5.3 DIO - additional digital interface (option) ............................ 53

6.2.6 XS8 - Expanded digital/analog interface (option) ................... 53

6.4 HIGH VOLTAGE CONNECTOR X3 ...................................................... 56

6.5 PE-TEST PROBE 94-4S CONTROL CONNECTOR X11 ........... 57

7 ACCESSORIES AND ATTACHMENTS ................................................. 58

7.1 TEST CABINET (OPTION)..................................................................... 58

7.2 WARNING LIGHTS 94-2C / F9-1A........................................................ 59

7.3 TEST PROBES 94-2A............................................................................ 59

8 MAINTENANCE AND CARE.................................................................. 60

8.1 FUSE REPLACEMENT .......................................................................... 60

8.2 CARING FOR THE HOUSING ............................................................... 60

8.3 CARING FOR THE TOUCHSCREEN DISPLAY .................................... 60

9 TECHNICAL DATA ................................................................................ 61

9.1

DEVICE-SPECIFIC TECHNICAL DATA........................................................61

9.2 COMMON TECHNICAL DATA DC- DEVICES ...................................... 62

9.3 INTERFACES, MISCELLANEOUS ....................................................... 62

10 TOUCHSCREEN DISPLAY MENU SYSTEM ........................................ 63

10.1 GENERAL............................................................................................... 63

10.1.1 Overview, HV test example ........................................................ 64

10.2 MAIN MENU ........................................................................................... 65

10.3 MANUAL TEST ...................................................................................... 66

10.3.1 Manual test with actual parameter ........................................... 67

10.3.2 Load parameter........................................................................... 69

10.4 PARAMETER SET MANAGEMENT ...................................................... 71

10.4.1 Load Parameter set..................................................................... 72

10.4.2 Edit Parameter set ...................................................................... 74

1. INTRODUCTION

Combi-tester G7-1G/-1H/-1T/-1U

10.4.3 Create parameter set .................................................................. 75

10.4.4 Delete parameter set................................................................... 76

10.5 TEST PLAN MANAGEMENT AND AUTOMATIC TESTING.................. 77

10.5.1 Load test plan / Auto testing ..................................................... 79

10.5.2 Automatic test ............................................................................ 81

10.5.3 Fault handling Auto Test ............................................................ 83

10.5.4 Edit test plan ............................................................................... 85

10.5.5 Create test plan........................................................................... 86

10.5.6 Delete test plan .......................................................................... 87

10.6 SETUP (DEVICE PARAMETER)............................................................ 88

11 TEST PARAMETERS............................................................................. 94

11.1 PARAMETERS FOR HIGH VOLTAGE TEST......................................... 94

11.2 PARAMETERS INSULATION RESISTANCE TEST ISO ...................... 98

11.3 SETTING PARAMETERS PROTECTIVE EARTH CONDUCTOR

TEST (PE)............................................................................................. 102

11.4 SETTING PARAMETERS BURN (OPTION) ....................................... 104

11.5 TIME-STEP........................................................................................... 107

11.6 CALCULATION OF THE IDLE TIME (HV / ISO).................................. 108

12 OPTIONAL OUTPUTS / INPUTS ........................................................ 109

12.1 BASE SETTINGS OUTPUTS/INPUTS................................................. 109

12.1.1 Digital Output/Input Setup ........................................................111

12.1.2 Analog Outputs/Inputs ............................................................ 112

12.2 ADDITIONAL DIGITAL INTERFACE OPTION G7-1 E06 .................... 114

12.3 EXPANDED DIGITAL/ANALOG INTERFACE OPTION G7-1 E07 ..... 115

12.4 CREATE PARAMETER BLOCKS........................................................ 116

12.4.1 Digital Outputs .......................................................................... 117

12.4.2 Analog Output........................................................................... 118

