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UNITEST®

� Instruction Manual Cat.- No. 9075

®

Machine-Test 204

Content ................................................................................................................page

References marked on instrument or in instruction manual: ................................31.0 Introduction/Scope of Supply ..................................................................4

2.0 Transport and Storage ..............................................................................5

3.0 Safety Measures ......................................................................................63.1 Safety Measures ......................................................................................73.2 Appropriate Usage ..................................................................................8

4.0 Operation Elements and Connections........................................................94.1 Front Panel of Machine Test 204 ..............................................................104.2 Instrument cover ......................................................................................124.3 Front Panel Residual Voltage Tester ..........................................................13

5.0 Measurements ..........................................................................................155.1 Preparations and Safety Measures............................................................155.2 Preparation of Machine Test 204 ..............................................................175.2.1 Turning on Machine Test 204 ....................................................................175.2.2 Test Lead Compensation ..........................................................................175.3 Measurement according to EN60204 / DIN VDE 0113 ..............................185.3.1 Continuity of the protective bonding circuit according

to EN 60204 / DIN VDE 0113, test of voltage drop (function Upe) ............185.3.2 Continuity of the protective bonding circuit ............................................

Test of Resistance (function Rpe)..............................................................195.3.3 Measurement of Insulation Resistance According to

EN 60204 / DIN VDE 0113 ........................................................................205.3.4 High Voltage Test (Flash Test) ..................................................................215.3.5 Measuring residual voltage ......................................................................23

Explanation of linear and non-linear mode ................................................255.3.5.1 Residual Voltage "linear mode" ................................................................255.3.5.2 Measuring Residual Voltage "non-linear mode" ........................................27

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6.0 Maintenance ............................................................................................286.1 Cleaning....................................................................................................286.2 Calibration Interval....................................................................................286.3 Replacement of Fuse ................................................................................296.3.1 Replacement of Fuse (mains fuse) ............................................................296.3.2 Replacement of Fuse

(internal fuse for protection of function Upe/Rpe) ....................................30

7.0 Technical Data ..........................................................................................317.1 General Technical Data (Maschine-Tester 204)..........................................317.2 Measurement Functions (Machine-Test 204) ............................................327.3 General Technical Data (Residual Voltage Tester) ......................................347.4 Measurement Function (Residual Voltage Tester) ....................................34

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References marked on instrument or in instruction manual:

Warning of a potential danger, comply with instruction manual.

Reference. Please use utmost attention.

Caution! Dangerous voltage. Danger of electrical shock.

Warning of potential danger caused by accumulators and batteries.

Symbol for the marking of electrical and electronic equipment (WEEE Directive2002/96/EC).

Conformity symbol, the instrument complies with the valid directives. It complieswith the EMC Directive (89/336/EEC) and the Low Voltage Directive (73/23/EEC)with their valid standards.

The instruction manual contains information and references, necessary for safeoperation and maintenance of the instrument. Prior to using the instrument (com-missioning / assembly) the user is kindly requested to thoroughly read the in-struction manual and comply with it in all section.

Failure to read the instruction manual or to comply with the warnings and refe-rences contained herein can result in serious bodily injury or instrument damage.

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1.0 Introduction/Scope of Supply

You have acquired a high-quality measuring instrument manufactured by Ch. BEHAGmbH, which will enable you to perform repeatable measurements for a very long peri-od of time. Ch. BEHA GmbH is member of the worldwide operating BEHA Group. BEHAGroup's main offices are located in Glottertal/Black Forest, home also to the technologypark. BEHA Group is one of the leading companies in the field of measuring and test in-struments.

The UNITEST Machine Test 204 is a measuring instrument used for final inspection anddocumentation of electrical equipment of machines, control cabinets, switchgears aswell as devices complying with EN 60204 / DIN VDE 0113.

Following features characterise the UNITEST Machine Test 204:

• Measuring of earth bond voltage drop with 10 A AC• Measuring of earth bond resistance with 10 A AC• Measuring of insulation resistance with 500 V DC• High-voltage test (flash test) with 1000 V AC, 50 Hz, 500 VA• Residual voltage test with separate compact residual voltage tester• Simple operation by means of rotary switch and START/STOP push-button• Compact case with accessory compartment• Connection diagram and limit values in instrument cover• One pair of connectors for all test functions• Test lead compensation during measuring of both earth bond voltage drop and

resistance• High-voltage test (flash test) can be inhibited by means of a key switch allowing ope-

ration by instructed personnel.• High-voltage test (flash test) with adjustable limit value for trip current

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Scopy of Supply

1 pc. UNITEST Machine-Test 2041 pc. UNITEST Residual Voltage Tester1 pc. Mains Lead2 pc. Safety-Test Leads (with touch protection)2 pc. Alligator Clips1 pc. Instruction Manual

For the creation of a test report, we offer test report forms (Cat. No. 1338). They supportquick and easy creation of test reports complying with EN 60204-1 / DIN VDE 0113-1.

