MT204-S Machinery Tester Users Manual GB
A MPROBE MT 204-S Users Manual c 2010 BEHA-AMPROBE 3 R
Limited warranty and limitation of liability ............................................ 6 Service ...................................................................................................... 6 References marked on the instrument or in this instruction manual ... 7 Introduction ............................................................................................. 8 The following features characterise the Machinery-Tester MT 204-S .. 8 Scope of supply .......................................
Fuse replacement ................................................................................... 41 Fuse replacement (mains fuse F1) ......................................................... 42 Fuse replacement (fuse F2 for RPE10A, Zl, RISO and HV functions) ...... 42 Fuse replacement (fuse F3 for RPE0.2A function) .................................. 43 Technical data ........................................................................................ 44 General data .................................
Limited warranty and limitation of liability It is guaranteed that this BEHA-AMPROBE product is free of material and manufacturing damages for the time period of 24 months starting from the date of purchase. This warranty does not include fuse malfunctions, as well as damages caused by accidents, negligence, misusage, unauthorised modifications, abnormal operating conditions or improper handling. The sales offices do not have the right to extend the warranty on behalf of BEHA-AMPROBE.
References marked on the instrument or in this instruction manual Warning of a potential danger, comply with instruction manual. ☞ Reference, please pay utmost attention. Caution, dangerous voltage. Danger of electrical shock. Symbol for marking of electrical and electronic equipment (WEEE Directive). Conformity symbol, the instrument complies with the valid directives. It complies with the EMC Directive and the Low Voltage Directive.
Introduction You have acquired a high-quality measurement instrument manufactured by BEHA-AMPROBE GmbH, which will enable you to perform repeatable measurements for a very long period of time. The Machinery-Tester MT204-S is a measurement instrument used for final inspection and documentation of electrical equipment of machines, control cabinets, switchgears as well as devices complying with EN 60204-1.
Scope of supply 1 pc 1 pc 1 pc 1 pc 1 pc 2 pcs 2 pcs 2 pcs 1 pc 1 pc 1 pc Machinery-Tester MT 204-S HV function lock key Mains cord (Schuko) Mains cord (Swiss) Mains cord (UK) Safety test leads 2 m Safety test lead extensions 10 m Alligator Clips USB interface cable CD with USB drivers and instruction manual Instruction manual in English/German/French/Italian/Spain Optionally we offer test report forms and professional PC software for quick and easy creation of final test reports complying with EN 60204-1
Safety measures The Machinery-Tester MT 204-S has been built and tested in compliance with the valid safety regulations and left the factory in safe and perfect condition. In order to maintain this condition and to ensure safe instrument operation, the user must pay attention to the references and warnings contained within this instruction manual.
HIGH VOLTAGE, DANGER OF ELECTRICAL SHOCK • The Machinery-Tester MT 204-S supplies high voltage of dangerous power. According to EN 50191 the following precautionary measures must be taken prior to a test: - Block access to danger area. - Put up warning signs (Attention! High voltage, danger to life). - Install warning lamps (red, green) to be easily visible. - Install EMERGENCY-OFF switch into the mains installation outside the dangerous area. ☞ These notes are just extracts of the EN 50191 standard.
Operation elements and connectors Front panel of the Machinery-Tester MT 204-S 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 IEC connector for mains supply Mains fuse (F1) "ON/OFF" mains switch (with red pilot lamp) Fuses for measurement functions RPE, RISO and HV (F2, F3) Measurement function selector HV lock key enabling / disabling the High-voltage test (flash test). The key can be removed in HV off position only.
Figure 1: Machine Test MT 204-S 13
LC-Display Display in a measurement function (e.g. RPE) RPE MAN C L 2.60 10A 0.
Safety measures WARNING Correct functionality of the instrument must be verified prior to any use. • Attention must be paid to proper condition of the test leads, measurement accessories and measurement instrument itself. • Test leads and measurement accessories may only be touched on protected areas. Touching of conductive probes is prohibited at all times. • The instrument may be used within specified measurement ranges only.
