Service Manual DTL PDF

BAUR Prüf- und Messtechnik GmbH · Raiffeisenstrasse 8 · A-6832 Sulz/Austria · T. +43/5522/4941-0 · F +43/5522/4941-3 · service@baur.at · www.baur.
at
Print date: 12.04.2005
Service Manual
Fully automatic dissipation and

resistivity measuring system DTL
Valid from series: _____
DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

service manual dtl page 1/47
Contents
GENERAL INFORMATION 3
DATA SHEET OF DTL 4
TECHNICAL DATA: DTL 5

TECHNICAL DATA: TEST CELL MC 2A 6
SYSTEM OVERVIEW 7
FUNDAMENTAL CLARIFICATIONS 7
FIRST STEPS TO FIND THE FAILURE 7
SERIAL NUMBER 7
LIST OF IMPORTANT DIAGRAMS 8
ERROR CODES 9
CAUSE OF A DEFECT BOARD A CAN BE: A WRONG ASSEMBLED TEST CELL!BASIC TESTS 15
BASIC TESTS 15
DISASSEMBLY OF THE DEVICE 17
IDENTIFICATION OF IMPORTANT PARTS 19
DESCRIPTION OF SINGLE PLUG-IN CARDS 25
TROUBLE SHOOTING LIST 35
PERFORMANCE TEST WITH KAC4RC PROCEDURE 41
EXAMPLE OF THE BAUR PERFORMANCE TEST REPORT 44
PERFORMANCE CHECK WITH KA 0.03 46
RECOMMEND SPARE PARTS 47

General information
Observe info signs! • For fast finding of important information the
corresponding text passages are marked with
symbols (symbols not stated here are self-
explanatory).
• More and special information concerning the

respective subject are available from BAUR.
• Important information about the instrument!

• In any case, read carefully!
• Important information text.
© Copyright by BAUR • © BAUR Prüf- und Messtechnik GmbH, 6832-Sulz

• All rights reserved
• No part of this publication may be reproduced,
transmitted, stored in a data processing system or
translated into another language without the
written permission of BAUR / Sulz, Austria.
Subject to modification! • In the interest of our customers we reserve the

right for modifications due to technical progress.
Illustrations, descriptions and delivery content are
therefore not binding.
Subject to modification! • This manual contains all information necessary for

the correct service of the system. Before you do it,
please read carefully these manual.
• This document is for BAUR representatives only.

• Observe all safety rules mentioned in the
operating manual of the systems.
• Any non-authorized changes on hardware,
software or parameters may destroy the system
and/or may be dangerous for the service
technician or an user. Before implementing any
changes, please contact BAUR Austria for more
detailes.
• On any questions or problems contact BAUR After
Sales Service in Austria
Tel: +43 / 5522 / 4941-0

Fax: +43 / 5522 / 4941 3
Email: service@baur.at

Data Sheet of DTL
DTL is the first fully automatic measuring bridge for ageing tests on insulating liquids.
Dissipation factor (tan δ)
Relative permittivity (εr)
Resistivity in Ωm
All known test sequences like IEC 247, VDE 0370, BS 148, ASTM 924 etc. are programmed
as standard.
Features of DTL:
• automatic calibration of empty cell
• resistance measurement 2.5 MΩm to 20 TΩm with both polarities up to 500 V DC (Option
up to 100 Tm)
• tan δ -measurement 4.0 to 1 x 10-5
• measurement of relative permittivity εr
• HF induction heating of cell: short heating times and uniform heating
• easy operation; measurement of dissipation factor and resistivity is made automatically
according to the preselected standard or according to individually selectable parameters
• direct temperature measurement with a probe inside the measuring electrode
• plug-in fixed value calibrator additionally available
• built - in interface RS 232 for PC-communication
• extensive security features
Test cell MC2A:
MC 2A is a three-electrode cell made of chromium-nickel steel. For heat-resistant isolation of

measuring electrode, quartz glass insulating rings are used, depending on recommendation
of the respective standard.
Features of test cell MC2A:
• test cell according to IEC 247, ASTM D924-96

