Users Manual

Phenix Technologies Inc.

DC DIELECTRIC TEST SET - 400P

MODEL NUMBER 4120-10

Version 2.2
 INTRODUCTION

The DC Hipot line offered by Phenix Technologies is ruggedly built suitable for
field or lab use, designed to test electrical switchgear, cables, motors, generators
and protective equipment. DC testing is popular because the equipment is more
compact and lighter in weight than comparable AC equipment.

Design and Safety Features

♦ Output voltage continuously adjustable to 120kV DC.

♦ “Zero Start” voltage interlock and external safety interlock.
♦ Leakage current measurements available from .01 to 10,000 microamps DC.
♦ Removable line cord.
♦ Rotary switch selection simplifies operation.
♦ Integrated cable storage bin in controls.
♦ Built in discharge circuit rated at 12 kilojoules.
♦ Light weight, portable, with controls enclosed in rugged, high-density
polyethylene case.
♦ Adjustable overcurrent trip point from 10%-110% of each range.
♦ Large, easy to read LCD meters
♦ Input Circuit Breaker / Power Switch
♦ Thermal resettable overload protecting high voltage transformer primary
circuits.
♦ Very low ripple, <2% RMS ripple at full output. (>40 Meg Resistive)

For full detailed specifications see Section 1-1.

 TABLE OF CONTENTS

Section Number

GENERAL SAFETY PRECAUTIONS

TECHNICAL SPECIFICATIONS 1

CONTROLS AND INDICATORS 2

ELECTRICAL SET-UP 3

OPERATING INSTRUCTIONS 4

RETURN-GROUND-GUARD CONNECTIONS 5

CALIBRATION 6

TROUBLESHOOTING 7

STORAGE OF EQUIPMENT 8

CIRCUIT DIAGRAM SYMBOLS 9

RECOMMENDED SPARE PARTS AND PARTS LIST 10

PARTS ORDERING INFORMATION 11

RETURNED MATERIAL 12

ELECTRICAL DIAGRAMS 13
 GENERAL SAFETY PRECAUTIONS

! CAUTION
HIGH VOLTAGE
This equipment is capable of providing POTENTIALLY LETHAL VOLTAGES!
Improper operation or test practices may result in injury or death to the
operator or surrounding personnel.

The operation of High Voltage test equipment should only be performed by

personnel familiar with HIGH VOLTAGE testing and safety procedures. The
operator of this equipment must be aware of all hazards associated with High
Voltage testing. The operator is responsible for himself and others in close
proximity of the testing area.

Some General Safety Practices for working with High Voltage Test Equipment
have been listed below for your reference.

• Become familiar with your instrument before performing an actual test

• Know your work area, check that all circuits are de-energized and locked
out.
• Never work alone; always work with another qualified worker.
• Mark off entire work area with barriers and warning tape.
• Make all personnel aware of your testing activities.
• Be aware of dangerous conditions that may arise from energizing a test
specimen.
• Never modify test equipment, modifications to equipment could introduce
an unknown hazard or hinder a designed-in safety feature.
• DO NOT operate damaged equipment. Remove power, and do not use
the equipment until safe operation can be verified by service-trained
personnel.

Phenix Technologies, Inc. assumes no liability for unsafe or improper use of test equipment.
 1-1

TECHNICAL SPECIFICATIONS
Input

120 VAC 10 Amps or 220 VAC 5 Amps, 50/60 Hz, single phase (refer to Unit Data Tag)

Output Rating (maximum)

120 kilovolts DC, 10 milliamperes

Internal Discharge Capability: 12 kilojoules

Duty Cycle

Continuous – Capacitive Charging

Type of Cooling: Natural convection

Ripple: Less than 2 percent, at 120kV, (> 40 Meg Resistive)

Output

Negative output, positive ground standard. Positive output available by special order. Filtered
voltage doubler circuit, equivalent to full wave rectification.

Operating Ambient Temperature

0 to 40 degrees Celsius

Output Termination

High voltage cable, shield grounded

Metering

Output Voltmeter: 3 ½ DIGIT LCD, accuracy 0.5% of full scale.

Ranges: 0 to 19.99kV, 0-120.0kV

Output Currentmeter: 3 ½ DIGIT LCD, accuracy 0.5% of full scale.