Available as accessories:

Test reports complying with EN 60204-1 / DIN VDE 0113Pad of 50 sheets with carbon copy, Cat. No. 1338

For measurement of leakage current

UNITEST leakage current clamp CHB 4 Cat. No. 93542Measuring ranges: 0.01 ...300.0 mA, 0.01 A...300 A

UNITEST leakage current clamp with harmonic measurement CHB 5 Cat. No. 93570Measuring range: 0.05 mA...50 A

Test leads extension set consisting of 2 pieces of 2 m each (Cat. No. 9078)

2.0 Transport and Storage

Please keep the original packaging for later transport, e.g. for calibration. Any transportdamage due to faulty packaging will be excluded from warranty claims.

Instruments must be stored in dry and closed areas. In the case of an instrument beingtransported in extreme temperatures, a recovery time of minimum 2 hours is requiredprior to instrument operation.

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3.0 Safety Measures

The UNITEST Machine Test 204 has been built and tested in compliance withthe valid safety regulations and left the factory in safe and perfect condition. Inorder to maintain this condition and to ensure safe instrument operation, theuser must pay attention to the references and warnings contained within this in-struction manual.

In order to avoid electrical shock, the valid safety and national regulations regar-ding excessive contact voltages must receive utmost attention, when working withvoltages exceeding 120V (60V) DC or 50V (25V)rms AC. The values in bracketsare valid for limited ranges (as for example medicine and agriculture).

The respective accident prevention regulations established by the professional as-sociations for electrical systems and equipment must be strictly met at all times.

Prior to any operation, ensure that test leads used, accessories and mains cableare in perfect condition.

The instrument may only be connected to input voltage as indicated on the typeshield.

The instrument may only be used within the operating ranges as specified in thetechnical data section.

Only touch test leads and test probes at handle surface provided. Never directlytouch test probes.

The instrument may only be used in dry and clean environments. Dirt and humi-dity reduce insulation resistance values and may lead to electrical shocks, in par-ticular for high voltages.

Never use the instrument in precipitation such as dew or rain. In case of conden-sation due to temperature jumps, the instrument may not be used.

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A perfect display of measurement values may only be ensured within the tempera-ture range of 0°C to +40°C.

Prior to opening the instrument, ensure that it is switched off and disconnectedfrom all current circuits.

To ensure a safe measurement only use original test leads and accessories.

Dangerous voltages may be present at units under test (UUT) caused by insulationtest or voltage test, don´t touch UUT!

Start any test series by earth bond resistance measurement.

At insulation resistance tests and earth bond resistance measurement unit undertest (UUT) must be voltage free. If necessary check that the unit is voltage free i.e.by testing with UNITEST voltage tester.

3.1 Safety Measures

The UNITEST Machine Test 204 supplies high voltage of dangerous power. Accor-ding to DIN VDE 0104 following precautionary measures must be taken prior to atest:

• Block access to danger area• Put up warning signs (Attention! High voltage, danger to life)• Install warning lamps (red, green) to be easily visible• Install EMERGENCY-OFF switch into the mains lead outside the dangerous area• Electrical trained persons may only test under supervision of specialist staff and

have to be trained regularly• Use safety probes with protection against contact or with two-hand operation

only. Always hold only one probe in one hand. • Connecting one terminal of the test object and working with one probe or hol-

ding both probes in one hand is prohibited.

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• It is prohibited to touch the test object during the test. If need be, additional mea-sures must be taken (e.g. cover by means of insulating mats) to protect the personperforming the test against inadvertent contact with the test object.

Testing may commence only after all safety measures were taken.

To avoid any risks of use of high-voltage measuring function "HV" by unauthori-zed or not instructed personnel the key must be removed from the key switch (6)when the device is not in use. The key can be removed in off position only, thusmechanically locking the high-voltage measuring function "HV". Other measuringfunctions remain accessible.

3.2 Appropriate Usage

The instrument may only be used under those conditions and for those purposesfor which it was conceived. For this reason, in particular the safety references , thetechnical data including environmental conditions and the usage in dry environ-ments must be followed.

When modifying or changing the instrument, the operational safety is no longerensured.