• magnetic valve for draining of test cell - dismounting of cell not necessary

Technical data: DTL
DTL
Test voltage AC adjustment range 500 to 2000 Vrms stability ± 100 ppm
for ± 10 % mains voltage variation
Measuring unit AC peak/ √ 2 , accuracy ± 1 %
Test voltage DC adjustment range 125 to 500 V
Measuring unit DC accuracy ± 0.5 %
Test frequency 50 Hz or 60 Hz selectable
Relative permittivity εr range 1.0 to 10.0 accuracy ± 1 % of measured value
Resistivity measurement range 2.5 MΩm to 20 TΩm (Option up to 100 Tm)
Rho+/Rho- (1 Ωm = 100 Ωcm)
Temperature range 5 to 120° C, accuracy ± 0.4 % resolution 0.1° C
measurement adjustment of set value 11 to 110° C
Measuring time acc. to cycle approx. 25 min for tan δ, εr and ± Rho
IEC 247 (including charging and discharging times)
Selectable standard IEC 247/VDE 0380, part 2 (1996) VDE 0380
programmes VDE 0370, part (1978) ASTM D 924-96 (100° C)
VDE 0371, part (1980) BS 148-1972
VDE 0374 AS 1767-1975
VDE 0375, part (1995) JIS C2101-1978
client specified parameters
Reference capacitor SF6 compressed-gas capacitor, 115 pF tan δ ≤ 1 ⋅ 10-5
Cell constant K (metric) equal to 0.113 pF x empty cell capacitance
Dissipation factor max. resolution 1 ⋅ 10-5; resolution range:
measurement tan δ 4095 digits in 3 decades, automatic adjustment
0.00001 to 0.04095
0.0409 to 0.4095
0.409 to 4.095 (= 400 %)
accuracy: ± 1 % of measured value + 0.00008
Display 2 x 40 digits, alphanumerical LCD display with cursor functions
Printer 24 digits matrix with ink ribbon paper, width 57 mm
External interface RS 232 (V 24), 2400 baud, 8 bit no parity, socket DP 25
Selectable parameters:
Test number 24 numeric digits
Test frequency 50 Hz or 60 Hz
Initial measuring ≥ 10° C
temperature ≥ 1° C
Temperature step size max. 110° C
Final measuring 500 ... 2000 Vrms
temperature ± 125 ... ± 500 V
Test voltage AC
Test voltage DC
Heater HF induction method,
heating time for cell: from 25° to 90° C; max. 16 min
Storage temperature - 20 to + 50° C
Operation temperature 0 to 40° C
Air humidity max. 95 RH (non condensing)
Power supply selectable 110 - 120 V / 220 - 230 V / 240 V; 50 Hz to 60 Hz
Power consumption 300 VA

Battery 3 pcs. 1.5 V (IEC R6) for data memory, clock and date
operating life approx. 4 years
Dimensions of measuring
bridge approx. 450 x 460 x 500 mm
with dust cover (w x h x
d)
Dimensions of measuring
bridge in wooden approx. 540 x 480 x 580 mm
transport case (w x h x d)
Weight (incl. cell) approx. 32 kg
Weight with case approx. 40 kg
Technical data: Test Cell MC 2A
Test Cell MC 2A
Assembly Three-electrode guard-ring cell with quartz glass insulator rings
continuous flow with drain valve
Material chromium-nickel steel
Sample volume 45 ml
Electrode gap 2 mm
Voltage withstand in air 2000 Vrms
Empty cell capacitance 70 pf
Viscosity of liquid sample max. 150 mm²/s at 20° C
Operating temperature 5 ... 120° C
Storage temperature - 20 ... + 150° C without glass rings
Dimensions with transport approx. 400 x 130 x 270 mm
case (w x h x d)
Weight approx. 5.20 kg

System overview
Fundamental clarifications
a) Ask the customer after to a fault description
Use for that purpose the official BAUR document “Complaint Report.doc”
First steps to find the failure
a) Make an optical check

b) Switch on the faulty unit and check all functions
c) If possible, check the output voltage
d) If the failure (e.g. error code) occurs, see the below trouble shooting list and search
for possibilities to solving the problem
e) If you need the actual circuit diagrams, send BAUR the claim description (include the
serial number)
Serial number
It is very important to know the serial number, only having this indication, we are able
to collect circuit diagrams and drawings for investigation!

List of important diagrams
Drawing number Description Kind of Diagram
031 074-2 Blockdiagram DTL Blockdiagram
031 065-1 Card A Components diagram

031 150-L Card A Circuit diagram
031 251-3 Card B Components diagram

031 252-2 Card B Circuit diagram
031 083-3 Card C Components diagram

031 081-2 Card C Circuit diagram
031 078-2 Card D Components diagram

031 101-1 Card D Circuit diagram
031 092-4 Card E Components diagram

031 094-3 Card E Circuit diagram
031 041-1 Card F Components diagram

031 050-2 Card F Circuit diagram
031 247-3 Card L Components diagram

031 248-4 Card L Circuit diagram
031 271-3 Card M high voltage card “Ωmeter” Components diagram

031 272-3 Card M high voltage card “Ωmeter” Circuit diagram
029 140-3 Card printer interface Components diagram

029 141-3 Card printer interface Circuit diagram

Error codes
The DTL Software hasn’ t got an error code list like DPA75, but if there will be indicate an
error code then you have to check the unit as following:
Error code 0 (zero):
The error message will be occured if the circuit of the high voltage has got a problem!
Please check according following description the device:
1. Check the supply voltage and the adjustement of the supply voltage block
2. Check the menu parameter "PARA" ... 2000VAC /500VDC should be on display
3. Check if the temperature sensor is on both sides correct pluged in!

4. Check the assembly of the test cell MC2A according the user manual.
5. Check the high voltage contacts, to ensure that the HV contact between the test cell
(yellow sockets) and the HV-unit itself is clean and fitting tight.
6. Open the panel and check if the black high voltage cable is plug in!

7. Check if all wires has got a good connection with the plug
Error code 65534 (or similar):
ERROR 65534 indicates one of the following failure springs:
Item 1: Poor connection contact from the temperature sensor to the test cell. Please make
sure that the temperature sensor is completely in the test cell and the plug is connected!
Look additional at page 4-3 in your instruction manual.

