User Manual

Franklin Tester FT-300

GOPAL ELECTRONICS
Gopal Electronics, Plot-11, Part-3,
Phone: 9016107635 Amarnath Estate Naroda - 382330,
Email: [email protected] Ahmedabad, Gujarat, India
 Table of content

Table of content .................................................................................................................................................... 2

Preface ..................................................................................................................................................................1
A1.Purpose of this manual ............................................................................................................................ 1
A2.Who should use this manual? ..................................................................................................................1
Introduction ........................................................................................................................................................... 2
Safety information ..........................................................................................................................................2
Accessories ...........................................................................................................................................................3
Principal of operation ............................................................................................................................................ 4
Button Layout and functionality ............................................................................................................................ 5
Testing procedure ................................................................................................................................................. 6
1. Connection of compressor ........................................................................................................................ 6
2. Power on ....................................................................................................................................................6
2. Meter ready ................................................................................................................................................6
3. Taking reading of surface A ...................................................................................................................... 6
4. Taking reading of surface B ...................................................................................................................... 8
Testing caution: ............................................................................................................................................. 9
Maintenance and Troubleshooting ..................................................................................................................... 10
1. Accuracy Verification Test .......................................................................................................................10
2. Cleaning the Brass Contacts ...................................................................................................................10
3. When to Send for recalibration ................................................................................................................10
Routine Maintenance Tips ...........................................................................................................................10
Technical specification ........................................................................................................................................11
Preface
Thank you for purchasing Gopal Electronics Franklin tester FT-300. This user’s manual contains useful
information about the functions, operating procedures, and handling precautions of the instrument. To ensure
correct use, please read this manual thoroughly before beginning operation.
After reading the manual, keep it in a convenient location for quick reference whenever a question arises
during operation.

A1.Purpose of this manual

This manual describes the general features, usage and specifications of the Franklin tester FT-300 .This
manual contains most of the information required for proper installation and general use of FT-300 Franklin
tester. To achieve maximum capability and to ensure proper use of the instrument we recommend to read this
manual thoroughly before operating the instrument.

A2.Who should use this manual?

This manual is intended for those operators who wants to test surface insulation resistance of coated
electrical steel sheets, punched parts and individual samples according to the testing procedure mentioned in
BIS:649 standard.

NOTE:-

According to the standard even with the best practices in design, instrumentation, maintenance, and operation,
the repeatability and reproducibility of the test method are greatly influenced by the nature of the surfaces of
the test specimens. Hence it is not considered possible to state meaningful values for repeatability and
reproducibility that are universally applicable.
While every precaution has been exercised in the compilation of this document to ensure the accuracy of its
contents, Gopal Electronics assumes no responsibility for errors or omissions. Additionally, no liability is
assumed for any damages that may be the result the use of the information contained within this Publication.

1
Introduction
The Gopal Electronics FT-300 Franklin Tester is a testing instrument designed for accurate measurement of
surface insulation resistivity (SIR) of flat-rolled electrical steel. This tester is developed in accordance with
BIS:649 standard, ensuring compliance with globally recognized testing procedures.
Surface insulation resistivity is a critical parameter for assessing the quality and consistency of insulating
coatings applied to electrical steel. The FT-300 provides a reliable and user-friendly platform for both
production quality control and laboratory evaluation, offering dual-mode (manual/automatic) drilling, regulated
DC power supply, and microcontroller based measurement system.
The FT-300 is suitable for use in steel manufacturing plants, transformer core manufacturing units, quality
assurance labs, and academic research institutions involved in electrical steel testing.

Safety information
FT-300 Franklin tester should be used by skilled people who have read and understood this user Guide.
Working with FT-300 involves the usage of pressure hydraulics, be sure to know how to test the metal sheets
and how to safely connect/disconnect pressure hoses.
General warnings
 Do not use FT-300 in any other way than as described in this user Guide.
 Do not use the instrument if it is not in its normal condition.
 Do not apply pressure and drilling on surface plate without specimen.
Caution
 To prevent damage to the display, do not use sharp objects on the screen.
 Before you start the test, make sure that you have the understanding of the instrument. Read this manual
thoroughly before using FT-300.
 Follow good engineering practice at all times.

2
Accessories
Each FT-300 unit undergoes thorough inspection at the factory to ensure it is free from scrapes, scratches,
and is properly calibrated before shipment. Upon receipt, the recipient is advised to carefully examine the
instrument for any signs of damage that may have occurred during transit. If any visible mechanical damage is
observed, the package appears incomplete, or the unit does not function as specified, please inform us (or the
dealer that provided you the unit) as early as possible. The standard accessories included are as follows.