The instrument may only be opened by an authorised service technician, e.g. forfuse replacement.

The Residual-Voltage Tester may only be used with closed battery case

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4.0 Operation Elements and Connectors

Figure 1: Machine-Tester 204

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5 6 7 8 9 10

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4.1 Front Panel of Machine Test 204

1. IEC connector for mains supply2. Mains fuse3. "ON/OFF" mains switch (with pilot lamp)4. Rotary knob "test lead compensation"5. Measuring function selector6. Key switch enabling the High-voltage test (flash test) (mechanic locking), key can

be removed in OFF position only7. The pilot LED "ready", indication of ready-to-start High-voltage test (flash test)

Pushing the button "START/STOP" (9), applies high voltage to the outputsockets (10).

8. Rotary switch for selection of trip current at the High-voltage test (flash test)9. Button "START/STOP" initiates or stops the selected measuring function10. Outlet sockets for all measuring functions11. Pilot lamp "ON" (white), measurement active12. Pilot lamp "1000 V" (red), high voltage test active13. Eyelet for fastening of holding cord of the device cover14. The LED display "hot" of excess temperature (for earth bond voltage drop and

earth bond resistance measuring functions)15. Unit LED display of measuring result16. LED display 17 mm red, indication of measuring result17. Front panel fastening screws (4 each)

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4.2 Instrument cover

18. Brief instructions with limit values19. Compartment for test leads and measuring accessories

Measuring accessories are stored in a pocket in the instrument cover, see figure2. Instrument cover holds also a card with brief instructions and limit values ac-cording to EN 60204 / DIN VDE 0113. This card is duplex printed (in German onone page and in English/French on the other).

The card is placed in a sheet protector and can be turned; to display requested langua-ge proceed as follows (see illustration below):

1) Open the hook and loop fastener on top of the leather strap and fold out the leatherstrap forwards.

2) Now you can pull the card out of the open side (left or right) and turn it 3) Close the hook and loop fastener again.

Figure 2: Instrument cover

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Figure 3: Residual voltage tester

4.3 Front Panel Residual Voltage Tester

20. The LED "Result" (green/red) lights GREEN if the residual voltage after 1 sec. (or after5 secs.) is max. 60 V, and RED if the residual voltage after 1 sec. (or after 5 secs.) ishigher than 60 V. The LED switch on for approximately 10 secs. and switch off againautomatically.

21. The LED "Machine power ON" (red) indicating a voltage present at the UUT. It swit-ches on after approx. 2 seconds, as soon as stable mains voltage (AC or DC) is app-lied to the measuring connectors (25).

22. Button "ON/OFF" for turning the Residual Voltage Tester on.A.) Non-linear mode (see description under 5.3.5.1): Turn the instrument on by pres-

sing the ON/OFF button (22) briefly and releasing the button immediately again.Only the LED "On/Off" (23) remains switched on. The Residual Voltage Tester isnow in non-linear mode.

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B.) Linear mode (see description under 5.3.5.2): Turn the instrument on by holdingthe ON/OFF button (22) for approx. 2 seconds pressed until all three red LEDs brie-fly illuminate (for approx. 1 second) and releasing the ON/OFF button again. Onlythe LED "On/Off" (23) remains switched on. The residual voltage tester is now inlinear mode.

Auto-Power-Off: If the instrument has not been used for more than 5 minutes itturns off automatically.

23. After turning the residual voltage tester on the LED "ON/OFF" keeps on illuminated.In the event of low or discharged battery this LED is blinking.

24. Switch "Test 5 sec. / Test 1 sec." to change measuring time during switch-off

1 sec. value is used for touchable wrap connections whereas the 5 sec. value isused for all touchable active components under residual voltage after switch-off

25. Measurement connectors (4 mm safety sockets)

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5.0 Measurements

5.1 Preparations and Safety Measures

Instrument's correct functionality must be verified prior to every use.

Attention must be paid to correct condition of test leads, measuring accessoriesand measuring instrument itself.

The instrument may be used within specified measuring ranges only.

During measurements of earth bond and insulation resistance as well as duringHigh-voltage test (flash test) the UUT must be voltage-free and disconnected frommains. In case of doubt, verify for no voltage by using a voltage detector.

The instrument is protected against overload up to 250 Vrms AC by an internalfuse.

Residual Voltage Tester's measuring input may be connected to max. 400 V AC /560 V DC while pay attention to the measuring circuit category CAT II / 300 V!

Measuring function selector must be set to required position prior to connectingprobes to the UUT.