Item 2: Poor connection contact from the test cell to the DTL. Please make sure that the test
cell is completely in the DTL.
Item 3: No high voltage, please check and adjust the AC voltage (2000V) and DC voltage
(500V) in the parameter menu.

Item 4: The test cell is mounted in a wrong arrangement. Please check the arranging of the
test cell and especially of the O-seal and the glass-ring. In case of a fault a short circuit can
be a result and print A can be damaged. Therefore check the voltage between the HV-
thread (plastic ring) and earth.
Item 5: To be sure that board A cause the error message, you have to check the device as
follows:
1. Dismount the BMC plug X28B from Card A

2. Disassemble the BNC plug
3. Connect a mA-meter according below block diagram (the mA-meter shall be able to
measure µA)
4. Start the measurement
5. Have a look at the Balance-LED => they must be indicate => in that moment you
have to measure approx. 50µA
a. If you measure this current, then Board A has got a problem and you have to
send the DTL back to Sulz.
b. If you do not measure this current, then you have to check once more the test
cell assembling

It is possible that a wrong assembled test cell caused the defect at PCB A!

Basic tests
Attention: After replacement of any component, the instrument needs to be readjusted

according to the "calibration instructions for DTL 2A with the KAC 4RC" (see manual for
calibrator KAC 4RC)
Used instruments for this investigation
• multimeter (with HV probe for 3 kV ∼)

• frequency counter (up to 300 kHz)
• oszilloscope
Functional check (general check)

• check the test cell for correct assembling
• check the test cell receptacle for any impurities (e.g. small pieces left from the
package) the contact spring on the bottom of the receptacle has to establish an
electrical connection to the high voltage electrode
• check if the plug of the temperature probe is properly connected to the cover plate
and to the test cell
• check AC voltage (2000 V) and DC voltage (500 V) in the menu "Parameter"
Ø Check power supply:
• check mains fuses and voltage selector (up to series 13 also for the heating
system)
• unscrew cover plate and hinge the front panel chassis forwards all LEDs (8
pieces) on printed circuit board F have to be illuminated (power supplies)
• check proper positioning of the connection cable
Ø Power supplies on printed circuit board A:
Unscrew board I (shielded)
o TP 1 +15V
o TP 2 - 15V
o TP 3 + 5V
o TP 4 - 5V
o TP 5 +12V
o TP 23 +1,000V (reference voltage)
o TP 6 55 Hz / approx. 16VPP
o TP 24 approx. 250 kHz TTL level
Ø Power supply on board B: (problems with heating board)
o TP 2 +12V (towards GND TP3 / board B)

o TP 1 approx. 1250 Hz if the heating is switched on (put the test cell
into the receptacle, plug in the temperature probe, start
measurement acc. to standard 01) - adjustment is possible via
R10 on board B

Ø Power supplies on board D: (problems with CPU, e.g. no display,… )
o TP 52 + 5V
o X 49/1 towards X 49/2 +4,5V
Ø Measuring voltage (2000 V ∼):
Select menu "Parameter“
o TP7 / board A approx. 9 VPP/55 Hz (at 2000 V ∼)

o Power supply V50 / board F pin 5 approx. 14,5 V
o X17/1 towards X17/2 on board F approx. 10 Vpp/55 Hz
o Check X20 on high voltage transformer with HV probe (approx. 2000 V ∼)
Measurement of high voltage at contact spring - test cell receptacle: Select standard 11 and
Parameter, start temperature 10 °C, enter Step .., Stop 000°C, bridge hood contacts, start
measurement
→ The high voltage can be measured as long as the LED´s „Balance“are illuminated
Ø Input amplifier board A:
Insert an empty test cell, plug in the temperature probe, bridge the hood contacts, select
standard 11 and Parameter, enter start temperature of 10 °C, enter Step “..”and Stop 000
°C, start measurement
o TP29/TP28/TP13 approx. 14 VPP/55 Hz sine wave

o TP27 approx. 0,9 VPP/55 Hz sine wave
o TP17 approx. 1,0 VPP/55 Hz sine wave
Ø Checking of R60 / board L: (problems with pos. and neg. Ωmeter measurement)
Switch off the instrument, measure from contact spring of receptacle to GND with Ωmeter →
approx. 10 Ω
Ø Handwritten overview of the position from the potentiometer and test points
Card A:

Disassembly of the device
Open of BAUR devices is only allowed for authorize people
(BAUR employees or BAUR agents)
!! Never touch parts inside of the unit without being earthed

(earth-wristlet) !!
a) Front view
hood complete
ID: 470-838
printer
ID: 461-755
front panel compl.