Ranges of 0 to 19.99µa, 199.9µA, 1.999mA, 10.00mA
Size and Weight

Controls: 21.25" W x 16.75" D x 13.75" H; 25* lbs.

(540 mm W x 426 mm D x 350 mm H; 11.4* kg)
HV Unit: 17.25" W x 12" D x 22" H; 110 lbs.
(438 mm W x 305 mm D x 559 mm H; 49.9 kg)
Cables: 9.5 lbs. (4.3kg)
*For 220 V units: add 10 lbs. (4.5 kg)
 2-1
CONTROLS AND INDICATORS
Control Unit (Refer to Figure 1.)

1. AC Power Input. Connect to a suitable grounded receptacle. See specifications tag on unit
for voltage and current requirements.

2. Voltmeter. Displays output voltage of test set.

3. Currentmeter. Displays current out of high voltage lead or into RTN terminal depending
upon mode of measurement.

4. Currentmeter Range Selector. Rotate to desired range.

5. J5. Interconnect cable between controls and HV unit connects here.

6. ANALOG CURRENT INDICATOR. Meter displays current from 0-100% of range to give
visual indications of capacitive charging conditions or to show changing current conditions
that are not easily determined from digital meters.

7. Output Voltage Control. Turn clockwise to increase output of test set. This control must
be in the full counter-clockwise position (zero start) in order to turn High Voltage On. Under
normal circumstances, Voltage Control should always be returned to zero and voltage
displayed on the voltmeter allowed to decay to zero before pressing High Voltage Off.

8. High Voltage Off/Ready. Press to turn off high voltage output. Under normal
circumstances the voltage control should be returned to zero, and the high voltage allowed
to decay near zero before switching High Voltage OFF. CAUTION: Capacitive loads may
retain voltage for a short time after high voltage is turned off while the internal
circuitry bleeds their charge to ground.
High Voltage Off/Ready lamp must be illuminated before High Voltage ON can be
activated. Conditions required for illumination are:

• External Interlock loop must be closed.

• Overcurrent Trip/Reset circuit must not be tripped. (Push Reset if circuit is

tripped)

9. High Voltage On. Press to turn on high voltage.

Conditions required before high voltage will activate are:

• Voltage control at Zero Start

• External Interlock loop closed.

10. Current Trip Adjust. Dial adjusts from 1 to 11 corresponding to approximately 10% to
110% of selected output current range. Current Trip/Reset lamp illuminates and high
voltage turns off when output current exceeds setting, causing circuit to trip. Circuit also
acts as short circuit and overload protection on high voltage output. To reactivate high
voltage, Voltage Control must be returned to zero, and Reset switch must be pressed to
clear Current Trip circuit.
 2-2
CONTROLS AND INDICATORS
11. Reset. Reset lamp illuminates to show that current trip circuit has tripped. High voltage
circuits are deactivated. Momentary Reset switch must be pressed to extinguish Reset
lamp to allow high voltage to be reapplied after returning Voltage Control to zero.

12. VOLTMETER RANGE SELECTOR. Rotate to appropriate setting for test voltage.

13. MAIN POWER INDICATOR. Lights to indicate that power is available for testing.

14. MAIN POWER CIRCUIT BREAKER. Press I to connect power, Press O to disconnect power.

15. F1. Control Power Fuse

16. THERMAL OVERLOAD. Circuit breaker protects primary of high voltage transformer. If
circuit breaker trips, turn High Voltage Off and return Voltage Control knob to zero before
resetting.

17. External Interlock. If desired, remove jumper from connector and replace with cable
connected to contact(s) that must be maintained closed during testing. Some examples
include footswitch, dead man switch, gate interlock, panic button, etc. Only non-energized
contact devices may be used. This is a series 120 VAC circuit that must be maintained
closed for high voltage to be activated, or maintained.

High Voltage Unit (Refer to Figure 2.)

1. J5. Interconnect cable from controls connects here.

2. Guard Terminal (GRD). Connect to Ground (GND) terminal (#3) for guard mode operation.
Connect currents that need to bypass the currentmeter to this point. Low potential side of
specimen must be isolated from ground to use this mode.

3. Ground Terminal (GND). Connects to Facility Ground. See (#2 and #4).

4. Return Terminal (RTN). Connect to Ground (GND) terminal (#3) for normal operation.
Always connect low side of test specimen to this point. This is the metered connection point
for current.

