DIGITAL TROUBLESHOOTING PROCEDURES

&FAULT LISTING
1. Knurr case removal.

2. Rittal case removal.

3. A/D board, I/O board, and controller board access instructions.

4. Voltage Busline and Crystal Checkout.

5. Open Ground fault indicator lamp lit.

• Open Ground circuit disable instructions for 6kV, 12kV, 24kV, D-Series
testers.

6. Hipot Trip fault indicator lamp lit.

7. Hipot Current Bar display not present.

8. CRT blank when PTT button depressed/surge mode.

9. Hipot voltage bar display not present.

10. Seconds/div, volts/div, µA/div, or function display incorrect.

11. Printer does not work properly.

12. No Baker logo displayed.

13. No Hipot voltage at test leads.

14. No surge voltage display.

15. Voltage drops when PTT button released.

16. Zero Start Interlock does not engage.

17. PI Value or current measurement inconsistent.

18. Display locked up after self-test.

19. Display unreadable and flashes on/off, does not initiate self-tests.

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 KNURR CASE REMOVAL
All digital series 6kV and 12kV models manufactured before August 1998 are enclosed
in a blue shock mounted Knurr design case. Removal from the case is necessary to
access internal components. Removal procedure is as follows.

1. Unlock the rear cover latches and unhinge the rear cover.

2. Locate and remove four (4) Phillips M4 x 10mm screws. Two are located on the left
side and two are located on the right side.

3. Reinstall the rear cover.

4. Locate and remove on the front panel four (4) M5 x 16mm black hex head screws.
Two are on the extreme left edge on the front panel and two are located on the
extreme right edge of the front panel.

5. Grasp the CRT bezel in one hand and the test leads with the other hand and pull
straight out of the blue Knurr case.

Handle Assembly for Knurr Case

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 RITTAL CASE REMOVAL
The Rittal case has been used on the Digital 6kV and 12kV models after serial number
327. Removal of this case is as follows.

1. Locate and pry open, with a small slotted screwdriver, six plastic covers that overlap
six M4 screws that hold the top cover to the case assembly.

2. Remove these six (6) M4 screws and remove the top cover.

3. Locate and remove four (4) M16 x 16mm screws that secure the front panel to the
case assembly. Two screws are located to the left of the CRT bezel and two are
located to the right of the test lead set as they exit from the front panel.

4. Locate and remove five (5) M5 x 12mm black hex head screws that secure the bottom
chassis to the left and right side case L brackets. Two are located to the left of the
CRT shield, two are located to the right of the high voltage transformer, and one is
located underneath the test select switch.

5. Locate and unplug the two (2) pin molex connector from the 12 volt fan to the wiring
harness. This fan is located directly behind the CRT tube. It may be necessary to
remove a tie wrap that secures the molex connector to the side case frame.

6. Slide the front panel and bottom assembly forward to remove from the case assembly.

Access will now be gained to all internal components and assemblies except the I/O
board, A/D board and the Controller Board. See the following instructions for access to
these assemblies.

Note: For D12000 and DS212 units that are Power Pack capable, this will involve an
additional step for removal of a pot core that is mounted adjacent to the 12 volt fan.

Handle Assembly for Rittal Case

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 A/D BOARD, I/O BOARD, AND CONTROLLER
BOARD ACCESS INSTRUCTIONS.
These assemblies can be accessed from the front panel from either the Knurr or Rittal
case. They are installed in the card cage portion of the unit.

1. To access the I/O board, locate on the front panel the small panel which has the
function knob, volts/div knob and the seconds/div knob.

2. Remove two (2) M3 x 7mm hex head screws located above the function knob and
below the seconds/div knob.

3. Grasp the function knob and the volts/div knob and pull away from the front panel.
These assemblies are 96-pin plug in type cards that slide on a card guide system and
plug into mating 96 pin connectors mounted on the Mother Board.

4. To remove the A/D board, locate the panel with the open ground/hipot trip indicator
lamps, intensity, vertical, and horizontal position knobs.

5. Remove two (2) M3 x 7mm hex head screws located above the open ground indicator
and below the horizontal position knobs.

6. Position fingertips behind the stenciled panel for this assembly and pull away from
the front panel.

7. Access to the Controller card is now gained, it will be the only card left in the card
cage. Simply grasp this assembly and pull away from the front panel.

Note: These assemblies contain C-MOS logic, which is ESD sensitive. Removal of
these cards are recommended to be performed at a grounded station by personnel
wearing a grounded wrist strap. Failure to do this may result in integrated circuit
damage.

VOLTAGE BUSLINE AND CRYSTAL CHECKOUT

All digital models are equipped with a Power Supply board which supplies +5 volts, +12
volts, -12 volts, and several crystals on the A/D board and Controller board. A loss or
loading of any of these supplies will result in the following conditions. To narrow down
to which assembly is defective can be done quickly by unplugging sequentially the I/O,
A/D, and the Controller boards and the CRT 10 pin connector one at a time and
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measuring if the supply that is defective is restored. If not, replacement of the Power
Supply board would be required. If a board is found to be loading a supply then any
component on that board that is tied to the supply can be suspect. To narrow to the
component level will require a one component at a time isolation from the supply via
desoldering.

1. Loss of or loading of the –12 volt supply will cause no output in the surge mode when
the PTT button is depressed. The trace will be visible at its most right upper position
on the CRT and will be non-adjustable with the vertical or horizontal position
potentiometers.

