Appendix A - Status messages Industrial Power Corruptor Manual Rev 1.
00
Armed.
The IPC is armed and ready to perform the next event. Press one of the “Fire” buttons to trigger the event.
Bad snubber fuse
The user has attempted to start and event, but the IPC has detected that one or more of the fuses on the IGBT snubber
board is open. This board is equipped with several spare fuses. Following all safety precautions, replace the fuse.
(These fuses may operate if there are large voltage transients on the AC line, which can be caused by very large
switching inductive loads.)
Brkr is off.
The main circuit breaker, on the rear of the IPC, is off, so the IPC is unable to begin the next event. Turn the breaker on
and try again.
Connected to PC.
The IPC has successfully established communication with a Windows computer running the IPC software package.
Doing event NN.N
The IPC is doing an event – a swell, a sag, an interruption, etc. Numbers are shown for longer events – they show the
approximate number of seconds remaining in the event.
Error(NNNN)01-NN
An internal fault has occurred in the IPC. The first 4 digits show the specific fault, and the last 2 digits show the
processor that caused the fault. Check the board-to-board cables inside the IPC. Cycle the IPC’s power. If the problem
occurs again, contact the factory.
IGBT fault
One of the four main IGBT’s (insulated gate bipolar transistors) has indicated an internal fault. This can be a tempo-
rary fault, typically caused by currents in excess of 800 amps. Adjust the load or source, and try again. If the IGBT
fault is permanent, then the IGBT has been damaged, and the IGBT module must be exchanged. Contact the factory.
Internal fault N
N=2, 3, 4, 5, or 6
The Control Processor is unable to communicate with one of the other internal processors in the IPC. The Panic signal
is asserted. Cycle the IPC’s power. If the problem occurs again, contact the factory.
Invalid phase.
You have attempted to initiate an event, but the phase selection doesn’t make sense. For example, you may have set
the Test Phases to “Delta”, but have the Phase Selector knob set for “L1-N” – there is no neutral in a Delta system, so
the IPC is not sure what you want to do. Check your selection on the Test Phases display against your selection on the
Phase Selector knob.
No motor drive.
The user has pressed the main circuit breaker “On” switch on the front panel, but the motor-operated circuit breaker
option is not installed. Turn the breaker on manually.
Overheated relay
The IPC has terminated an event because one of its bypass relays has reached a programmed temperature limit. This
is usually caused by rapidly repeating several long, very high current events. Allow the relay to cool. You can monitor
its temperature on the front panel meters.
Ready.
The IPC is ready to begin the next event.
Ready. (bad freq)
The IPC is ready to perform an event, but the zero-crossings on the channel selected by the Phase Selector knob show
a frequency that is outside the acceptable range for the IPC. Use the IPC’s frequency meter to diagnose the problem,
and correct it.
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Industrial Power Corruptor Manual Rev 1.00
Ready. (no AC)
The IPC is ready to perform an event, but it cannot find any zero-crossings on the channel selected by the Phase
Selector knob. Apply power to the IPC, or choose the correct phase.
Starting up… N
The IPC is proceeding through its normal start-up process, which includes booting up all processors, coordinating their
operation, etc. Wait for the process to conclude.
Trip:Brkr motor
The IPC tripped its main circuit breaker because the motor drive option is installed, but it failed to operate the circuit
breaker in the time allowed by the IPC. This may indicate that the motor drive option was not aligned correctly when it
was installed, or it may indicate that the motor drive option is plugged in electrically but is not installed mechanically, or
it may indicate a defective motor drive option. Service is required. However, to avoid testing delays, the motor drive
option may be removed and the circuit breaker may be operated by hand.
Trip:ld L1-N V
Trip:ld L2-N V
Trip:ld L3-N V
Trip:ld L1-L2 V
Trip:ld L2-L3 V
Trip:ld L3-L1 V
The IPC tripped its main circuit breaker because the voltage between the indicated pair of terminals, on the load side,
exceeded 125% of the IPC’s voltage rating.
