1236 Test Equipment DCAE Course Numbers 1236 and 3853 Avionics Technician TEST EQUIPMENT MODULE TRAINING USE ONLY -1- ISSUE 1 1236 Test equipment ELECTRICAL SAFETY 1. Electricity can kill or main – directly or indirectly. 2. Directly by the shock effect. 3. Indirectly from smoke inhalation and burns from fires started by electricity. 4. All electrical equipment (including ‘battery operated’) presents the hazards of electric shock and electrical fire due to misuse or damage to the equipment. 5. When high voltage supplies are used, the danger of LETHAL electrical shock must be considered. Service regulations (1988) define potentially LETHAL voltages as those in excess of: a. 50 V ac (rms.) b. 120 V dc Thus, the domestic mains supply of 240 V ac is LETHAL. However, all voltages must be considered dangerous. 6. To reduce the risk/severity of electric shock or fire, the following precautions are recommended: a. Examine the equipment and associated leads for damage before connecting to the supply voltage. b. Remove or cover rings, bracelets, watches, medallions, etc. c. Have a tidy work area (no drinks, liquids, flammable waste, etc). d. When connecting/disconnecting test equipment leads (including the Fluke) do so one lead at a time using one hand (the other hand in your pocket). -2- 1236 Test Equipment DIGITAL MULTIMETERS INTRODUCTION 1. The accuracy of readings obtained with single function meters is dependent on the efficiency of the operator when interpreting the pointer position on the scale plate. Digital multimeters remove this subjective element from readings, as you only have to read off the illuminated digits on the display panel. FLUKE 25 2. This is a fully self-contained auto-ranging digital multimeter (see figure 1) housed in a plastic storage case, and can be used in almost any environment in which the mechanic is likely to encounter. It has the following features: • Carrying handle/stand • Four digit (max count 3200) Liquid Crystal Display (LCD) • 10-function rotary selector switch • Manual/Auto range selector • Hold facility • Analog bar graph • Low battery warning • Range overload warning • Audible bleeper • Diode/continuity test facility CARRYING HANDLE/STAND 3. To enable the tilt bail to be used as a stand, pull the base out approximately 4" and rest the DMM on its end and the stand. To use it as a carrying handle, pull the bail up approximately 1" and relocate the two bottom lugs into the alternate holes provided. DISPLAY PANEL 4. This is a four digit LCD with a maximum count of 3200. Also displayed are polarity and other various annunciators (indicators) for range selection, function selection, battery indication etc. This display updates two times per second. -3- 1236 Test equipment -4- 1236 Test Equipment Figure 1 ROTARY SELECTOR SWITCH 5. The ten-function rotary selector switch selects the various functions, separate selections required for ac and dc voltage and current ranges. On the Ohm’s range, the common terminal is the negative terminal. 6. As the rotary switch is moved from the OFF position, the meter performs a brief self-check, culminating in all indications on the LCD panel being displayed. 7. When the Fluke 25 DMM is in voltage mode the meter requires a high internal impedance approximately 10M to ensure that the measurements taken are as accurate as possible. MANUAL/AUTO RANGE SELECTOR 8. On initial range selection, the DMM is in the auto-ranging mode. Press the range button (top left of the control panel) once to hold the minimum range, and press repeatedly to step through, in ascending order, all possible ranges for that particular function selected. To return to the auto-ranging mode once more, press the range button and hold for 2 seconds. During range selection, auto or manual, shunts or multipliers are selected as required to effect the range change. -5- 1236 Test equipment HOLD FACILITY 9. There are two hold modes: a. Auto-Touch Hold. Press the hold button (top right corner of the control panel) once, with the range selected, and the stable measurement will be captured and displayed (except for readings around zero) only updating when another stable measurement is taken - accompanied by an audible bleep. This is useful when taking measurements in a difficult environment, as the display can be read when convenient. To exit from the auto-touch hold mode, press the Hold button for 2 seconds and release when an audible bleep has been heard. b. Manual Touch Hold. Press and hold the Hold button whilst moving the range selector switch from the OFF position to the desired range. Release the hold button after 2 seconds and then press it again momentarily. The display will now only be updated when the hold button is depressed momentarily. To exit from the manual touch hold