ID: 470-837
paper roll, 57 mm width ID: 565-514

Ink ribbon for printer ID: 565-513

b) Front view with open hood and test cell
cover plate
plastic pane ID: 461-092
ID: 433-609
collapsible handle
ID: 650-248
device buttom
ID: 650-130
c) Back view
earth spindle
ID: 440-052
main connection
oil escape pipe ID: 462-190
ID: 441-148
O-Ring φ 11,3x2,4
ID: 620-017
cape
Sealing R1/2” ID: 660-114
ID: 442-112

Identification of important parts
a) Disconnect device from mains
b) Put out the temp. probe
c) Remove the 4 screws of the cover plate
Retaining bent
ID: 431-838
temp. probe (ID: 461-115)

d) Items of the cover plate
Rim socket
ID: 552-334
Front frame
ID: 541-165
Top cover (white) Potentiometer lin
ID: 541-164 ID: 525-205
Lamp 14V, 1,2W
ID: 542-000
Cable print B “swisstac-switch”
ID: 461-100
Key switch element
ID: 541-141
e) Lift up the cover plate and fix it with the locking handle
contact bridge
ID: 650-139
locking handle
ID: 650-065
locking handle cap
ID: 650-066
locking handle nut
ID: 650-067
turning bolt
ID: 440-770
locking handle connector
ID: 431-837

e) Press and remove fasteners and lift down the front panel carefully,
it is fixed with a cord!
f) Overview with open operation panel and open cover plate

g) View into the device from above
reference cap
ID: 470-934
add inductor heating

ID: 471-481
mains transformer
ID: 566-159
mains filter
ID: 462-191
PCB B PCB M
ID: 461-740 ID: 461-845

h) View into the device from the front
PCB F HV-Transformer
ID: 461-732 ID: 461-094
PCB A
ID: 460-389

i) View into the frontpanel from above
PCB printer interface PCB D

ID: 461-036 ID: 461-942

Description of single plug-in cards
Exchange of DTL Print A (only valid for pre-adjusted boards)
General
These adjustment instructions must be followed every time the analog printed circuit board
(PCB) "A" is changed. Follow the instructions step by step. If for any reason the adjustment
has to be repeated always start at the beginning.
Following equipment and circuit/ component diagrams are needed:
- PC or notebook with serial interface

- KAC 4RC calibrator, comprising basic DTL and 4 additional precision resistors *)
- Hood contact bar (bridges the safety contact of the DTL hood) *)
- Test EPROM 1 *)
- Software disk " DOS start diskette for PC-XT/AT" (adjustment program version 2.1 KAC 4RC) *)
- RS 232 interface cable (wire 2 and 3 are crossed) *)
- Frequency counter
- Digital voltmeter (min. 2500 VAC/600 VDC)
- Oscilloscope input sensitivity ≤ 5 mV/Div.
*) was delivered with KAC 4RC
Diagrams:
- PCB L component diagram

- Analog PCB A diagram with test points and potentiometers
- Digital PCB D component diagram
- KAC 4RC test report
Note:
- Output, which is displayed on the screen, is printed in italics in this documentation.
AC voltage 2000 V
- Input which must be carried out by the user is printed in bold face in this documentation.
8000 <enter >

Safety regulations
Warning:
Note that the calibrator consists of components, which carry high voltage. All work
must be carried out with great care and with regard to safety regulations. When the
hood contact bar is lowered the high voltage switches to the measuring system.
Improper handling can be highly dangerous!
See fig. 3.1/3.2. Always connect temperature sensor first before inserting KAC 4RC
in the opening provided.
Change of Print A and preparation for adjustment
- Switch off DTL and disconnect mains cable

- Remove the 4 screws on the cover and fold it back.
- Remove the 2 pressure locks on the front plate by pressing down briefly and tip the
front plate forwards.
- Remove PCB (screen cover), disconnect earth plug.
- Disconnect all cables connected to Print A and check if they are labeled enabling you
to connect them back on the new board.
- Disconnect the small pcb connected to Print A
- Unscrew the distance bolts which are holding Print A
- Change Print A and reconnect all cables and small pcb.
- Replace EPROMs 1 and 2 on PCB D with TEST EPROM 1 ( Version. 2.1) (EPROM
socket 2 is not used).
- Open jumper "X 58" => upper right hand corner on PCB D
- Connect PC port to DTL 2A port using an RS 232 interface cable.
- Insert "BAUR" software disk (autostart disk) into the disk drive and switch on PC.
- Use mains cable to connect DTL to mains supply and switch on DTL.
X58
Eprom 1 Eprom 2
RS232

The following message appears on the PC screen:
"Adjustment program for adjustment of the BAUR DTL DIELTEST"
"Ready? Press any key to continue"
Press any key – “menu 1”appears.
∗∗∗∗∗∗∗∗ MENU 1 ∗∗∗∗∗∗∗∗
AC / DC setting (1)
tandelta. epsilon comp. (2)
Input (1) (2)
If no message appears check the connection between PC and DTL and the position of
TEST EPROM 1.
Adjustment
Checking / Adjusting high voltage:
- Switch off DTL,

- Connect DVM 2kV to ⊥ = X18 / supply voltage PCB F (common earth point at the
backside) and X20 on PCB L

