General tips and important advice relating to the AT / ATi:


You have bought a testing device which can do far more than anything you have previously known! In order to exploit its potential to the greatest possible extent, you should pay attention to the points detailed below.
The AT 3600 can perform up to 10 tests per second!!! This means that you do not need to “limit” the number of tests, but instead that you can subject your components to even more tests than usual.
The precision and reproducibility of ALL measurement results is entirely dependent upon the ADAPTER.
The following rule of thumb applies: it is essential to measure all components whose winding resistance is 1 Ω or less with an adapter equipped with KELVIN CONTACTS – under no circumstances with spring contacts.
If you construct adapters with spring contacts, you should preferably choose spring contacts with continuous spools and ALWAYS connect EVERY spring contact/Kelvin contact to the adapter with two separate conductors. According to the manufacturer, “normal” spring contacts when in use have a (transitional) resistance at each pass of +/- 150 mΩ, which makes them completely unsuitable for measurements on small resistors.

For more than three years, we have been running our own construction facility for adapters!!!

We offer our customers a facility for manufacturing and/or purchasing universal adapters – or customised adapters for any desired component or configuration. The reproducibility of measurements – and naturally their precision – depends to a very large degree on the adapter. In addition, the “down time” of your adapters is heavily dependent on the choice of the correct contacts/constructional form.


Screen resolution

Upon opening the Editor program or also the Server program, it is possible that a warning notice will appear, stating that the resolution and/or display are incorrect.
If necessary (in the case of incorrect display characteristics), please modify the screen resolution as necessary, by selecting a lower level of screen resolution.


The “REMOTE” port – and “START”; “RUN”

We have found that most customers use „RUN“ ” (at the top right, near the display), to “start” the test program.
Although there is fundamentally nothing wrong with this method, sooner or later it will cause wear and defects in the foil keypad.
It is, in fact, better to use the “REMOTE” port! The 9-pole D-sub connector transmits the signals “Start”, “Stop”, “Busy”, “Pass” and “Fail” to external interfaces.
If you attach a sensor to Pin 3 + Pin 7 of the “REMOTE” port, you can start your device with a simple touch of the sensor. (Active Low)
However, you should always apply a clear, see-through foil over the foil keypad and display, in order to avoid damage – and to prolong the life of the keypad.



Important notice: If you use the “OUT TEST” (to address external relays), you must be aware that the external relays are only in fact switched on if the program which is generated is complete and running: when creating the tests, the relays are NOT switched on.
However, if you wish this to be arranged differently, we can offer you a solution in combination with our “relay board”. If you purchase and connect up your “own” relays, you must ensure that you purchase 12 V relays with a coil resistance of not less than150 Ω.

Please do not feed in any separate voltage source or current!


Defects in the AT 3600 – Warning notice!!!

Your AT 3600 automatic test system is extremely versatile – and particularly well equipped, with an available range of more than 40 different tests for all wound components.
But even with the assistance of your AT 3600, you will NOT be able to test 100 % of ALL components.
There will always be limits where we must say that certain types of test are not possible.

Please do NOT try to use circuitry tricks, external voltage sources, external high voltage supplies or other external elements to overcome the innate characteristics of the equipment!

The “control element” of the AT 3600 contains a relay matrix of 80 reed relays. These reed relays were specially developed and built for VOLTECH.
A very complex circuit monitors and controls the tester’s functions, with transitional resistors, no-current switch-on, etc.
However, if external voltage inputs supply the device with voltage/current, this may lead to the need for extremely expensive repairs.

If you find that the AT 3600 does not meet all your needs, please ask us about any problems!
With more than 20 years of experience, we have encountered almost every problem at one time or another. If there is a solution, you will be provided with it – at no additional cost!


Entering figures/testing values

Please note that it is normal in Great Britain, North America and other countries to use a decimal point instead of the “decimal comma” used in Central Europe. Please ensure, therefore, that you always use a decimal point when entering measurement values, tolerances or time periods, etc.


