239-437-0494

sales@voltech.com
August 2011
www.voltech.com

Voltech  AT  Series  Automatic  Transfomer  Testers  

Extended  Measurement  Capability    

Introduction. ....................................................................................................................... 2  
Essential Capability ........................................................................................................... 3  
Extended Capability ........................................................................................................... 4  
Surge Testing (AT3600 Only) – The Ultimate Stress Test ............................................... 4  
External AC Power (AT3600 only) – Flexible power source for larger transformers. ....... 5  
External DC Bias – Real Test Conditions for Power Transformers and Chokes .............. 7  
Updating an AT3600 or ATi ............................................................................................... 8  
Test Descriptions ............................................................................................................... 9  
Test Specifications........................................................................................................... 11  

© Voltech 2011 86-759/1 AT3600 Strength to Strength Page 1 of 13

Introduction.
The unique AT3600 and ATi automatic transfomer testers combine the features of a
precision LCR meter, ac source, HiPot tester and 20-way kelvin switching matrix to provide
fast and accurate testing of all parameters on most kinds of small transformers and
chokes.

The cost and quality benefits of the AT Series testers are well known to our customers and
this technical note describes the latest extended features of the AT3600 and ATi.

Before Voltech With Voltech

Special skills were required to design, All tests in one station, up to 10 different tests per
maintain, program and operate transformer second with automatic connection to different
testing equipment. windings.

Voltech AT Series testers.

- going from strength to strength -

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Essential Capability
The testers have the built-in capability described below.

AT3600 ATi

Capability: AT3600 ATi

20 way switching matrix  
PC test editor and results server  
Quick-change Fixture System  
Test fixture system  
Small signal tests (e.g. inductance, capacitance, turns ratio)  
Telecomms. tests (e.g. return loss, longitudinal balance)  
Insulation resistance 7000V 500V
Hi-pot (AC) 5500V
Hi-pot (DC) 7000V
Magnetizing current and open circuit voltage 270V, 2A
Watts, Stress Watts 40W
Leakage Current 2A

To make use of this capability, the testers may be fitted with a number of different tests
such as inductance, ac resistance, turns ratio, watts or ac hipot.

Tests are sold in packages such as ‘Standard” or “Gold’ or may be purchased individually
and fitted by the user via firmware upgrade.

The complete list of available tests is shown at the end of this document.

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Extended Capability
Surge Testing (AT3600 Only) – The Ultimate Stress Test

Before Voltech, a dedicated measurement instrument carried out surge stress testing of
windings. SURG is now an option on all AT3600 testers.

SURG test - High energy discharge into the winding and waveform analysis

• Finds insulation defects inside a winding.

• Roots out faults with high density windings
• Applies high energy transients for waveform analysis
• AT3600 reports a “Volt-second” result as pass/fail

SURG Surge Stress 1mVs to 1kVs 100V to 5kV 3.0%

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External AC Power (AT3600 only) – Flexible power source for larger transformers.

The AT3600’s programmable internal ac source may be used to provide up to 270V at 2A

RMS from 20Hz to 1500Hz. This suppy is used for measuring magnetizing current, watts
and open-circuit volatges on iron laminate transformers. The tests are usually made with
the transformer off load or open circuit such that transformers rated at 2kVA or more may
be tested.

This internal ac source has several advantages, perhaps the most important being the
ability to ramp up the voltage and current under real time software control to minimize
inrush current and test time.

The Voltech AC Interface allows external ac sources (including simple step-up or step-
down transformers) to provide extended ac power seamlessly within the AT3600 test
environment.

Voltech AC Interface

With the AC Interface, the AT3600 capabiility may be extended up to 600V at 10A RMS

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External AC Sources that may be integrated into the AT3600 test environment include:

• Simple step up transforners (providing up to 600V @ 0.8A)

• Simple step-down transfomers (providing up to 10A @ 20V)

• Fully programmable external ac sources (providing up to 600V @ 10A).

Tests for the AT3600 and AC Interface

MAGX Magnetizing 50mA to 10A 5V to 600V 20Hz to 5kHz 0.1%

Current
(External
Source)
VOCX O/C Voltage 100µV to 650V 1V to 600V 20Hz to 5kHz 0.1%
(External
Source)
WATX Wattage 1mW to 6kW 5V to 600V 20Hz to 5kHz 0.3%
(External
Source)

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External DC Bias – Real Test Conditions for Power Transformers and Chokes

Power transformers and chokes that carry a high dc current are common in power supplies
and inverters. Testing these parts at their rated dc current provides complete confidence
that the parts have been correctly wound, assembled and terminated.