Preparation of the Machinery-Tester MT 204-S Turning on the Machinery-Tester MT 204-S 1) Connect the Machinery-Tester MT 204-S to correctly installed schuko mains socket using supplied mains cord. 2) Use the mains switch "ON/OFF" (3) to turn on the MT 204-S. 3) After turning on the MT 204-S, pilot lamp of the power switch (3) will switch on and LC-Display (16) will show initial readout of selected function. 4) Connect both safety test leads (with touch protection) to MT 204-S test sockets (9).
Limit value setting This function is available in measurement functions RPE, ZI and RISO. For limit value setting press the "LIM" menu key (14), then use the "+" and "–" menu keys to set appropriate limit value. The "EXIT" function key shall be used to exit limit value setting display. RPE MAN C - L 0.51 0.2A 0.51 + Figure 5: Limit value setting ☞ In case test result comply with set limit value, there are two short sound signals present after finishing the measurement.
External voltage display, display in case of blown fuse • If there is an external voltage present at test tips in RPE, RISO or HV functions prior to a measurement, the "VOLTAGE" sign appears on the display and start of the measurement is blocked. • If there is an external voltage applied to test tips after starting the RPE 10A measurement or if there is an over-voltage applied in Zl or HV function, fuse F2 may blow. The sign "(FUSE F2) 12.5A" appears on the LC-Display.
Measurements according to EN 60204-1 Earth bond resistance measurement (RPE function) • Complying with EN 60204-1, continuity of protective bonding circuit between PE terminal and relevant points of the protective conductor system must be checked by injecting a measurement current of 0.2 A up to approx. 10 A. • Limit values are the values which correspond to the length, cross section and material of measured conductor. 1) Set the measurement function selector (5) to RPE position.
Loop impedance / Prospective short-circuit current measurement (Zl/IPSC function) • According to EN 60204-1, the conditions for protection against electric shock in installations with automatic disconnection of mains voltage are: • Measurement or evaluation of fault loop impedance and testing the over-current protection device involved in the fault loop. • Limit values are shown in the Table 10 of EN 60204-1. 1) Set the measurement function selector (5) to Zl position.
• For saving displayed measurement result press the "SAVE" function key (12) twice, for further instructions see the "Memorizing example" section. • By setting the test current to 20 A, the loop impedance measurement will be executed quickly and accurately. Potential motor protection switch or residual current device (RCD) can be triggered during the measurement, because of high test current.
Insulation resistance measurement (RISO function) • According to EN 60204-1, the insulation resistance between shorted active conductors of power circuit and the earth bonding system must be checked applying a test voltage of 500 V DC. The limit value is 1 M. • Ensure that all switches on the unit under test are closed in order to test all it’s components. For purpose of the measurement, all active conductors (L1, L2, L3, N) must be shorted. 1) Set the measurement function selector (5) to RISO position.
that the unit under test is discharged through the measurement instrument (not through short circuit)! • For saving displayed measurement result press the "SAVE" function key (12) twice, for further instructions see the "Memorizing example" section. Note! Connect COM test lead to chassis if the object under test is grounded.
High voltage test (HV function) • According to EN 60204-1, electric equipment must withstand a voltage test between shorted active conductors of power circuit and the earth bonding system for approx. 1 s. The test shall be carried out at twice the rated supply (or 1000 V whichever is greater) 50 Hz. Components not rated for this test voltage may be disconnected before carrying out the test. WARNING, DANGER OF ELECTRICAL SHOCK The Machine tester MT204-S supplies high voltage of a dangerous power.
• In case of flashover in the unit under test, the test is terminated immediately, both pilot lamps (8) and (10) switch off and the "FAIL" mark is displayed. 7) Stop the test by pressing the "START/STOP" button again.
Residual voltage / Discharge time measurement (URES, tRES function) • What are residual voltages? Residual voltages are such voltages that exist even after switch off a machine or a device. This can be caused e.g. by built in capacitors or subsequent generators. This measurement is performed using the function "URES, tRES".