Safety and safety regulations

A particularly important point relates to the subject of high voltage.
Under extremely unfavourable circumstances, it is even possible that the AT 3600 may become damaged or be functionally destroyed. In particular, in the case of “AC HiPot” you should include a delay of 0.2 seconds when setting up the test. Try to avoid a sudden delivery of high voltage to the component under test.
ALWAYS link all primary and secondary connections to a SINGLE point. If possible, NEVER test single wound components against each other. Under unfavourable transmission circumstances, voltages in excess of 10,000 Volts AC may be produced and cause extensive damage to the equipment.
Please pay close attention to statutory and professional safety regulations!!!
You will be able to solve all problems related to safety by the use of a photoelectric barrier. For this purpose, you should consult the relevant information in our homepage „Safety“. Please note that there is not only the threat of high voltage dangers as described, but also in consequence of the direct application of the supply current to a component under test.

In the event that the casing of the testing device (AT 3600/ATi) is opened, this may give rise to the danger of electric shock. Please also be aware that the guarantee and/or warranty applicable to the testing device are automatically invalidated in the event of such interventions by unauthorised persons.

We shall be pleased to offer you advice about the configuration of a workplace for the operation of the device (AT 3600/ATi) and in relation to the various possible ways of ensuring the safety of the operator/installer.


Warranty in the case of damage

KUST Messgeräte GmbH accepts no form of direct or indirect liability. Any damage caused by a failure to comply with the safety instructions or which results from incorrect use of, or unauthorised interference with, the AT 3600, are EXCLUSIVELY the responsibility of the user.
This also applies to all forms of damage which are caused by adapters and accessories.


The surge current test

The surge current test is a rather difficult, but very important and informative test. By means of this test, any existing damage to a component may be identified! It may also help you to avoid the need to submit claims for damage, in particular in the case of network transformers.
We shall be very pleased to offer our customers relevant training free of charge. It is also possible for basic questions related to this test to be dealt with as necessary by telephone.


The Editor

Menu points in the Editor program

The Editor program is available in English and has been extensively translated into German. In the menu bar of the Editor program, look for “SETUP“. Click on SETUP and “Sprache/Language”. Select “ENGLISH” or “GERMAN” as desired, confirm this with OK and close the Editor.
The next time you call up the Editor program, the operator interface will be in the English or German language, as previously selected. When you first use this program, you should take account of the following tip: Under the first menu point of the Editor “Test program for”, the submenu point “Letterhead” appears. Under this item, you can already give “your” component a name/product description before beginning the programming.
When you later click on the menu item “Print preview”, after completing the program setup, you will find there, ready for printing, the complete documentation, including all tests.
With our new software, you also automatically have complete documentation available for your customers!!!


Please also take into consideration our NEW evaluation program: RESULT ANALYSIS You can find the Beta Version for free downloading here.

Your evaluation of test results could look just like this!



Setting up operations for AT 3600

Before starting with the creation of a circuit structure or system program, the AT 3600 and the PC must be set up for operation!



The first important aspect of the setup process is the “SAFETY INTERLOCK” on the rear of the device. At the back of the tester, there are THREE individual and independent safety connections. These prevent the possibility that an outgoing current of more than 20 V may be created WITHOUT a safety circuit. All interfaces and their allocations are comprehensively described in Section 8 of the Handbook/Manual.
We would once again emphasise that the relevant professional safety regulations must be complied with. The simplest way of achieving this is by means of our “photoelectric barriers”, which are particularly easy to install (3 connectors).
For the purposes of testing and setup, it is possible to create your own “short circuit connector” as a “temporary solution” (to short-circuit all safety systems). To do this, take a 9-pole D Sub connector and connect pins 2 + 9 with a 6.8 kΩ resistance; then short-circuit pin 5 + pin 6, and then short-circuit pin 3 + pin7. You have then circumvented all the safety features (ONLY for the purpose of testing!!!) and can now test all voltages, including high voltages.
At this point, we once again offer a safety warning: when the safety features are eliminated, this creates a situation which may cause direct danger of death or personal injury!
For this reason, KUST Messgeräte GmbH accepts no responsibility for the consequences if you choose to follow this course of action.


Connection of AT 3600 to PC:

Please initially install the “Server software” and the “Editor software” on your PC/laptop. The latest versions of these programs may also be downloaded from the VOLTECH homepage, under AT-Editor-Software.

The Editor/Server software functions correctly in all cases with systems up to and including Microsoft “Windows 7”, and is downwardly compatible with systems going back to Windows 95 (and possibly even Windows 3.11).