The Voltech DC1000 25A dc current supply will seamlessly integrate into the AT3600 or
ATi test environment to provide up to 250A (10x DC1000 in parallel) of smooth,
programmable dc bias current with minimal effect on the ac inductance measurement.

• 25A programmable dc current

• 250A with 10x DC1000
• Works seamlessly with AT3600 or ATi
• Unique “electronic inductor” design minimizes effect on the ac inducatnce
measurement
• Can be used on almost any LCR meter. Alternative for Agilent, Wayne Kerr and
Chroma types.

Tests for the DC1000 and AT3600 / ATi

LSBX Inductance with 1nH to 1MH 1mV to 5V 20Hz to 3MHz 0.05%

External Bias
(Series)
LPBX Inductance with 1nH to 1MH 1mV to 5V 20Hz to 3MHz 0.05%
External Bias
(Parallel)
ZBX Impedance with 1mΩ to 1MΩ 1mV to 5V 20Hz to 3MHz 0.2%
external bias

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Updating an AT3600 or ATi

Any AT3600 or ATi less than 10 yers old may be upgraded to include the lalest tests or
accessories available. Most tests may be fitted by upgrading the firmware using the
Voltech PC Editor. Contact your local supplier for the costs and availablity of fitting new
tests via firmware upgrade.

If your AT3600 or ATi is over 10 years old we will either offer to re-furbish it at our factory
or offer you a trade-in value against the purchase of a new Voltech tester,

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Test Descriptions

Test Description Main Application Winding Tested Reason for Test

CTY Continuity All transformers Properly installed fixture
Properly installed fixture
R DC Resistance All transformers All windings Correct wire used
Integrity of terminations
Inductance
LS Correct primary turns
(Series circuit)
Right grade of core material
Inductance Core correctly assembled
LP
(Parallel circuit)
QL Quality Factor
Most transformers
One winding usually the
Equivalent Series But usually not line frequency
RLS primary
Resistance transformers
Right grade of core material
Equivalent Parallel Core correctly assembled
RLP Check for shorted turns
Resistance

D Dissipation Factor

LL SMPS transformers Check windings have been

Leakage Inductance Communication transformers Selected windings installed in the correct position
LLO Others as applicable relative to the core

High frequency transformers Check winding positioning Check

C Interwinding Capacitance insulation thickness between
Isolating transformers windings
Most transformers, but usually
Check windings have correct
TR Turns Ratio and Phasing not line frequency All windings
turns and phasing
transformers
As with Turns Ratio but used
Turns Ratio by Check windings have correct
TRL where there is poor flux All windings
Inductance turns and phasing
linkage between windings.
MAGI Magnetising Current Correct primary turns
One winding, usually the
Correct core material properly
MAGX MAGI (External Source) primary
assembled

VOC Open Circuit Voltage Usually line frequency

transformers
VOCX VOCX (External Source) Correct secondary turns
All other windings
Correct phasing
Low Voltage
LVOC
Open Circuit
Winding isolation check where
IR Insulation Resistance All transformers Between selected windings
safety is not involved
HPDC Hi-Pot (DC) All transformers especially Between selected windings
those used for safety usually primary to secondary, High voltage safety insulation
HPAC Hi-Pot (AC) insulation screens and core
Inductance with Bias Transformers for use in
LSB Correct number of turns
Current (Series Circuit) applications where passing
One winding Right grade of core material
Inductance with Bias significant (dc) bias current is
LPB Core correctly assembled
Current (Parallel Circuit) part of the normal operation

WATT Wattage Correct core material

50Hz Iron core transformers One winding
WATX WATT (External Source) Properly assembled

