1. BAUR BASIC CHECK .......................................................................................................................... 2 1.1. Check the serial number/version .................................................................................................. 2 1.2. Clarify failure with customer .......................................................................................................... 2 1.3. Safety ............................................................................................................................................ 2 1.4. Mechanical check ......................................................................................................................... 2 1.5. Electrical check (if possible no high voltage) ................................................................................ 2 1.6. High voltage test ........................................................................................................................... 2 1.7. Final .............................................................................................................................................. 2
2. SAFETY: ............................................................................................................................................... 3 3. COMPONENTS OF SSG: .................................................................................................................... 3 4. Open device .......................................................................................................................................... 4 5. TESTING .............................................................................................................................................. 5
5.1. MECHANICAL TEST: ................................................................................................................... 5 5.2. ELECTRICAL TEST (without High Voltage) ................................................................................. 6 5.3. ELECTRICAL TEST (High Voltage) ............................................................................................. 8 5.4. EXCHANGE ELECTRODES ........................................................................................................ 9
6. ADDITIONAL INFORMATION ............................................................................................................ 11 6.1. SSG8 Information ....................................................................................................................... 11
7. Failure List .......................................................................................................................................... 12 8. TEST REPORT .................................................................................................................................. 13 9. Final Check ......................................................................................................................................... 14 10. Datasheet ....................................................................................................................................... 14
08.08.2012 Page 2 of 14 Michael Oberjörg
1. BAUR BASIC CHECK
Things you can clarify when you are at customer’s site
1.1. Check the serial number/version
1.2. Clarify failure with customer
- History of device - What happened - What’s the present defective - What did customer try to do - When did the failure appear for the first time? - Were there any changes in the system? - What other devices may be affected?
1.3. Safety
- Be sure when working on open devices that nothing can be harmful to you - Before, while and after testing observe safety rules - Always use good grounding conditions
1.4. Mechanical check
- Can you see anything burned or broken? - Are there any loose parts, bad connections or parts missing? - Check moveable parts by pushing, pulling or turning them. - Clean the device and take a look at wear parts - A good optical check can help you find several failures before turning device on
1.5. Electrical check (if possible no high voltage)
- Turn device on and check if all lights are working (red, green, yellow, Lamps / LEDs, …) - Check turn-on/ switch-off logic (emergency off internal, external, rods, O, I, …) - Are the moveable parts working? (Discharge unit, spark gap, motors, …) - Check the voltage for the control for example at the lamps (12V, 5V,+15V/-15V, …) - Measure power supply (ex. 230V~) - Measure significant voltages as written in service manuals
1.6. High voltage test
- Test the output voltage with a voltage divider and compare it with values of the device - Check function of discharge unit - Test short circuit - Adjust device if necessary according to the service manual
1.7. Final
- Optical check again - Fit device back to system or into it’s case - Put all accessories to the device - Put a test sticker with name and date onto the device (when calibrated/adjusted) - Check function again
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2. SAFETY:
This device can be extremely harmful to the human body (heart flutter, heart trouble, heart failure, burnings, death, …)
It is important to discharge the SSG and all of its components (high voltage capacitor) before any handling inside the device
To prevent reloading of the capacitor it should be in lowest position 8kV (SSG8: 2kV) -> all of the 4 capacitors are parallel now.
Never leave the device unsupervised
When doing high voltage tests always wear a ear protector
3. COMPONENTS OF SSG:
mains switch voltage selector
discharge unit
discharge magnet
HV connection and spark gap
capacitor C5
variable transformer
CARD C
high voltage capacitor
discharge magnet DC magnet (fork over electrodes)
stroke magnet
Card D1
Card D2
HV Transformer
CARD A
Pulse Motor
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!
4. Open device
Loose the 6 screws in the front panel
Unplug the connections from the rear side of the device
Ask a teammate to have a look at the backside of the device when pulling it out of the rack to prevent damages on the cables and connectors
Use a plate (for example wood) to prevent scratches on the surface of the system
Pull out the device and remove the metal cover on top of it with the 8 screws
Device is now ready for service / maintenance
high voltage transformer CARD A
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5. TESTING
5.1. MECHANICAL TEST:
Take a look at every part inside the device (see and smell). It is important to check if there are any parts burned or damaged.