Note: Further explanation of terminals occurs later under Return-Ground-Guard Section.

5. Grounding Clip-The grounding clip must always be connected from the Ground (GND) post
to either the Return (RTN) post or the Guard (GRD) post. Do not operate the unit with the
clip removed or disconnected.

6. High Voltage Bushing Well. High voltage output cable connects here. Opposite end
attaches to the high potential side of the test specimen.
 J5
VOLTAGE (kV DC) CURRENT
AC INPUT

206043−1

R
VOLTAGE RANGE CURRENT RANGE
EXT. INTLK.
20 kV 160 kV 200 uA 2 mA
20 uA 10 mA

206430−1
PHENIX
TECHNOLOGIES
Accident, Maryland, USA

20 40 60 80
THERMAL 0 100
F1 OVERLOAD CHARGING CURRENT VOLTAGE CONTROL
% OF RANGE
PHENIX
TECHNOLOGIES

50
CURRENT
TRIP 40 60

2
MAIN POWER
30 70

I MIN MAX
HIGH VOLTAGE
20 80

0 ON HV HV
RESET
ON OFF
10 90

! CAUTION
0 100

ZERO START

120 kV DC DIELECTRIC TEST SET MODEL 4120−10

FIGURE 1
2-3
 2-4

FIGURE 2

DANGER

HIGH VOLTAGE

206036−1

J5 GUARD GND RETURN

1 2 3 4 5
 3-1
ELECTRICAL SET-UP

1. Locate the desired location for the test set. Prepare the main power input cable for plugging
into the proper facility power (i.e., 120 volts AC or 220 volts AC). Leave plug unconnected at
this time.

High Voltage Connection

WARNING: Main Power switch on front panel must be in the OFF (O) position before
proceeding. Make sure Test object is de-energized and discharged.

1. Place currentmeter in desired mode of operation by connecting the jumper clip between
Return (RTN) and Ground (GND) or Guard (GRD) and Ground (GND) binding posts. The
normal connection is between Ground and Return. See Section on Return-Ground-Guard for
more information on this connection.

2. Connect the Ground (GND)” connection to facility ground using the ground test lead provided.

3. Connect the low potential side of test specimen to terminal labeled Return (RTN). Use red
test lead provided.

4. Connect the high voltage output cable to HV unit re-entrant bushing and to high potential side
of test specimen. Keep shielded part of high voltage cable away from test specimen high
voltage points.

5. Connect cable from controls to High Voltage unit

6. Connect the input main power cable to appropriate power source. Check Technical
Specifications tag on unit, for proper input voltage.

7. Read and understand entire operating instructions before applying power.

CAUTION: Improper contact with the test leads on this equipment can cause harmful or
fatal electrical shock. Do not touch test leads while a test is in process. This equipment
should only be operated by someone familiar with high voltage testing and safety
procedures.
 4-1
OPERATING INSTRUCTIONS

Caution: This equipment should only be operated by personnel familiar with high voltage
testing and safety procedures. Improper operation may result in injury or death and can
cause damage to the unit or test object.

1. Ensure proper electrical set-up has been performed.

2. Check that the Voltage Control dial is set to "0" (Zero Start position).

3. Select the proper voltmeter range and currentmeter range.

High Voltage Applied

4. Turn on the Control Main Power switch. The Power On lamp will illuminate.

5. Momentarily press the HV On pushbutton. The high voltage will be applied to the cable and
the HV On switch lamp will illuminate. (Zero Start and External Interlock Loop conditions
must be met.)

6. With HV On, rotate the Voltage Control dial and watch the Output Voltmeter and Output
Currentmeter until desired levels are reached.

Note: When testing samples that are largely capacitive in nature, it may be necessary to
place currentmeter range switch in the X1K position. Operator must then slowly raise output
watching the currentmeter and allowing the test sample to "charge up".

7. Record data, if desired, and lower the Voltage Control to Zero after testing is completed.
Use Discharge or Grounding stick to discharge specimen or allow voltage to return to zero.
Press HV Off button; high voltage will be shut off and the HV On switch lamp will extinguish
and the High Voltage Off/Ready lamp will illuminate.