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 Test Description Main Application Winding  Tested   Reason for Test
All transformers, especially
SURG Surge Stress Test Selected windings To identify shorted turns
those using fine wire
Transformers with variable / To adjust transformer to give
TRIM Trimming Adjustment
trimmable components specific measured values
Allows the AT to perform external
OUT Output To User Port switching as part of the test
program.
Checks matching between
R2 DC Resistance Match SMPS, audio & telecom All windings
windings
SMPS, audio & telecom Checks matching between
L2 Inductance Match All windings
transformers windings
SMPS, audio & telecom Checks correct winding position
C2 Capacitance Match All Windings
transformers on bobbin
General Longitudinal Checks common mode rejection
GBAL Audio & telecom transformers Selected Windings
Balance ratio
Checks common mode rejection
LBAL Longitudinal Balance Audio & telecom transformers Selected Windings
ratio
Checks losses within the
ILOS Insertion Loss Audio & telecom transformers Selected Windings
transformer
Checks losses over a range of
RESP Frequency Response Audio & telecom transformers Selected Windings
frequencies
Checks losses returned by a
RLOS Return Loss Audio & telecom transformers Selected Windings
transformer
Checks impedance at a given
Z Impedance Audio & telecom transformers Selected Windings
frequency
Checks impedance at a given
ZB Impedance + bias Audio & telecom transformers Selected Windings
frequency
STRW Stress Wattage Checks integrity of inter-turn
Line frequency & High One Winding (Usually the
insulation, the magnetic material
STRX STRW (External Source) Frequency Transformers primary)
and joints
Finds phase shift between
ANGL Impedance Phase Angle Audio & telecom transformers Selected Windings
Voltage and Current on a winding.
Measures phase shift between a
PHAS Interwinding Phase Test Audio & telecom transformers Selected Windings
pair of windings
Between Primary and Checks for a common mode
ILK Leakage Current Test Medical applications
Secondary Windings current due to capacitance
Wound components that Checks number of turns, right
Inductance with External usually carry a significant DC grade of correctly assembled core
Selected Windings
LSBX Bias (Series Circuit) Bias current in normal material, where bias current is
operation. greater than LSB test can handle.

Wound components that Checks number of turns, right

Inductance with External usually carry a significant DC Select Windings grade of correctly assembled core
LPBX Bias (Parallel Circuit) Bias current in normal material, where bias current is
operation. greater than LPB test can handle.

Checks impedance at a given

Impedance with External Selected Windings frequency, while applying a
ZBX Audio & Telecom
Bias greater bias current than is
possible with ZB test.
ACRT Hi-Pot Ramp (AC) All transformers especially Between selected windings
those used for safety usually primary to secondary, High voltage safety insulation
DCRT Hi-Pot Ramp (DC) insulation screens and core
ACVB Voltage Breakdown (AC) Between selected windings
Transformers with MOV fitted usually primary to secondary, High voltage safety insulation
DCVB Voltage Breakdown (DC) screens and core

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Test Specifications

User Entered Test Data

Test AR(1)
Measurement Range Test Signal Test Frequency(4)
CTY Continuity 10kΩ to 10MΩ n/a n/a n/a
R DC Resistance 10µΩ to 10MΩ n/a n/a 0.1%
LS Inductance 1nH to 1MH 1mV to 5V 20Hz to 3MHz 0.05%
(series circuit)
LP Inductance 1nH to 1MH 1mV to 5V 20Hz to 3MHz 0.05%
(parallel circuit)
QL Quality Factor 0.001 to 1000 1mV to 5V 20Hz to 3MHz 0.5%
D Dissipation Factor 0.001 to 1000 1mV to 5V 20Hz to 3MHz 0.5%
RLS Equivalent Series 10µΩ to 10MΩ 1mV to 5V 20Hz to 3MHz 0.05%
Resistance
RLP Equivalent Parallel 10µΩ to 10MΩ 1V to 5V 20Hz to 3MHz 0.05%
Resistance
LL Leakage Inductance 1nH to 1kH 20µA to 100mA 20Hz to 3MHz 0.1%
LL0 Leakage Inductance 1nH to 1kH 20µA to 100mA 20Hz to 3MHz 0.1%
with user offset
C Inter-winding 100fF to 1mF 1mV to 5V 20Hz to 3MHz 0.1%
Capacitance
TR Turns Ratio and 1:100k to 100k:1 1mV to 5V 20Hz to 3MHz 0.1%
Phasing
TRL Turns Ratio by 30:1 to 1:30 1mV to 5V 20Hz to 3MHz 0.1%
Inductance
MAGI Magnetizing Current 1µA to 2A 1V to 270V 20Hz to 1500Hz 0.1%
(2)
MAGX Magnetizing Current 50mA to 10A 5V to 600V 20Hz to 5kHz 0.1%
(External Source)
VOC Open Circuit 100µV to 650V(3) 1V to 270V 20Hz to 1500Hz 0.1%
Voltage
VOCX O/C Voltage 100µV to 650V(3) 1V to 600V 20Hz to 5kHz(2) 0.1%
(External Source)
LVOC Low Voltage 100µV to 650V(3) 1mV to 5V 20Hz to 3MHz 0.1%
Open Circuit
IR Insulation 1MΩ to 100GΩ 100V to 7KV n/a 1%
Resistance
HPDC Hi-Pot (DC) 1µA to 3mA 100V to 7KV n/a 3.2%
(4)
HPAC Hi-Pot (AC) 10µA to 30mA 100V to 5KV 50Hz to 1kHz 3.0%
LSB Inductance with Bias 1nH to 1MH 1mV to 5V 20Hz to 3MHz 0.05%
(Series)
DC Bias 1mA to 400mA
LPB Inductance with Bias 1nH to 1MH 1mV to 5V 20Hz to 3MHz 0.05%
(Parallel)
DC Bias 1mA to 400mA