URES LIN 2 F: t 2 1s 1 V MODE TIME 3 4 Figure 11: Measurement function URES 1 Display of measurement function, parameters and set limit value 2 "F: t / F: U" menu key, for selection of measurement function (Residual voltage or Discharge time) 3 "MODE" menu key, for selection of measurement mode "LIN" or "UNLIN" 4 "TIME" menu key, for selection of measurement time (1 s or 5 s) tRES Umax=60V 2 1s 1 s F: U LIM 2 3 Fig 12: Measurement function tRES 1 Display of measurement function, paramete
Explanation of linear and non-linear mode Residual voltage measurement "Linear mode" In linear mode it is assumed there are only "linear" components involved in discharge process (capacitors, resistors, inductors etc.) and therefore discharge characteristic is exponential, see the diagram below. In linear mode displayed result refers to peak value of mains voltage, see the figure 13.
Residual voltage measurement "Non-linear mode" In non-linear mode it is assumed there are also "non-linear" or unknown components involved in discharge process (relays, gas lamps etc.) and therefore discharge characteristic is non-exponential or even unpredictable, see the diagram below.
Menu functions For further selection, entry and display of instrument’s settings, press the "MENU" function key (12), the following selection menu appears.
"MEMORY" menu In this menu the following selections are available: SAVE TO USB: Transfer of stored data to USB memory stick. The whole storage, individual customer, machine, measurement location or only measurement result can be transferred. Data records to be transferred can be selected with the "◄", "►" and "▼" menu keys and transfer action by pressing the "" menu key. CLEAR: Erasing of measurement results.
"DATE/OPERATOR" menu There are the following selection possibilities: DATE: Setting of actual date. Use the "▼", "▲" and "►" menu keys to set the date then confirm it by pressing the "" menu key. OPERATOR: Entry of the operator. After date confirmation, the cursor is automatically placed to the last character of the operator’s name. Modify / enter the name by using the "▼", "▲" and "" menu keys then confirm it by pressing the "" menu key. DATE: 01.01.
"LANGUAGE" menu There are the following selection possibilities: ENGLISH, GERMAN, FRENCH, ITALIAN or Spanish language. ENGLISH GERMAN FRENCH ITALIAN SPANISH Figure 18: LC-Display menu "LANGUAGE" "CONTRAST" menu Contrast of the LC-Display can be adjusted by using the "-" and "+" menu keys.
"BACKLIGHT" menu Backlight of the LC-Display can be switched either off or on by using the "OFF" and "ON" menu keys. BACKLIGHT OFF ON Figure 20: LC-Display menu "BACKLIGHT" "TESTER INFO" menu The following instrument information can be read in this menu: Model, Serial number, Catalogue number, Firmware version and Hardware version. MODEL: SER NO: CAT NO: FW VER: HW VER: MT204-S XXXXXXXX 9085 1.XX 1.
Memory features Any memory address consists of a customer name, machine name and location name. The memory address should be entered / selected before storing measurement results. Date and operator must be entered before carrying out the measurements as they are attached to any measurement result immediately after finishing the measurement. Memory structure Measurement result, limit value and parameters are saved to selected memory address upon receiving the SAVE command.
General memory operations Menu key "▼" Menu keys "◄" and "►" Menu key "REN" Menu key " " Menu keys "▼" and "▲" Menu key "" Function key "EXIT" Recall (RCL) Storage level (customer, machine, location, No.) is selected. Already entered names (for customer, machine, location, Nr.) can be selected. A new name can be opened by using the "►" menu key. Rename, already entered name can be modified. Individual characters are deleted. Entry of characters, "A…Z, 0…9, +, -, _, /, #, and space" can be selected.
5) Select the next storage level "MAC" (machine) by using the "▼" menu key. 6) Select already entered machine name by using the "◄" and "►" menu keys. If wished machine name is not entered yet, then setup a new machine by using menu key "►", offered default name is "XXXX". Press the "REN" menu key and delete default name "XXXX" by using the "" menu key. 7) Enter a new machine name for example "MAC001" by using the "▼" and "▲" menu keys. Confirm entry by pressing the "" menu key.
Recall data In order to recall stored measurement result follow the following instructions: 1) Press the "RCL" menu key (12). 2) Level "CUS" (customer) is already marked. Select wished customer name by using the "◄" and "►" menu keys. 3) Select the next storage level "MAC" (machine) by using the "▼" menu key. Select wished machine name by using the "◄" and "►" menu keys. 4) Select the next storage level "LOC" (location) by using the "▼" menu key.