Before selecting a new function or another measuring range the test leads mustbe always removed from the tested objects.

Bear in mind that during measurements of earth bond resistance contact resi-stances at the place of measurement affect the measuring result. Ensure good con-tact between the test probe (or crocodile clip) and UUT.

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Results of earth bond resistance measurements may be falsified by impedancesof additional operating current circuits connected in parallel or by equalising cur-rents.

In the event that many earth bond resistance measurements are performed overa longer period of time with only "short" breaks in between, the internal protectionagainst over temperature will respond and the LED display "hot" (14) will switchon.

Next measurement cannot start until the instrument has cooled down (approx. 3-5 minutes) and the LED display has switched off again. This protects the instru-ment against damage.

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5.2 Preparation of Machine Test 204

5.2.1 Turning on Machine Test 204

1) Connect the Machine Test 204 to functional and correctly installed Schuko mainssocket.

2) Use the mains switch "ON/OFF" (3) to turn the Machine Test 204 on.3) As soon as the Machine Test 204 is turned on, the pilot lamp of the power switch

(3) switch on and the LED display (16) shows "---". 4) Connect both test safety test leads (with touch protection) to both output

sockets (10).5) Measuring instrument is now ready for use.

5.2.2 Test Lead Compensation

1) Set the measuring function selector (5) to position Upe 10A ~.2) Connect both test probes to each other; if need use enclosed crocodile clips.3) Start measurement by pressing "START/STOP" (9) push button4) Pilot lamp "ON" (11) indicates active measurement.5) Using the control knob "test lead compensation" (4) adjusts the display to 0.006) Stop measurement by repeated pressing of the "START/STOP" (9) push button

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5.3 Measurement according to EN60204 / DIN VDE 0113

5.3.1 Continuity of the protective bonding circuit according to EN 60204/ DIN VDE 0113, test of voltage drop (function Upe)

Complying with EN 60204 / DIN VDE 0113 the continuity of the protective bon-ding circuit between PE terminal and relevant points of the protective conductorsystem must be checked by injecting a current of at least 10 A AC 50 Hz.

Following limit values must be observed during measurement of the voltage drop.

UPE max. PE conductor cross section3,3 V 1,0 mm2

2,6 V 1,5 mm2

1,9 V 2,5 mm2

1,4 V 4,0 mm2

1,0 V 6,0 mm2

Table 1, limit values for voltage drop EN 60204 (1997) / DIN VDE 0113 (1998)

Optionally, it is also possible to perform a loop measurement (e.g. using UNITESTTelaris 0100 plus, Cat No. 9073).

1) Set the measuring function selector (5) to Upe 10A ~ position.2) Connect both test probes (or crocodile clips) to the UUT3) Start measurement by pressing "START/STOP" (9) button4) Pilot lamp "ON" (11) indicates active measurement.5) Read off the value and pay attention to corresponding limit values according to

EN 60204 / DIN VDE 0113, see also table 1.6) Stop measurement by repeated pressing "START/STOP" (9) button

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5.3.2 Continuity of the protective bonding circuit Test of Resistance (function Rpe)

1) Set the measuring function selector (5) to Rpe 10A ~ position.2) Connect both test probes (or crocodile clips) to the UUT3) Start measurement by pressing "START/STOP" (9) button4) Pilot lamp "ON" (11) indicates active measurement.5) Read off the value.6) Stop measurement by repeated pressing "START/STOP" (9) button

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5.3.3 Measurement of Insulation Resistance According to EN 60204 /DIN VDE 0113

Complying with EN 60204 (1997) / DIN VDE 0113 (1998) the insulation resistancebetween active conductors of power circuits and the earth bonding system mustbe checked applying a test voltage of 500 V DC. The limit value is 1 MΩ.

Ensure that all switches on UUT are closed in order to test all its components. Forthe purpose of measurement, all active conductors (L1, L2, L3, N) may be shor-ted.

1) Set the measuring function selector (5) to Riso/ins position2) Connect both test probes (or crocodile clips) to the UUT3) Start measurement by pressing "START/STOP" (9) button4) Pilot lamp "ON" (11) indicates active measurement.5) Read off the value and pay attention to the corresponding limit value according

to EN 60204 / DIN VDE 0113.6) Stop measurement by repeated pressing "START/STOP" (9) button

Due to measurement of insulation capacitive UUTs will be charged with test vol-tage. The UUT will discharge after performed measurement of insulation at ap-prox. 3 MΩ. The UUT can retain dangerous voltage in the event of premature re-moval of test leads. Ensure that the UUT is discharged through highly resistiveresistance (not shorted!).