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 User Entered Test Data
Test AR(1)
Measurement Range Test Signal Test Frequency(5)
WATT Wattage 1mW to 40W 1V to 270V 20Hz to 1500Hz 0.3%
(2)
WATX Wattage 1mW to 6kW 5V to 600V 20Hz to 5kHz 0.3%
(External Source)
SURG Surge Stress 1mVs to 1kVs 100V to 5kV n/a 3.0%
TRIM Trimming n/a n/a n/a n/a
Adjustment
STRW Stress Wattage 1mW to 40W 1V to 270V 20Hz to 1500Hz 1%
(2)
STRX Stress Wattage 1mW to 6kW 5V to 600V 20Hz to 5kHz 1%
(External Source)
R2 DC Resistance 1:1000 to 1000:1 n/a n/a 0.2%
Match
L2 Inductance Match 1:10000 to 10000:1 1mV to 5V 20Hz to 3MHz 0.1%
C2 Inter-winding 1:1000 to 1000:1 1mV to 5V 20Hz to 3MHz 0.2%
Capacitance Match
GBAL General 0dB to 100dB 1mV to 5V 20Hz to 3MHz 0.5dB
Longitudinal
Balance
LBAL Longitudinal 0dB To 100dB 1mV to 5V 20Hz to 3MHz 0.5dB
Balance
ILOS Insertion Loss -100dB to 100dB 1mV to 5V 20Hz to 3MHz 0.5dB
RESP Frequency Response -100dB to 100dB 1mV to 5V 20Hz to 3MHz 1.0dB
RLOS Return Loss -100dB to 100dB 1mV to 5V 20Hz to 3MHz 0.2%
Z, ZB Impedance, 1mΩ to 1MΩ 1mV to 5V 20Hz to 3MHz 0.2%
Impedance + bias
OUT Output to User Port n/a n/a n/a n/a
ANGL Impedance Phase ° to ° 1mV to 5V 20Hz to 3MHz °
-360 360 0.05
Angle
PHAS Inter-winding Phase ° to ° 1mV to 5V 20Hz to 3MHz °
-360 360 0.05
Test
ILK Leakage Current 1µA to 10mA 1V to 270V 20Hz to 1kHz 0.5%
Test

ACRT Hi-Pot Ranp (AC) 10µA to 5mA(4) 100V to 5.5KV 50Hz to 1kHz 3.0%
DCRT Hi-Pot Ramp (DC) 1µA to 3mA 100V to 7KV n/a 3.2%
(4)
ACVB Voltage Break down 10µA to 5mA 100V to 5.0KV 50Hz to 1kHz 3.0%
(AC)
DCVB Voltage Break down 10µA to 3mA 100V to 7KV n/a 3.2%
(DC)

Yellow Shade AT3600 Only

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Notes:

1. AR = The basic relative accuracy (see the user manual for the full specification).
2. Depends on external source type.
3. 650Vrms for AC measurements, or 1000V for DC measurements.
4. Peak value.
5. 1MHz may be the maximum bandwidth for some testers manufactured before 1999. Consult
your supplier for details.
6. Where used, the bias current accuracy is +/-10% of the requested value.
7. Test Frequency Accuracy
a. F <= 16kHz, error is +/-0.25Hz +/- 0.01% of requested frequency
b. F >16kHz and <= 250kHz, error is +/- 4Hz +/- 0.01% of requested frequency
c. F > 250kHz, error is +/- 64Hz +/- 0.01% of requested frequency

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