mode, press the hold button for 2 seconds and an audible bleep will signify that the hold function has been terminated. The corresponding annunciator on the display panel will also disappear. To enter the auto-touch hold mode, the instrument must first be switched off and then back on again, followed by the instructions in sub-paragraph an above. ANALOG BAR GRAPH DISPLAY 10. The analog bar graph display shows, in a graphic form, the measurement being taken and performs the same function as an analog needle, but it eliminates the mechanical overshoot inherent in needle movements. Care must be exercised, however, as the hold mode, whilst freezing the digital display, does not freeze the bar graph display. Therefore, when using the hold facility, it is best to ignore the indications provided by the bar graph. The display is updated 25 times per second. 11. A negative (-) annunciator is displayed at the left end of the bar graph when taking a reverse polarity dc measurement. Assume that a slowly varying dc voltage is the input. As the input goes more +ve (from zero), a segment is displayed and additional segments are displayed from left to right, to indicate that the input is increasing. Now assume that the input is slowly decreasing. Fewer segments are displayed and the -ve annunciator flashes as the input passes through zero. As the input goes more -ve, the -ve annunciator stops flashing (remains on) and additional segments are displayed from left to right, indicating a more -ve input. If the input is equal to or exceeds the range selected, then the bar graph displays an arrow at the far right of the display. LOW BATTERY WARNING 12. Each time the function switch is moved to a new position, battery voltage is tested. Under normal usage, the battery life should be in excess of 1000 hours. When the low battery indicator is displayed on the LCD panel, it indicates that less than 60 hours life remains in the battery and that it should be changed. -6- 1236 Test Equipment RANGE OVERLOAD WARNING 13. Range overload warning is indicated by ‘OL’ being displayed. This is caused by the input exceeding the particular range selected. Refer to the range table in the handbook for the maximum inputs for the particular range selected. AUDIBLE BLEEPER 14. The audible bleeper sounds when either the range button or the hold button is depressed, or when using the diode/continuity test function (see below). DIODE/CONTINUITY TEST FACILITY 15. The diode/test facility measures the voltage dropped across the test component utilising a calibrated current produced by the DMM. Developed voltages in excess of 2.08 V result in an overload indication. As the voltage developed falls below 0.7 V (corresponding to a resistance of approximately 1000 ohms) a single bleep is emitted, and if the voltage falls below 0.1 V (corresponding to a resistance of approximately 150 ohms) a continuous tone is emitted. The LCD panel indicates voltage drop (in volts) and not ohms. 16. Audible continuity testing is also performed in this mode. A continuous tone sounds for test resistances below approximately 150 ohms. An intermittent connection produces erratic beeps, and can be a valuable troubleshooting aid. Test resistances from approximately 150 ohms to 1000 ohms produce a short tone similar to a forward biased diode. Test resistances less than 20 Kilo-ohms will produce an on-scale reading. CONDUCTANCE MODE 17. Conductance measurement is performed with the function selector switch in the ohms function. The conductance range can only be entered using manual range selection; auto-range cannot enter the conductance range. The conductance range can be used to measure conductance (1/ohms, the inverse of resistance) or to measure very high resistances (greater than 32 Mohms). 18. Conductance measurements are displayed in nanosiemens (nS). Calculate mega-ohms by dividing 1000 by the number of nanosiemens displayed. Example: 2 nS = 1000 2 = 500 Mohms. PRE-USE CHECKS 19. a. Labels. Check that the calibration certificate and the routine service labels are in date. b. Cables. Ensure that there is no physical damage to the supply or test leads. c. Case. Ensure there is no physical damage to the instrument. d. Face. Ensure that the display is not damaged and that all the controls are free to operate in a positive manner. -7- 1236 Test equipment e. Extras: (1) Examine all accessories and leads for signs of damage, fraying, cracks or splits. (2) Check the leads using the ohms range. (3) Check the fuses in accordance with paragraph 23. WARNING TO AVOID ELECTRICAL SHOCK OR DAMAGE TO THE METER, DO NOT APPLY MORE THAN 1000V BETWEEN ANY TERMINAL AND EARTH/GROUND. WARNING INSTRUMENT DAMAGE AND OPERATOR INJURY MAY RESULT IF THE FUSE BLOWS WHILE CURRENT IS BEING MEASURED IN A CIRCUIT