12.4.3 Digital Inputs (Input)................................................................. 120

12.4.4 Analog Inputs............................................................................ 121

12.5 Create Test plans (Input/Output) ...................................................... 123

12.6 Load and execute test plans (Input/Output)..................................... 124

12.6.1 Start /execute test plan (auto- mode)...................................... 124

12.6.1.1 Read digital input ................................................................ 125

12.6.1.2 Read analog input................................................................ 125

12.6.1.3 Set digital output ................................................................. 126

12.6.1.4 Set analog output ................................................................ 126

12.6.2 Start /execute test plan

(step mode).........................................127

12.6.2.1 Read digital input ................................................................ 127

12.6.2.2 Read Analog Input ............................................................... 127

12.6.2.3 Set Digital Output ................................................................ 128

12.6.2.4 Set Analog Output ............................................................... 128

13 ELABO LITE-SOFTWARE ................................................................... 129

13.1 COMMANDLINE TOOL:....................................................................... 129

13.2 FLASH-PROGRAMER FÜR FIRMWARE UPDATE ............................ 129

13.3 TREIBER TEST ................................................................................... 129

13.4 RESULT EXPLORER/MESSWERTSPEICHER AUSLESEN............... 129

13.5 RS-CONFIG / SERIAL INTERFACE RS232 ....................................... 130

13.6 TRANSLATION TOOL.......................................................................... 130

14 FAST START MODE ............................................................................ 131

14.1 FAST START MODE OVERVIEW ........................................................ 132

14.2 FAST-START-MODE STATUS DISPLAY ............................................. 133

15 OVER VIEW OPTIONS......................................................................... 135

15.1 OPTION E03 SAFETY CURRENT LIMITATION AC-TESTER............ 136

Load characteristic current-limited................................................... 137

1. INTRODUCTION

free page

Combi-tester G7-1G/-1H/-1T/-1U

TouchDisplay H4

S1/H1

H3 S2/H2

1. INTRODUCTION

Combi-tester G7-1G/-1H/-1T/-1U

A OPERATING ELEMENTS

base-

device types display HV

(V AC)

(mA)

ISO

(V DC)

(A)

G7-1G yes 100 ... 2500

200 ... 5000 max. 100 1200 5 ... 32

G7-1T no

G7-1H yes 100 ... 1500

200 ... 3000 max. 200 1200 5 ... 32

G7-1U no

X9a X7 X8 X6 X11 X2

F1/X1 X10 X3

1. INTRODUCTION

Info about device versions and options

The device can be delivered with some optional features, this options

are completes or enhances the performance range of the device. Some

optional features are only as single option possible. ELABO completes

the number of options constantly (as required). Optional features of the

device, are described in the appendix „Options“

Combi-tester G7-1G/-1H/-1T/-1U

1. INTRODUCTION

No. Equipment Function

F1 Fuse drawer Adapter for mains fuse

S1/H1 Toggle switch/pilot lamp Mains switch with indicator lamp

S2/H2 Illuminated button Reset (red) Switching OFF test voltage / Reset

S3/H3 Illuminated button Set (green)

Ready for testing

Starting test run (only at display devices)

H4 TouchDisplay Operating of the tester

Cold appliance mounting jack with

fuse adapter 10 A

Main cable connection / mains fuse (ne wire fuse

T 3.15 A - 5 x 20 mm)

X2 HV-jack Connection high voltage + / ~ (high potential)

X3 HV-jack Connection high voltage - / ~ (low potential)

X4 HV-jack Feed back of high voltage ( + / ~) for X2 (Option)

X5 HV-jack Feed back of high voltage ( - / ~) for X3 (Option)

X6 Socket (Warning Lamps) Connection warning lamps

X7 Socket (D-SUB 25pole) female DA-interface - digital Inputs/Outputs, Safety circuit

X8 Socket (D-SUB 37pole) male

DA-interface - additional digital/analog inputs/out-

puts (options)

X9 RJ45 (DSUB, USB) - socket

Ethernet bus interface (RS232, USB - option)

for automatic control of the tester (and rmware

update of touch display module)

X9a Socket (D-SUB 9pole)

RS-232 - Service-interface (rmware update control

module)

X11 HV-jack Connection high voltage - parallel to X2

X12 HV-jack Connection high voltage - parallel to X3

Combi-tester G7-1G/-1H/-1T/-1U

1. INTRODUCTION

1 INTRODUCTION

The safety of all personnel who come into contact with the tester essentially

depends on an adequate understanding of the device. For this reason:

Prior to the rst putting into operation read these operating

instruction!