• Surge trigger will be present, but no surge waveform will be attainable when the
PTT is engaged.
• In the Hipot mode, a Hipot trip LED will illuminate and the voltage bar will show
a six (6) division up and the current bar will be extended off the screen. No Hipot
output will be attainable and numeric display for voltage and current will stay at
zero (0).

2. Loss of or loading of the +12 volt supply will cause a total non-operation of the tester.
There will be no display upon power up or self-tests or no change when any of the
output controls are used.

3. Loss of or loading of +5 volt supply will cause a total non-operation of the tester.
There will be no display upon power up or self-tests or no change when any of the
output controls are used.

4. Loss of crystal frequency X1 on the A/D board will cause the loss of positional trace
control with the surge waveform in the upper right quadrant.

• In the Hipot mode, after PTT is depressed hipot voltage and current bars will
be the same as in step #1 but numeric display for voltage will show 11950
volts and the current will show 996.0 µA. Replace X1.

5. Loss of crystal frequency on U6 on the A/D board will show an erratic unstable
sawtoothed pattern once the PTT button is depressed and also will fail the A/D
memory self-test upon power up. Replace U6.

6. Loss of crystal frequency on XTA1 on the Controller board will cause total non-
operation of the tester. There will be no display upon power up or self-test, or no
change when any of the tester controls are used. Replace XTA1.

7. Loss of frequency on Y1 on the Controller board will cause a blinking effect on the
tester CRT with no recognizable lettering or numeric display. Tester will not initiate
it’s self-tests nor will any controls have any change on the display. Replace Y1.

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 OPEN GROUND FAULT INDICATOR LAMP LIT
1. Check that the tester is being operated with a two wire cord with a ground prong.

2. Check for a broken ground connection in the power cord.

3. Check that if being powered from an isolation transformer that a proper ground is
supplied to the tester.

4. Check the mating ground pin receptacle at the power outlet for a bad connection.

5. Check continuity from the ground prong on the input power receptacle to the Power
board P2 pin 1 and also to chassis ground.

6. Check MOV 1, MOV 2, MOV 3 for electrical damage. If damage is found also check
for burnt traces on both sides of this assembly. Replace Power board if traces are
damaged.

• Also to prevent future damage to this assembly or possible further damage,

measure and correct line voltage fluctuations so that they remain consistently with
the following parameters.

Unit Line Voltage Range

Lower Upper
D6000 100 Volts AC 120 Volts AC

D12000 100 Volts AC 120 Volts AC

DS206 220 Volts AC 250 Volts AC
DS212 220 Volts AC 250 Volts AC

7. Check signal at Q1 collector on the Power board for a .4 volt ripple, if not replace Q1.

8. Check U9 pin 3 on the I/O board for a 0 volts and U9 pin 4 for five (5) volts DC, if
not replace U9.

9. Check Q6 on the I/O board for a collector to emitter short, if so then replace Q6.

10. Check for a shorted Open Ground LED.

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Open Ground Circuit Disable instructions for 6kV, 12kV, and 24kV D
Series Testers.

In a testing environment where no ground can be supplied to the surge tester, the
following steps can be done so that the tester will operate. Read and follow these
instructions prior to proceeding.

1. Locate and remove the two (2) M4 x 7mm black hex head screws on the front panel.
The first is located above the function switch knob, and the second is below the
seconds/division knob.

2. Grasp the function switch knob in one hand and the seconds/division knob with the
other hand and pull away from the tester. By doing this the I/O board will no unplug
from the Motherboard.

3. Locate and remove the two (2) M4 x 7mm black hex head screws on the front panel.
The first is above the open ground lamp socket and the second is below the horizontal
potentiometer knob.

4. With your fingertips, grasp behind the front panel A/D board assembly and pull away
from the tester. By doing this the Power board will now unplug from the
Motherboard. Caution: DO NOT damage the potentiometers or cause fractured
solder joints at the legs of the potentiometers.

5. Remove the remaining printed circuit board, the Controller board. Grasp at the edges
of this assembly and pull away from the testers front panel.

6. For the 15kV and 24kV only locate and remove four (4) Phillips screws that secure
the blue top cover to the case assembly. Two (2) will be located on the left side and
two (2) will be located on the right side. This step applies to 15kV, and 24kV models
only. Remove the top cover. Skip to step 10.

7. For 6kV or 12kV models manufactured before August 1998 which are enclosed in a
blue shock mounted Knurr design case, removal of the inner chassis from the case
will be necessary. If enclosed in a Tan Rittal design case proceed to step 9.

8. Unlock the rear cover latches and unhinge the rear cover. Locate and remove four (4)
Phillips M4 x 10mm screws. Two are located on the left side and two are located on
the right side. Reinstall the rear cover. Locate and remove the front panel four (4)
M5 x 16mm black hex head screws. Two are on the extreme left edge and two are
located on the extreme right side of the front panel. Grasp the CRT bezel in one hand
and the test leads with the other hand and pull straight out of the Knurr case. Skip to
step 10.

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9. If a 6kV or 12kV model was manufactured after August 1998 and is enclosed in a tan
Rittal design case locate six (6) gray hinge covers on the top cover. With a small
slotted screw3driver pry the covers so that six (6) Phillips screws that secure the top
cover are visible. Remove all six (6) screws to remove the top cover.

10. Locate the card cage that houses the Power and Signal Boards.

11. Remove the top cover of the card cage. It is secured by eight (8) M4 x 7mm black
hex head screws and two (2) M4 kep nuts. Remove this hardware. Position one hand
inside the card cage and lift up at the back end to remove the top cover.