Overcurrent Failure

8. If an overcurrent situation occurs (output current exceeds Overcurrent Trip set point), the
overcurrent relay will activate, deenergizing the test set (High Voltage Off). To regain high
voltage the Reset button must be depressed and, the Voltage Control dial must be returned
to zero. Press the HV On button momentarily to turn High Voltage back on.

9. After all testing is completed; turn off the front panel Main Power switch. Remove the input
power cable from the facility power input.

10. Make certain that the test specimen is totally discharged and grounded before
removing test cables.
 4-2
OPERATING INSTRUCTIONS

Calculating Meg-Ohms The Impedance of a test object can be determined by the formula :

V/I=R where voltage in Volts divided by current in Amps equals Resistance in Ohms.

Resistance divided by 1,000,000 then equals Meg-Ohms: R/1,000,000=Meg-Ohms

When voltages are in Kilovolts and currents are in Milliamps, a more direct method is to directly
divide Kilovolts by Milliamps to obtain the result directly in Meg-Ohms.

KV/mA=Meg-Ohms

Example: 10kv divided by 2mA equals 5Meg-Ohms

Many times though, the current will be in micro amps. In this case, micro amps must first be
converted to milliamps, or the formula must be changed to accommodate micro amps.
Micro amps can be converted to milliamps by dividing by 1,000.
uA/1,000=mA Example: 50 uA/1,000=0.05mA. The result can now be used directly in
the above formula. 10kV divided by .05mA equals 200Meg-Ohms

An alternate method is to use the formula; Kilovolts divided by Microamps multiplied by 1,000
equals Meg-Ohms.

KV/uA x 1,000=Meg-Ohms

Example: 10kV divided by 50uA times 1,000 equals 200Meg-Ohms

 5-1

RETURN-GROUND-GUARD CONNECTIONS

The unit contains a currentmeter feature useful in measurement of different current sources.

1. Return Mode (RTN) (Grounded Return Mode)

This is the standard measurement configuration. The Ground jumper is installed between the
Ground (GND) post and the Return (RTN) post. The low potential side of the test specimen is
connected to Return. It can initially be isolated from ground or tied to ground. When it is
connected to Return in this mode, it will be grounded through the Ground jumper if it was
initially isolated from ground.

If the low potential side of the test specimen will not or cannot be isolated from ground, this
hookup mode must be used. Any connections made to Guard must be isolated from ground
in this mode and will bypass the currentmeter. All currents to Ground and Return will be
measured in this mode.

2. Guard Mode

In this mode, the Ground jumper is connected to the Guard post and Ground post. The low
potential side of the test specimen must be isolated from ground and connected to the Return
post. Only current to the Return post will be measured by the currentmeter. Any stray
leakage currents to ground or from sources connected to Guard will bypass the currentmeter
and not be measured such as stray leakage currents to ground, stray currents to shields or
housings tied to Ground or Guard, etc. In this mode, the low potential side of the specimen
must be isolated from ground. If the low side of the specimen can not or will not be isolated
from ground, this mode can not be used to accurately measure current flow.

NOTE: Do not operate unit with the ground jumper removed or not connected to either
Return or Guard. Make sure the Ground post is connected to a good earth ground. See
connection diagrams on next pages.
 5-2
RETURN MODE SETUP
LOW POTENTIAL SIDE OF TEST SPECIMEN MAY BE GROUNDED OR UNGROUNDED.

HV Output Test Specimen High Side

Test Specimen
DANGER

HIGH VOLTAGE

Note that jumper is between RETURN and GND

206036−1

J5 GUARD GND RETURN

Red Return Lead

Test Specimen Low Side
Control Interconnect
Facility Ground

GUARD MODE SETUP

Low potential side of the test specimen must be isolated from ground to use Guard Mode.

HV Output Test Specimen High Side

Test Specimen

DANGER

HIGH VOLTAGE

Note that jumper is between GUARD and GND

206036−1

J5 GUARD GND RETURN

Red Return Lead

Test Specimen Low Side
Control Interconnect
Facility Ground

ATTENTION:
DO NOT OPERATE WITH THE "GUARD GROUND RETURN" JUMPER REMOVED.
JUMPER MUST ALWAYS BE INSTALLED!!!