Clean the surface of the capacitor and the high voltage transformer as well as all high voltage lines
The discharge unit should be easily moveable and should touch the connections inside the brown plastic part
Clean the high voltage connection panel on the rear side (the sparks produce fine metal dust)
Take a look at the electrodes (every time of maintenance or after a year) and if necessary grind it till it looks according to the picture above or exchange these parts against new ones from BAUR
Check all connections! Bad connections will probably burn after some time -> very high current in a short period of time
burned electrode but
form is still good
> possible to grind < grinded electrode
grinded calotte
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Check all screws (be aware when you want to tighten the screws of the capacitor -> if you pull too strong the capacitor will begin to leak or will be damaged inside – connection will break inside the capacitor which is filled with oil. This round metal ducts shouldn’t turn by tightening)
Check fuses in front panel and on Card A
Moveable parts should be of easy motion. The DC fork discharge unit and the stroke magnet can be moved by hand
5.2. ELECTRICAL TEST (without High Voltage)
First unplug the cables on the little capacitor in the right corner of the device as you can see in the picture (Step 1) so no high voltage is produced.
Test the functions for switching on and turning off (Emergency off, O, external Emergency off, …) – depends on the system you are using
Measure the Voltage between the two unplugged lines from Step 1. Here you should have a voltage you can regulate with the variable transformer in the front between 0 and 230V AC (system has to be HV-ON)
from the top: discharge unit
rear side: DC fork
rear side: DC fork
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Select pulses (single and 2x automatic; time: 100-200ms) and control function.
In DC – mode the Spark Gap should close in this order: stroke magnet closes for 300-400ms – DC magnet closes (fork over electrodes) – stroke magnet opens (only hearable)
When choosing impulse mode after DC mode the spark gap will open and the fork will release the electrodes (moveable again)
When you switch on device the discharge magnet will lift the arms for discharging (typical sound). When pressing “O” the arms will fall down and you will hear a “clack”
Check function of lamps at the front panel and also the external lamps
Control switch-off-point by slowly pulling the kV-switch (> if pulled device should lit green lamp and can’t be switched on again until kV-switch is in position again)
HV-on is not possible if variable transformer is not in position 0 (HV-ready is possible)
measure the pulse - time
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5.3. ELECTRICAL TEST (High Voltage)
See picture above and plug cables from STEP1 back to the capacitor C5 (Cables from STEP1 and STEP 2 should be plugged in that way as you can see in the picture – blue to blue and black to black – otherwise this capacitor will explode or produce a short circuit).
Have a look at STEP3 (Picture Page 6) in failure case this overvoltage protection may lit up
When doing High Voltage tests watch for smoke or noise appearing from the device (prevent device from taking more damage)
Start the high voltage in position 8kV (A). Therefore use a Voltage divider at the end of the line. Set kV-Meter to 0. Adjust the Voltage at 8kV with the potentiometer behind the kV-Meter of the device (use an antistatic spray for the kV-meter – the glass may get static charge). Control the Value at 4kV. In Position 16kV Test the values 8kV/16kV and in position 32kV the values 16kV and 32kV as you can see in test report.
Make a short circuit (B) and measure the primary current (at the mains cable) of the SSG in position 8kV. Depending on the device you will get a current of 12A - 24A (see test report)
Make a short circuit at the end of the line (B) and adjust the breakdown voltage to 400-800V DC in position 8kV. Therefore raise voltage and make a single pulse. If you are higher than 400-800V DC close the gap (after discharging with a rod) from the rear side a little bit and test again
until you are within 400-800V DC. The nut for changing the fixed electrode is behind the plastic nut. Open it with a 22 flat wrench and move the electrode. When fixing the nut again be careful that you are not pulling too strong to prevent damages.
Use a spark gap and pulse in every position (single shot and automatic shots) with 8,16 and
32kV – See picture (C) (please wear an ear protector because the noise will easily reach more than 100dB)
adjusting kV-meter at 8kV
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5.4. EXCHANGE ELECTRODES
If the flashover is not between 400 and 800V it is possible that the electrodes are burned. Removing the electrodes will require opening the Equipment.
Important! Handlings inside only in Position 8kV and unit is off for about 1h! Remove the HV cable from the rear side Carefully remove now the black cable from the nut with a 22 fork spanner It is possible to remove the fixed electrode now by opening the three plastic screws that fix the triangle plate to the rear side.
Spark Gap
Power connection: pulse magnet
Ground
Micro switch Pushed by round
backelite plate and detects closed
spark gap
Moveable electrode
Fixed electrode
Hole for exchange of electrode (Fixing moveable part with screwdriver)
Thumper Magnet
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Removing the fixed electrode is quite difficult. First you need to block the moveable part with for example an Alan key like in the picture. Move the electrode until the Alan Key drops into the hole and the electrode can’t turn anymore. Turning the electrode without fixing can damage the HV connection.