12. Locate on the Motherboard an insulated jumper wire J7 that is positioned between
connectors J2 and J3. If you intention is to run the tester without a supplied ground
permanently, set step 14.

13. If your intentions is to move the tester between environments that do and do not have
a supplied ground, see step 15.

14. Remove jumper at J7.

15. Remove jumper at J7. Install two 22 gauge wires one at each connector hole at J7
and exit these wires from the right side of the card cage. The length of these wires
should be long enough to reach the front panel. Tie wrap and secure these wires
along the right side of the card cage. Obtain a two-position toggle switch that has a
common/ NO and NC contacts. Drill a hole between the leads energized light and the
right side of the card cage and mount this toggle switch to the front panel

16. Solder the wires from the J7 connector to the toggle switch. This will now enable
you to more easily disable the open ground fault detection circuit.

Note: The Open Ground LED will still be lit when the tester does not sense a ground
connection, but now the tester will operate.

HIPOT TRIP FAULT INDICATOR LAMP LIT

1. Check that the winding under test is not indeed shorted.

2. Check for a shorted high voltage transformer secondary to ground. Measure with a
multimeter from D3 anode on the Stack board to ground. Normal measurements are
approximately 12K ohms with the function switch in either the 10 or 100 µA position
or approximately 20K ohms in the 1 µA position. If found to be much lower
resistance, replace T1 high voltage transformer.

3. Check for shorted SCR’s on the Stack board by measuring the resistance across all
cathode/anode junctions of each SCR. These measurements can be obtained easily by
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 measuring across resistors R1 through R10. Good measurements will be 70K ohms
or higher. Replace any SCR’s found to be shorted.

4. Check U2 pin 7 on the I/O board, this should be a zero (0) volts DC, if at five (5)
volts DC then replace U2 and U7.

5. Check Q3 on the I/O board for a collector to emitter short, if so replace Q3.

6. Check for shorted Hipot trip lamp on the A/D board, if so replace D3.

HIPOT CURRENT BAR/DISPLAY NOT PRESENT

1. Check continuity from test lead one (1) alligator clip to deck one (1) of the selector
switch.

2. Check continuity from test lead ground alligator clip to the metal spacer adjacent to
D1 and D2 on the Discharge board.

3. For the purposes of troubleshooting this circuit, set up will require the tester to be in
the Hipot mode with leads one (1) and ground connected to a 10 megohm 35 watt
resistor. Use a digital multimeter from these measurements with the negative lead of
the meter connected to pin 29C on the I/O board. Set tester to 100µA/division.

4. Measure at U11 pin 3 on the I/O board and raise output control to 6 kV. The
measurement should increase negatively as more current is drawn through the test
load. At 6 kV this should be approximately -.040 volts DC. Measurement at the
output U11 pin 6 on the I/O board should be identical. If not replace U11.

5. Measure at U10 pin 6 as the output control is raised to 6kV. At 6kV, this
measurement will increase to approximately 2.9 volts DC. If not replace U10.

6. Measure at RPK1 pin 15 and then pin 2 for the output as described in step 5, if not
present at RPK1 pin 2, Replace RPK1.

7. Measure at U25 pin 8, use a 10X scope probe, set scope to 1 volt/division and 5 ms
and an internal trigger at the 3 volt level. Raise output of tester to 6kV across the 10
megohm load. Measure for approximately 3 volts with a negative going square wave
approximately .4 volts at a 5 ms duration. If not present, replace U25.

8. Measure at U22 pin 18 for the same signal as in step 7 and then measure at U22 pin 9,
the output of u22 should be doubled to approximately 6 volts with the same negative
going square waveform. If not replace U22.

9. Measure at U23 pin 7, if same measurements taken in step 8 is not present, replace
U23.
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 CRT BLANK WHEN PTT BUTTON
DEPRESSED/SURGE MODE
This particular fault is associated with the loss of one or more of the following signals:
line trigger, stack power, real test or sync trigger.

1. Check the stack power signal at P1 pin 2 on the Power board, this signal should be a
360 volt AC sine wave with the negative portion clipped at zero (0) volts. Frequency
will be at approximately 60 Hz. If not present remove the P1 connector on the Power
board and remeasure at R2. If still not present, check T1, D1, and R2 for defects and
replace. If this signal is loaded down upon reconnecting, then check FET Q6 on the
Stack board for defects.

2. Check the line trigger signal starting at the junction R1 and T1 pin 5 on the Power
board. This signal will be an AC sine wave with an approximate amplitude of 900
volts peak to peak with a 60 Hz frequency. At P1 pin 1 this signal changes due to
components tied to this signal line on the I/O board. At his point, this signal will be a
1.2-volt square wave with a frequency of 60 Hz. If this signal is not present or
incorrect proceed to the I/O board. Check D1, Q2, and U9 for defects and replace if
necessary. Signal at U19 pin 3 should be a 5-volt square wave with a frequency of 60
Hz.

3. Check the real test signal at U29 pin 16 on the Controller board. This signal will be
5-volt logic and should be a positively pulsed waveform with a changing high state
duration of approximately 1 to 20ms. Frequency will be 5 Hz. Depressing the PTT
button will activate this signal. This signal is then routed to the I/O board at U19 pin
5 and also through an inverter U4 to U19 pin 4, if these signals are missing or
incorrect, then any of the three components listed above are suspected to be faulty.

4. Sync trigger will be the output from the flip-flop U19 pin 1. This signal should be a
positively pulsed waveform with an approximately 450µS high state duration with a
frequency of 6 Hz.