The PC is connected with the AT 3600/ATi via two serial RS232 interfaces. For this purpose, please use the cables (Server cable, Editor cable) which are included in the delivery package!
If your laptop or PC DOES NOT HAVE an RS232 port, please use two RS232 to USB adapters. But please be careful! We have found that not all adapters work correctly for this purpose. We shall be pleased to supply you with details of suitable sources, or to obtain the adapters on your behalf.
In the Editor program, the ports are selected via the menu bar “Setup” and “Select COM PORTS”.
Similar provisions apply for the Server program.
Important!!! The Comms connection must be located in the area from 1 to 10!


Cable connection

The delivery package includes a Server cable and an Editor cable. These should be connected to the SERVER interface of the AT 3600 (Server cable) and to the AUXILIARY port (Editor cable).
This concludes all matters related to “Setting up operations”.


Switching on the AT 3600/ATi

You should now remove any adapter which may be attached to the AT 3600 – and then switch on the AT 3600! (Important! When you switch on the AT 3600, a series of tests is carried out automatically, and these tests also include the provision of a current to the spring contacts of the adapter mounts.)
After the “Start procedure”, reattach the adapter, fix it and then proceed as follows with the actual “PROGRAM GENERATION”.


Self testing

The self test facility of the AT 3600 is intended exclusively for DIAGNOSTIC PURPOSES!
This “diagnosis tool” is used in the case of a defect – or presumed malfunction – of the AT 3600. By this method, it is possible for us to carry out a remote diagnosis.
If the device “passes” a self test, any possible problems CANNOT be located within or on the device, but it must instead be presumed that there are problems with the software, adapter, cables, etc.

To clarify the purpose of the self test: it is NOT intended for adjusting or calibrating the test equipment.



KUST Messgeräte GmbH is the world’s sole official, authorised service agency for VOLTECH Ltd. (This service is carried out in our own internal DKD – Calibration Laboratory.)

ALL VOLTECH devices, ranging from power measurement devices to the AT 3600/ATi, can ONLY be repaired, adjusted or calibrated by the manufacturer or by KUST Messgeräte GmbH!!!
We stock all spare or replacement parts in our stores – and will, if necessary, be pleased to offer our customers the loan of a replacement device until the original device is once again available.


Programming the device

We would firstly like to consider the requirements for an extremely simple component/print transformer. To deal with the principles of programming the tester, let us assume we are dealing with a print transformer with a single primary winding and two secondary windings.
After calling up the Editor program, you will see on the screen the pin allocations for pins 1 to 20, representing the way in which they are arranged when you look at the adapter frame of the AT 3600/ATi.
In the menu item “Program” – “Options”, you will find in the lower screen area a text field, in which you can enter important information concerning the component, connections, etc. – and also, after opening the program in the display screen of the AT/ATi, have the details displayed there.


Setting up a switching diagram:

Click on the menu item “Set up a switching diagram” and then click on “Add winding”. A winding symbol appears on the screen, and you can drag this to anywhere on the screen by using the mouse. Move the winding symbol to any location on the LEFT of the screen (this indicates automatically that it is a primary winding) and press the left mouse button.
In the window containing directions, the Editor program now requests you to give an identity to the two connection points. Let us call them simply P1 and P2 (Primary 1 + Primary 2). After entering these identities, click on the “ENTER” button.
The Editor program will now place the winding at the top centre of the screen, and the connection points P1 and P2 will appear on the left of the screen. If you now look closely at the start of the winding “P1”, you will be able to see a point marking the start of the winding. This denotes the “hot” end of the winding – an important consideration when determining the winding direction and phase location.
These elements are also tested incidentally when other tests are being carried out.
Next, click once again on the menu item “Set up a switching diagram”, and once more on “Add winding”, and place the winding symbol which now appears somewhere on the right of the screen. After you have once again pressed the left mouse button, the Editor program will request the name of the two winding connection points. In the same way as in the example above, let us call these points S1/S2 for “Secondary 1 + Secondary 2”. The winding will now appear on the screen in a position opposite the primary winding.
You should next create the second primary winding in the same way as above and give it the identity PP3 and PP4!
In this way, you have created an image of a transformer circuit with two primary and one secondary windings. In a similar way, and with similar techniques, you can add to this a core contact, create a shielding system – or remove them once again, by clicking on the winding / shielding or other items – and then under the menu item “Create circuit” by clicking on the items “Remove winding”, “Remove connection from core”, etc., and by confirming this choice with “OK”.
An important point is how to create a power tapping connection. For demonstration purposes, a power tapping connection may be added to the primary winding, as follows.
Go to “Create circuit” / “Add winding” and enter the contact points as “P2” and “P33” - and the system immediately creates a power tapping connection with pins P1/P2/P33.
To remove the power tapping connection, mark these pins with the mouse, go to “Create circuit”, then “Remove winding”, and confirm this choice with “OK”. The power tapping connection then disappears.


