ARC RESISTANCE TEST MACHINE

Designed to comply with

STANDARD : ASTM D 495 –89

Dry Arc resistance Testing Machine

This machine is designed to comply with ASTM D495 standard for Dry
Arc Resistance Testing of electrical insulating materials. All the seven
cycles mentioned in the above ASTM standard are implemented in this
machine. This machine uses advanced electronic circuitry in place of
mechanical arrangements suggested in the standard document. It also
has an additional feature to turn OFF the test automatically after a
conducting path is formed. This feature can be used while testing
insulating materials that fail by forming a conducting path.

A Brief Description of the test

This test tests the electrical insulating material by exposing it to Arcing
under high voltage. The test specimen is placed under electrodes which
are spaced at a specified distance (6.35mm or 1/4 inch). And an Arc is
generated between these electrodes. The test consists of 7 cycles
starting from cycle 1. As the cycles progress the test becomes
progressively harsher. The test specimen that have lower insulating
strength fail earlier in the first few cycles while those with higher
insulating strengths endure through higher cycles. The test is halted
when the specimen fails and the time taken from the start of the test till
the failure is used for comparing insulating strengths of various insulating
materials. The test specimen may fail by forming a conducting path, by
burning into flames, by melting or any other physical, visual deformities.
Operating cycles

The unit is programmed to operate in 7 cycles according to ASTM

Standard D495-89. Each cycle will be for duration of 60 seconds.
Arc Current Time Cycle Total time, Sec.

Cycle 1 10mA ¼S ON, 1¾S OFF 60

Cycle2 10mA ¼S ON, ¾ S OFF 120

Cycle3 10mA ¼S ON, ¼ S OFF 240

Cycle4 10mA Continuous 300

Cycle5 20mA Continuous 360

Cycle6 30mA Continuous 360

Cycle7 40mA Continuous 420
These cycles are programmed to automatically change to the next cycle
after the current cycle duration is completed. At the end of the last cycle
the system automatically stops. However a provision is provided to
choose the starting cycle.
By selecting the cycle number with help of select switch, the operator
can choose the starting cycle (Note: Choosing the starting cycle is not
part of the ASTM standard document). The cycle in progress is also
displayed.

Note: Please refer to the ASTM standard document D495 for

complete details of the test procedure
 ARC Resistance Testing Machine

Volt Meter select

Display Unit

Start Stop

Control Section

Electrode A Electrode B

Rest Plane
Arc Section

ON/OFF Switch

Fatal Voltages exist inside

Do not open any part of

the machine
Auto Transformer
Do not ever operate the machine without proper earthing

A Note of Caution !!!

Dangerously high voltages exist inside the
machine. Please do not open any part of the
machine. Only qualified and properly trained
engineers can open the machine. Unqualified
and untrained persons opening the machine
can encounter high voltage electric shock
which can cause death of the person.

ALSO DO NOT OPERATE THE MACHINE

WITHOUT PROPER EARTHING.
This also can lead to experiencing high voltage
shocks on the machine body

Always switch the machine OFF while doing

any settings or while placing and removing test
specimen.
 Machine Settings
Electrode Gap Adjustment
Loosen the screws and allow the electrodes to freely rest on the resting
plane. Place the distance gauge in between the two electrodes. With
distance gauge between the electrodes, slightly press the resting plane
down and rotate the electrodes (if necessary) until the flat surfaces of the
electrode are parallel to the resting plane and are properly resting and
tighten the screws maintaining this position.

Caution!!
Before removing the electrodes switch OFF the power.

Voltage Setting
The high voltage required for the test is 12,500 volts (12.5kV). This
voltage has to be adjusted after turning ON the machine with the help of
auto transformer knob. Rotate the knob and adjust the voltage 12.5kV is
read on the volt meter display. While the test is in progress, if this voltage
happens to vary, adjust it as and when it varies.