5. The PTT button again needs to be depressed to activate this signal. If signal is not
present, replace U19 on the I/O board. Check the stack trigger signal at R22 on the
A/D board for a 10-volt positively pulsed waveform with a frequency of 5 Hz. If not
present, check Q1, Q2, and Q3 for faults. The Stack trigger signal is then routed to J1
pin 4 on the Stack board. Possible loading of this signal can also be attributed to
component defects in the Stack board trigger and charging circuit such as C1 or Q6.

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 HIPOT VOLTAGE BAR/DISPLAY NOT PRESENT
1. Check DC voltage at J1 pin 1 on the Stack board. Voltage output will depend on
where the output control is set. A normal range will be from zero (0) volts at
minimum output setting to approximately 3 volts DC at 6 kV output. If not present
check all SCR’s Q1 through Q10 for shorts by measuring the resistance across all
cathode to anode junctions of each SCR. Replace those SCR’s found to be shorted.
Readings should be 700K ohms or higher. Bad junctions will read much lower.

2. Check for same rise in DC voltage at U12 pin 3 on the I/O board, if not present, check
connection between these two points.

3. Check at U12 pin 6 on the I/O board for the same increase in voltage, if not present,
replace U12.

4. Check U3 pin 6 on the I/O board for the same increase, if not present, replace U3.
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5. Check U25 pin 4 on the A/D board for the same increase in voltage, if not present,
check connection between U3 pin 6 on the I/O board and RPK1 pin 16. Then check
RPK1 pin 16 to RPK1 pin 1 for 47K ohms resistance. If open replace RPK1.

6. Check U25 pin 8 for a 2.5-volt positively pulsed waveform with a frequency of
200ms with the tester set at 6kV output with no current deflection on the CRT. If not
present check U25 pins 1, 15, 16. Only pin 1 should have a signal which should be a
5-volt waveform pulsing negatively to zero (0) volts every 200ms. If these signals
are present at pins 1, 15, and 15 with a measured input at U25 pin 4 then replace U25.

7. Check U22 pin 9 for a 5-volt positively pulsed waveform with a frequency of 200ms.
Set the tester to 6 kV output with no current deflection on the CRT. If not present
replace U22.

8. Check U23 pin 7 for the same signal. If not present, replace U23.

SECONDS/DIV, VOLTS/DIV, µA/DIV OR

FUNCTION DISPLAY INCORRECT.
1. The seconds/division display is controlled by switch S1 on the I/O board and pull up
resistors R40, R41, R16, R2, R3, R4, R19, R20, and R43. This in turn connected to a
series of AND, NAND and Inverter IC’s set up to control a binary pattern for control
lines Sweep A, B, C, and D. See4 binary chart on the I/O board. A typical fault
would be seen as a duplication of any one of the possible displayed sweep settings
such as CHANGE, 2µS, 6µS, 10µS, 20µS, 60µS, 100µS, 200µS, 600µS, or 1mS.
Possible failures can include a logic gate stuck high or low such as U1, U8, U4, U5 or
U6 or mux U18. Check the pull up resistors listed above. Check that S1 grounds
sequentially as it is rotated.

2. The volts/division display is controlled by switch S2 on the I/O board and pull up
resistors R10, R8, and R11. This in turn is connected to a series of Inverters and/or
gates to set up a binary pattern for control lines V DIV 1 and V DIV 2. See binary
charge on the I/O board. A typical fault will be seen as a duplication of any one of
the possible volts/division settings such as 500 volts, 1000 volts, 2000 volts, or 3000
volts. Possible failures can include a logic gate stuck high or low such as U4 or U5 or
mux U17. Check the pullup resistors listed above. Check that switch S2 grounds
sequentially as it is rotated.

3. The µ/A division display is controlled by switch S3:A on the I/O board and pull up
resistors R36 and R38. This in turn is connected to a series of Inverters to set up a
binary pattern for control lines µA/DIV 1 and µA/Div 2. See binary chart on the I/O
board. A typical fault will be seen as a duplication of any one of the possible µA/
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 division settings such as 100µA, 10µA, or 1µA. Possible failures can include a logic
gate stuck high or low such as U6 or mux U17. Check the pull up resistors listed
above. Check that switch S3:A grounds sequentially as it is rotated.

4. The function display is controlled by switch S3:A on the I/O board and pull up
resistors R42, R12, and R14. This is in turn connected to a series of Inverters at U6.
A typical fault will be seen as the CRT display not matching the function control
knob. Possible failures can include a logic gate stuck high or low such as U6, U5,
mux IC’s U17 or U15. Check pull up resistors listed above and also pull up resistors
at RPK3 pins 8 and 9. Check that switch S3:A grounds sequentially as it is rotated.

PRINTER DOES NOT WORK PROPERLY

1. Check that the printer cable is plugged into the printer port.

2. Check for faulty or damaged printer cable by checking continuity between all 25 pins
in both ends. Try a replacement printer cable.

3. Digital models with a serial number 001 through serial number 370 or ones
manufactured before December 1997 must be used with an Epson FX dot matrix
printer. And it must be configured properly to interface. Firmware revision 1.35 is
used with the Epson dot matrix printer. Digital models after serial number 370 or
ones manufactured after December 1997 will have firmware revision 1.36 which will
use an Epson DeskJet 600 printer.

