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High Withstand Voltage Tester Operation Manual

1. The following commands are used to control actual output voltage and current from the instrument Please observe all safety precautions TEST RESET Abort a test in Process or Reset Failures SACG Set Auto Charge LO TEST Starts the test sequence at the selected memory location that has been loaded into the instruments memory RAM RESET Stop or abort a test Also used to reset a latched failure condition 54 CXI ech SACG Set the Charge LO parameter for the DCW test The cables and any test fixture should be connected before executing the command The test parameters that are set for the memory will be used when performing the auto setting This command will perform an actual test and all safety precautions should be observed when using this command 9 8 2 File Editing Commands The following commands are used to create or modify Test Setup Files FL lt memory number gt File Load memory number 1 50 ADD Add all parameters of a lt test p1 p2 p3 gt test SF 1 0 Fail Stop 1 On 0 Off FL lt memory number gt Load a file by memory number from non volatile memory into random access memory RAM ADD lt test p1 p2 p3 gt This command edits all parameters in a memory location Parameters will be edited at the memory location that has been selected The parameter lt test gt indicates the test type The test type values ACW or DCW must be used The parameters lt p1 p2 gt etc indicate the individual setti
2. Ramp UP Time setting Advance the menu to the Ramp UP time parameter The display will show ACW Units DCW Units Ramp UP XXX X s or Ramp UP XXX X s Range 0 3 999 9s Range 0 4 999 9s Use the Numeric keys to enter the Ramp UP time setting then press the ENTER key The program will store the Ramp UP time setting and advance to the Dwell Time setting automatically Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set 5 2 5 Dwell Unit setting Advance the menu to the Dwell Unit parameter The display will show Dwell Unit Second or Dwell Unit Minute lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to toggle between the Seconds and Minutes The program will store the Dwell Unit setting and advance to the Dwell Time setting automatically 5 2 6 Dwell Time setting Advance the menu to the Dwell Time parameter The display will show Dwell Time XXX X s Dwell Time XXX X m Range 0 3 999 9s 0 Const Range 0 4 999 9m 0 Const 35 CX sc Use the Numeric keys to enter the Dwell Time setting and then press the ENTER key The program will store the Dwell Time setting and advance to the Ramp DOWN time setting automatically The unit is second and 0 1 second per step The display will show the elapsed time during the testing Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set If the D
3. 8 1 to 9 8 6 of this manual The identification command IDN and the Status Reporting commands are also available through RS 232 The RS 232 cabling should be configured as follows for a 9 pin serial port interface Instrument RS 232 Port PC Bus Controller RD 2 2 RD SIG 5 5 SIG GND GND The COM port should have the following configuration 9600 baud 8 data bits 1 stop bit no parity This interface does not support XON XOFF protocol or any hardware handshaking The controller should be configured to ignore the handshaking lines DTR pin 4 DSR pin 6 CTS pin 8 and RTS pin 7 If the port cannot be configured through software to ignore the lines then the handshake lines should be jumpered together in two different sets Pins 4 and 6 jumpered together and pins 7 and 8 jumpered together at the controller end of the cable 53 CX sc When sending command over the RS232 bus the instrument will send a response string of 06 hex or 6 decimal the Acknowledge ACK ASCII control code if the transfer was recognized and completed by the instrument If there is an error with the command string that is sent the instrument will respond with 15 hex or 21 decimal the Not Acknowledge NAK ASCII control code The ACK or NAK response allows for software handshaking to monitor and control data flow When requesting data from the instrument 1t will automatically send the data back to the controller input buffer The controller input buffer will accumul