Cleaning Electrodes
If excessive accumulations of products of decomposition occur on the
electrodes, clean them gently with laboratory tissue. Switch OFF the
power before starting the cleaning process. Application of a
continuous 40mA Arc for approximately 1 min also can further clean the
electrodes. To do this, place a ceramic plate on the rest plane and select
cycle 7 and turn ON the test. The Arc will automatically stop after one
minute.
 Operating modes

Manual OFF Mode

In this mode of testing, the test will be stopped until the Stop switch is
pressed. Even if a conducting path is formed, the test will continue. Arc
might not be visible after a conducting path is formed, but the test will
continue and test sample will continue to burn by the current that flows
through the conducting path that has been formed. The test will come to
a stop after pressing the Stop switch. If the stop switch is not pressed the
test will continue till the end of the seventh cycle. After seventh cycle
ends the test will automatically stop.
In the event the door is accidentally opened while the test is in progress
the test will be automatically stopped (For operator Safety).

Auto OFF Mode

When the test is done in this mode, the test is automatically stopped
after a conducting path is formed. The time incrementing process is
stopped and the elapsed time is retained on the display. This time
indicates the time it took from the start of the test to forming the
conducting path.
Even while in Auto OFF mode, the test can be stopped at any time by
pressing the Stop switch. In this case also the time elapsed until
switching OFF the test is retained on the display.
In the event the door is accidentally opened while the test is in progress
the test will be automatically stopped (For operator Safety).

Note on Auto OFF & Manual OFF modes

Auto OFF mode will work only when specimen fails by forming a clear
conducting path. The specimen may fail in other ways. The person
conducting the test should use his experience in selecting the mode.
Placing test sample and turning ON the machine
Power OFF the machine. Open the transparent door and place the test
sample under the electrodes by slightly pressing down rest plane. Now
close the door and turn ON the power ON/OFF Switch. Adjust the auto
transformer until 12.5KV is displayed on the volt meter.

Mode Selection
The default setting of the machine is manual OFF mode. Immediately
after the power is turned ON the display shows Auto Off. This means the
machine is in manual OFF mode. Pressing the Start switch displays Auto
Off which means auto off feature is set and the test will be automatically
terminated after the sample forms a conducting track.
At this stage pressing Start push button again and again toggles the test
setting between auto OFF yes and auto OFF no which means Auto OFF
mode and Manual OFF mode respectively.

Start Cycle Selection

Note: As per ASTM test specifications the test starts from first cycle
and continues through next cycles until the sample fails. However a
provision is provided in this machine to start the test with any of
the 7 cycles as the starting cycle.

Starting cycle can be selected by Pressing the select switch. Each time
the switch is pressed the cycle is incremented by 1 until cycle 7. The
numbers 1 to 7 are displayed on the display beside the start switch. If the
switch is pressed while in cycle 7 it comes to mode selection. If the
switch is pressed again it comes to cycle 1. In this way pressing the
select switch again and again the selection process passes through all
the cycles and then through mode selection and then again through all
the cycles in a cyclic fashion. The cycle number at which you stop will
get selected.
Note on Auto OFF & Manual OFF modes
Auto OFF mode will work only when specimen fails by forming a clear
conducting path. The specimen may fail in other ways. The person
conducting the test should use his experience in selecting the mode.

Starting the test

After placing the sample and selecting the test mode & cycle you are
ready to start the test. Press the start switch once and it starts the test.
Before starting the test once again make sure that the volt meter reads
12.5KV. If this voltage has changed due to possible power fluctuations,
adjust the voltage. This adjustment has to be done whenever the power
fluctuates while the test is in progress.

Test in progress
While the test is in progress the cycle in progress is displayed (number 1
to 7) and the current in milliampere is also displayed in and the time
elapsed from the start of the test is also displayed. The display is
incremented every second. As long as the test is ON, the red lamp
glows. In case the door is accidentally opened while test is in progress,
the testing process is automatically stopped and the time elapsed is
retained.