4. Check for faulty printer, try a substitute printer.

5. Measure with a 10x-scope probe the following points on the I/O board. To activate
these signal lines a printer will need to be connected and the print softkey will need to
be depressed. Monitor PRN DB0 through PRN DB7 from U14 on the I/O board for
data transfer. Data transfer is defined as a 5-volt logic level that changes in frequency
of pulses as the data transfer sequence changes. Set the oscilloscope to 5
volts/division and a 5ms-sweep rate. If this output is not det4ected on one or more
printer lines, check the resistance of all resistors in RPK2. Replace if defective. If
RPK2 checks good, replace U14, U16, and U9. Check also the resistance of RPK1
and R50 through R54. Replace if necessary.

NO BAKER LOGO DISPLAYED

1. Upon power up if no display is seen on the CRT, the first step to ensure is that the
intensity output potentiometer is turned clockwise are enough to see a display,
generally at least a 2 O’clock position should be sufficient.

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2. See Voltage Busline and Crystal Checkout procedures and correct any voltage
Busline or crystal output and frequency problems.

3. To determine if the CRT tube is defective a check is needed to ensure that +12VDC is
present on P1 CRT pin 7 and then pins 1 and 10 are grounded.

4. Check P1 CRT pin 2 with a digital multimeter, this measurement will be adjustable
with the intensity potentiometer, it should range from –14VDC to +5.6VDC, if not
check R9 on the A/D board and its connections.

5. Check P1 CRT pin 3, this measurement should be approximately –110VDC.

6. Check P1 CRT pin 4, this measurement will be adjustable with the intensity
potentiometer and will range from –110VDC to +5.6 VDC, if not check R9 on the
A/D board.

7. Check P1 CRT pin 6 for a 4-volt square waveform pulsing negatively to zero (0)
volts. Repetition rate will be every 30µS and the negative duration will be 4µS. If
signal is not present trace back to U24 pin 4 and then to U1 on the Controller board.
Replace if necessary.

8. Check P1 CRT pin 9 for a 5-volt positively pulsed waveform. Repetition rate will be
every 17mS and the positive duration should be 500µS. If not present, trace signal
back to U1 on the Controller board. Replace if necessary.

9. Check P1 CRT pin 8 for 2.4 volt data entering from the Controller board U27 pin 13,
replace if necessary.

10. If above signals and voltages are correct, replace CRT tube.

NO HIPOT VOLTAGE AT TEST LEADS

1. Ensure the tester function switch is in the hipot mode at 100µA/Division and that the
test lead select switch is in the Hipot selection.

2. Measure at T2 pin 2 with a digital multimeter, connect positive lead at this point and
the negative lead to chassis ground. Set the meter to AC volts. This point should be a
line voltage upon turning the on/off switch to the on position.

3. Measure at T2 pin 3, this point will be variable depending on the position of the
output control knob. At the full counter-clockwise position this voltage will be less
than 3 volts AC. At approximately ½ output turning clockwise this voltage will be ½
line voltage. If not present, check the neutral connection to the variac, if this
connection is present replace T2.
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4. Check at the terminal block adjacent to the high voltage transformer T1 at the orange
wire for the same AC voltage starting with the output control to full counter-
clockwise position and than at ½ output. If not present, see the section on the Zero
Start Interlock does not engage.

5. Locate the secondary T1 high voltage transformer wire connected to D3 anode on the
Stack board and disconnect. Connect a P6015A high voltage scope probe or
equivalent to the T1 secondary wire with the probe negative lead connected to chassis
ground. Set the volts/div on the oscilloscope to 2 volts and the timebase to 5ms.
Turn the output control approximately to ½ output. This measurement should be
14kV AC peak to peak.

6. Verify that all other primary and secondary wires of T1 are connected to their
respective destinations with a digital multimeter. Ensue that power is off and
disconnect when making these measurements. If measurement in step 5 is not present
and all connections are verified, then replace the high voltage transformer T1.

7. Reconnect T1 secondary wire and lift D3 cathode on the Stack board. Connect the
P6015A probe to this point with the negative lead to chassis ground and turn output
control to ½ output. Set scope settings to the same as in step 5. This measurement
should be approximately 7kV AC with the negative portion clipped by the diode. If
not present replace D3 on the Stack board.

8. Check the SCR cathode to anode resistance for Q1-Q10. Ensue that the power is off
and disconnected. These measurements can be obtained by measuring across R1
through R10. Replace any SCR’s that are shorted. Good measurements will be 700K
ohms or higher while defective SCR’s will have much lower readings.

9. Check the resistance of the 25K-ohm 25-watt resistor that connects to the J5 wire
from the Stack board. Replace if open.
10. Check continuity from lead 1 alligator clip to the 25K 25 watt resistor. If open,
replace test lead 1. Check continuity from the ground lead alligator clip to the
Discharge board ground stud. If open, replace the ground lead.

NO SURGE VOLTAGE DISPLAY

1. Ensure the tester function switch is in the surge mode and that the test lead select
switch is in a test lead selection. Set the tester to 500 volts/division and at
6µS/Division. Connect test load across test leads.

2. Measure at T2 pin 2 with a digital multimeter, connect positive lead at this point and
the negative lead to chassis ground. Set the meter to AC volts. This point should be
at line voltage upon turning on/off switch to the on position.

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3. Measure at T2 pin 3, this point will be variable depending on the position of the
output control knob. At the full counter-clockwise position this voltage will be less
than 3 volts AC. At approximately ½ output turning clockwise this voltage will be ½
line voltage. If not present, check the neutral connection to the variac, if this
connection is present replace T2.

4. Check at the terminal block adjacent to the high voltage transformer T1 at the orange
wire for the same AC voltage starting with the output control to full counter-
clockwise position then at ½ output. If not present, see the section on the Zero Start
Interlock does not engage.