THE GROUND TERMINAL ON THE HIGH VOLTAGE TANK MUST ALWAYS BE

CONNECTED TO A GOOD EARTH GROUND.
 5-3

Simplified Electrical Diagram

RETURN MODE (STANDARD MODE)

HIGH VOLTAGE CONNECTION

HV
OUT

HV
UNIT TEST
OBJECT
INTERNAL
CURRENT
METER
RETURN (METERED)

A GROUND

GUARD (BYPASS)

GUARD MODE

HIGH VOLTAGE CONNECTION

HV
OUT

HV TEST
UNIT
OBJECT
INTERNAL
CURRENT
METER
RETURN (METERED)

A GROUND

GUARD (BYPASS)
 6-1
CALIBRATION
Caution: Calibration should only be done by persons familiar with High Voltage testing and
safety procedures.
All calibrations have been done at the factory. Periodic calibration of the output voltmeter and
output currentmeter should be done approximately every six months.

NOTE: Refer to Electrical Diagram Section for schematics pertaining to the model number of
your test set.

Locating the Calibration Adjustments

The calibration points are shown in the following diagram.

R1
R101 R103 R235 R201 R202 R203 R204 R2
20kV
10% 110% Range 20mA 2mA 200uA 20uA 120kV
VM
Ovld Ovld Ovld CM CM CM CM VM

1. Output Voltmeter

Connect a precision high voltage voltmeter across the output to ground on low range. Raise
the output to approximately 80% of range. Adjust the reading on the panel meter (M1) by
means of potentiometer R1 to a corresponding reading. Check Linearity and calibration at
various other main points of the range such as 20%, 40%, 60%, 100%. Repeat for High
range, adjusting R2.
 6-2
CALIBRATION

2. Output Currentmeter
It is necessary to connect adequately rated High Voltage loads (isolated from ground) to the
high voltage unit that will allow each full range current to be drawn at approximately 15% or
higher output voltage. This allows sufficient resolution to adjust current levels.

Place Binding Post Configuration in GUARD MODE. (Jumper clip is installed between
Guard and Ground posts.)
Connect a precision ammeter between the low potential side of the appropriate high voltage
load and the Return post. Select the low current meter range (20uA). Raise the output to
approximately 80% of range (16uA). Adjust the reading on the panel meter (M1) by means
of potentiometer R204 to the corresponding reading of the standard meter. Repeat for
200uA, 2mA, and 5mA ranges; adjusting R203, R202, and R201 respectively. (High Voltage
load will need to change when changing range).

An optional method is to use DC current injection between “RTN” and “GND” (Guard
Mode). If using this method, do not turn High Voltage ON!

3. Overcurrent

This calibration should not need adjustment (factory adjusted). If the overcurrent circuit is
out of calibration, perform the following steps.

a. With unit off, short the output terminal to ground through an appropriate currentmeter.
(A High Voltage Load will give better resolution and make calibration easier and more
accurate. Minimum recommended resistance: 100K ohm, 100 watt.).

b. Set the Current Trip potentiometer on the front panel to "1 and the current range
switch to 5mA.

c. Turn on HV On and adjust the output current slowly until 10% of rated current (.5mA)
is displayed on the currentmeter.

d. Adjust potentiometer R101 until the Reset lamp illuminates and high voltage is shut
off.

e. Set the Current Trip potentiometer on front panel to "11".

f. Turn on HV On and adjust the output current slowly until 110% of rated current (22mA)
is displayed on meter.

g. Adjust potentiometer R103 until the Overload lamp illuminates and high voltage is shut
off.

h. Repeat steps "B" through "G" as necessary until both settings are calibrated.

4. Range Overcurrent. R235 sets an overcurrent for the ranges and should be set to trip at
approximately 112% of 2mA range.
 7-1
TROUBLESHOOTING
General

If the controls do not operate properly after having been used according to the instructions, the
following hints may help.

• Check main facility input power to the test set.

• Check indicating lamps. (Spare lamps are available through Phenix Technologies.)
• Check fuse-F1.
• Check all external plug connections on the test set.

Specific Problems, Refer to appropriate electrical diagrams.

1. High Voltage cannot be turned on?

• Voltage Control dial is not in Zero Start position.

• External interlock circuit open.
• Current Trip setting too low, or needs reset.
• Current trip circuit damaged, won’t reset, try replacing U101 (LM311N)
• Faulty HV On switch, faulty HV Off switch.
• Relay K1 dislodged or faulty.

2. Voltage control inoperable?

• Tripped or faulty Thermal Overload.