WHICH EXHIBITS AN OPEN CIRCUIT VOLTAGE GREATER THAN 600V. DO NOT ATTEMPT AN IN-CIRCUIT CURRENT MEASUREMENT WHERE THE POTENTIAL IS GREATER THAN 600V. Caution During resistance measurement turn test circuit power off and discharge all capacitors before attempting in-circuit resistance measurements. METER CONNECTION Table 1 shows input terminals and limits for connection of this meter. FUNCTION Black Lead MIN DISPLAY READING MAX DISPLAY READING MAXIMUM INPUT 1000V 1000V INPUT TERMINALS Red Lead V V V COM 0.001V mV mV V COM 0.1 mV 320.0 mV V COM COM 0.1 0.01 nS 32.00 M 32.00 nS V COM 0.001V 2.08V COM 0.01A COM 0.01 mA 320.0 mA 320mA 600V COM 0.1 A 3200 A 320mA 600V (nS) A mA/A mA/A mA A A A mA A 500V 10A* 600V 7252/24 20. * 10 A CONTINUOUS Table 1 -8- 1236 Test Equipment BATTERY REMOVAL AND REPLACEMENT 21. The DMM uses one PP3 type battery. To gain access, ensure that the rotary selector switch is in the off position and remove the test leads. Turn the instrument over and remove the four cross-point screws located under the stand. Pull the battery cover/holder out and disconnect and remove the battery. Fitting is the reverse of removal. Care must be taken to ensure that the battery leads are located in the slots provided in the holder prior to fitment as damage to these leads could otherwise occur. FUSES 22. Three fuses are provided, all of the fast blow type; 630 mA, 3 A and 15 A. These are located in the battery compartment, access being identical to that of battery replacement (see above). 23. Testing of these fuses are carried out as follows: a. To test the 15 A fuse (which protects the Amps range) connect a test lead to the V terminal and connect the other end the A terminal. Select the Ohms range and an indication of 0.0 - 0.3 indicates a serviceable fuse. b. To test the 3 A and 630 mA fuses (which protect the milliamps and microamps ranges respectively), connect a test lead to the V terminal and connect the other end to the mA/µA terminal. Select the Ohms range and an indication of 5.3 - 6.0 indicates both fuses are serviceable. A ruptured fuse will result in an overload reading. -9- 1236 Test equipment - 10 - 1236 Test Equipment INSULATION AND CONTINUITY TESTERS INTRODUCTION 1. Introduction testing may be divided into two basic categories, testing of components and testing of cables. In both cases the principle is the same. The insulation is subjected to a higher than normal voltage, whilst at the same time its resistance is measured. This test voltage is at least twice the normal working voltage of the circuit under test. The test is carried out using the high voltage, to try to pass a current where normally no significant current would flow. If the voltage used to supply the current is known, then by simple application of Ohm’s Law, the resistance of the insulation may be calculated. For example: R V I Where the voltage applied is 200 volts and current is measured at 0.0001 amps: R= 200 2 Mohms 0.0001 2. Thus the resistance of the circuit being tested is 2 M. In practice, the insulation tester will produce a known voltage at the test lead terminals, this is then used to try to pass current through an insulator, ie, and the insulation resistance is high. The instrument will have a dial calibrated in kilohms or megohms, and thus a direct reading of insulation resistance may be made. SAFETY PRECAUTIONS 3. Because high voltages are employed to stress the insulation, it is important that insulation tests are carried out in the approved manner, and only when an approved maintenance schedule is being used or with the authority of a suitably qualified engineering officer. In particular, insulation tests are never to be carried out on circuits containing electro-explosive devices (EED), also, because most semiconductors are damaged by high voltages, circuits or components containing these devices are not subject to high voltage insulation tests. 4. Although the voltage employed in the instrument (250 V dc – 1000 V dc) is high there is normally no risk of injury while in use as the current is limited, due to the way the instrument is designed. 