5. Locate the secondary T1 high voltage transformer wire connected to D3 anode on the
Stack board and disconnect. Connect a P6015A high voltage scope probe or
equivalent to the T1 secondary wire with the probe negative lead connected to chassis
ground. See the volts/div on the oscilloscope to 2 volts and the timebase to 5ms.
Turn the output control approximately to ½ output. This measurement should be
14kV AC peak to peak.

6. Verify that all other primary and secondary wires of T1 are connected to their
respective destinations with a digital multimeter. Ensure that power is off and
disconnected when making these measurements. If measurement in step 5 is not
present and all connections are verified, then replace the high voltage transformer T1.

7. Reconnect T1 secondary wire and lift D3 cathode on the Stack board. Connect the
P6015A probe to this point with the negative lead to chassis ground and turn output
control to ½ output. Set scope settings to the same as in step 5. This measurement
should be approximately 7kV AC with the negative portion clipped by the diode. If
not present replace D3 on the Stack board.

8. Check the SCR cathode to anode resistance for Q1-Q10. Ensure that the power is off
and disconnected. These measurements can be obtained by measuring across R1
through R10. Replace any SCR’s that are shorted. Good measurements will be 70K
ohms or higher while defective SR’s will have much lower readings.

9. Check continuity of test leads 1, 2, and 3 back to the selector switch, replace any
found to be open.

10. Check continuity from the ground lead alligator clip to the Discharge board ground
stud. If open, replace the ground lead.

11. With a 10X scope probe measure at pin 32B on the I/O board with the negative probe
lead connected to chassis ground. After engaging the zero interlock turn the output
control to approximately ¼ output. Set the oscilloscope to 1 volt/div and 10µS sweep
rate. The signal at this point should be about a 1.8-volt surge waveform. If not check
continuity with the tester AC input disconnected from P1 pin 32B & 32C on the I/O
board to J1 pins 3 and 4 on the Discharge board.
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12. Access the Discharge board by removing the Stack board and check resistance
measurements of the following components and replace if necessary. Ensure that
power is disconnected when making these measurements and disassembling the unit.
Check R1 through R14.

13. If the signal in step 11 was noted proceed to check that relay K1 on the I/O board has
no contact resistance between pins 2 and 3. If pin 7 of the relay is at a low state and
contact resistance is detected, replace relay K1. If pin 7 is at approximately +12 volts
DC, then check U6 pin for +5 volts DC, then replace Q1 on the I/O board. If U6 pin
6 is at a low state, replace U6.

14. Replace U19, U20 and U14 on the A/D board.

VOLTAGE DROPS WHEN PTT BUTTON

RELEASED
In all digital models previous to serial number 210, an intermittent problem was detected
in that when an operator of the test was to attain the desired test voltage and release the
PTT button, the displayed voltage would drop approximately 10%. To correct this
problem the addition of K1 and K2 chassis relays were added. In older revisions the AC
line voltage was switched directly from the PTT button or the footswitch to the T2 variac.
The Zero Start Interlock board would switch the voltage from T2 pin 3 to the primary of
the high voltage transformer. To engage the Zero Interlock, the following needs to occur
at the Zero Start Interlock board.

1. AC line voltage is connected through the footswitch or PTT button to J1 pin 1.

2. +13 volts DC is supplied to J2 pin 5 supplied from the I/O board J1 pin 2B.

3. /PTT signal at J2 pin 2 needs to switch from +5.6 volts DC to .4 volts DC when the
PTT button is depressed.

4. The output control variac needs to be adjusted completely counter-clockwise.

After Serial number 210 Baker has changed from revision D to a revision F chassis
wiring diagram. Major changes incorporate using a +12 volt DC supply wired through
the footswitch and the PTT button. Also K1 and K2 were added. These relays hold the
displayed test voltage slightly longer so that the A/D memory has enough time to capture
the displayed test voltage. Relay K2 can be fitted to mount o the side of the card cage
above the Zero Start Interlock board and K1 can be mounted on the chassis next to the
Zero Start Interlock board. Mount by drilling two mounting holes and securing with
mounting hardware. Wiring additions or changes involve the following. To perform this
modification removal from the case is required. Remove mounting hardware on the
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variac and selector switch for easier access. Remove the A/D, I/O and the Controller
boards from the card cage.

1. Remove the AC Hot (black) wires from the PTT button and the footswitch. Connect
the black wire to K1:B common, K2:B common, and K2C common.

2. Connect a 20 gauge red wire to TB2 pin 1 on the Power Supply board and terminate
the other end to the footswitch pin 1,one end of the PTT button and one end of K1:A
coil.

3. Remove wiring from footswitch pin 2 (red) to the PT button to J1 pin 1 on the Zero
Start Interlock board to T2 pin 2.

4. Replace the wiring on the other end of the PTT button with a wht/grn wire and
connect to the footswitch pin 2 and also K2:A coil and an added 1N4936 cathode.

5. Connect the other end of K2:A coil to the 1N4936 anode and also to the ground
terminal block.

6. Connect a red 20 gauge wire from J1 pin 1 on the Zero Start Interlock board to K2:C
NO contact.

7. Connect a red 20-gauge wire from T2 pin 2 to K1:B NO and K1:A NO.

8. Connect a 26-gauge jumper on the rear of the I/O board from U6 to P1 pin 1A.

9. Remove top cover of card cage held by eight (8) M4 x 7mm black hex head screws
and two (2) M4 kep nuts.

10. Remove four (4) kep nuts securing the Motherboard to the back of the card cage and
solder a 26 gauge wire to the rear of the Motherboard J3 connector pin 1A. Run this
wire out of the card to a small breadboard containing a 4.7K ohm ¼ watt resistor and
a 2N2222 transistor. See schematic for electrical connection of this circuit. This
breadboard needs to be mounted on the side of the card cage by drilling one hole and
mounting with a nylon spacer and M4 hardware adjacent to the K2 relay.