Description Qty
Calibration certificate 1
FT-300 Catalog 1
FT-300 User Guide 1
Mains cord 1
200mm x 100mm Copper plate 1
Compressor unit (optional) 1

3
Principal of operation
This test method covers a means of testing the surface insulation resistivity of single strips or punchings of
flat-rolled electrical steel under predetermined conditions of voltage, pressure, and temperature.
Ten metallic contacts of fixed area are applied to one of the surfaces of the specimen and electrical contact is
made with the base metal by two drills. The effectiveness of the surface insulation is then indicated by a
measurement of average electrical current flowing between the contacts and the base metal under specified
applied voltage. This measurement can be used to determine the surface insulation resistivity value which is
then used as indicator of insulation quality. FT-300 will be providing both average current of both surfaces,
and resultant resistivity of the specimen.

The average of electrical current measurements is usually acceptable for evaluating surface insulation. After
testing the specimen, FT-300 will display the average current reading, current reading for both surfaces of the
specimen and the resultant resistivity of the specimen; for user to determine the insulation quality.
Ri, the surface insulation resistivity of the test specimen (two surfaces in series) is calculated from I average
(the average current reading shown when Result is pressed) as follows:
Ri = 6.45 ((1/I) − 1) Ω. cm2 /lamination
Here,
I = average current of both surfaces
Ri = the surface insulation resistivity
The calculation method is as per BIS:649 standard.

4
Button Layout and functionality

3 2

No Button Functionality
This button will start the testing of first surface of the specimen. To stop/save
1 Surface A
the result press Result.
This button will stop the testing and save the value of current reading for
2 Result
corresponding surface.
This button will start the testing of second surface of the specimen. To
3 Surface B
stop/save the result press Result
This button will move the surface plate up and stops when it sets 300 PSI
4 Up button
pressure.
Manual Rotate the knob to Manual to drill the specimen
OFF Rotate the knob to OFF when no drilling is needed. (no
5 Drill knob specimen is there)
Auto Rotate the knob to Auto to automate the process of drilling for
specimen.
6 Down button This button will move the surface plate down.

5
Testing procedure
Follow the steps below to perform a complete test using the FT-300 Franklin Tester:

1. Connection of compressor
Connect the compressor output to the pressure input terminal as shown below :

2. Power on
Connect the mains cord and turn on the tester.
When the tester is powered on, the start up screen will be displayed.
The screen shows:

2. Meter ready
The tester will display “Meter Ready”, indicating that the system is prepared to begin testing.

3. Taking reading of surface A

Put intended testing specimen on surface plate (as shown in figure below - All brass electrode and drill point
should cover the specimen area (recommended specimen size is 200mm x 100mm) and press the UP button
to position the surface plate up.

6
 Specimen

Surface Plate

Make sure that the pressure gauge shows between 38.5 and 40 PSI pressure, here the pressure gauge
reading will have to be multiplied by the scaling factor 7.8, so if gauge shows ~38.5, the actual pressure is:

38.5 X 7.8 = 300.3 PSI

Now If the Drill knob is positioned on Auto, the drill will be done automatically. If not then rotate the knob to
Manual position to drill the specimen. After the specimen is drilled press Surface A to start the testing for first
surface (Surface A).
The screen will display the following live parameters

Here,
V: Supplied voltage (~0.5V)
I: Live current reading of ammeter in ampere
Ia: Live current reading of surface A
Ib: Saved current reading of surface B
Let the reading stabilize. After the reading stabilizes now to save the reading press the “Result” button.

7
The tester saves the current reading of surface A to Ia and displays the following screen.

Here,
V: Supplied voltage (~0.5V)
I: Current reading of ammeter in ampere
Ia: Saved current reading of surface A
Ib: Saved current reading of Surface B
*Ri: Resultant surface insulation resistivity

4. Taking reading of surface B

Press down button to position the surface plate down. Now flip the specimen and press UP button to position
the surface plate up.
Make sure that the pressure gauge shows pressure between 38.5 and 40 PSI pressure. Now drill the
specimen. After the specimen is drilled press Surface B button to start the testing for second surface (surface
B) of the specimen.
The screen will now display

