TMS Test Data Sheet Date: 9/2/20 Serial Number #5

Caution: High Voltage will be exposed in some of the following steps.

Pulse Driver Board Bench Test Board Serial Number: 17
Attach a Gate Drive Board for a load. Prepare a variable voltage transformer to apply
line voltage. Verify line voltage neutral connects to the white input lead. Isolate the
Oscilloscope Line Cord Ground with a Ground Adaptor. Attach the Oscilloscope Probe
Ground to the Neutral test point on the Pulse Driver Board. Attach probe to the output
rail (see ​schematic​at ​https://jeffreagan.weebly.com/schematics-tms-5.html​).

Apply Line Voltage.

Verify the green LED illuminates. OK
Using Oscilloscope, log the stable line-voltage range for 15 Pulses Per Second (PPS)
(Design Goal 90 VAC to 140 VAC):
Low Line Voltage Limit High Line Voltage Limit

72 VAC 150 VAC

Log timing trim capacitor values:

C3: .012 uF C4: .0035 uF

Log the stable line-voltage range for 12 PPS operation (Design Goal 90 VAC to 140
VAC):
Low Line Voltage Limit High Line Voltage Limit

82 VAC 149 VAC

Log cap value on rotary switch (C22): .01uF
Log the stable line-voltage range for 10 PPS operation (Design Goal 90 VAC to 140
VAC):
Low Line Voltage Limit High Line Voltage Limit

82 VAC 143 VAC

Log Ringback Delay Time (pulse width seen at output rail, design goal; 1.4 milliseconds)

Ringback Delay: 1.4 Milliseconds.

Log stable Ringback Delay Low Line Voltage Limit. (Design Goal 90 VAC):
10 PPS 12 PPS 15 PPS

82 VAC 87 VAC 84 VAC

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

System Tests
Use a variable voltage transformer equipped with a voltmeter to provide line voltage. A
current transformer, a compensated high voltage divider, and an Oscilloscope will be
used to measure Applicator Coil peak current and various voltages of interest within the
system. Position an AC Ammeter between the Power Control assembly and the High
Voltage Transformer to measure high voltage transformer primary current. For further
details, see ​photos​(at ​https://jeffreagan.weebly.com/test-data.html​).

Power Application
Plug system in. Verify a Green LED illuminates on the Pulse Driver Board. OK
Power Cycle Timing and Control
Turn on power. Wait 15 seconds. View Applicator Coil peak current on the Oscilloscope.
Watch the pulse train; log the duration of pulsing (design goal, 3.5 - 4 Seconds):

Pulse Train duration: 3.75 Seconds

Use a Stopwatch to time four consecutive power cycles. Four complete cycles should
take between 55 and 65 seconds:
Cycle Time multiplied by 4: 57 Seconds
Verify Red and Yellow LEDs illuminate when high voltage comes on. OK
Verify Incandescent lamp on high voltage transformer illuminates. OK
Verify Neon Lamp illuminates on Switch Assembly. OK
Verify Neon Lamp illuminates on Cap Bank Bleeder Board. OK

Fan Power Supply Failure Detection

Unplug the Applicator Coil fan power supply. Turn system ON.
Wait 20 seconds. Verify High Voltage never energizes. OK
Plug the power supply back in. Verify normal operation resumes. OK
Fan Failure Detection
Turn off Primary Power. Remove the protective shield.
With the Power Switch in the OFF position, physically stop the Applicator Coil fan from
turning. Turn the Power Switch ON with the Fan rotor locked. Wait 15 seconds.
Verify the Red LED cycles ON and OFF normally. OK
Verify Yellow LED does not illuminate. OK
Verify High Voltage does not energize. OK
Release the Fan Rotor. Verify the Yellow LED cycles normally again. OK
Verify normal operation resumes. OK

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

15 PPS High Voltage Transformer Phasing

Set line voltage for 120 Volts, Rheostat for full power, and select 15 PPS. Transformer
primary power wires shall be swapped to identify correct phasing. Primary current
should read about two amps lower with the correct transformer phasing.