11. Run a 20 gauge green wire from the 2N2222-transistor emitter and connect to the
ground terminal block.

12. Reassemble unit.

ZERO START INTERLOCK DOES NOT ENGAGE

1. Check that the output control knob is completely adjusted counter-clockwise.

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2. Ensure that the test lead select switch is not positioned in the leads ground position.

3. Check that the unit is supplied a proper ground.

4. With a digital multimeter set to DC volts, check the voltage at J2 pin 5 on the Zero
Start Interlock board with the negative lead connected to chassis ground. This
measurement should be approximately +13.5 volts DC and drop to about +12.7 volts
when the PTT button is depressed. If this voltage is not present or is low the fault can
be in the following circuits. The microswitch S1 which is mounted on the test lead
select switch can be open. Check Q5 base on the I/O board for +12.6 volts DC, if
present replace Q5.

5. Check at Q4 base on the I/O board, this should be approximately .7 volts DC, if
present replace Q4.

6. Check U8 pin 13 for a +5.5 volts DC, if measured low replace U7.

7. Check U8 pin 12 also for a +5.5 volts DC, if at a low state check R13 and U9.

8. Check at U8 pin 11 for low state, if at +5.5 volts DC, replace U8.

9. Measure at J2 pin 2 on the Zero Start Interlock board, this measurement needs to be
+5.5 volts DC and change to approximately .4 volts DC when the PTT button is
depressed. If this is present check Q1 through Q5 and OC1, OC2, and OC3 for faults.

10. Measure between R9 and KE2 pin 1, this coil voltage should change from –6.4 volts
DC to -.7 volts DC when the PTT button is depressed. If this is noted, replace K1
relay on the Zero Start Interlock board.

11. If the measurement at step 9 is not present, check U15, U7, and R18 for defects,
replace if necessary.

PI VALUE OR CURENT MEASUREMENT IS

INCONSISTENT
The digital series design tester will produce accurate results to a +/- 5% specifications.
The operators of the digital series may notice fluctuations in the current readings,
megohms values and PI data due to fluctuations in the input line power. Small variations
in the line power specifically at the one-minute and ten-minute intervals may cause
inconsistent readings even when the same windings are analyzed. To greatly improve
this occurrence, the steps below can be followed.

1. The use of a Patriot line conditioner in series with the power to the tester will reduce
line fluctuations. Contact Baker Instrument Company for price and availability.

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2. Connecting AC power from an isolated outlet does not have other equipment with
high current demands.

To check the internal current calibration of the tester will require the I/O board to be on
an extender card. Follow the steps in the Quality Control and Calibration Procedure. If
one or more range readings outside of +/-5% still occur, see the steps below.

1. Further adjustment may be necessary by altering the values of R33, R35, and R37.
Slight resistive value changes of no more than 10% of the existing value up or down.

2. Continue monitoring offset value at the I/O board pin 2A to pin 29C for an offset
which drifts away from the nominal measurement of 0.000 volts +/-0.010. If drifting
is detected, replaced U10 and U11.

DISPLAY LOCKED UP AFTER SELF-TEST

In this fault mode, an operator will see after the on/off switch to the on position that the
tester will illuminate the Baker logo and proceed with it’s internal memory test. All self-
tests will pass. After an attempt to begin testing by depressing the PTT button, there will
be no change in the testers display. Also no change will take place when a softkey is
used. A shorted softkey or a faulty mux integrated circuit on the I/O board is more than
likely the cause.

1. Check that all softkeys are not stuck, closed, or shorted. This type is normally open
and should have high resistance across the two terminals used.

2. Check at U15 pin 2 for a high state, if this state is not high replace RPK3. Depress
softkey 1. At this point it should change to a low state.

3. Check at U15 pin 4 for a high state, if this is not high replace RPK3. Depress softkey
2. At this point it should change to a low state.

4. Check at U15 pin 6 for a high state, if this is not high replace RPK3. Depress softkey
3. At this point it should change to a low state.

5. Check at U15 pin 8 for a high state, if this is not high replace RPK3. Depress softkey
4. At this point it should change to a low state.

6. Change U15.

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 DISPLAY UNREADABLE AND FLASHES
ON/OFF, DOES NOT INITIATE SELF TEST
1. A check of the DC supplies and crystal frequency to verify proper conditions, see
Voltage Busline and Crystal Checkout procedures.

2. A loss or loading of any one or more of the following lines due to faulty components
or connections will cause this occurrence. Since these signal lines are tied to the A/D
board, I/O board, and the Controller card it will be necessary to troubleshoot in the
manner outlined in step 3.

___ ____ __________ _________ _________ _________ ____

RD, Reset, CRT Enable, 103 Enable, 102 Enable, 101 Enable, SAD, RD/WR, ALE,
Reset, DB0 through DB7, AD1 through AD7 and AD8 through AD14.

3. To determine which printed circuit is defective, unplug the A/D board and the I/O
board with the power off. Turn on the tester and observe the tester response. If the
tester now begins with a Baker logo then the fault is not on the Controller card. The
tester will fail the A/D Memory test due to the A/D card not being inserted into the
Motherboard. Turn off the testers power.