Here,
V: Supplied voltage (~0.5V)
I: Current reading of ammeter in ampere
Ia: Saved current reading of surface A
Ib: Live current reading of Surface B
Let the reading stabilize. After the reading stabilizes now to save the readings press the “Result” button.
The tester saves the Surface B current reading to Ib and displays:

8
Here,
V: Supplied voltage (~0.5V)
I: average current of both surfaces in ampere
Ia: Saved current reading of surface A
Ib: Saved current reading of Surface B

*Ri: Resultant surface insulation resistivity in Ω. cm2 /lamination

*Note: if the surface B is not sampled Ri will not show the correct resultant surface insulation resistivity and Ib or Ia will
display 0.0000, To get the resultant insulation resistivity, user must test both surfaces and save the readings by pressing
result button.

After testing both surfaces of one specimen the tester displays resultant surface insulation resistivity, which is
direct indicator for the quality of the insulation coating of the metal sheet specimen.
Here the user can confirm the quality of the surface insulation by the displayed average current reading of
both surfaces Ia and Ib, or by displayed surface insulation resistivity Ri.
User must take the reading for both surfaces of the specimen to get the correct result.
Once the specimen is tested, user can put the surface plate down by pressing down button and test another
specimen by following the same procedure.
Keep in mind that as per standard; even with the best practices in design, instrumentation, maintenance, and
operation, the repeatability and reproducibility of test method are greatly influenced by the nature of the
surfaces of the test specimens. Hence it is not considered possible to state meaningful values for repeatability
and reproducibility that are universally applicable.

Testing caution:
 Do not press Up and Down button at the same time
 Do not Press Surface A or Surface B button when the surface plate position is down, as pressing Surface
A or Surface B will start the voltage supply to the brass nodes.
 Make sure to press Result button to save the reading to the corresponding surface, and then press the
Down Button. - Do not press down button when testing is still on.
 Make sure to test both surfaces of the specimen to get the correct result for Ri.
 The result screen displays “Average current” of both surface current Ia and Ib, do not mistake it for live
current or last tested current reading.
 If both sides of the specimen are coated, do not use the same area to test both sides

9
Maintenance and Troubleshooting
To ensure the FT-300 Franklin tester continues to operate accurately and reliably, follow the instructions
below for regular checking and maintenance.

1. Accuracy Verification Test

To verify the meter’s accuracy as per the standard:
Use a pure conductive copper plate as the test specimen.
Observe the current reading during the test.
Expected Result:
The current reading should be greater than 0.99 A.
Interpretation:
 If current ≥ 0.99 A:
 The meter is functioning correctly. No calibration is needed.
 If current < 0.99 A:
 The reading is lower than expected. This may be due to contamination or wear of the test contacts.

2. Cleaning the Brass Contacts

If the current reading is low:
Turn off the instrument and unplug it if applicable.
Carefully inspect the brass metal contacts on the test head for any signs of dirt, oxidation, or wear.
Clean the brass contacts. Solvent cleaning is preferred over abrasive methods, as abrasives can wear down
the contact tips, leading to rounded edges and reduced contact surface area.
After cleaning, repeat the accuracy verification test using the copper plate.

3. When to Send for recalibration

If, after cleaning, the current reading during the copper plate test still remains below 0.99 A:
The instrument may be out of calibration. If the results are not accurate and you want to send it for re-
calibration please contact Gopal electronics (contact details are given at the end of the manual).

Routine Maintenance Tips

 Store the tester in a clean, dry environment.
 Avoid exposing the instrument to high humidity or corrosive environments.
 Handle the test head with care to prevent mechanical damage.
 Periodically perform the copper plate check (recommended once every 6 months or before critical
measurements).

10
Technical specification

Category Specification

Warm up time 30 minutes

Operating temperature 10 °C to 35 °C

Operating humidity 20% to 55% RH, non-condensing

Storage temperature (Non operating) 10 °C to 40 °C

Testing voltage 0.5V

Accuracy of Voltmeter 0.1% , Resolution = 0.1mV

Accuracy of Ammeter 0.1% , Resolution = 0.1mA

Test head contacts Equipped with 10 brass metal contact

Total contact area 6.45 cm² ±0.1%

Applied pressure Up to 600PSI

Pressure on sample Gauge reading X 7.80

Standard sample size 200mm x 100mm

GOPAL ELECTRONICS
Gopal Electronics, Plot-11, Part-3,
Phone: 9016107635 Amarnath Estate Naroda -11 382330,
Email: [email protected] Ahmedabad, Gujarat India