Ending the test

In auto OFF mode the test is automatically terminated after a conducting
path is established and the time elapsed is retained on the display.
In manual OFF mode press the Stop switch to stop the test. In this mode
operator visually determines the completion of the test. The test cycle
comes to a stop and the time elapsed is retained on the display.
The time will continue to be displayed until it is reset, by pressing select
switch.
 HV Primary Side Circuit Diagram

Panel Door Switch

T2T2

T1
T1
RL6 R10-1 R10-2 R10-3 R10-4
T3
T3

RL5 R20-1 R20-2 R20-3

T4
T4
RL4 R30-1 R30-2 R30-3 R30-4

T5
T5
RL3 HV Transformer
R40-1 R40-2 R40-3 R40-4

ON PCB
230V AC Input

Variac (Auto Transformer)

 HV Transformer Secondary side Circuit

Electrodes (Tungsten)

8 Air core coils (Inductors)

T6 15K

T7

Power Supply Circuit

To Volt meter (Panel)

Auto Transformer
Fuse

To primary side
Circuit of HV

ON/OFF Switch

To Control Circuitry
3 Pin Socket (Power In)
 INPUT / OUTPUT Circuitry

Relay RL2

T8 230V Lamp

T9

0V (Signal Ground)

Select (Push button Switch)

T12

ON (Push button Switch)

T13

OFF (Push button Switch)

T14

Door operated limit switch

T15
(NC contact)
 TERMINALS ON PCB

T7
T6

T1
T2
T3

T4
T12
T5
T13

T14 T8
T9
T15
T10
12V 0V 5V T11
 CONTROL SECTION COMPONENTS

TO FAN

CONNECTOR
PCB

POWER SUPPLY

TO
DISPLAY

PCB
TRANFORMER
Right Side View (Calibration)

10mA 20mA

L2cx a

30mA 40mA

L - Wire link (Place for inserting

mA meter while calibrating)

10mA – Knob for 10mA calibration

20mA – Knob for 20mA calibration
30mA – Knob for 30mA calibration
40mA – Knob for 40mA calibration

CAUTION!
Always ensure that link L is in
place while testing. Removing
L may cause unnecessary
arcing at undesired places
and may cause personal
injury.
This link is meant to be
replaced by a milli ammeter
only at the time of calibration.
 Calibration

Please study these instructions and understand

them thoroughly before attempting to calibrate the
unit. The calibration instructions given here are to
be strictly followed while calibrating.

The calibration process involves calibrating at 5 places

• Open Circuit Operating Voltage Calibration
• 10mA Calibration
• 20mA Calibration
• 30mA Calibration
• 40mA Calibration

Note: Open Circuit Voltage calibration and 10mA calibration are to be

done in tandem, calibrating one will affect the other. So we first calibrate
open circuit voltage and then 10mA current, after this again calibrate
open circuit voltage and again 10mA current. We do this a few times till
no changes are observed. After calibrating open circuit voltage and
10mA current, other currents are calibrated.

CAUTION!!!
While calibrating for open circuit voltage, always
make sure that link L is put back in place. Trying to
calibrate without L in place may cause arcing at
undesired locations and can damage the machine
and may also cause injuries to persons near the
machine.
Open circuit Operating Voltage:
Turn OFF the power supply. Put back the link L in place if has been
removed for inserting the ammeter. Remove the tungsten electrodes
(This creates enough gap to avoid arcing while calibrating). Attach the
leads of the high voltage probe to the electrode holders. Attach the
ground lead of the probe to holder of electrode A and attach the High
voltage lead of the probe to the holder of electrode B (Refer to the figure
“Arc resistance Testing Machine” on page No.3). Now turn ON the
power and select cycle 4 and start the test cycle by pressing the start
switch. The red light will glow as usual. Adjust the autotransformer until
12.5KV is obtained on the calibration meter.
If the cycle jumps to 5 while calibrating (which it does after 60seconds),
halt the calibrating process temporarily, stop the test cycle by pressing
Stop switch. Using select switch, select cycle 4 and resume calibration.
Note If any minor Arcing is seen or vibration is felt while holding the high
voltage probe during calibration, then remove one of the hexagonal
electrode holders and attach the probe to the electrode block which
holds the hexagonal holder and restart the calibration process.