Attachment of test sample

This is how to attach a transformer / example component:
Go with the mouse to the contact point of “P1” and hold the right mouse key down firmly. By moving the mouse, you can now link the connection point “P1” with any desired point of the adapter (pins 1 to 20).
To summarise, you should click on a connection point with the right mouse key, firmly hold down the right mouse key and by “drag and drop” techniques draw it to the desired point on the adapter, and then release the mouse key. You have thus created the first connection within the circuit diagram. As an example, P1 may be connected with pin19 and P2 with pin 17. On the primary side, S1 may be connected with pin 20, S2 with pin 18, PP3 with pin 4 and PP4 with pin 2.
The circuit diagram has thus been created, and all connections have been linked and allocated.

In the following section, consideration is given to the creation of the actual programs themselves.


Creating a program:

In order to test a prototype – or when giving a demonstration/introduction to the programming facility and the design of a circuit diagram using the “MEASURE” process – it is naturally necessary to connect up an appropriate component at least “provisionally” (without 4-conductor measurement) to the AT 3600. It does not matter whether this is done by means of grip clamps, crocodile clamps, or by other methods.
You will ALWAYS be able either to connect up the component BEFORE creating the circuit diagram – and then to program it appropriately – or to connect it up gradually DURING the process of creating the program.

For the actual process of program creation, you should now click on “Minimise” at the top right in the Editor program.

After you have clicked on “Minimise” a list of all existing tests will appear on the right of the screen.
If you have not bought an “AT 3600 Gold”, your choice of available tests will be limited to those shown in bold type. All other tests may be ordered – and activated – at any time, as required.

The list of tests is shown in the sequence in which it is intended that they should be programmed, i.e. all “low voltage tests” are shown BEFORE the “high voltage tests”.


Resistance test

To begin the test “R”, double click with the mouse on “Winding resistance”. In the screen which is then revealed, you will find most of the entry fields which recur in the case of almost all tests.
Integration: The AT 3600 carries out a number of measurements and determines from these the “mean value”. Integration levels “short”, “medium” and “long” are intended only to indicate whether more or fewer tests are undertaken in order to determine the mean value of a measurement.
Terminals: In this case, you are requested to provide a fundamental designation of the winding contacts on which you wish to carry out measurements during the testing process which has currently been initiated.
In this example, let us assume that the first step is to measure the winding resistance of the primary winding. To do this, you should enter “P1” under “High terminal” and “P2” under “Low terminal”. If you click on “Measure”, the result is then displayed. In this example, a value of 18.711 Ω is shown for the primary winding. The test sample is obviously NOT a network transformer, as was at first thought.)
In the case of this test, you have – as with most of the many other tests – up to four different possibilities for defining limits for the distinction between “GOOD” and “BAD”.
You should then proceed as follows: Enter (in %) the lower and upper limits (negative/positive), and for nominal values enter the limiting values in figures.
When doing this, you should bear in mind that: The measured value in the first case must be larger than the value XX, whereas the measured value in the second case must be lower than the value ZZ (where values XX and ZZ are your chosen min/max values).
In the example shown, the limits are set at 18.5 Ω for the lower value and 19.0 Ω for the upper value. After clicking on “OK”, you have successfully completed setting up the first test.

IMPORTANT NOTICE: The “OK” field in each test creation screen can be activated only if the relevant test has been fully and correctly completed!!! If it IS NOT POSSIBLE to conclude the test setup by clicking on “OK”, check the keys ./, - Enter, the GOOD/BAD limits, etc.

It is now possible to measure in an exactly identical manner the winding resistance of the two secondary windings.
The winding S1/S2 is measured at 131.55 mΩ, whereas a measurement of exactly 39.321 mΩ is recorded for.the winding PP3/PP4.
Thus three different tests have already been completed.