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5.3.4 High Voltage Test (Flash Test)

Complying with EN 60204 (1997) / DIN VDE 0113 (1998), electric equipment mustwithstand a voltage test between conductors of all protective circuits and the earthbonding system.

The test is performed at double rated voltage (but at least 1000 V), by a voltage AC 50Hz, with min. power of 500 VA for test period of at least 1 second. Exempted are currentcircuits powered by PELV voltage. Components not rated for this test voltage may be di-sconnected.

The UNITEST Machine Test 204 supplies high voltage of dangerous power. Ac-cording to DIN VDE 0104 following precautionary measures must be taken priorto a test:

• Block access to danger area• Put up warning signs (Attention! High voltage, danger to life)• Install warning lamps (red, green) to be easily visible• Install EMERGENCY-OFF switch into the mains lead outside the dangerous area• Electrical trained persons may only test under supervision of specialist staff and

have to be trained regularly• Use safety probes with protection against contact or with two-hand operation

only. Always hold only one probe in one hand. • Connecting one terminal of the test object and working with one probe or hol-

ding both probes in one hand is prohibited.• It is prohibited to touch the test object during the test. If need be, additional

measures must be taken (e.g. cover by means of insulating mats) to protectthe person performing the test against inadvertent contact with the test object.

Testing may commence only after all safety measures were taken.

Ensure that all switches on UUT are closed in order to test all its components. Forthe purpose of measurement all active conductors (L1, L2, L3, N) may be shor-ted.

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1) With the rotary switch "trip current" (8) select the required current, if need be startwith the lowest value.

2) Release the measuring function high voltage by using the key switch (6) and byturning the key switch anti-clockwise.

3) Set the measuring function selector (5) to "HV 1000 V ~" position4) Now the pilot LED "Ready" (7) is switched on.

If the Machine Test 204 was switched off or disconnected from mains in the me-antime, the LED (7) is not switched on any longer. As safety function, you have toswitch from function "HV 1000 V~" to any other function and back again.

5) Connect both test probes (or crocodile clips) to the UUT6) Start measurement by pressing "START/STOP" (9) button.

7) Pilot lamp "ON" (11) indicates active measurement. To additionally indicate acti-ve high voltage at output sockets the red pilot lamp "1000 V" (12) switch on andan acoustic signal sounds.

In the event of flashover on the UUT the test is terminated immediately, both pilotlamps (11) and (12) switch off and the pilot LED "ready" (7) switch on again.

8) Stop measurement by repeated pressing "START/STOP" (9) button

After finishing the high voltage tests change the setting of the measuring functionselector (5) to other than "HV" function, lock the measuring function using the keyswitch (6) and secure the instrument against unauthorized use by removing thekey!

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5.3.5 Measuring residual voltage

What are residual voltages? Residual voltages are such voltages that exist evenafter switch off a machine or a device. This can be caused e.g. by capacitors orsubsequent generators. This measurement is performed using the Residual Vol-tage Tester.

Complying with EN 60204 (1997) / DIN VDE 0113 (1998), live parts having a re-sidual voltage exceeding 60 V after switch-off must discharge within 5 seconds(permanently connected machines) or within 1 second (plugged-in machines) to≤ 60 V. Proof of this must be given through tests.

In the event of non-compliance, additional measures (discharge devices, warning infor-mation, covers etc.) according to EN 60204 / DIN VDE 0113 must be taken.

Residual voltage can be measured in both linear and non-linear mode, see 5.3.5.1or 5.3.5.2.

1) Connect both test leads to the connectors (25) of the Residual Voltage Tester2) Pressing the "ON/OFF" button (22), turns the residual voltage tester on. Select the

requested measuring mode (linear or non-linear).3) Connect both test probes (or crocodile clips) to the UUT and select points of at-

tachment that may be hazardous due to residual voltage (power supply, toucha-ble busbars, capacitors, subsequent motors etc.).

4) With the switch (24) select desired measuring time during switch-off

The value of 1 sec. is used for touchable plug connectors, the value of 5 secs. isused for all touchable active components.

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5) Turn on the UUT, the LED "Machine on" (21) switches on and shows existing vol-tage.

6) Turn off the UUT, the LED "result" (20) shows the result of the test: green for pas-sed and red for failed.

Applicable for linear mode only: In the event that the mains voltage was interrup-ted at low value, i.e. calculation using the peak value is not possible, the green LED"Result" (20) starts blinking and the measurement process must be repeated!