- Switch on DTL => Danger high voltage!
- Select menu 1, point 1 at PC (“AC/DC setting”)
PRESS ANY KEY TO CHANGE FROM AC TO DC OR TO MENU
AC VOLTAGE 2000 ←
- Using potentiometer (VAC) on cover plate set the voltage to 2000 V (display
voltmeter).
- Using potentiometer R 120 set PC display to same value as displayed at voltmeter
(+/- 1%)
- Switch off DTL
- Connect DVM at TP X21 on PCB L
- Switch on DTL
- Select “AC/DC setting”in “Menu 1”and press <enter> to change to DC voltage.
∗∗∗∗∗∗∗∗ MENU 1 ∗∗∗∗∗∗∗∗
AC VOLTAGE 2000
DC VOLTAGE 500,0 ←
- Using potentiometer (VDC) on cover plate set the voltage to 500 V DC (display
voltmeter).
- Using potentiometer R 117 set PC display to the same value as displayed at
voltmeter (+/- 1%).
- Switch to menu 1 (press any key)
- Switch off DTL and remove test lead
Frequency check
- Fix cover plate with 4 screws.

- Calibrator KAC 4RC (without resistor): insert sensor, insert calibrator
- Apply hood contact bar to short circuit hood contact interlock.
- Connect oscilloscope to TP 13
- Switch on DTL
- Select menu 1, point 2 (tandelta & epsilon adjustment)
∗∗∗∗∗∗∗∗ MENU 2 ∗∗∗∗∗∗∗∗
CLOSE HOOD OR USE BRIDGE FOR HOOD CONTACT

DEFAULT EPSILON VALUE = 8000
1 INDIVIDUAL VALUE EPSILON

2 INDIVIDUAL VALUE TANDELTA.
3 AUTOADJUST EPSILON
4 AUTOADJUST TANDELTA.
5 RESISTANCE TEST
6 BACK TO MENU 1
TYPE (1) TO (6)

1 <enter> (individual value epsilon)

INPUT EPSILON VALUES < 0 > BY 0 BACK TO MENU 2
EPSILON AD CONV.
8000 <enter>
8000 xxxxx
- Check frequency at TP 13 (should be 55 Hz +/- 0,05 Hz)

- Check frequency at V34, pin 12 (should be 250 Hz)
Key input < enter > 0 <enter > (menu 2 reappears)
Tandelta value: zero adjustment
- Connect oscilloscope to test point TP 15

- Select menu 2, point 3 (autoadjust epsilon):
∗∗∗∗∗∗∗∗ MENU 2 ∗∗∗∗∗∗∗∗
CLOSE HOOD OR USE BRIDGE FOR HOOD CONTACT

DEFAULT EPSILON VALUE = 8000
1 INDIVIDUAL VALUE EPSILON

2 INDIVIDUAL VALUE TANDELTA.
3 AUTOADJUST EPSILON
4 AUTOADJUST TANDELTA.
5 RESISTANCE TEST
6 BACK TO MENU 1
TYPE (1) TO (6)
3 <enter >
EPSILON AD CONV.
32768 16509-
. .
. .
28456 71-
28460 108+
28458 13+
28457 33-
If the EPSILON step is 1 digit only (for example from 28458 to 28457) than interrupt with
< enter > (menu 2 reappears)
- Select menu 2, point 2 (individual value tandelta.):
INPUT TANDELTA. VALUES 1 TO 409500 / 0 = BACK TO MENU 2
EPSILON AD CONV.
8 <enter> (input the value 8)

8 xxxxx ←
- Adjust signal at TP 15 to the minimum amplitude (at the oscilloscope) with

potentiometer R 30 and potentiometer R 56 (both must be adjusted alternating for
minimum amplitude)
- Set the “AD CONV”value displayed on the PC to zero with potentiometer R 90 (+/-
5 digits).
< enter > 0 <enter > (menu 2 reappears)
Important:
If hood contact is not made the program stops with an error message.
The hood must be closed - the program must be restarted.
Adjust epsilon value:
- select menu 2, point 1 (individual value epsilon):
INPUT EPSILON VALUES < 0 > 0 = BACK TO MENU 2
EPSILON AD CONV.
xxxxx < enter > (input the epsilon value from KAC 4RC report)
xxxxx xxxx
- Input the KAC 4RC epsilon value shown in the test protocol, for example 27.734 (see
attached copy)
- Adjust the signal of TP 15 at the oscilloscope to the smallest amplitude with
potentiometer R 56
< enter > 0 < enter > (menu 2 appears)
Adjust tandelta end range:
In order to adjust the DTL (set end range), only use the 500 MΩ resistor. The other resistors
(2 TΩ, 50 MΩ, 5 MΩ) should only be used for checking purpose.
- Switch off DTL

- Insert resistor, R = 500 MΩ
Switch on DTL. If DTL was switched off for longer than 1 min. allow to warm up for 10
mins.
Warning: Only change resistors when the DTL is switched off !!!
- select menu 1, point 2. (tandelta & epsilon adjustment)

- Select menu 2, point 3 (autoadjust epsilon):
EPSILON AD CONV.
32768 16509-
. .
. .