Incorrect Phasing primary current: 13 Amps

Correct Phasing primary current: 11 Amps

Peak Voltage and Current Measurements

Note: when changing line voltage, the system is allowed to stabilize before
measurements are taken. Current transformer and compensated divider outputs are
monitored with an Oscilloscope. Line voltage is set while the unit is pulsing; then we log
Applicator Coil peak currents (positive and negative), peak Capacitor Voltages (positive
and negative), and HV Transformer Primary Current. Measurements are taken at 103
VAC, 115 VAC, and 127 VAC.
15 PPS Full Power Test Data
Line Voltage: 103 VAC 115 VAC 127 VAC
Positive Pulse Measurement:
Peak Applicator Coil Current: 1126A 1266A 1408A

Peak Capacitor Voltage: 1898V 2144V 2376V

Negative Pulse Measurement:
Peak Applicator Coil Current: -898A -1000A -1108A

Peak Capacitor Voltage: -1494V -1702V -1880V

Transformer Primary Current: 8A 10.5A 13A

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

15 PPS Minimum Power Test Data

Line Voltage: 103 VAC 115 VAC 127 VAC
Positive Pulse Measurement:
Peak Applicator Coil Current: 909A 1028A 1146A

Peak Capacitor Voltage: 1556V 1756V 1948V

Negative Pulse Measurement:
Peak Applicator Coil Current: -715A -813A -909A

Peak Capacitor Voltage: -1240V -1372V -1550V

Transformer Primary Current: 7.5A 8.5A 9.5A

12 PPS Full Power Test Data

Line Voltage: 103 VAC 115 VAC 127 VAC
Positive Pulse Measurement:
Peak Applicator Coil Current: 1168A 1307A 1464A

Peak Capacitor Voltage: 1996V 2232V 2476V

Negative Pulse Measurement:
Peak Applicator Coil Current: -929A -1040A -1157A

Peak Capacitor Voltage: -1584V -1772V -1980V

Transformer Primary Current: 7.8A 9A 11.5A

12 PPS Minimum Power Test Data
Line Voltage: 103 VAC 115 VAC 127 VAC
Positive Pulse Measurement:
Peak Applicator Coil Current: 996A 1107A 1241A

Peak Capacitor Voltage: 1696V 1878V 2108V

Negative Pulse Measurement:
Peak Applicator Coil Current: -791A -883A -896A

Peak Capacitor Voltage: -1350V -1512V -1684V

Transformer Primary Current: 6.5A 7.4A 8.4A

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

10 PPS Full Power Test Data

Line Voltage: 103 VAC 115 VAC 127 VAC
Positive Pulse Measurement:
Peak Applicator Coil Current: 1215A 1365A 1514A

Peak Capacitor Voltage: 2070V 2316V 2576V

Negative Pulse Measurement:
Peak Applicator Coil Current: -965A -1086A -1195A

Peak Capacitor Voltage: -1652V -1854V -2042V

Transformer Primary Current: 6.8A 8.2A 11A

10 PPS Minimum Power Test Data
Line Voltage: 103 VAC 115 VAC 127 VAC
Positive Pulse Measurement:
Peak Applicator Coil Current: 1051A 1178A 1303A

Peak Capacitor Voltage: 1790V 2006V 2208V

Negative Pulse Measurement:
Peak Applicator Coil Current: -834A -935A -1037A

Peak Capacitor Voltage: -1424V -1596V -1772V

Transformer Primary Current: 5.8A 6.8A 7.8A

Generator Ratings

Generator Manufacturer: PRAMAC INDUSTRIES

Generator Model EG2800MHHPI-A00T2

Peak Power: 2800W

Continuous Power: 2520W

Voltage: 120VAC

Current: 21.7A

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

Generator Test Data

Power Factor Correction (PFC) Capacitor Size:
None 205 uF

No Load Output Voltage: 126V 154V

Full Power Minimum Power

15 PPS PFC Test Data
Line Voltage 115V 119V
Positive Pulse Measurement:
Peak Applicator Coil Current: 1332A 1136A

Peak Capacitor Voltage: 2262V 1944V

Negative Pulse Measurement:
Peak Applicator Coil Current: -1048A -896A

Peak Capacitor Voltage: -1820V -1546V

Transformer Primary Current: 10.5A 9A

15 PPS No-PFC Test Data

Line Voltage 100V 104V
Positive Pulse Measurement:
Peak Applicator Coil Current: 1086A 939A