Trip:N-G Voltage
The IPC tripped its main circuit breaker because the voltage between the neutral terminal, on either the load side or the
source side, and the Ground (protective earth) terminal, exceeded 125% of the IPC’s voltage rating.
Trip:PE curr ld
The IPC tripped its main breaker because the current flowing in the Protective Earth (ground) terminal, on the load side,
exceeded the IPC’s programmed limit.
Trip:PE curr Pwr
The IPC tripped its main breaker because the current flowing in the Protective Earth (ground) terminal, on the IPC’s
power cord, exceeded the IPC’s programmed limit.
Trip:PE curr src
The IPC tripped its main breaker because the current flowing in the Protective Earth (ground) terminal, on the source
side, exceeded the IPC’s programmed limit.
Trip:src L1 Amps
Trip:src L2 Amps
Trip:src L3 Amps
Trip:ld L1 Amps
Trip:ld L2 Amps
Trip:ld L3 Amps
The IPC tripped its main circuit breaker because the current on at least one of the source (“src”) or load (“ld”) terminals.
There are three different overcurrent limits: an instantaneous limit, typically 600 amps; a single-cycle limit, typically
300% of the trip current setting; a 75-cycle limit, typically 200% of the trip current setting; and a 250-cycle limit,
typically 125% of the trip current setting.
Trip:src L1-N V
Trip:src L2-N V
Trip:src L3-N V
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Trip:src L1-L2 V Industrial Power Corruptor Manual Rev 1.00
Trip:src L2-L3 V
Trip:src L3-L1 V
The IPC tripped its main circuit breaker because the voltage between the indicated pair of terminals, on the source side,
exceeded 125% of the IPC’s voltage rating.
Trip:Stuck0 RLNN
The IPC tripped its main circuit breaker because the one of its internal relays, indicated by NN, failed to transition from
its “off” state to its “on” state in the time allowed by the IPC. The relay may be defective, or it may need mechanical re-
alignment. Service is required. Contact the factory.
Trip:Stuck1 RLNN
The IPC tripped its main circuit breaker because the one of its internal relays, indicated by NN, failed to transition from
its “on” state to its “off” state in the time allowed by the IPC. The relay may be defective, or it may need mechanical re-
alignment. Service is required. Contact the factory.
Turn Brker on.
If it is safe to do so, turn the main circuit breaker on. It is located on the back of the IPC, in the center.
Turning Brkr on.
This message only occurs if your IPC has the motor-operated circuit breaker option. It shows that the motor is in the
process of turning on the main circuit breaker, on the back of the IPC.
Waiting for PC.
The IPC is ready to begin communication with a Windows PC running the IPC software package. (Under certain
circumstances – after a lengthy communication interruption — this message may appear even when the IPC and the PC
are communicating. Press the “disconnect” button on the IPC software package, then reconnect.)
Xfrm NNNC ovrtemp
The IPC’s internal transformer is NNN degrees C over its programmed temperature limit, probably due to a rapid
sequence of lengthy, high current sags or swells. Allow it to cool. It will automatically clear this error message when it
is no longer over its temperature limit.
B - Software error messages
“Your computer is running too slow for once-per-second power readings. The readings will be updated as rapidly as
possible.”
Most recent event terminated due to no setup”
MostRecentEventOutcomeStrings(2) = “Most recent event terminated due to panic”
MostRecentEventOutcomeStrings(3) = “Most recent event terminated due to blown snubber fuse”
MostRecentEventOutcomeStrings(4) = “Most recent event terminated due to IGBT fault”
MostRecentEventOutcomeStrings(5) = “Most recent event terminated due to overheating relay”
MostRecentEventOutcomeStrings(6) = “Most recent event terminated because event was canceled”
MostRecentEventOutcomeStrings(7) = “Most recent event terminated because no zero crossing was found”
Command N was rejected by processor N
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Industrial Power Corruptor Manual Rev 1.00
Appendix B - Specifications - general
General specifications
Voltage Sag/Dip and Swell testing per SEMI F47, IEC 6100-4-11, CBEMA, ITIC, MIL
STD, FAA, SAMSUNG, and other international standards. With Power Flow Analysis
Functional
option, also performs to SEMI E6, current inrush testing, harmonic current testing, and
more.