The fixed electrode is blocked to the axis with a small headless screw. Open it with a small Alan Key and remove it. Now you can remove the moveable electrode without damaging the thread. Grind the electrodes or exchange them completely (depending on depth of burned material). Most important is that the shape of the electrodes is still good. When reassembling the electrodes, they should not touch each other when the gap is closed (move by hand). The distance of the electrodes should be set to 400-800V breakdown in 8kV Position. Therefore turn in single pulse a little bit up and make a breakdown to short circuit against ground (HV cable, sheath of cable and ground are connected to station ground). Make some pulses in between without a breakdown that the air in the spark gap can move and the ionized air is getting out, else the breakdown will always get lower and lower. When you reached the recommended voltage level (500V is ideal). TIP! Mark the electrode from the rear side with a pen because small changes have a big effect on the breakdown voltage! Fixing the M22 screw for the fixed electrode should be done carefully – hold the triangle Bakelite plate to prevent the plastic screws from taking damage.
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6. ADDITIONAL INFORMATION
For testing any kind of BAUR device it is necessary to use good grounding conditions. So be sure that your Earth Line is perfectly fitted to device and to station ground. The Power of the SSG 19” in surge Mode can be harmful to the user if your ground condition is bad.
If changing any part of the device it is good to take some photos before you start working
In case you need BAUR – Support, please always inform the after sales service as soon as possible (What happened? BAUR Serial Number? What is the failure? Send photos or video, …)
A good mechanical check and cleaning can help you to find most of the problems in this device
If you don’t know how to switch on a system where the devices are fitted in, ask customer, Baur Service or take a look at the circuit diagrams
When using a surge supplement SZ 1000/1600 (max. 4kV) also check the voltage. When checking without high voltage, please test that SZ is only possible when position 8kV is selected. You need to pull the rod for SZ > HV ready and HV ON (“I”) only possible if voltage selector is in position 8kV
The SSG 8 has no distance between the electrodes of the spark gap. Because of less high voltage the electrodes should touch each other to give the maximum power to the cable
When you need to exchange a high voltage capacitor take a wire and shortcut all of the capacitors before sending it to BAUR
Never use the high voltage switch when device is not completely discharged - the capacitor, rectifier cards D1 / D2 or the switch itself may take massive damages.
6.1. SSG8 Information
There are small differences between normal SSG 32 and the SSG8:
a. Voltage Steps 2,4 and 8kV b. Voltage divider looks different on Card D1 and D2 c. No distance between movable and fixed electrodes when surging Important: the two sides need to be movable – if blocked; the electrodes will get soldered after first surge.
Moveable
HV Connection core
HV Connection sheath
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7. Failure List
Symptom / Problem Check Solution
Red/green lamp stays dark Lamps, 12V supply, check fuses in front plate and on card A
exchange lamp, exchange card A, exchange fuses
No high voltage is produced Check point 5.2 Ok -> capacitor/transformer defective No 0 - 230V at step 1 check card A, check variable transformer, check thermal fuse in front plate
Strange sound from capacitor Card D1, D2 for burned parts, oil coming out from the capacitor
D1, D2 defective, capacitor defective
kV-Meter no indication or get stuck
High Voltage output kV-Meter defective, no high voltage produced
HV switch used when device was not completely discharged
Burned contacts Voltage selector damaged or function still ok
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8. TEST REPORT
SSG 1500 Type of SSG
Instrument no: Serial number on rear side 10 725 XX XXX
Test passed on: XX . XX . XXXX
Tested by: Oberjörg Michael
Power supply: Special Voltages written here 240 V; 50 / 60 Hz
Serial number of high voltage capacitor: You will find this number on the capacitor
Position HV-switch Value kV - meter SSG Value voltage divider Tolerance
8 kV 4,0 kV 4,03 kV 0,2 kV
8 kV 8,0 kV Adjusted value:8,00 kV 0,2 kV
16 kV 8,0 kV 8,02 kV 0,4 kV
16 kV 16,0 kV 15,99 kV 0,4 kV
32 kV 16,0 kV 15,97 kV 0,8 kV
32 kV 32,0 kV 31,99 kV 0,8 kV
Maximum current at short circuit in position 8 kV: depending on the used SSG I pr = 21,85 A
Remarks:
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9. Final Check
Every cable is connected inside the device
Capacitor and HV-transformer cleaned
Spark gap is cleaned and electrodes are grinded
Cards are fixed, no screws are missing
Device is working and can be fitted back into the system
Put device back into it’s rack – take a look at point 4 Open device Ask a teammate for help to take a look at the rear side (cables, other devices, connectors) Everything should be of easy moving
Control the HV-cable if there are any damages
Make a final test (let customer do a test with his system to see everything is ok or not) Including tests with SZ 1000 or SZ 1600
10. Datasheet
SSG 1100 SSG 1500 SSG 2100 SSG 3000
mains supply 110-120 / 240 V with external autotransformer, 220-230 V
110-120 / 240 V with external autotransformer, 220-230 V
110-120 / 240 V with external autotransformer, 220-230 V
110-120 / 240 V with external autotransformer, 220-230 V