In the event that the mains voltage already registered at the connectors as constant vol-tage increases or drops by more than 10%, the LED "Machine on" (21) keeps blinkinguntil new voltage has been detected!

Evaluate always the first displayed result directly after turning off the mains voltage onthe UUT! In the event of extremely high capacities with slow discharge it may occasio-nally happen that the measurement process starts again. Such result is invalid, howe-ver!

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Explanation of linear and non-linear mode

5.3.5.1 Residual Voltage "linear mode"

This operation mode can be used for UUTs inluding linear components (R, L, C). In thiscase exponential voltage drop can be detected upon switch off of the UUT.

In linear mode the value refers automatically to the mains voltage peak value, see figure 4.

Figure 4: Linear mode

In linear mode the residual voltage tester detects automatically three standard systemvoltages:

110 V.......................Uin = 110 V ± 10%230 V.......................Uin = 230 V ± 10%400 V.......................Uin = 400 V ± 10%

1s / 5s

U (correct value)RES

URES

1s / 5s

Ucoincidental switch off at any mains voltage

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To include mains overvoltage, the measured residual voltage is calculated with referen-ce to the peak value of the mains overvoltage, i.e.:

171 Vp = 110 V x 1.1 x 1.41....... standard system voltage 110 V

357 Vp = 230 V x 1.1 x 1.41....... standard system voltage 230 V

620 Vp = 400 V x 1.1 x 1.41....... standard system voltage 400 V

If the actual input voltage differs by ± 10% from standard system voltage, the residualvoltage tester scales the result to peak value of measured effective value (referring to si-nusoidal voltages).

Example: Uin = 173 V the result refers to 244 Vp = 173 V x 1.41

Turning the linear mode on:

1) Holding the ON/OFF button (22) pressed for approx. 2 seconds until all three redLEDs briefly illuminate (for approx. 1 second) turn the instrument on and releasethe ON/OFF button again. Only the LED "On/Off" (23) remains switched on.

2) The Residual Voltage Tester is now in linear mode.

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5.3.5.2 Measuring Residual Voltage "non-linear mode"

This operating mode is used for measurements of non-linear or unknown items invol-ving besides R, L, and C components also non-linear internal components (relays, gaslamps etc.). The flow of stress after switched off of the UUT is not exponential and thusit is impossible to refer to a peak value. I.e. actual value after the end of measuring timeis registered and evaluated.

Figure 5: Non-linear mode

In this operation mode the measurement must be repeated several times to ensure theUUT was tested under varying shutoff conditions. The highest measured value must berecorded.

Turning on non-linear mode:

1) Pressing the ON/OFF button (22) briefly turns the instrument on and releases thebutton immediately again. Only the LED "On/Off" (23) remains switched on.

2) The residual voltage tester is now in non-linear mode.

urelay may be switched off

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6.0 Maintenance

When using the instrument in compliance with the instruction manual, no special main-tenance is required. However, should functional errors occur during normal operation,our after sales service will repair your instrument without delay.

6.1 Cleaning

If the instruments are dirty after daily usage, it is advised to clean them by using a humidcloth and a mild household detergent.

Never use acid detergents or dissolvents for cleaning.

Prior to cleaning, remove the machinery tester from all measurement circuits andfrom mains.

After cleaning, do not use the voltage tester until complete drying.

6.2 Calibration Interval

We suggest a calibration interval of one year. If the instrument is used very often or if itis used under rough conditions we recommend shorter intervals. If the instrument isused few times only the calibration interval can be extended on to 3 years.

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6.3 Replacement of Fuse

If, due to overload or improper operation, a fuse blows it is necessary to obey followingnotes for the replacement of fuses:

Prior to replacement of fuse the Machine Test 204 must be disconnected from allmeasuring circuits and mains supply and test leads must be removed.

Use only fuses of current / voltage rating and dimensions specified in technicalspecification.

Use of auxiliary fuses and in particular shorting of fuse-holders is prohibited.

Spare fuses can be obtained from all electric supplies wholesale shops or fromour factory service.

6.3.1 Replacement of Fuse (mains fuse)

In the event that the power switch pilot lamp does not illuminate after using the powerswitch (3) on and neither the LED display (17) shows any indication, it is possible thatthe mains fuse in the fuse-holder (2) has blown.

To replace the fuse proceed as follows:

1) Open the fuse-holder (2) above the ON/OFF switch by using a screwdriver2) Remove the defective fuse and replace it3) Close the fuse-holder (2) again

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6.3.2 Replacement of Fuse (internal fuse for protection of function Upe/Rpe)

In the case that after the start of the measurement the LED display (17) for functionsUpe/Rpe displays overflow indication "1. " also when test leads are shorted, it is possi-ble that the internal fuse has blown.