Designed to meet U.S. and Canadian safety standards, CE certification requirements,
Agency approvals FCC requirements. Fully meets requirements of IEC-1010, and IEC-61000-4-11. Fully
meets requirements and recommendations of SEMI F47.
Rated as Class I equipment. Rated for Installation Category II (local level, appliances,
Equipment ratings portable equipment). Rated for Pollution Degree 2 (Normally, only non-conductive
pollution occurs.)
Indoor use. Altitude up to 2000 m. Temperature between 5°C and 40°C. Max relative
Operating environment humidity 80% for temperatures up to 31°C decreasing linearly to 50% relative humidity at
40°C.
Instrument Power 100 to 240 Vac (±10%), 50/60 Hz, 4 Amps max.
Industrial Power Corruptor program for setup/operation of IPC, viewing real-time and
downloaded data, and collecting information for test report generation. With Power Flow
Analysis option, software includes vector scope, real-time oscilloscope, and real-time
Software
spectrum analyzer. ChannelScope II software for viewing, zooming, scrolling, and
synchronizing power waveforms. FlowScope software for graphing and examining power
flow over time. Requires PC with Windows 98 or XP.
Communications Front panel RJ-45 jack for serial connection to PC.
19 inch rack-mount unit in rugged polyethylene case measuring 21in. W x 11in. H x 30
Physical
in.L (50cm x 28cm x 76cm). 130lb (59Kg)
Permissible Test Conditions
100 – 480 Vrms, 50 or 60 Hz, 1-phase or 3-phase. Voltage is limited to 240Vrms on
Voltage Range
some model numbers.
Single phase or 3-phase (Y or delta) connection to unit. Voltage dropout testing can occur
Voltage Configuration on all phases simultaneously. Voltage sag and swell testing on a single pair of phases, or
phase to neutral. Phase selection for events is done with front panel dial.
Up to 200 Amps per phase continuous, depending on model number. 600 Amps peak.
Load Current
Front panel dial for user selection of current trip point.
Voltage Sag / Swell Testing
0% to 125% of nominal voltage in 2.5% steps. User can select 0% sag to be either high
Magnitude
impedance or low impedance.
Duration User selected duration from 0.1 cycles to 34 seconds in 0.1 cycle steps.
Magnitude/Duration Margin A front panel switch allows quick 5% or 10% increase in event magnitude and duration.
Phase Angle 0 to 359 degrees in 1-degree steps.
Manual front panel “Arm” and “Fire” switches locally trigger event. Rear panel BNC
Event Trigger Input/Output connectors provide bi-directional 24V logic level (falling edge) trigger output and input
capability.
As well as manual event configuration, the user can semi-automatically step through a
Semiautomatic Sequencing
industry standard recipe on a single or 3-phase system.
High speed, gapless switching, IGBT package with patent-pending override design for
Switching Method
long duration events.
Three Phase Voltage Dropout and Current Inrush Testing
Magnitude Full voltage and current rating of Industrial Power Corruptor
Max instantaneous current ±1 000A instantaneous
recording
Interruption Duration 0.3 to 34 seconds.
0 degrees to 355 degrees in 5 degree steps. Referenced to user selected voltage
Phase angle
channel.
Switching Method Mechanical relays, with calibrated switching times to 0,4 milliseconds
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Industrial Power Corruptor Manual Rev 1.00
Data Acquisition
Internal Analog Input 13 internal voltage channels, 6 internal current channels, 3 protective earth current
Channels monitoring channels.
External Analog Input 3 front panel ±600V (AC or DC) channels, 6 front panel ±100V ( AC or DC) channels.