5. Safety Precautions to prevent injury a. Ensure that a pre-use check has been carried out on the tester. b. If possible, avoid carrying out insulation tests on damp equipment or in damp conditions. c. Ensure no EEDs are fitted to the circuit to be tested. d. Disconnect capacitors, if practicable, or ensure that they are discharged after testing. - 11 - 1236 6. Test equipment Safety Precautions to prevent damage a. Ensure that testing is carried out in accordance with an authorized procedure. b. Ensure that the correct test voltage is being applied. c. Never connect an insulation tester to a live circuit. d. Avoid using a tester in the presence of strong magnetic fields. e. Never test circuits containing semiconductor devices. Figure 1 – Robin KMP 3075DL Insulation/Continuity Tester DESCRIPTION 7. The tester (see figure 1) is a compact high specification digital continuity and insulation tester. The case uses themomory plastics to give an enhanced look as well as durability. The design of the case is such that it is an integral part of the unit. The instrument is protected in transit by its own integral lid. Microprocessor technology provides advanced functionality and maximizes the user-friendly aspects. In the past digital insulation testers have been removed for the excessive scatter of digits as capacitive circuits are charging, ie, digital flicker. The effects have been eliminated with this unit. • Display panel • Rotary selector switches • ‘TracLoc’ selector switch • Back light button • Press-to-test button - 12 - 1236 Test Equipment • Analogue bar graph displaying applied voltage • Low battery warning • Out of Range (OR) warning • Live circuit warning indicator including audio alert • Auto null • Accessories 8. Display Panel. This is a four-digit display with a maximum insulation resistance (IR) reading of 0-2000 M also in IR mode an analogue display bar is shown to give a reading of the applied voltage of the test. When selected to Continuity mode the display reads up to 2000 . 9. Rotary Selector Switches. The two rotary switches are similar in style but carry out separate tasks switch 1 provides an off position, voltage applied in insulation testing mode and an all-purpose ohms reading position plus an auto null position. Rotary switch 2 is the range position switch red numbers for insulation and green for continuity. 10. ‘TracLoc’ Switch. An additional feature of this unit is a function called ‘TracLoc’. This enables the unit, when in Loc mode, to maintain a display of the reading after the test source voltage has been removed, and a continuous assessment of the circuit when selected to Trac Mode. 11. Backlight Button. A backlight for the display is provided in low light conditions. 12. Press to Test Button. Press to carry out a test, additionally if a continuous test is to be carried out the button can be twisted and will remain in the test condition until it is pressed again. 13. Analogue Bar Graph. Displays the applied voltage while the circuit is under insulation testing. 14. Low Battery Warning. Is displayed when the internal battery is not holding enough charge as to continue the test. The batteries are housed inside the panel underneath the unit. Six AA cells are required to power the unit. 15. Out of Range Warning (OR). This is displayed whenever the circuit under test cannot be measured within the selected range. The range should be moved up to a greater one and tested again. 16. Live Circuit Warning Indicator. Insulation testing should never be carried out on circuits that have power still applied, to warn the operator of a live circuit a static flash symbol will be illuminated on the display there is also a low audible buzzer which will sound while the warning sign flashes. If this symbol is displayed, testing should cease immediately. 17. Auto Null. This function allows for the test leads resistance values to be removed from the final reading on the display when undertaking continuity testing. - 13 - 1236 Test equipment Connect the test leads to the instrument and switch to the Auto Null and 20 continuity range. Short the leads out and return to the selection. 18. Accessories. The kit will also come with a bag set comprising two sets of test leads. Set one is a short set and Set two a much longer set of leads. PRE-USE CHECKS 19. a. Labels. Check that the calibration certificate and the routine service labels are in date. b. Cables. Ensure that there is no physical damage to the supply or test leads. c. Case. Ensure there is no physical damage to the instrument. d. Face. Ensure that the display is not damaged and that all the controls are free to operate in a positive manner. e. Extras. Ensure battery is serviceable. OPERATION 20. Insulation resistance testing as with continuity testing has no hard or fast rules that can be laid down to cover every eventuality. However, there are certain basic rules, which must be followed whenever insulation testing is to be undertaken. These are as follows: a. Isolate the circuit to be tested from the power supply. b. Remove the circuit fuses or trip circuit breakers and fit appropriate dummy servicing devices. c. Disconnect all earth connections. Disconnecting at the earth terminal block(s) will normally do this. Do not disconnect at the earth stud. d. Short circuit any normally open relay contacts. e. Any capacitor in the circuit should be disconnected before commencing the test. LETHAL WARNING IF CAPACITORS HAVE