xxxxx xx
- Select menu 2, point 2 (individual value tandelta.):
INPUT TANDELTA. VALUES 1 TO 409500 / 0 = BACK TO MENU 2
LOSSFAC.. AD CONV.
xxxx < enter > (input tandelta. Value from KAC 4RC report)
xxxx xx ←
- Enter tandelta. value according to KAC 4RC test protocol, for example 3 646 (see
attached copy)
- Use potmeter R 29 to set “AD CONV”value displayed at PC to 0
< enter > 0 < enter> (menu 2 reappears.)
Final checks
Checking tandelta value
- Select menu 2, point 4 (autoadjust tandelta.)
After adjustment the measured tandelta. value must not vary more than ± 5
digits.
epsilon AD CONV.
32768 16509
. .
. .
xxxxx xxx
LOSSFAC. AD CONV.
40900 xxxxx
. .
. .
xxxx ← xx (result)
Result = tandelta value printed at KAC 4RC test report ± 5 digits

Checking resistance :
- Select menu 2, point 5 (resistance test)
resistance test positive polarity

offset (1) = 1
.

.
offset (1) = 1
VK1 = 1
v1 = 0
.
.
vm = 1 area 1
v1 = 0
.
.
vm = 2 area 2
v1 = 20
v1 = 21
.
.
vm = 21 area 3
current = 20.8
Resistance value 4.95413768 V3 = 496.9 V (V3 = DC voltage)
Formula used for resistance value: v3/v2 x 109
discharge time 20 secs.
RESISTANCE TEST NEGATIVE Polarity
offset (1) = 1
.
.
offset (1) = 1
VK1 = 1
v1 = 0
.
.
.
vm = - 1 area 1
v1 = 0
.
.
.
vm = - 2 area 2
v1 = - 20
v1 = - 21
:
vm = - 21 area 3
current = - 20.8
Resistance value 4.95413768 V3 = 496.9 V V3 = DC voltage
Formula used for resistance value: v3/v2 x 109
- Press any key to return to menu 1

- The measured resistance value must be within a range of ± 3%.
- Repeat 5. Final checks using 5 MΩ / 50 MΩ and check result according to KAC 4RC
test protocol.
- For 2 TΩ repeat resistance test only and check result according to KAC 4RC test
protocol.

KAC 4RC Test Report
Note: The 2 TΩ resistor is designed exclusively for resistance range control.
Caution! The maximum operating voltage of the resistor TΩ is 400 V~.
Reassembling
- Insert jumper "X 58"

- Remove test EPROM and replace original EPROMs
- Switch DTL back on and check normal operation.
- Switch off DTL and disconnect mains cable.
- Remove the 4 screws on the top cover plate.
- Fix PCB (screen cover), connect earth plug.
- Swing back the front panel and fix it with the 2 pressure locks.
- Fix again the top cover plate.
Adjusting by a tan δ tolerance
Should it be, that by the calibration of the tan δ value the nominal value is not inside the
tolerance, you have the possibility to make a correction at PCB A (identify number: 460-389):
1. If the tan δ value is higher as the nominal value, than you have to calculate the
relation of the tolerance, and wire a additional resistor parallel to the orginal resitor
(e.g. R63).
2. If the tan δ value is smaller as the nominal value, than you have to calculate the
relation of the tolerance, and wire a additional resistor series to the orginal resitor
(e.g. R65).

3. Following sketch is come from the original diagram 31 150 – L and shows the
possible modifications.
4. Allocation of the resitors:
R63 => 10-5 be valid for 500MΩ resistor

5. The commponent diagram 031 65 – 1b from PCB A shows the right positions of the
above mention resitors (R63 to R65).
See following sketch:

Trouble shooting list
Exchanging of the lifting magnet from the DTL
Possible cause: Earth short after pushing the lifting magnet switch.
Development of the oil receptacle:
1. Open the cover disk, 4 screws solve, covers raise

2. Behind the oil receptacle 2 brass tubes are visible
3. Loosen the 3 screws with the lower brass tube (oil outlet pipe), outside and pull the
pipe out
4. Unscrew the nut with the upper pipe inside
5. Loossen the screws of the oil receptacle at the housing lower surface
6. The screws of the card B likewise at the housing lower surface, so far solve that the
card B easily be tilted can
7. Likewise unscrew the nut of the oil overflow pipe at the exterior
8. After development of the entire oil receptacle the under and upper section can be
separated also few energy expenditure and the sealing ring can be exchanged if it
were leaky
9. Befor you can exchange the liftinh magnet you have to extend the complete lower
part
After the assembly of the sections on it pay attention that the red high-voltage
cable is not plugged off, or to it note that no other cables the high-voltage cable
touch.
Testing and Changing the Bistable Relays
Preparing the software and hardware environment for the test
Hardware:
Connect the DTL to PC by means of the serial cable (9 to 25 pole type)

Insert KAC 4RC calibrator (the resistor value is unimportant, but do not use the 2TΩ
reference resistor, maximum allowed voltage is only 400V))
Turn on and let the DTL run at least half an hour for warming up
Software:
DTL:
Select test standard 11 (client specific)

Under the parameter menu set (for turning off the heating and resistivity measurement, and
for setting continuous measurement):
T-START: 15
T-STEP: 00
T-STOP: 100
Ωm: OFF