Channels
Three front panel meters (including min. and max. values) can be selected to display any
Analog Input Viewing data acquisition channel in real time. Alternatively, these channels can be monitored
using a connected PC and the software provided.
15 bits equivalent per individual sample on 1000V / 1000A channels, 12 bits per individual
Resolution
sample on other channels, 16 bit equivalent for average and RMS measurements
Guaranteed accuracy ±1,0% FS on voltage and current. Typical accuracy ±0,25% FS
Accuracy (voltage and current), ±0,5% FS (power parameters), ±1,0% FS (harmonics), ±1°
(between any voltage and current channel)
Sampling Rate 0.8 KHz to 7.68 KHz
With Power Flow Analysis option, software phase-lock to user-selected voltage channel –
Phase lock
for precision harmonic and power flow calculations
Standard accessories included
CD-ROM Includes the latest software and diagnostics for the IPC, and the IPC User’s Manual
Power cord IEC-compatible power cord with North American plug
BNC caps Protective, military-style metallic caps for every front-panel BNC connector
Wire Adapters Set of 10 custom designed wire adapters required for connection to terminal blocks when
using smaller gauge wire.
Communication cable RJ-45 to DB-9 serial communication cable for connecting IPC to serial port on Windows
computer
Re-useable shipping crate Custom, furniture-grade wooden shipping crate, with high-density fitted foam inserts and
with custom padding external shock absorbing feet. Wing-nut fasteners for easy re-use. The IPC must always
be shipped in this case.
Options
Circuit Breaker Motor Customized motor operator to operate circuit breaker handle from front panel switch
Operator operation. Required for rack-mount installations. Recommended for safety enhancement.
Software package for detailed power analysis and harmonics analysis. Includes
Power Flow Analysis FlowScope graphing program for reviewing downloaded data, real-time Vector Scope,
package real-time oscilloscope, real-time spectrum analyzer. Optimized for recording power
consumption of industrial processes, including SEMI E6.
Upgrade from Increases continuous current from 25 amps to 50 amps, and increases voltage rating from
240V-25A to 240V to 480V. Requires brief return-to-factory for various internal upgrades.
480V-50A
Upgrade from Increases continuous current from 50 amps to 100 amps. Requires brief return-to-factory
480V-50A to for various internal upgrades.
480V-100A
Upgrade from Increases continuous current from 100 amps to 200 amps. Adds “combat mode” for
480V-100A to extended capabilities. Requires brief return-to-factory for various internal upgrades,
480V-200A including additional fans.
Strongly recommended. A Windows PC laptop, pre-loaded with all IPC software, and pre-
Laptop controller
configured for immediate use. Eliminates any questions about computer compatibility.
Set of 10 custom designed wire adapters for connection to terminal blocks when using
Additional Wire Adapters
smaller gauge wire.
Additional communication RJ-45 to DB-9 serial communication cable for connecting IPC to serial port on Windows
cable computer
Test lead kit Set of high and low-voltage connectors and cables for typical external data acquisition.
Custom, furniture-grade wooden shipping crate, with high-density fitted foam inserts and
Replacement shipping crate
external shock absorbing feet. Wing-nut fasteners for easy re-use. The IPC must always
with custom padding
be shipped in this case to reduce chance of damage from shock and vibration.
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Industrial Power Corruptor Manual Rev 1.00
Appendix C - Specifications - Maximum allowable current
Note 1: During a sag/swell event, there is a 600-amp instantaneous trip point. On IPC’s rated for
200 amps, this trip point can be increased to 700 amps by placing the IPC into Combat Mode.
Note 2: The time for this threshold is frequency-dependent. It is set to 75 consecutive cycles.
Note 3: The time for this threshold is frequency-dependent. It is set to 250 consecutive cycles.
Your IPC’s main circuit breaker has an internal trip curve, shown in red on the graph
above.
The firmware in your IPC watches the current on each of the three source-side phase
terminals, and each of the three load-side phase terminals. It will trip the main breaker if any
of these currents, based on average-sense RMS calibration, exceed the following limits: 300%
of the front-panel current trip point for a single cycle, or 200% of the front-panel current trip
point for 75 consecutive cycles, or 125% of the front-panel current trip point for 250 consecutive
cycles.
