FOSTERBELL SG600C Surge Generator Instruction Manual

SG600C, SG100C
Surge Generator
INSTRUCTION MANUAL

**** SAFETY INSTRUCTIONS

Read this information carefully before using this instrument

• This is a high-energy Surge generator; this instrument should be used only by trained personnel. The following caution must be exercised every time before, during, and after using this equipment.
• DO NOT use this instrument in an explosive environment, as this instrument generates sparks that might ignite such an environment.
• Pacemaker users should stay away and not use this equipment.
• The user of this equipment comes in close contact with a 230V line and high-voltage sparks; hence, the greatest caution should be used while touching any metal part of the equipment or lead set.
• Always wear safety gear like rubber footwear, eyeglasses or a safe chamber if available, and rubber gloves.
• DO NOT OPERATE THIS EQUIPMENT while the room’s relative humidity is above 70%, as this may cause internal sparking of high voltage components.
• Make sure a well-established ground is connected to the PE terminal of the equipment.
• An isolation transformer is necessary with this equipment, for DUT supply.
  High voltage capacitors might be charged and stay charged for many days.
  THE INSTRUMENT MUST ONLY BE OPERATED BY SUITABLY TRAINED AND COMPETENT PERSONS

What is in the box

The following items are included in the box, usually shipped in 2 or 3 boxes.

General description

The surge tests required by the immunity standards listed under EMC Directives. The products that pass under surge immunity test can self-declared CE marked under EMC protection requirements, all other EMC Directives and requirements are still applicable as per EMC Directives and local laws.
The term “surge” is often described as a transient increase in the mains supply voltage with the rise time measured in μs ( microseconds) and last for upto several hundred μs.
These are caused due to

1. Switch disturbance of main power line, line large loads such as motors, generators, etc.
2. High Frequency Switches, like Solid State Switching Device.
3. Short Circuit due to device failure
4. Power Factor Capacitor Banks
5. Lightning surge that is injected on the power line on power transformer, sub transformer, sub-station, etc.
6. Direct or Indirect Lighting Surge hitting device, due to induction of nearby voltages and currents.

Surge Generator is a surge-type device with a high potential that is used to perform an EMC test or surge immunity performance test on electronic equipment in accordance with the IEC 61000-4-5 standard. Provision for varying surge voltages from 500 volts to 6 kilovolts is made available.
The surge generator produces high-voltage and high-current pulses in the power line for the device under test.
It has an integrated Coupling Decoupling Network (CDN) capable of handling up to 16 amps.

Features

Emergency stop switch
HV Key lock
MCB protection for input of Isolation transformer unit
MCB protection for input of DUT Supply

Preparations for Use

Initial instructions
Unwrap packing and remove main instrument, isolation unit, voltage regulator unit, power leads, jumper cables, and HV leads set (3).
Familiarize yourself with position of Power inlets/outlets, Surge out, CDN input and output sections on front panel.
Read complete manual before use, especially Safety and Warning sections.
Supply voltage: 90 to 265 V rms ac at 50 Hz.
Choose a well ventilated, temperature controlled and isolated place for instrument installation.
Electrical switchboard wiring should be done according to the nearby figure shown. Make sure to use right wire guage, and quality dual pole MCB.

Factory Calibration
The SG600C and SG100C are supplied with a factory calibration certificate as part of Fosterbell’s final test procedure.
HV Lead Color Codes

Preparations for Use

Pre-installation requirement

• You need two power supply connections to operate this instrument, as shown in the earlier section.
• While selecting the location of the machine consider the following.
• The working area/table must have rubber insulated mat for insulation from ground. Availability of mains power supply.
• The working area must be well lit for clear visibility.
• The working area must be clear of obstructions.
• The working area must be clear of inflammable and explosive material.
• Power Supply: Single Phase 230V 50Hz AC
• Plug Type: 230V ±10% 50Hz , Current 6Amps and 16 Amp, fused at 2 Amp.

Principle of working
The nearby diagram shows working principle of the Surge Generator. Energy Storage mechanism stores high amount of energy replicating energy load which generates high voltage spike in the line. Waveshaping network replicates line network forms close to real life surge wave which is strictly according to IEC standard. Coupling network and Decoupling network prevents surge from entering into other parts of your supply.