4. H 3 1 2 7472 Functional Specifications Output Rating 12KVDC 10mA DC WITHSTAND VOLTAGE Output Voltage DCV 0 12000 10 2 of setting 10V Output Ripple lt 5 12KV 9999uA at Resistive Load SETTINGS Hi Lo Limit DC Current HA 0 0 999 9 1000 9999 0 1 1 2 of setting 2counts Ramp Up Time second 0 4 999 9 0 1 Ramp Down Time second 0 0 1 0 999 9 0 1 0 1 0 05sec 0 0 4 999 9 sec Dwell Time O continous 0 1 0 0 1 999 9 min 0 1 O continuous i 0 0 1 999 9 hr 0 1 O continuous Cycle Test 0 9999 Times 0 continuous Arc Detection 1 9 ranges 9 is the most sensitivity DC Current Offset pA Ramp High Current Charge Low Current HA Discharge Time Maximum Capacitive Load 0 0 200 0 or Auto Set Option ON OFF User Selection 0 0 350 0 or Auto Set lt 200 msec 15uF lt 2KV 0 28uF lt 4KV 0 18uF lt 6KV 0 15uF lt 8KV 0 15uF lt 10KV 0 12uF lt 12KV MEASUREMENT DC Voltage KV 0 10 00 0 01 1 5 of reading 2counts 0 350 0 0 1 DC Current Range pA 300 3500 1 2 of reading 3counts 3000 9999 10 CX sc 3 1 3 7473 Functional Specifications Output Rating 20K VAC 10mA AC WITHSTAND VOLTAGE Range Resolution Accuracy Output Voltage ACV 0 20000 10 2 of setting 20V Output F
5. If the Fail stop is off and a failure occurs during the test sequence the RESET button will light and a short alarm will sound but the sequence will continue to the end At the end of the test 28 cXI sc H sequence the RESET button will light and alarm will sound indicating failure during the sequence Pressing the RESET button will silence the alarm and reset the instrument A display of the first eight connected memories PASS FAIL results on items tested is provided at the conclusion of the last connected memory The display will show the results of the eight memories as follows Test P F P F P F P F Mem 22 23 24 25 26 27 28 29 The pass fail status is indicated by the letter F Fail or P Pass Toggle the Fail Stop function or press the SETUP key to forward to the LCD Contrast selection Press the EXIT key to return to the operation mode The program will store the Fail Stop setting automatically 4 1 3 LCD Contrast Press the SETUP key to advance the menu to the Contrast parameter The display will show Contrast x Range 1 9 9 High Use the Numeric keys to enter the LCD Contrast level then press the ENTER key The program will change the LCD Contrast immediately when the ENTER key is pressed so the setting can be viewed The LCD Contrast level may be adjusted from 1 9 Level 1 is the lowest contrast and level 9 is the highest contrast Change the LCD Contrast again or press the SETUP key to advance to the Alarm
6. Keep unqualified and unauthorized personnel away from the test area e Arrange the test station in a safe and orderly manner e Never touch the product or connections during a test e Incase of any problem turn off the high voltage first e Properly discharge any item tested with DC before touching connections 1 5 Introduction to Product Safety Testing 1 5 1 The Importance of Safety Testing Product Safety Tests are specified during the design and development stages of a product as well as in the production of the products to insure that it meets basic safety requirements These tests are designed to verify the safety of the electrical products in that they do not jeopardize the safety of the people domestic animals and property of anyone who may come in contact with these products In an era of soaring liability costs original manufacturers of electrical and electronic products must make sure every item is as safe as possible All products must be designed and built to prevent electric shock even when users abuse the equipment or by pass built in safety features To meet recognized safety standards one common test is the dielectric voltage withstand test Safety agencies which require compliance safety testing at both the initial product design stage and for routine production line testing include Underwriters Laboratories Inc UL the Canadian Standards Association CSA the International Electrotechnical Commission IEC t