Note on operating instructions!!

These operating instructions apply to devices with and without the

touchscreen display. The menus shown can be useful for illustrating

the functions on devices without a display and therefore contribute

to an improved understanding of the device.

1.1 GENERAL INFORMATION

These operating instructions will make it easier to become familiar with

tester and its possible uses prior to placing in operation, and to use it

correctly. They contain information that will ensure functionally correct,

cost-effective and safe operation and they must always be available in

the place where the device is used.

The operating instructions are not only an indispensable aid for new trainee

operators, they also contain useful tips, information and suggestions for

the experienced operator. They are a necessary reference work for all

users. By reading the operating instructions

•Hazards will be avoided

•Operating sequences will be optimised and accelerated

•Repair costs and downtimes will be minimised

•Reliability and service life will be increased

The operating instructions should also be read carefully by the device

owners and managerial staff. In particular in relation to transport and in-

stallation, as well warranty aspects.

In chapter 2 important safety instructions and information about hazards

is given that will prepare you for hazardous situations that may occur.

Reading up during operation is unfortunately too late. Also note the fol-

lowing basic principle:

Cautious and careful working is the best protection from

accidents!

The quality of the tests performed using the device is crucially depend-

ent on maintenance and care. Regular maintenance work and care are

described in these operating instructions. If repairs are necessary, we will

be pleased to provide you with support and supply you with the necessary

original spare parts.

If you have questions after reading the operating instructions, the ELABO

hotline (telephone +49 7951/307-202) is available to provide information.

Combi-tester G7-1G/-1H/-1T/-1U

•1

•

1. INTRODUCTION

1.2 ABBREVIATIONS AND SYMBOLS

Special option that is not included as standard

List, here the recommended sequence of actions is to be followed

List

CAUTION ELECTRIC HIGH VOLTAGE - DANGER TO LIFE!

Hazardous point, risk of serious injury to the operator and other person-

nel! - chapter 2.1

Risk for the device! - chapter 2.1

Information on efcient and cost-effective operation - chapter 2.1

Combi-tester G7-1G/-1H/-1T/-1U

1.3 SHORT DESCRIPTION OF THE TESTERS

The tester G7-1G are designed for operation by using the integrated

touchscreen display and also via interface.

As an alternative, the device G7-1T are intended to be controlled using

an external PC/PLC. For this reason there is no display.

The modular design of the tester permits optimal adaptation to the indi-

vidual needs of the user. Expansion modules, standard accessories and

individual accessories offer the right solution for every application.

The basic devices available are automated devices (without display) for

use in test systems and „stand-alone“ devices (with display).

By optional features the devices can be equipped with additional functions.

The uses for the device family range from an individual manually operated

test bench, through a PC-controlled test station (with control, evaluation,

statistics and test plan management via PC software) to a complex fully

automatic test station with conveyor belt, autom. contact, labeling etc..

ELABO offers a modern software package for controlling this device series

and the management of the data via a PC.

Devices with touchscreen display

The user can be operated entirely using the touchscreen panel. This

operation covers the control of the device during the test, the generation

and management of test steps and test plans.

The display informs the operator at all times about the parameters and

the status of the tests.

HV part:

The device serves for the insulation test and withstand voltage test at elec-

trical equipment, machines, construction elements and insulating material.

The test is carried out with AC up to 5000 V/ test current maximal 100 mA.

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