In addition, during a sag or swell event, the firmware will trip the main breaker if the
absolute value of any single current sample exceeds 600 amps, regardless of the IPC rating or
the front-panel current trip point. (IPC’s that are rated for 200 amps have a Combat Mode - in
Combat Mode, this limit is increased to 700 amps.)
The blue curve is controlled
In addition, the firmware will trip the main circuit breaker if any phase-to-phase or phase- by the front-panel Trip
to-neutral voltage exceeds 550Vrms (for IPC’s rated at 480V) or 300Vrms (for IPC’s rated at Current setting.
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Industrial Power Corruptor Manual Rev 1.00
240V) for a single cycle.
Here is a complete list of reasons that the IPC may trip its main circuit breaker:
1. Overcurrent on any source or load phase conductor (see discussion on previous page)
2. Overvoltage between any pair of phases, or between any phase and neutral (see discussion above)
3. Inherent breaker trip curve (see red portion of curve on previous page)
4. Current on Source Protective Earth terminal exceeds 500mA AC
5. Current on Load Protective Earth terminal exceeds 500mA AC
6. Current on power cord ground terminal exceeds 500mA AC
7. “Panic” signal asserted on rear-panel BNC connector
8. One or more of the 31 main relays is stuck on
9. One or more of the 31 main relays is stuck off
10. Red “Off” mushroom-cap button pressed on front panel of IPC
11. Instrument power is removed, or turned off
12. Throughout the IPC’s start-up sequence
13. Failure of the IPC’s internal communication network between its Control Processor and any of the other five processors.
14. (If breaker motor-drive option is installed): more that 5 seconds have elapsed while trying to change the state of the
breaker to ON without succeeding.
The following events do not trip the main circuit breaker, but always immediately terminate any disturbance event:
1. Transformer temperature exceeds 80°C.
2. Bypass relay temperature exceeds 80°C.
3. IGBT-generated fault (either IGBT overcurrent shutdown, or damaged IGBT).
4. Event cancelled by user pressing either of the two fornt-panel “Stop” switches
5. No zero-crossing found on the source side of the selected event phase, after waiting at least 25 milliseconds.
6. One or more of the fuses on the IGBT snubber board is/are blown
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Appendix D - Theory of Operation
The IPC is inserted between an AC power source and Equipment Under Test (EUT).
Power terminals on rear panel:
The power terminals are grouped into "source" and "load" terminals. Each set of terminals can accept up to three (3)
phase conductors, an optional neutral conductor, and a required protective earth conductor. All of the terminals are
internally connected to 0,5 inch bus bars. The three source-side phase terminals pass through current transformers, then
are connected directly to the main circuit breaker. Spring-loaded contacts pick up the source and load voltages. The three
load-side phase terminals also pass through current transformers. Both protective earth terminals are connected directly to
the IPC chassis, and pass through PE current sense transformers. If more than 500mA is detected on either PE terminal, the
panic signal is asserted.
Main circuit breaker:
The main circuit breaker includes three trip mechanisms: a fast magnetic trip, a slow thermal trip, and a shunt trip.
The shunt trip is activated whenever the red front panel Off button is pressed, and whenever the Panic signal is asserted for
any reason.
Phase configuration relays:
These sixteen electro-mechanical relays connect the source power terminals and the load power terminals appropriately.
They can bypass the IPC completely, or they can connect any phase, or pair of phases, as inputs or outputs to the sag/swell
generator section. These relays are also used for three-phase interruptions; the operate and release time of each relay is
factory calibrated in flash memory, so precision phase angles can be obtained.
Power up sequence:
The IPC begins by shunt-tripping its main circuit breaker, for safety reasons. Then the Control Processor, which
manages all of the firmware, boots up each of the other four processors, and loads them with their firmware. Finally, the
Control Processor turns its attention to the front-panel serial port and waits for communication from the IPC program
running on a Windows computer.