7. U S A 60 per second in other countries 50 times per second 1 3 Glossary of Terms As used in this manual Breakdown The failure of insulation to effectively prevent the flow of current sometimes evidenced by arcing If voltage is gradually raised breakdown will begin suddenly at a certain voltage level Current flow is not directly proportional to voltage Once breakdown current has flown especially for a period of time the next gradual application of voltage will often show breakdown beginning at a lower voltage than initially Conductive Having a volume resistivity of no more than 103 ohm cm or a surface resistivity of no more than 105 ohms per square Conductor A solid or liquid material which has the ability to let current pass through it and which has a volume resistivity of no more than 103 ohm cm Current The movement of electrons through a conductor Current is measured in amperes milliamperes microamperes nanoamperes or picoamperes Symbol I Dielectric An insulating material that is positioned between two conductive materials in such a way that a charge or voltage may appear across the two conductive materials Direct Current DC Current that flows in one direction only The source of direct current is said to be polarized and has one terminal that is always at a higher potential than the other Hipot Tester Common term for dielectric withstand test equipment Insulation Gas liquid or solid material
8. a continuous closure dependent on the length of time the reset button is held in an active state 8 2 Signal Inputs of Remote I O and Memory Access The High Withstand Voltage Tester remote connector enables remote operation of the TEST RESET and REMOTE INTERLOCK functions and allows the operator to select Memory 1 Memory 2 and Memory 3 When the PLC Remote mode is on the High Withstand Voltage Tester will respond to simple switch or relay contacts closures A normally open momentary switch can be wired across pins 3 and 5 to allow remote operation of the TEST function A minimum pulse width or contact closure of 20mS is required to guarantee a test start A normally open momentary switch can be wired across pins 2 and 5 to allow remote operation of the RESET function A minimum pulse width or contact closure of 50mS is required to guarantee that a running test will abort When the PLC remote function is ON the TEST switch on the front panel will be disabled to prevent a test from being activated through this switch For safety the front panel RESET switch remains active even when a remote reset switch is connected so that high voltage can be shut down from either location The High Withstand Voltage Tester also allow access to three MEMORY PROGRAMS through the remote control connector This gives the user the capability to quickly change parameters and initiate a test remotely The built in memory programs of the instrument are used to ac
9. ii E ar adage ce 33 5 2 Setting o tia lahat ls 34 De RSV IC A vaste ter udasties e aT AEE eaa EAr r a Oaa E 39 5 4 Default Test Parameters eissii i na a E EE E E A R E A tevieags 39 6 OPERATING INSTRUCTIONS 2 20 tea dd cda 39 6 1 Preparation and Instrument Connections ooooooccconoconnononononoconocono nono ncon nono no nano nonnn con nano nn cn nnnnnno 40 62 PO WE A II II A A ER 40 0 34 SEUUES IC o 40 MEA is rias 41 0 Performing a VE A AA A AA A E AAA EA ALA 42 7 DISPLAY ED MESSAGES das o o 43 1 1 R nning Test Messages US NANA a 43 7 2 Additional Displayed messages for DC UNiS ooooocnnccinococonccconoconnnonnnconccnonocnnn nono ncon cnc nccncnnnnss 46 do USAR CMOlE Message url li tit 46 T4 Fatal ETTO cig fase tov ons ina eats ata asa Nah aha ata say esas cat aa 47 Ro JUVOUL A O ass 47 8 CONNECTION OF REMOTE 1 0 0 ccccccccscscsssssessssessccsesessscseseseseeecececseseseseeseseseeeeeeees 48 8 1 Signal Outputs on Remote Visca 48 8 2 Signal Inputs of Remote I O and Memory ACCESS oococccooccooccconnconncconocononononcon nono nocnnn non ncnnnno 49 9 BUS REMOTE INTERFACE GPIB RS 232 OPTION 0oocononiononociconociccconinoncnonnnincnnons 51 A A A O at een eae onan ea A 51 RA e a a E N R RORE 51 A A aU a AR eR ee Poe Pe ce EERE ne eR RE 51 94 GPIB CONMeClOn O R a le nena aia a ra alee ads 51 9S IS AGC SS ate Stats as ata ices bier a stasis ates hy tule eutunceauiy E ah Sy aa se nasa E E EGE S 52 9 6 Interface FUNCIONS