• High voltage is not on (see number 1 above).
• Faulty Variable transformer "T1".
• Faulty High Voltage tank assembly.

3. Over current inoperable?

• Faulty U101 (LM311N).

• Faulty DC Power Supply circuit.
• Defective over current relay K101.
• Faulty R7 over current trip potentiometer.

4. Currentmeter inoperable?

• Improper connection of GUARD/GND/RETURN jumper (J1) for mode of operation.

• Improper connection of test specimen.
• Faulty U201 or U202 (LM348).
• Meter damaged.
• Faulty currentmeter range switch SW5.
• Faulty connection in currentmeter circuit.
• Faulty DC Power Supply Circuit.

5. Voltmeter inoperable?

• Meter damaged.
• No high voltage present at output.
• Faulty connection in voltmeter circuit.

6. No output voltage from high voltage section?

• Defective metering circuit.

• No input to voltage regulator section, possible problems with K1 relay or Thermal
Overload.
• High Voltage Cable shorted to shield of cable.
• Faulty High Voltage Unit.
 8-1
STORAGE OF EQUIPMENT

If the equipment will be stored for a prolonged period, the following precautions are
recommended.

1. The equipment should be covered and kept in a warm, dry environment (95% maximum
humidity, 5 to 40° Celsius).

2. In no case should the test unit be stored outdoors (unless previously specified in the original
purchase agreement).
 9-1
CIRCUIT DIAGRAM SYMBOLS
SYMBOLES POUR SCHEMA DE CIRCUIT
SYMBOLE ZU SCHEMA

REF SYMBOL DESCRIPTION DESCRIPTION BEMENKUNG

A Amplifier Unite d'amplificateur Verstarker

ARSR Surge Arrestor Parafoudre Ueberspannungsableiter

C Capacitor Condensateur Kondensator

BSHG Bushing Tranversee Durchfuehoung

C Electrolytic Capacitor Condensateur electrol Eleckrolytik kondensator

F Fuse Fusible Sicherung

CT Current Transfomer Transformateur de Stromtransformer
Courant
CB Circuit Breaker Interupteur Unterbrecher

K Relay, Contactor Relais, Contacteur Relais, Schutz

L Inductor Self Drossel, Spule

MOT Motor Moteur Motor

MOV Movistor Parafoudre Movistor

NE Neon Parafoudre Ueberspannungsableiter

LP Lamp, Indicator Lampe Meldeleuchte

R Resistor Resistance Widerstand

R Variable Resisitor Resistance Variable Widerstand

T Transformer Transformateur Transformer

TB Terminal Block Borne Losbare Klemme

X Connector Prise de Courant Steckverbindung

Relay Contact Contact Normalement Schlierskontakt

K Normally Open Ouvert

K Relay Contact Contact Normalement Oeffnungskontakt

Normally Closed Ferme

K Changeover Contact Contact de Umschaltkontakt

Changement
Shielded Wire Cable blinde Abgeschirmetes Kabel

TR Transistor Transisteur Transistor

M Analog Meter Insrument Analogue Analog Meter

D Diode Diode Diode

Z Zener Diode Zener Zener

SCR Thyristor Thyristor Thyristor

SW Normally Open Interrupteur Normalement Schrittschalter

Maintained Switch Maintenu Ouvert (Schliesser)

SW Normally Closed Interrupteur Normalement Schrittshalter

Maintained Switch Maintenu Ferme (Oeffner)

SW Normally Closed Interrupteur Normalement Druckschalter

Momentary Switch Ferme Momentanement (Oeffner)

SW Normally Open Interrupteur Normalement Druckschalter

Momentary Switch Ouvert Momentanement (Schliesser)

DP Current Overload Dispositif De Sur UeberstromschutzEinheit

Device Intensite
 10-1
4120-10 RECOMMENDED SPARE PARTS

Phenix Technologies recommends that the customer purchase and stock the following parts for
normal maintenance of the unit. The recommended quantity should be sufficient to support the
unit during normal operation.

If the unit will be operated at an isolated site for an extended period or will be subjected to unusual
stresses, a larger quantity of parts should be stocked as spares. In such cases, contact Phenix
Technologies for a recommendation.