Induction (without bias)

The following step deals with the measurement of the inductance of the primary winding.
At this point, it should be noted that the measurement frequency can be set at an infinitely variable level (between 20 Hz and 3 MHz). In this context, it should also be understood that the AT 3600/ATi exhibits a frequently surprising characteristic: if you call up the test for “LS” inductance by means of a double click and enter or fill out only the two terminals (P1 + P2) – and then simply click on “Measure” WITHOUT making any previous entries for signal and frequency, the AT 3600 will automatically determine for itself the CORRECT voltage – and in most cases, in addition, immediately set the correct measurement frequency. (In the case of the example, it actually indicates 50 Hz.)
The inductance value amounts to 18.689 mH. (A network transformer would in this case be measured at a value of 20 H to 50 H.).
The winding S1/S2 has an inductance of 207.51 µH – and the measurement of the winding PP3/PP4 indicates 10.763 µH.
Thus six different tests have already been generated.

The possibilities now range from measurements of inductance with a bias current (incidentally, we offer our own DC bias unit, which makes it possible to produce a bias current of up to 500 A by cascading methods), Q, Z, phase angle, leakage inductance, winding capacities, etc., as well as various high current tests.
The next step is to consider voltage ratios.


Voltage ratio

The voltage ratio may in general be measured in two different ways:
Test “TR” – winding ratio via current (preferably for network transformers) – and test “TRL” – winding ratio via inductance (preferably for ferrite cores).

As it has been established that the test sample is NOT a network transformer, the winding ratio of the component should be measured with the test “TRL”. To start this, double click on “TRL” and check which fields must now be completed.
The selection of the test voltage should preferably (unless this is specifically stipulated otherwise) be left to the automatic functions of the AT 3600. The frequency should be set to 100 Hz. The first step is to measure from the primary winding P1/P2 to S1/S2. Thus (as primary terminals) P1 and P2 should be entered, or alternatively it is possible to click in the relevant “Pull-down-menu” box (to the right of the terminal) on the desired designations of the windings, as well as on the secondary terminals S1 and S2. The measurement thus takes place from the primary terminals to S1/S2. The result is 9.4348 to 1.
In the same fashion, it is possible to measure the winding ratio from the primary terminals to PP3 and PP4.
The result is 47.168 to 1.
Set the acceptable tolerance to +/- 2 %.
Thus eight different tests have already been completed.

For a network transformer, it would now be appropriate to measure the no-load current “MAGI”, as well as determining the no-load voltages and the power dissipation.
The final tests on a network transformer would be the usual high current test “HPAC” and perhaps the surge voltage test (to check on possible previous damage to the windings).


High current test HPAC

Using the same demonstration object, let us now consider the high current test, and then how to save the complete test data, as well as how to load the tests INTO the AT 3600 and – most important of all – how to conduct these tests in series production processes.
In relation to the high current test “HPAC” you should proceed as follows: (This test is incidentally ALWAYS included in every delivered package)

Double click on “HPAC” and the test field opens up. At the top left is the heading “Current”: this is where the chosen test current should be entered, either in Volts (e.g. 3500) or in kV (3.5), entirely as preferred.
In the field on the right of the current, the ramp-up time is located.
It is always recommended to set a small ramp-up time of 0.2 sec. (This avoids the possibility that the test voltage /high voltage may cause damage through a sudden surge.)
Now set the frequency at 50 Hz and the hold time/persistence duration at a “normal” 2 sec. (It may be questioned here whether 100 Hz and 1 sec. respectively would not have much the same effect.)

During the next setting for the test “HPAC”, ALL primary pins and ALL pins on the secondary side MUST ALWAYS each be grouped separately to a single measurement point.
In this case: In the first two boxes “Available” and “In use” the winding connections P1/P2 should be transferred by double clicking on them and dragging them from the box “Available” to the box “In use”.
Thus P1/P2 have been grouped to a single point /measurement point.