PC:
Start lvrteinstall.exe to install the National Instruments LabView Run-Time Engine

Copy to your hard drive and start DTL_Test.exe
Follow the instructions seen in the yellow rectangle:
Select the serial port: 0 = COM1, 1 = COM2
Select the language version of your DTL
Enter a valid path and file name to store the measured values
Repeat the above steps on the right side if you wish to test two DTLs in the same time
Performing the test
DTL: Start the client specific measurement

PC: Press the Start button to start the data acquisitions
The software displays automatically the tanδ and ε values measured by the DTL. The X axe
of the diagrams is adjusted as the number of test sequences increases. To adjust the range
of the Y axe, click on a number next to the axe, modify the value and press enter.
Let the test run at least six hours. If you see more than ±(1% + 0.00008) difference in the
tanδ measurement, all of the bistable relays must be upgraded to the new developed lower
current type.
Changing the bistable relays
K6
K2
K5
K4
Remove the shield plate over board A and the board itself
Desolder the four bistable relays found in the top left corner of the card (K2, K4, K5, K6, type:
DS2E-ML2-DC12V)
Solder the new ones (type DS2E-L2-12V, 562-012)
Repeat the whole test again to make sure that the tanδ measurement is stable.
Recalibrating of the DTL is required!

Heating problems
For the measurements, you have to bridge the two safety contacts by the hood
contact bar!
(1) Checking card B (heating)
1. TP2: +12V (ground is TP3)

2. TP1: approx. 1250 Hz if the heating is switched on (put the test cell into the
receptacle, plug in the temperature probe, start measurement acc. to
standard 01)
Card B components diagram (series dependent!): 31 251 3c.pdf (series 30, 31)
(2) Checking card A (main card)
Card A components diagram (series dependent!): 31 065 1b.tif (from series 2)
A. Check the 1.2V reference voltage for the over/under temperature

comparators:
R104, on the right side of the small plug-in card (Card H), 3rd resistor from left,
check the pin closer to the card edge. (Exchange V78 - ICL8069 low voltage
reference if not correct, then adjust R100 till TP23 is 1.00V.)
B. Check the analog output of the temperature sensor: TP21, right to the bottom
connector of the plug-in card. It should be 10mV/C till the temperature is
reached. Try another temperature probe if not correct.
C. Check the same signal after the analog multiplexer (can be checked till the
epsilonmeasurement starts): TP22 next to V33, it should be the same as TP21

D. Check the voltage between X3-2 and V6 (anode). There have to be approx.
400VDC.
E. Check the control signal of the Thyristor V7 (Gate). In our opinion is the
Thyristor the initiator of this cause. V7 is responsible that a current is flowing
through the heating coil. But please note, there are 400VDC existence!
400VDC
• Card B (ID 461-740)

• V7 (ID 512-513)

Modification instruction of DTL heating up to series 11
Identify number of this modification kit: 471-276
Use following diagrams:
- 31 258-3
- 31 259-4
- 31 260-3
1. Disconnect instrument from mains
2. Remove cell
3. Unscrew top panel, 4 screws
4. Disconnect all plugs from PCB B
5. Dismount PCB C (alu box), 4 screws on rear panel of instrument
6. Dismount PCB B with chassis angle, 2 screws on ground panel
7. Remove capacitors C8 and C9 (blue 1000uF, 6 screws on ground panel
8. Please pay attention till serie 16 to drawing 31-258-3
9. Mount chassis angle of PCB B old on PCB B new and install it in instrument
10. Connect plugs to PCB B according to components diagram
11. Modify micro switch, PCB A – X 30 according to drawing
12. Modify X 61 according to drawing

Exchanging of Eproms
!! Never touch parts inside

of the unit without being
earthed (earth-wristlet) !!

Performance test with KAC 4RC procedure
About the KAC 4RC
The KAC 4RC is intended for the performance check of the fully automatic dissipation factor
and resistivity measuring system DTL, and may be only used for this purpose. This
resistance value together with the value fo the reference capacitor should be periodically
checke. It ist the responsibility of the user to take care of this checking process.
Circuit diagram of KAC 4RC
Eingabe
DTL –Temperature probe
BNC Cable
Figure 1.1 Circuit diagram
Operating instructions for KAC 4RC
Always connect the temperature probe or the BNC cable first! The tester can
only be used when the temperature probe or the BNC cable is connected to
DTL, otherwise the cover of the tester can be at high-voltage!
1. Disconnect DTL from mains, open protective hood and front plate
2. Connect temperature probe or BNC cable to KAC 4RC
3. Insert tester in the opening, connect temperature probe or BNC cable to DTL
4. Put hood contact bar on to bridge the safety contacts
5. Unscrew the cover of the reference resistor on KAC 4RC
6. Insert the reference resistor in the direction as indicated in Fig 2.1
7. Replace and secure screw back the cover of the KAC 4RC
8. Connect the mains to DTL
9. Turn the DTL on