Current prices may be obtained by contacting the Parts Ordering Department at Phenix
Technologies.
Computer Recommended
Part Name Number Quantity

Digital Panel Meter, 3 ½ Digit LCD, 2V (M1,2) 1506400 1

Analog 1 ½” Charging Current Meter (M3) 1501016 1

Lamps, 60 V, EAO 1420150 5

EAO Momentary – 1 POLE Switch (SW 2,34) 1860120 1

Limit Switch (SW7) 1866005 1

LM311N Comparator IC (U101) 1794493 4

OP400GP OP AMP (U201,U202) 1794105 2

Relay, Control (K1) 1700610 1

Fuse, 1 A, 250 V, (F1) 1603601 1

Power Input Cord 1077167 1

Binding Post- RED 1351102 1

Binding Post - GREEN 1351103 1

Binding Post - WHITE 1351104 1

High Voltage Cable Assy. 30070007 1

Return Cable Assy. 30080010 1

Ground Cable Assy. 30080011 1

Interconnect Cable Assembly 30160002 1

 10-2
4120-10 PARTS LIST
ITEM DESCRIPTION QTY PART NO.
CONTROLS
C1, 4 47uF 20V Capacitor 2 1096510
C2, 3 1 uF 50V Capacitor 2 1094051
C5, 6 .033 uF 630v Capacitor 2 1093300
CABLE-INTERCONNECT 25 FT. INTERCONNECT CABLE ASSY. 1 30160002
CASE HD POLY CASE 1 2100507
CB1 CIRCUIT BREAKER, 10 AMP, 2-POLE 1 1601314
CB2 7A PUSHBUTTON THERMAL OVERLOAD 1 1601420
CORD INPUT POWER CORD 1 1077167
F1 FUSE, 1 AMP 1 1603601
F1 FUSE HOLDER 1 1603920
J5 CONNECTOR, 14 POS 1 1151156
J5/SX1 CONTACT PINS, FEMALE 7 1151174
K1 RELAY-3 POLE 120 VAC COIL 1 1700610
K101 RELAY – 2 POLE12 VDC COIL 1 1701033
LP1 LENS CLEAR LENS EAO 1 1422153
LP2 LENS LENS, RED EAO 1 1422150
LP3 LENS LENS, GREEN EAO 1 1422151
LP4 LENS LENS, BLUE EAO 1 1422148
LP1 SOCKET LAMP SOCKET EAO 1 1423300
LP1-4 LAMP 60V EAO 4 1420150
M1, M2 METER-DIGITAL, 3 ½ DIGIT LCD 2 1506400
M1-CM METER PROTECTION BOARD ASSY. 1 31126500
M2-VM METER PROTECTION BOARD ASSY. 1 31126502
M3 METER-ANALOG 1 ½” 1 1501016
MOV1 MOVISTOR, V130LA10A 1 1606100
P1 POWER INPUT RECEPTACLE 1 1153228
PCB Assy. PCB1257-4120-10 CONTROL BOARD 1 31125717
PCB PCB 1223 (MTG FOR R1-R5) 1 1112231
R1, R2A,B RESISTOR, 750 OHM, .5W, 1% 3 1711900
R3A,B RESISTOR, 7.5K OHM, .5W, 1% 2 1712150
R4A,B RESISTOR, 75K OHM, .5W, 1% 2 1713500
R5A,B RESISTOR, 750K OHM, .25W, 1% 2 1725050
R6A RESISTOR, 39K OHM, .25W, 1% 1 1722618
R6B RESISTOR, 1.5 MEG OHM, .25W, 1% 1 1735140
R7 POTENTIOMETER, LINEAR, 10K, 2W 1 1761098
R7 DIAL BLACK STATOR 1 1355905
R7 DIAL 0-11 NUMBERED DIAL 1 1355910
R7 KNOB BLACK KNOB 1 1355101
R7 KNOB KNOB CAP 1 1355102
R8A RESISTOR, 40.2K, .25W, 1% 1 1734040
R8B RESISTOR, 274K, .25W, 1% 1 1734274
SW1 ROLLER CAM MICROSWITCH 1 1866005
SW/LP 2,3,4 SWITCH, PUSHBUTTON, MOMENTARY, 1-POLE 3 1860120
SW5 SWITCH, ROTARY, 3 POLE, 4 POS.-SH. 1 1863042
SW6 SWITCH, ROTARY, 2 POLE, 2-6POS.-SH. 1 1863047
SW5, 6 KNOB KNOB, ¼” 2 1355310
SW7 SWITCH, ROLLER, CAM, ZERO START 1 1866005
SX1 4 PIN CHASSIS CONNECTOR 1 1151152
SX1 4 PIN CABLE CONNECTOR 1 1151162
SX1 CABLE CLAMP 1 1151186
SX1 CONTACT PINS-MALE 2 1151176
T1 VARIABLE TRANSFORMER 1 1890120
T2 (220V ONLY) STEP DOWN AUTO TRANSFORMER 1 1894433
Z1-4 1.5KE18A TRANSORB 4 1780065
Z10 1.5KE18C TRANSORB 1 1780069
 10-3
4120-10 PARTS LIST
ITEM DESCRIPTION QTY PART NO.
HV UNIT
CAP HV JACK PROTECTIVE CAP 1 1150968
C11 1Uf, 50v 1 1092098
J2 BINDING POST, GREEN 1 1351103
J1 BINDING POST, RED 1 1351104
J3 BINDING POST, WHITE 1 1351102
J1-3 SHORTING BAR 1 1351110
J5 CHASSIS CONNECTOR 1 1151158
J5 CONTACT PINS- 20 GA MALE 4 1151170
J5 CONTACT PINS – 16GA MALE 4 1151172
J5 PROTECTION COVER 1 1151196
MOV2 MOVISTOR V130LA10A 1 1606100
GND CABLE 20 FT. GROUND CABLE ASSY. 1 30080011
HV CABLE 20 FT. HV CABLE ASSY. 1 30070007
RTN CABLE 20 FT. RED RETURN CABLE ASSY. 1 30080010
SG1-2 90 V SPARK GAP 2 1605110
Z5-6 TRANSZORB 1.5KE18A 2 1780065
Z7-8 1.5 KE18C TRANSORB 2 1780069