Peak Capacitor Voltage: 1858V 1620V

Negative Pulse Measurement:
Peak Applicator Coil Current: -856A -744A

Peak Capacitor Voltage: -1440V -1280V

Transformer Primary Current: 10A 8A

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

Full Power Minimum Power

12 PPS PFC Test Data
Line Voltage 118V 120V
Positive Pulse Measurement:
Peak Applicator Coil Current: 1407A 1224A

Peak Capacitor Voltage: 2418V 2102V

12 PPS Negative Pulse Measurement:
Peak Applicator Coil Current: -1120A -981A

Peak Capacitor Voltage: -1924V -1672V

Transformer Primary Current: 10A 8A

12 PPS No-PFC Test Data
Line Voltage 102V 105V
Positive Pulse Measurement:
Peak Applicator Coil Current: 1158A 1014A

Peak Capacitor Voltage: 1996V 1770V

Negative Pulse Measurement:
Peak Applicator Coil Current: -924A -818A

Peak Capacitor Voltage: -1598V -1392V

Transformer Primary Current: 7.5A 6.5A

10 PPS PFC Test Data
Line Voltage 118V 120V
Positive Pulse Measurement:
Peak Applicator Coil Current: 1474A 1303A

Peak Capacitor Voltage: 2530V 2236V

Negative Pulse Measurement:
Peak Applicator Coil Current: -1162A -1032A

Peak Capacitor Voltage: -2018V -1790V

Transformer Primary Current: 9.5A 7.5A

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

Full Power Minimum Power

10 PPS No-PFC Test Data
Line Voltage 104V 107V
Positive Pulse Measurement:
Peak Applicator Coil Current: 1226A 1089A

Peak Capacitor Voltage: 2098V 1876V

Negative Pulse Measurement:
Peak Applicator Coil Current: -974A -865A

Peak Capacitor Voltage: -1690V -1500V

Transformer Primary Current: 6.75A 6A

48 Hour Burn In
Remove the Current Transformer, Amp Meter, and High Voltage Probe; Replace
protective cover. Set Line Voltage for 120 VAC. Run some of the burn in at each pulse
repetition frequency. Return the system to 15 PPS and full power for the last day.
Time: Date:

15 PPS Full Power Burn In Start: 4:28 pm 7/20/20

After one hour of operation, take an Infrared temperature measurement and log
Applicator Coil hotspot temperature:
Time: Date: Hotspot Temperature
5:36 pm 7/20/20 176 F
5:18 pm 7/21/20 201.7 F
10:47 am 7/22/20 183.7 F
15 PPS Minimum Power Burn In
Set the system to 15 PPS, reduce power level to minimum (full counterclockwise). Note:
some heating will occur with the Rheostat. Waxy smell may appear initially. Run the
system until the waxy smell is gone.
Start Time: Date:
10:52 am 7/22/20
After one hour of operation, take an Infrared temperature measurement and log
Applicator Coil hotspot temperature:
Time: Date: Hotspot Temperature
12:25 pm 7/22/20 171 F

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

15 PPS Minimum Power Burn In Finish

Time: Date: Hotspot Temperature
1:52 pm 7/23/20 164 F

Post Burn In Inspection

Turn OFF power. Remove cover promptly. Discharge capacitors with the shorting stick.
Feel various system parts for excessive temperature buildup.
No abnormal heating detected: OK

Unit is ready for service.

Burn In Test Technician:

Name: Jeff Reagan

Note:
Unit was modified to have three frequency settings: 10 PPS, 12 PPS, and 15 PPS. A
summary burn in was implemented afterward.
15 PPS Full Power Burn In Start:
Time: Date:
5:39 pm 9/9/20
After one hour of operation, take an Infrared temperature measurement and log
Applicator Coil hotspot temperature:
Time: Date: Hotspot Temperature
7:05 pm 9/9/20 165 F

12 PPS Burn In start:

After one hour of operation, take an Infrared temperature measurement and log
Applicator Coil hotspot temperature:
Time: Date:
7:05 pm 9/9/20
After one hour of operation, take an Infrared temperature measurement and log
Applicator Coil hotspot temperature:
Time: Date: Hotspot Temperature
8:05 pm 9/9/20 170 F

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TMS Test Data Sheet Date: 9/2/20 Serial Number #5

System Data
High Voltage Capacitor Net Value: 18 Microfarads

Calculated pulse energy at 10 PPS, 115 VAC: 41.37 Joules

Calculated pulse energy at 12 PPS, 115 VAC: 44.84 Joules

Calculated pulse energy at 15 PPS, 115 VAC: 48.27 Joules

Number of turns on the Applicator Coil: 35 Turns

Applicator Coil outer diameter: 55 Millimeters

Ampere-Turns, 115 VAC, 10 PPS:47,775 AT

Ampere-Turns, 115 VAC, 12 PPS: 45,745 AT

Ampere-Turns, 115 VAC, 15 PPS: 44,310 AT

Delivered Pulse Width, measured at the baseline: 84 Microseconds

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