Temperature probe Cover of reference resistor
Hood contact bar
Figure 2.1 Connection of the temperature probe
Performance DTL with the check of KAC 4RC
1. Remove batteries for at least one minute to reset memory content (cell capacitiy, date
and time). Text “CALIBRATE CELL”will be printed out when trying to start a new
measurement. If the memory content is not erased before the calibration, the ε and
Ωm values will be false!
2. DTL should be turned on for at least 30 minutes.
3. Inssert KAC 4RC without resistor, connect temperature probe!
4. Turn DTL on
5. Select test standart No. 11 (client specific), press button “Para”and set parameters
as follows.
T-Start: 15° and 50 Hz

T-STEP: ..°
T-STOP: 000°
6. Put hood contact bar up
7. Press button “Start”
8. Compare ε value of DTL to KAC 4RC (Tolerance 1,5%) tan δ should be between –
0.00008 and + 0.00008, Ωm should be larger as 20 TΩm
9. Turn DTL off

10. Insert 500MΩ resistor in KAC 4RC, trun DTL on
12. Compare the displayed tan δ and Ωm values to the reference. Allowed tolerance
range: tan δ: +/- (1,5% + 0.00008 digits)
a. (Digit means the last significant digit of the displayed value) Ωm: +/- 3%
13. Repeat steps 27-30 with resistor 50 MΩ and 5 MΩ
14. Turn DTL off
15. (Only for DTL with “TerraΩ”option.) Measure resistance with the 2 TΩ resistor. Insert
resistor and set AC voltage im menu parameters (Press button “Para”) to < 400
17. Compare resistance value to reference, tan δ value can be ignored and discarded
Recommendation
The guarantee the testing accuracy it is recommended to calibrate the DTL and/or the KAC
4RC once a year two years after purchase.

Example of the BAUR Performance Test Report

Performance check with KA 0.03
1. Open the protection cover of the DTL
2. Insert the KA 0.03 (see figure below)
3. Connect the KA 0.03 by plugging-in the
connection cable to the DTL (see figure
left)
4. Switch-on the DTL
a. "ON" lamp on operating panel is
illuminated
b. the last selected test standard
appears on the display
5. Select test standard 11 and set the values:
T-START : 10°
T-STEP : ..
T-STOP : 0°
Ωm : off
(only the tan δ values are of interest)
For the correct tan δ values please see the test report of your KA 0.03
KA 0.03 => Identify number: 471-030

Recommend Spare Parts
In trying to offer our BAUR partners a rapid and efficient repair service we have
ensured that this section contains a compilation of the most important spare parts.
These are spare parts which in our experience are exposed to increased wear and
tear or corrosion and these are also assemblies (PCBs) which support rapid repairs.
This is why these spare parts should be kept in stock at each service location. The
given number of pieces per device is for information only.


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BAUR Prüf- und Messtechnik GmbH · Raiffeisenstrasse 8 · A-6832 Sulz/Austria · T. +43/5522/4941-0 · F +43/5522/4941-3 · service@baur.at · www.baur.

Print date: 12.04.2005

Fully automatic dissipation and

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

TECHNICAL DATA: DTL 5

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

• More and special information concerning the

• Important information about the instrument!

• Important information text.

© Copyright by BAUR • © BAUR Prüf- und Messtechnik GmbH, 6832-Sulz

Subject to modification! • In the interest of our customers we reserve the

Subject to modification! • This manual contains all information necessary for

• This document is for BAUR representatives only.

Tel: +43 / 5522 / 4941-0

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

Test cell MC2A:

MC 2A is a three-electrode cell made of chromium-nickel steel. For heat-resistant isolation of

Features of test cell MC2A:

• test cell according to IEC 247, ASTM D924-96

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

Technical data: Test Cell MC 2A

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

a) Ask the customer after to a fault description

First steps to find the failure

a) Make an optical check

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

Drawing number Description Kind of Diagram

031 074-2 Blockdiagram DTL Blockdiagram

031 065-1 Card A Components diagram

031 251-3 Card B Components diagram

031 083-3 Card C Components diagram

031 078-2 Card D Components diagram

031 092-4 Card E Components diagram

031 041-1 Card F Components diagram

031 247-3 Card L Components diagram

031 271-3 Card M high voltage card “Ωmeter” Components diagram

029 140-3 Card printer interface Components diagram

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

Error code 0 (zero):

Please check according following description the device:

3. Check if the temperature sensor is on both sides correct pluged in!

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

Error code 65534 (or similar):

ERROR 65534 indicates one of the following failure springs:

Look additional at page 4-3 in your instruction manual.

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

Look additional at page 5-12 in your instruction manual.

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

Look additional at page 3-4 in your instruction manual.

1. Dismount the BMC plug X28B from Card A

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

DVR: 0438146 · FN 77324m · Landesgericht Feldkirch

Attention: After replacement of any component, the instrument needs to be readjusted

Used instruments for this investigation

• multimeter (with HV probe for 3 kV ∼)

Functional check (general check)

Ø Check power supply:

Ø Power supplies on printed circuit board A:

Unscrew board I (shielded)

Ø Power supply on board B: (problems with heating board)

o TP 2 +12V (towards GND TP3 / board B)