Entry of memory address using external keyboard The optional USB keyboard is a welcome accessory when inserting memory address construction (customer, machine and location) in order to do the job quickly and simply. Connect the USB keyboard to USB2 connector, three sound signals follow after plugging it, as a confirmation of USB-device recognition. Now, the external keyboard is operational.
Entry of memory address using barcode reader The optional USB barcode reader is a welcome accessory when inserting memory address structure (customer, machine and location) in order to do the job quickly and simply. Connect the USB barcode reader to USB2 connector, three sound signals follow after plugging it, as a confirmation of USB device recognition. Connect the barcode reader to USB2 connector.
Maintenance When using the instrument in compliance with the instruction manual, no special maintenance is required. However, should functional errors occur during normal operation, our after sales service will repair your instrument without delay. Cleaning If the instrument is needed to be cleaned after daily usage, it is advisable to use a wet cloth and a mild household detergent. Prior to cleaning, remove the machinery tester from all measurement circuits and from mains.
Fuse replacement (mains fuse F1) In case mains switch pilot lamp (3) does not illuminate after connecting the Machinery-Tester MT204-S to mains outlet and switching on the mains switch and neither the LC-Display (16) shows any indication, it is very likely mains fuse (2) to be blown.
Fuse replacement (fuse F3 for RPE0.2A function) Internal fuse F3 (FF 1.0 A / 500 V, 6.3 x 32 mm) has blown if: • Text "FUSE (F3) 1.0A" appears on the LC-Display in RPE0.2A function • Check the fuse also if "FUSE (F2/F3)" appears on the LC-Display in RPE0.2A or RPE10A function To replace the fuse proceed as follows: 1) Unlock corresponding fuse holder (4) by using an appropriate screwdriver 2) Remove the defective fuse and replace it with a new one (FF 1.0 A / 500 V, 6.3 × 32 mm).
Technical data General data Display Limit value display Limit value setting Memory Interface (USB1) Interface (USB2) Graphic LC-Display, 128 x 64 dots Optic and acoustic Within measurement range (in functions RPE, Zl and RISO) Approx. 2000 memory locations, 3 levels (customer, machine, measurement location), additional measurement No. is created. USB 2.0 device, USB interface to PC USB 2.
Measurement functions Earth bond resistance (RPE 10A) Measurement range 0.12 ... 20.00 Display range 0.00 ... 20.00 Resolution 0.01 Accuracy ± (3% rdg. + 2 digits) Test current approx.10 A AC (mains voltage 230 V ± 10%, standard test leads 2 × 2 m and external resistance 0.1 ) Test voltage (open circuit) approx. 5.5 V AC (floating) Measurement principle Two-wire connection Test lead compensation Up to 5.00 by pressing the "COMP" key Protection against ext.
Loop impedance / Prospective Measurement range Zl Display range Zl Resolution ZI Accuracy ZI Display range IPSC Calculation IPSC Accuracy IPSC Voltage range Test current Measurement principle Test lead compensation short-circuit current (Zl/IPSC LOW) 1.2 ... 9.9 , 10 ... 500 1.2 ... 9.9 , 10 ... 500 0.1 , 1 ± (3% rdg. + 6 digits)* 0.4 A ... 191 A for 230 V (+/-10%) IPSC = 230 V / Zl outside above range IPSC = Umeas / Zl Depends on Zl accuracy 200 ... 253 V, 50 Hz approx.
Breaking current (It) Accuracy of trip current Breaking time after reaching breaking current Selectable 5 mA, 10 mA, 25 mA or 50 mA ± 15% of It <20 ms Residual voltage / Discharge time (URES, tRES) Input voltage range 0 ... 440 V AC, 50 Hz 0 ... 622 V DC Measurement range URES 10 ... 622 DC oder ACp Accuracy URES (general) ± (2% rdg. + 2 V) Accuracy (LIN mode, AC input) - 0 V ... + 15 V Measurement range tRES 0.8 ... 300.0 s Display range tRES 0.0 ... 300.0 s Accuracy tRES ± (2% rdg.
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