To replace the fuse proceed as follows:

1) Remove the holding cord of the instrument cover from the front panel; for thisrelease the clip from the eyelet (13).

2) Unscrew the 4 screws (17) on the front panel3) Lift the front panel from the instrument and put it aside next to the portable case.4) The fuse-holder with the fuse is located on the board nearby the key switch.5) Remove the defective fuse and insert a new fuse.6) Place the front panel carefully back in the portable case.7) Attach the front panel in the portable case again using the 4 fastening screws (17)8) Clip the holding cord for the instrument cover in the eyelet (13) again.

In the event that the internal fuse has disconnected repeatedly (e.g. due to im-proper operation), the instrument should be sent to factory for check.

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7.0 Technical Data

7.1 General Technical Data (Maschine-Tester 204)

Display ............................................LED 3 1/2 -digit, 20 mmOperating temperature range ..........0 to 40°C (the mentioned tolerances refer to thisrange)Storage temperature range ............-30 °C to +60 °CMax. humidity ................................85% r. H. (0 to 40° C)Reference humidity range ..............40% to 60% r. H.Height above MSL: ..........................up to 2000 mPower supply ..................................230 V ± 10%, 50-60 Hz Max. power consumption ..............500 VA

Built in fuses:Mains fuse (on front plate) .............. 6.3A / 250V time-lag (5 x 20 mm)For functions Upe and Rpe (internally) ........................16A / 500V time-lag (6.3 x 32 mm)

According to ....................................EN 61010-1 / DIN VDE 0411-1Over voltage category (power supply) CAT II / 300 VMeasurement category (input /output) CAT I / 1300 V

The measuring input /output is insulated with basic insulation against earth, themaximum output voltage (open voltage at maximum mains input voltage) amountsto 1300 V.

Pollution degree ..............................2Protection class ..............................IProtection degree ............................IP 40Dimensions (W x D x H) ..................with handle 345 x 320 x 170 mmWeight ............................................approx. 8.5 kg

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7.2 Measurement Functions (Machine-Test 204)

Earth Bond Voltage Drop acc. EN 60204/DIN VDE 0113

Measurement range ........................0.01...3.30 VDisplay range: ..................................0.01...19.99 VResolution ......................................0.01 VTolerance ........................................±(5% rdg. + 0.1V)

Earth Bond Resistance

Measurement range ........................0.01...0.33 ΩDisplay range: ..................................0.01...19.99 ΩResolution ......................................0.01 ΩTolerance ........................................±(5% rdg + 5 Digits)Test current ....................................>10 A AC (at mains voltage of 230 V ± 10%, with

standard test leads 2 m and a max. resistance of0.33 Ω)

Test voltage......................................<12 V AC (not grounded)Measuring principle ........................two poleTest lead compensation ..................manual compensation up to 0.09 ΩOver voltage protection. ..................at connection to external voltage by an internal fuse

16 A / 500 V time-lag

To keep the test current of 10 A AC and also allow a correct test lead compensa-tion, a maximum extension for the test leads of 2 x 2 m is allowed.

At longer test leads a correct test lead compensation is not possible and the testcurrent does not comply to the specifications.

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Insulation Resistance acc. EN 60204/DIN VDE 0113

Measurement range ........................0.20 to 19.99 MΩDisplay range ..................................0.00 to 19.99 MΩResolution ......................................0.01 MΩTolerance ........................................±(5% rdg. + 5 Digits)Test voltage(UN) ..............................500 V DC (output “- / ~”grounded)Tolerance ........................................UN -0% ...+50%Test current (at 500 kΩ load) ..........>1 mA DCShort circuit current ........................<5 mA DC

High Voltage Test (Flash Test) acc. EN 60204/DIN VDE 0113

Test voltage......................................1000 V AC (output not grounded)Open circuit voltage ........................ 1000 to 1300 V AC at mains voltage 230 V ± 10%Tolerance of displayed test voltage ..– 0 to + 30 VOutput power ..................................>500 VASelectable trip current......................10 mA, 50 mA, 100 mA, 200 mATolerance of trip current ..................±20% of pre-set valueTrip out time after reaching pre-set trip current .......................... <30 ms

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7.3 General Technical Data (Residual Voltage Tester)