BEEN CHARGED UP DURING THE TESTING PROCESS, THEY MUST BE DISCHARGED IMMEDIATELY THE TEST IS CONCLUDED. - 14 - 1236 Test Equipment - 15 - 1236 Test equipment Safety Ohmmeter 1681 INTRODUCTION 1. The safety ohmmeter 1681 is a hand held tester that can be used to measure resistance values between 1 milliohm and 20,000 ohms. 2. The instrument enables measurement of low resistance of electrical bonds and wiring in electrical installations, contact resistance of circuit breakers and switches, the resistance of bus bar joints, fuses etc. - 16 - 1236 Test Equipment SAFETY PRECAUTIONS 3. This tester may be used by suitably trained personnel in potentially explosive atmospheres. It must not be connected to any other powered source. 4. To avoid any possibility of electric shock do not use the tester on live installations. If in doubt, check for the presence of high voltages with suitable test equipment against a known “good” earth prior to any resistance measurement being made. DESCRIPTION 5. The safety ohmmeter is a portable, battery powered tester. It is comes in its own carrying case, which also houses the array of test leads provided. The tester is used from within the case and the front panel incorporates a range selector switch, a liquid crystal display incorporating a battery condition annunciator. an on button and a backlight switch. The test leads also plug into the unit on this panel and there is access to the zero adjustment screw. 6. The safety ohmmeter testing is carried out using the four wire test this technique would highlight the following common faults: Individual strands of wire broken Squashed wires Wrong gauge wire fitted Dirty connections Poor crimp connections Dry solder joints Poorly mating connectors When measuring low resistance measurements using the four-wire technique the test lead or test interface wiring will be automatically nulled out. PRE-USE CHECKS 7. a. Labels. Check that the calibration certificate and the routine service labels are in date. b. Cables. Ensure that there is no physical damage to the test leads. c. Case. Ensure there is no physical damage to the instrument. d. Face. Ensure that the display is not damaged and that all the controls are free to operate in a positive manner. e. Extras. Ensure battery is serviceable. OPERATION - 17 - 1236 8. Test equipment To avoid any possibility of electric shock, do not use tester on live installations. a. Switch the Tester ON b. Connect one test lead to one side of the bond to be tested, making sure that a clean, reliable connection is made. c. Apply the second test lead to the other side of the bond to be tested. d. Note the bond resistance indicated and verify that the resistance is within required limits. OFFSET CONTROL AND EXTENSION LEADS 9. In normal use, no pre-calibration or pre-setting of the zero is necessary. Accurate measurements can be made with all of the test leads supplied up to and including the 5-meter lead. The OFFSET control is provided to compensate for offsets introduced during testing when long extension leads or probe adaptors are used. In normal use the zero control is set to counter clockwise, when using extensions over 5 meters connect the ends together and adjust the screw clockwise to give a zero indication on the display. - 18 - 1236 Test Equipment - 19 - 1236 Test equipment TIME DOMAIN REFLECTOMETER INTRODUCTION 1. The Time Domain Reflectometer (TDR) is a pulse reflection Cable Test set, for locating cable faults and evaluating changes in impedance caused by connectors, taps, terminations etc. Pulses transmitted into a cable are reflected by cable imperfections. The transmitted pulse and the reflected pulse(s) are shown on the display. The time taken by the pulse to travel to the fault and return is a measure of the distance to the fault. Distance to fault is displayed on the screen after the cursor is positioned to coincide with the start of the fault pulse. The type of fault can be determined by analysis of the displayed waveform. 2. The TDR test set was designed principally for 50, 75 and 93 coaxial cables it is equally effective on other cables types as a fault locator. Impedance mismatches can be measured in terms of Return Loss (dBRL) with the location displayed in feet, meters or time. - 20 - 1236 Test Equipment DISCRIPTION 3. The TDR Model T631 comprises off the unit, carry bag, AC Adaptor, rechargeable batteries (8) user guide and test leads 4. The TDR Model T631 has the facility to store up to 15 traces with the ability to transfer to a printer or PC; it also has dual cursors for point-to-point measurements. 5. The test set can be power by its own internal rechargeable batteries or by the mains adaptor. The fully charged batteries will give up to 8 hours operation and the test set will automatically switch off before the batteries are fully discharged. 