Internal communication and control:
In general, each circuit board on the IPC has at least one processor, and each processor has at least one 4-channel serial
communications chip. Serial communications was chosen to maximize reliability and to minimize noise problems. In
addition to the serial communications between processors, three open-collector negative-true signals are routed throughout
the IPC: arm, trigger, and panic. These three signals are available on BNC terminals on the rear of the IPC. The arm signal
is asserted by the Relay Processor prior to performing an event. The trigger signal goes low at the precise beginning of an
event, and returns high at the precise end of an event. The panic signal trips the main circuit breaker through its shunt-trip
mechanism.
Power for the IPC:
Power for the IPC enters an IEC connector at the bottom left of the back panel. It immediately passes through a high-
frequency noise filter, then progresses by cable to the Power Supply board. The earth connection on this cable passes
through a current transformer; if 500 mA or more is ever detected on the earth conductor, the Power Supply board asserts
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Industrial Power Corruptor Manual Rev 1.00
the Panic signal, and the main circuit breaker is tripped. On the Power Supply board, the AC supply is fused on both line
and neutral, and has MOV surge suppressors. From the Power Supply board, the AC supply then passes through a cable to
the Front Panel Board, where the IPC on/off switch is located. AC returns from this switch, on the same cable, to the IPC
power supply. The IPC has a single 24V dc power supply. 24Vdc from this supply is brought to the Power Supply Board
via a short jumper cable. Several large electrolytic capacitors on the Power Supply Board back up the 24V dc. Each
separate circuit board in the IPC has one or more switching regulators to convert the +24Vdc to +5Vdc, +/-12 Vdc, and/or
+/-15 Vdc. Some of these switching regulators provide isolation and floating signals for communication.
External communication and control:
The IPC communicates serially at 115k baud to a Windows program running on a user-supplied computer. The serial
communication ports are all floating from earth, with at least 1kV of isolation. The Ethernet port also floats with 1kV of
isolation. Three control signals are available on rear-panel BNC connectors: Panic, Arm, and Trigger. All three are open-
collector, active-low signals, weakly pulled up internally to +24V. Panic may be asserted externally by shorting the Panic
connector. Arm and Trigger may be used externally to trigger data acquisition devices.
Data acquisition:
The IPC contains many differential-input data acquisition channels. The standard full-scale ranges are ±1000V ,
±100V, and ±1000A. The channels are fully differential, and are equipped with 5kHz low-pass filters. A variety of A/D
schemes yield effective resolutions ranging from 12 bits plus sign to 16 bits plus sign. For Power Flow mode, the IPC
phase-locks its 128-sample-per-cycle to the L1-N channel (if N is not in use, this is effectively L1-PE). For Disturbance
Mode, no sampling is used. For breaker trip monitoring, average-sense RMS-calibrated 16-sample-per-cycle is used. All
offset calibration is performed in firmware, using factory-set constants stored in Flash. No gain calibration is required.
Sag/swell generation:
The IPC uses a patent-pending multiple-tap auto-transformer to generate sags and swells. The transformer has the
equivalent of taps at every 2.5% from 0% to 125%. Relays configure the taps, and connect the transformer to the appropriate
phases and neutral if necessary. A pair of IGBT switches transfer the output from the 100% tap to the selected tap, then
back to 100% tap at the end of the event. Using a patent-pending technique, the IGBT's are bypassed by electromechanical
relays during the event, to minimize power dissipation, allowing the IGBT's to be used only during the transitions. The
IGBT module has a patent-pending set of snubber circuits, which include fuses. Optically-isolated sensors detect if any of
the fuses have operated. The IGBT module also monitors its internal temperature and overcurrent limits.
Protective earth:
The IPC senses current on every protective earth terminal, and asserts Panic (i.e. trips the main breaker) if excessive
current is observed. Every element of the IPC chassis and enclosure has a dedicated, solid copper buss link connecting it
to protective earth.
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