The following surge wave timing diagrams are essential part of the testing. The instrument should be calibrated according to the following timing diagrams of open circuit voltage and short circuit current. Open circuit voltage should comply to 1.2/50 us diagram, shown in detail below.

The short circuit current should comply to 8/20 μs diagram, shown in detail below.

Instrument controls

Familiarize with instrument controls shown below of Surge Generator main unit and Isolation transformer unit.

Installation steps

Installation steps

Software Operation Manual

Once you start the instrument you will see greetings and then options to select a program as shown below.

Program Bar
Program Number: Shows program number selected.
EUT Power: Turn ON or OFF EUT Power.
Back: Back to change program.
Save: to save program in the memory.
Run: it saves and starts the program.
Voltage settings
Start voltage: Initial voltage setup for program Step Voltage : You can program voltage progress in steps in the multiple of 100V. Set Step Voltage to 0, if you want to test at start voltage only. End Voltage: Final voltage for program can be set here.

Coupling settings
Coupling is set for surge applied to terminal with respect to another terminal. You can set one or more coupling modes. for ex. L-N means surge is applied to L with respect to N and N-G means surge is applied to N with respect to G. Please note don’t confuse it with the polarity of surge. Surge can be positive as well as negative on any
terminal.
Polarity settings
Surge polarity can be positive or negative. you can set one or both. While program run it will be automatically alternated according to IEC standard.

Impedance settings
Impedance can be either 2 ohms, 12 ohms or 42ohms (optional).
Set it according to IEC standard applicable for your product.

Synchronization settings
It is also known as angle synchronization settings, you can set it either asynchronization or “Async” or synchronization or “Sync”. In the Sync option you will have to select one of the four options, for your convenience we have defined 3 standard options either

1. 90° and 270°
2. 0°, 90°, 180° and 270°
3. 0°, 45°, 90°, 135°, 180°, 225°, 270° and 315°
4. Specific angle from 0° to 359° (resolution of 1°)

Time interval settings
You can set time interval from 10 seconds to 999 seconds.
Please note for higher voltages time interval is automatically increased to the optimal value and it will also be less than or equal to 60 seconds which is specified by IEC standard.
Number of pulses settings
You can set number of pulses from 1 to 999.
Please note according to this setting each configuration is repeated for set number of pulses.

Program run status screen
Once program is run. LCD will show all the program settings, and count down is displayed in timer section, once the countdown is completed, the HV pulse is triggered in the object under test. Progress of testing is shown on progress bar. One can stop the running program any time, and can see the program is stopping on top bar, but be aware that there might be a residual voltage in the instrument hence do not touch the leads at least for 30 seconds after emergency stop. You may pause the program for object inspection in the middle, take care of HV and turn off 230V line before touching it.
Last Test History
History page, Last pulse fired before stop or completion of last program is shown on this page.

Information Screen
This page shows model number, manufacturer/brand name, manufacturing date and compliance information.

Troubleshooting guide

• The power-on light does not glow.
  Check the fuse. If faulty, replace it.
  If it blows again, check the supply transformer.
  If the fault persists, please contact the manufacturer.

• No surge is generated.
  Check the set voltage and raise it; it may be set to zero.
  Check if the SG output is connected to the CDN input via jumper cables. Use only the jumper cables provided by the manufacturer.
  Check if the coupling is selected as either 2 ohms or 12 ohms.

• If the fault persists, please contact the manufacturer.
  If EUT is not powered via the AUX supply.
  Verify that the DUT supply is connected to test terminals or a 3-pin plug.
  Check if the MCB switch on the back panel is tripped. It happens if the DUT is short-circuited.
  If the fault persists, please contact the manufacturer.

• If the system restarts in the middle of the test run.
  Check if Earth is properly connected to the earthing terminal on the front panel.
  Earth and Neutral voltage should be less than 2V, i.e. strong earthing.

Fosterbell Technologies Pvt Ltd
Office Address: 2 Govansh, Kailash Nagar, Nashik 422 003
Phone +91-98228-09743 / +91-90674-20250
www.fosterbell.com
sales@fosterbell.com
©2022 All the copyrights of all technical or non-technical work are reserved with the owner. Fosterbell is a registered trademark.
The company reserves the right to change the specifications or design without prior notice.

References

• fosterbell.com

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