6. The test set has a LCD display panel, with backlight (will auto switch off after 5 mins). The 24 press buttons give the operator access to all functions of the test set, some buttons have dual operation. 7. A BNC socket allows connection via test lead to cable under test. A 9 way D connector give interface connection to printer or PC. 8. The AC adaptor connects into the side via jack socket and access to the rechargeable batteries is from the rear. PRE-USE CHECKS 9. a. Labels. Check that the calibration certificate and the routine service labels are in date. b. Cables. Ensure that there is no physical damage to the test leads. c. Case. Ensure there is no physical damage to the instrument. d. Face. Ensure that the display is not damaged and that all the controls are free to operate in a positive manner. e. Extras. Ensure the AC Adaptor if required is serviceable. - 21 - 1236 Test equipment SAMPLE TRACES 10. Open circuit/high impedance series faults Note: Positive (upward) reflection Reflected Pulse Transmit Pulse 11. Short circuit/low impedance shunt faults Note: Negative (downward) reflection Reflected Pulse Transmit Pulse 12. Inline connection and Aerial Termination Joint gives ‘S’ shaped reflection Transmit Pulse Reflected Pulse Aerial (Reflection could be positive dependent on aerial type) - 22 - 1236 Test Equipment OPERATION 13. The unit has 4 display modes a. b. c. d. A ‘live’ trace A stored trace recalled from memory A live and stored trace together for comparison The difference between a live and stored trace These can be selected using the ‘Mode’ button on the front control panel 14. For correct operation the cable under test should be taken out of service with all sources of supply removed. Any RF signals present on the cables may corrupt the display. 15. Power the unit from previously charged internal batteries or from the AC adaptor. Press the ON button and the display should appear, rotate the contrast control to obtain a well-defined trace. 16. The display will be similar to Fig 1 below 1.703m 2ns 50 LINE 6m A1 p667 Figure 1 17. The TDR on initial switch on will be in the ‘Live’ trace mode, on the 6m range, a propagation velocity factor of 0.667 and impedance of 50. The left hand cursor, (dotted), will be at the start of the transmitted pulse (0m) and the right hand cursor, (solid); will be approximately one third across the display (1.703m). 18. The distance units, impedance and propagation velocity factor mode can be reprogrammed via the ‘HELP’ (?) button. 19. Connect the cable under test directly to the BNC socket or via test lead supplied. Move the left hand cursor to the end of the test lead if used; this removes the length of the test lead from the distance reading. - 23 - 1236 Test equipment 20. The TDR can be used to locate the cable fault using the unit in manual mode. Full description of the operational procedures for the manual mode can be found in the operating manual. 21. This TDR can automatically scan a cable and locate the nearest significant feature and configure the parameters of the unit to optimally display the feature. To ensure the best possible benefit is achieved in this mode of operation, the left and right hand cursors must be placed at the point that the cable under test is connected to the TDR. This will start the scan at the correct point and not include any test lead connected. 22. Once the cable under test is connected and the cursors set to the correct point, the operator can press the ‘FIND FAULT’ button to start the automatic sequence. Pressing the button a second or subsequent time locates the next significant feature alone the cable. 23. This automatic feature is intended for use on co-axial cables where the reflection from a fault may be quite small, so the sensitivity used is quite high. On a power cable or twisted pair, mismatches due to joints, or change of cable type may give rise to many reflections, which the instrument will detect even though they are not faults. 24. To save the live trace to memory, press the ‘SAVE’ button and select the required storage location, note any trace already in the selected location will be overwritten. 25. To recall a saved trace press the ‘RECALL’ button and select the location as required. The TDR display will now show the recalled trace and the location it is held in i.e. M1 26. To compare a live trace against a stored one, press the ‘MODE’ button and select option 3 (live & memory). The traces are overlaid on one another, but they can be separated by use of the ‘SHIFT’ buttons. To use the difference between live and memory, select option 4 from the mode selection. 27. The TDR has an internal help section available when the ‘?’ button is selected. - 24 -