FOR INTERNAL TANK PARTS, REFER TO HV UNIT SCHEMATIC

 J5
VOLTAGE (kV DC) CURRENT
AC INPUT

206043−1

R
VOLTAGE RANGE CURRENT RANGE
EXT. INTLK.
20 kV 160 kV 200 uA 2 mA
20 uA 10 mA

206430−1
PHENIX
TECHNOLOGIES
Accident, Maryland, USA

20 40 60
THERMAL 80
0 100
F1 OVERLOAD CHARGING CURRENT VOLTAGE CONTROL
% OF RANGE
PHENIX
TECHNOLOGIES

50
CURRENT
TRIP 40 60

2
MAIN POWER
30 70

I MIN MAX
HIGH VOLTAGE
20 80

0 ON HV HV
RESET
ON OFF
10 90

! CAUTION
0 100

ZERO START

120 kV DC DIELECTRIC TEST SET MODEL 4120−10

10-4
 11-1
PARTS ORDERING INFORMATION

Replacement parts are available from Phenix Technologies, Inc.

Changes to Phenix Technologies' products are sometimes made to accommodate improved

components as they become available, and to give you the benefit of the latest technical
improvements developed in our Engineering Department. It is, therefore, important when ordering
parts to include the serial number of the unit as well as the part number of the replacement part.
When your purchase order is received at our office, a representative of Phenix Technologies will
contact you to confirm the current price of the part being ordered. If a part you order has been
replaced with a new or improved part, an Applications Engineer will contact you concerning any
change in part number.

Your order for replacement parts should be sent to:

Replacement Parts Department

Phenix Technologies, Inc.
75 Speicher Drive
Accident, Maryland 21520
 12-1

RETURNED MATERIAL

If for any reason it should become necessary to return this equipment to the factory, the Service
Department of Phenix Technologies, Inc. must be given the following information:

Name Plate Information

Model Number
Serial Number
Reason for Return
Cause of Defect

If Phenix Technologies, Inc. deems return of the part appropriate, it will then issue an
"Authorization for Return".

If return is not deemed advisable, other inspection arrangements will be made.

NOTE: Material received at this plant without the proper authorization shall be held as
"Customer's Property" with no service until such time as the proper steps have been taken.

Your cooperation is requested in order to ensure prompt service.

 13-1
ELECTRICAL DIAGRAMS

Drawing Number Description

1. 9400124 Model Number 4120-10 Control

2. 8430124 HV DC Tank Assembly—4120-10