All current calibrations are to be done in the presence of Arc.

10mA Calibration
Refer to the figure “Right side view (Calibration)” on page No.14
Turn OFF the power supply. Replace the tungsten electrodes in their
place with regular gap. Adjust the gap with the gap gauge. Disconnect
the link L. Connect the Ammeter probes in place of the link L. Place a
Ceramic plate on the rest plane below the electrodes such that the
electrodes rest on it. Now Switch ON the power supply. Select cycle 4
and start the test by pressing start switch. Arc will be seen between the
electrodes and the Ammeter will show a reading of approximately 10mA.
Adjust 10mA Knob until the ammeter reads 10mA exactly. Observe for
sometime for stable current reading. Make further fine adjustments of the
knob if necessary and stop the cycle by pressing Stop switch. Maintain
cycle 4 till the end of 10mA calibration.
Repetition of Open circuit voltage & 10mA Calibration
The 10 mA calibration might have changed the open circuit voltage. So
repeat the open circuit voltage calibration and the 10mA calibration a few
times until both do not change each other. This process should end with
open circuit voltage calibration. While calibrating the open circuit voltage
for the last time, adjust the reading on the panel voltmeter to read 12.5kV
when the voltage reading on the calibration meter is also 12.5kV. This
adjustment is done by following the procedure mentioned in the section
Panel meter calibration on the next page.

20mA Calibration
Refer to the figure “Right side view (Calibration)” on page No.14.
Turn OFF the power supply. Replace the tungsten electrodes in their
place with regular gap. Adjust the gap with the gap gauge. Disconnect
the link L. Connect the Ammeter probes in place of the link L. Place a
Ceramic plate on the rest plane below the electrodes such that the
electrodes rest on it. Now switch ON the power supply. Select cycle 5
and start the test by pressing start switch. Arc will be seen between the
electrodes and the Ammeter will show a reading of approximately 20mA.
Adjust 20mA Knob until the ammeter reads 20mA exactly. Observe for
sometime for stable current reading. Make further fine adjustments of the
knob if necessary and stop the cycle by pressing Stop switch. Maintain
cycle 5 till the end of 20mA calibration.

30mA Calibration
Refer to the figure “Right side view (Calibration)” on page No.14.
Turn OFF the power supply. Make sure the tungsten electrodes are in
place on the Ceramic plate. Make sure the ammeter is connected in
place of link L. Now switch ON the power supply. Select cycle 6 and start
the test by pressing start switch. Arc will be seen between the electrodes
and the Ammeter will show a reading of approximately 30mA. Adjust
30mA Knob until the ammeter reads 30mA exactly. Observe for
sometime for stable current reading. Make further fine adjustments of the
knob if necessary and stop the cycle by pressing Stop switch. Maintain
cycle 6 till the end of 30mA calibration.
40mA Calibration
Refer to the figure “Right side view (Calibration)” on page No.14.
Turn OFF the power supply. Make sure the tungsten electrodes are in
place on the Ceramic plate. Make sure the ammeter is connected in
place of link L. Now switch ON the power supply. Select cycle 7 and start
the test by pressing start switch. Arc will be seen between the electrodes
and the Ammeter will show a reading of approximately 40mA. Adjust
40mA Knob until the ammeter reads 40mA exactly. Observe for
sometime for stable current reading. Make further fine adjustments of the
knob if necessary and stop the cycle by pressing Stop switch. Maintain
cycle 7 till the end of 40mA calibration.

Panel meter calibration:

Open the front cover of the panel volt meter. There are 2 potentiometers
towards the right corner as shown in the figure
S –span adjustment Z – Zero adjustment
Adjust S such that the calibrated voltage of 12.5kV SZ
is read 12.5KV on this meter also.

Completion of Calibration
Turn OFF the unit. Disconnect the ammeter and connect the link L into
it’s place and observe if it is properly secured by pulling out one end at a
time with a little force. Securing this link L properly is very essential for
proper and safe functioning of the machine.

The unit should not be switched ON without replacing link L