On the right side under “Low terminals”, double click on S1, S2, PP3 and PP4. The winding connections, having been clicked on in this way, must then be transferred from the box “Available” to the box “In use”. Thus these four connections are also grouped together to a single measurement point.
Only one field now remains to be completed, namely Max. current in mA. (By this method, the dividing line between “GOOD” and “BAD” is defined.) It is quite common to carry out this test with 1 to 2 mA. Only in the case of toroidal core transformers is it necessary to be careful, as these by their very nature have a very high capacitative current element. It may therefore be the case that a toroidal core transformer displays a capacitative current of 8 mA to 12 mA. (This test is carried out only when the complete test programme is running down.)

Once again here, it is important to NOTE that tests can only be ended with “OK” if they have been entirely and correctly completed.
Thus in total nine different tests have now been created, and it is now possible to test the abovementioned demonstration object on the AT 3600.


Setting the created test program “into action”:

Saving this to the PC

Firstly, click in the menu bar of the Editor program on the menu points “Program” and “Options”.
In this field, click on the following box: “Results to server”, which will send new results to the server. (A tick will appear in the box to confirm this action.)
Furthermore, then enter “Batch number”/“Job number” and if appropriate the identity of the operator.
At the top left, the option is offered (if a printer is attached to the AT 3600) to decide whether all the results should be printed, whether these should be printed only in the event of defects, or not at all.
The AT 3600/ATi has an “Epson compatible” interface. You can therefore, for example, connect it up to a small “roll printer” in order to print a defect notice directly on to defective components.

In the field “Test adapter description” a name/description MUST be entered for the adapter used. (In the case of a demonstration run, it is sufficient to enter a simple identity such as “Test”.) This identity should then be confirmed by clicking on “OK”, and the complete field will disappear.


Saving test programs:

Click at the top left on the menu point “Test program for” and “Save under...”. In the field which then appears, enter the name, component number, description, etc.
Name the test which has been created: “Non-network transformer” and confirm this by clicking on the “Enter” key or “OK”.

The test program has now been created and saved.


Print preview

In the menu point at the upper left “Test program for…” and then “Print preview” you will now see:
Part number, adapter name, circuit diagram with connections – and when you click on “Next Page”, you can now look up on a page by page basis all the established tests and results.
You can use this printout for your documentation.


Sending a program to the tester

This is how to send the program you have created to the tester AT 3600:
Go in the Editor program to the menu point “Tester” – and click on “Send program to tester”!
The program is then saved in the AT 3600 and then the following notice appears on the screen: “The program has been loaded successfully”. Confirm this by clicking on “OK”.


Undertaking a first test run:

Go in the Editor program to the menu point “Tester” and click on “Start”.
After a few seconds – a typical example for a test program is 16.8 sec – a window appears with the title “Test results”. This window contains all tests which have been carried out, together with the test results.
If you now click in this window on “Repeat test”, a new program run is started and the same component (or the next component, if selected) is tested once again.

In the case of the example quoted above, the testing time on this occasion is only 5.34 sec!!! (This includes 2.2 seconds to reach high voltage.)
This means that a 100 % testing of a component can be achieved in approximately five seconds.
(The AT 3600 determines measurement areas and sources and saves these, with a time saving of 60 %.)

Naturally, it is now also possible to continue to carry out a testing series by pressing the “RUN” button on the AT 3600.

It should, however, be noted at this point that the measurement results can be saved only when the equipment is operating in “Server mode”. (Detailed instructions on this aspect are also available.)


Evaluation of measurement results, statistics and remote operation:

If your customers wish to see measurement results, or if you wish to evaluate your measurement results, to present the results in diagrammatic form or to prepare distribution curves, and also if you require production-related evaluations for your manufacturing operation, we have the answer:

Our new software "Kust Result Analysis" offers you a wide range of evaluation methods, diagrams, production data, archiving facilities and methods of printing information direct on to components, and so on.

If you have items of equipment at different locations and wish to operate these from a central site, or if you wish to save the measurement results from different locations at this central site, we can also facilitate this:

Our new "Remote Control" software offers the possibility of operating your equipment from any location around the world, to load programs and to access measurement values “online” and save them at a central site.
You can simultaneously access and save measurement values “online” from up to 10 items of test equipment at different locations.


A "Beta-Version" is available for free downloading!!!

KUST Messgeräte GmbH · Friedenstraße 26 · D-35578 Wetzlar · Fon +49 (0) 64 41 / 44 71 22 3 · Fax +49 (0) 64 41 / 44 71 22 5 · E-Mail: info(at)