4. Insert the A/D board into the J1 connector and switch power on. If the display returns
to the original fault condition, then a fault will be on the A/D board. Turn off tester
power.

5. Insert the I/O card into the J3 connector of the Motherboard and turn on the testers
power. If the display returns to the original fault condition, then the fault will be
located on the I/O board.

6. After determination as to which card is defective, remove power and the defective
card. Install the faulty card on an extender card and apply power.

7. With a 10X-scope probe begin monitoring the data, address and signal lines noted in
step 2. It will be helpful to record all lines, which do not have data present. See
Motherboard DST Series schematic for pinout contacts of these signal lines to each
card. Data is defined as a high frequency 0 to 5-volt amplitude logic level changes
determined by the programmed U3 27C256 EEPROM located on the Controller card.

8. After determination as to which signal lines are stuck low or high, it will be necessary
to trace the defective signal lines to all components that are tied to the same line and
replace one at a time. It may also be necessary to check defective signals lines with a
digital multimeter set to ohms for shorts to GND and to +5 volts DC. Also check

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 continuity on defective signal lines from components that are tied to the same signal
line.

9. If the fault is located to either A/D board or the Controller card, replacement boards
can be sent without affecting the calibration on the unit. An I/O board replacement
will require a calibration of the unit.

A/D BOARD, I/O BOARD, CONTROLLER

BOARD ACCESS INSTRUCTIONS
When MTA for Windows is installed or an Epson 640 or compatible printer is used, it
will be necessary to replace U3 on the Controller Board. For this program to function,
install the replacement 08-011R, firmware revision 1.37 for a 12kV tester. Please see the
MTA for Windows users manual for further explanation of the procedure.

1. These assemblies can be accessed from the front panel from the Knurr, Rittal or
Schroff design cases. These assemblies are installed in the card cage portion of the
unit located to the right of the CRT display.

2. To access the I/O board, Baker part 80-108, locate on the front panel which has the
function knob, Volts/Division knob and the Seconds/Division knob.

3. Remove two (2) M3 x 7mm hex head screws located above the function knob and
below the Seconds/Division knob.

4. Grasp the Function knob and the Volts/Division knob and pull away from the front
panel. This assembly is a 96-pin plug in type card that slides on a card guide system
and plugs into mating 96 pin connectors mounted on the Motherboard.

5. To remove the A/D board, Baker part 80-106, locate the panel with the Open
Ground/Hipot trip indicator lamps Intensity, Vertical and Horizontal Position knobs.

6. Remove two (2) M3 x 7mm hex head screws located above the Open round indicator
and below the Horizontal position knob.

7. Position fingertips behind the stenciled panel for this assembly and pull away from
the front panel.

8. Access to the Controller board, Baker part 80-107, is now gained. This will be the
only board left in the card cage. Simply grasp this assembly and pull away from the
front panel.

9. Remove the Controller board and replace U3 with one labeled firmware revision 1.37.
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10. Install all boards back into the card cage and secure with the original hardware.

NOTE: These assemblies contain C-MOS logic which are ES D sensitive. Removal of
these boards are recommended to be performed at a grounded station by personnel
wearing a grounded wrist strip. Failure to do this may result in integrated circuit damage.

ECO RECORD
Engineering changes have taken place since the manufacturer of D12000 S/D 001.
D12000 series after serial number 210 should have these changes installed at the factory.
These changes are designed to add more capability and improve the tester’s performance.
Also they will increase the tester’s reliability by protecting components and circuits
which have shown over the years to be vulnerable to failure in certain testing
applications. The following is a list of these changes we recommend to be checked for
installed during servicing.

1. A cooling fan for the CRT circuits was added to eliminate scrolling of the CRT
display when internal temperatures reach above 105 degrees.

2. Power board components R3 and C1 were changed to increase reliability of Q1 on the

Power board.

3. Discharge board changes include changes in the value of resistor R5 to provide for a
greater incoming signal to the I/O board. This allows for a better capability to shape
the surge signal so that the displayed surge signal on the CRT display more closely
resembles what is shown at the test leads on an oscilloscope.

4. Other changes to this assembly isolation of the surge readout cable from Discharge
board ground and ground routing changes. This will improve the noise resolution
seen of the first displayed positive peak when surge testing at higher voltages.

5. Changes in the values of Stack board components R1 and R34 were performed to add
greater reliability in SCR’s Q1-Q5.

6. Changes in the revision of the Zero Start Interlock board form a common neutral
design to a common ground design. This revision change allows for the elimination
of false hipot trips and adds the capability to disable the Zero Start Interlock when
testing armatures when a footswitch is used.

7. The addition of relays K1 and K2 and associated wiring harness changes were added
to eliminate the condition where the displayed surge voltage on the CRT would drop
approximately 10% when the PTT button was released.

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8. EEPROM IC U3 is now at revision level 1.37. These firmware revision changes have
added the following capability. A Polarization Index clock was added so that the
operator can reset the clock after proper test voltage was reached, resulting in a full
one or ten minute megohm test. Other changes in the firmware have added the
capability to recall in any summary all three-surge test patterns with the test voltages
of each lead displayed. This 1.37 revision change is necessary to upgrade to an inkjet
Epson 640 printer or compatible printer. It is also necessary to be installed if this
tester is used with MTA for Windows operating software system.

9. A/D board grounding changes, clamping diodes and bypass capacitors were added to
increase the reliability of IC U14.

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