Display ............................................via LED’sOperating temperature range .......... 0 to 40° C (the mentioned tolerances refer to thisrange)Storage temperature range ............-30° C to +60° CMax. humidity..................................85 % r. H. (0 to 40° C)Reference humidity range ..............40% to 60% r. H.Height above MSL: ..........................up to 2000 mPower Supply ..................................Battery 9V Alkaline IEC 6LR61According to ....................................EN 61010-1 / DIN VDE 0411-1Measurement category ....................CAT II 300 VPollution degree ..............................2Protection class ..............................II (double insulated)Protection degree ............................IP 40Dimensions (W x D x H) ..................160 x 85 x 35 mmWeight ............................................approx. 0.15 kg

7.4 Measurement Function (Residual Voltage Tester)

Residual Voltage Test acc. EN 60204/DIN VDE 0113

Max. input voltage ..........................440 V AC or 620 V DCStart of measurement (automatic trigger) ..........................ΔU/Δt > 20 V/sInput resistance ..............................20 MΩSelectable test time..........................1s , 5sLimit for residual voltage ................60 V DC (+ 0 V/ - 6 V)Display ............................................two-color LED green/red........................................................green: Limit value comply≤ 60 V........................................................red: Limit value not comply >60 VMeasuring principle ........................two pole

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24 month Warranty

UNITEST instruments are subject to strict quality control. However, should theinstrument function improperly during daily use, your are protected by our 24months warranty (valid only with invoice).

We will repair free of charge any defects in workmanship or material, providedthe instrument is returned unopened and untampered with, i.e. with undama-ged warranty label.

Any damage due to dropping or incorrect handling are not covered by the war-ranty.

If the instrument shows failure following expiration of warranty, our service de-partment can offer you a quick and economical repair.

BEHA reserves the right to make change.10/2006 PTEB90750000

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Die BEHA-Gruppe bestätigthiermit, dass das erworbeneProdukt gemäß den festgeleg-ten Beha Prüfanweisungenwährend des Fertigungspro-zesses kalibriert wurde. Alleinnerhalb der Beha-Gruppedurchgeführten, qualitätsrele-vanten Tätigkeiten und Prozes-se werden permanent durchein Qualitätsmanagements-ystem nach ISO 9000 über-wacht.

Die BEHA-Gruppe bestätigtweiterhin, daß die während derKalibrierung verwendeten Prüf-einrichtungen und Instrumenteeiner permanenten Prüfmittel-überwachung unterliegen. DiePrüfmittel und Instrumentewerden in festgelegten Abstän-den mit Normalen kalibriert,deren Kalibrierung auf nationa-le und internationale Standardsrückführbar ist.

The BEHA Group confirmsherein that the unit you havepurchased has been calibrated,during the manufacturingprocess, in compliance withthe test procedures defined byBEHA. All BEHA proceduresand quality controls are moni-tored on a permanent basis incompliance with the ISO 9000Quality Management Stan-dards.

In addition, the BEHA Groupconfirms that all test equip-ment and instruments used du-ring the calibration process aresubject to constant control. Alltest equipment and instru-ments used are calibrated atdetermined intervals, using re-ference equipment which hasalso been calibrated in com-pliance with (and traceable to)the calibration standards ofnational and international labo-ratories.

Le groupe BEHA déclare quel´appareil auquel ce documentfait référence a été calibré aucours de sa fabrication selonles procédures de contrôle dé-finies par BEHA. Toutes cesprocédures et contrôles dequalité sont régis par le systé-me de gestion ISO 9000.

Le groupe BEHA déclare parailleurs que les équipements decontrôle et les instruments uti-lisés au cours du processus decalibrage sont eux-mêmessoumis à un contrôle techniquepermanent.

Ces mêmes équipements decontrôle sont calibrés réguliè-rement à l´aide d´appareils deréférence calibrés selon les di-rectives et normes en vigueurdans les laboratoires de re-cherche nationaux et interna-tionaux.

El grupo BEHA declara que elproducto adquirido ha sido ca-librado durante la producciónde acuerdo a las instruccionesde test BEHA. Todos los proce-sos y actividades llevados a ca-bo dentro del grupo BEHA enrelación con la calidad del pro-ducto son supervisados per-manentemente por el sistemaISO 9000 de control de calidad.

Adicionalmente, el grupo BEHAconstata que los equipos e ins-trumentos de prueba utilizadospara la calibración también sonsometidos a un permanentecontrol. Estos equipos e instru-mentos de prueba son a su vezcalibrados en intervalos regu-lares valiéndose de equipos dereferencia calibrados de acuer-do a directivas de laboratoriosnacionales e internacionales.

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Qualitätszertifikat • Certificate of Quality

Certificat de Qualité • Certificado de calidad