10. in environments with the following limits Temperature ocooocccinoncnnnns 40 131 F 40 55 C FRITS mais 25 000 feet 7 620 meters The instrument should also be protected against temperature extremes that may cause condensation within the instrument CX sci 3 Specifications and Controls 3 1 Functional Specifications 3 1 1 7470 Functional Specifications Output Rating 10K VAC 20mA AC WITHSTAND VOLTAGE Range Resolution Accuracy Output Voltage ACV 0 10000 10 2 of setting 10V Output Frequency 50Hz 60Hz 100ppm User Selection Output Waveform Sine Wave THD lt 2 Resistive Load Crest Factor 1 3 1 5 Output Regulation 1 of output 10V From no load to full load SETTINGS Hi Lo Limit AC Current mA 0 9 999 10 00 20 00 0 001 0 01 2 of setting 2counts Ramp Up Time second 0 1 999 9 0 1 Ramp Down Time second 0 0 999 9 0 1 0 0 3 999 9 sec 0 1 O continuous 0 1 0 05sec Dwell Time ee 0 1 O continuous 0 0 1 999 9 hr 0 1 O continuous Cycle Test 0 9999 Times O continuous Arc Detection 1 9 ranges 9 is the most sensitivity AC Current Offset mA 0 2 000 or Auto Set Option MEASUREMENT AC Voltage KV 0 10 00 0 01 2 of reading 2counts 0 3 500 0 001 E AC Current Range mA 2 of reading 3counts 3 00 20 00 0 01 18 CXI sc
11. it SS Check to be sure that the correct input line voltage has been selected on the CAUTION rear panel either 115 volts AC or 230 volts AC Connect the power input plug into its socket on the rear panel of the instrument Connect the male end of the plug to the outlet receptacle Please be sure that the safety ground on the power line cord is not defeated and that you are connecting to a grounded power source Turn on the POWER switch located on the lower left hand side of the front panel The initialization screen will appear The initialization screen will appear as follows EXTECH HIGH WITHSTAND VOLTAGE TESTER Note X Numeric 7471X VER X XX After the initialization screen disappears the Settings screen will be displayed The Settings screen will appear as follows MXX Set XXX X s XX XX KV X XXX xA The High Withstand Voltage Tester comes with all of the memories loaded with the withstand default parameters The initial test loaded for use is Memory 1 If this test is unacceptable for your DUT then refer to the section 5 Test Parameters Setup Procedure for instructions on how to program tests into the instrument If these parameters are acceptable then connect an appropriate set of test leads to the device under test DUT or test fixture Connect the return lead Black alligator clip insulator to the DUT or test fixture then connect the high voltage output lead Red alligator clip insulator Make sure the safety grou
12. memory indicated by memory number 1 50 See the ADD command for the list of parameters A comma will separate each parameter and will be preceded with the memory number 9 8 6 IEEE 488 2 Common Commands These commands are required by the IEEE 488 2 standard with the exception of PSC PSC Most of these commands are not available over the RS 232 bus except for the IDN command 58 cXI sc H which can be used to retrieve the instrument identification information and the four status reporting commands ESR ESE ESE and STB Identification Query Extech Electronics Ltd Co Model Number Serial Number Firmware Revision TST Self Test Query 0OH OK 01H TEST EEPROM ERROR CLS Clear Status Command Clear Standard Event Status Register Clear Service Request Register operations complete ESR BITO 1 operations complete Output Queue 1 A A Power on Status Clear Command 1 Power on clear enable registers 0 Power on load previous enable registers 7 Poweron Stats Clear Query if SSCS Standard Event Status Register Query 0 255 ESE lt value gt Standard Event Status Enable value 0 255 Command PSC 1 0 i N td no Standard Event Status Enable Query 0 255 Read Status Byte Query Read Status Byte gt Service Request Enable Command value 0 255 Service Request Enable Query 0 255 X 238 alg AA Q Q IDN Read the instrument identification string Com
13. s If the DUT current exceeds the HI Limit of AC Withstand Voltage test and the leakage current is within the metering range the display will show MXX HI Limit XXX X s XX XX KV XX XX mA If the DUT current exceeds the HI Limit of AC Withstand Voltage test and the leakage current is not within the metering range the display will show 44 CXI sc H MXX HI Limit XXX X s XX XX KV gt 10mA If the DUT current is well beyond the metering range of AC Withstand Voltage test the instrument assumes that the failure is due to a short circuit the display will show MXX Short XXX X s KV gt 10mA If the DUT current is well beyond the metering range of AC Withstand Voltage test and an Arcing condition beyond the Arc Sense limit is indicated the display will show MXX Breakdown XXX X 8 XX XX KV gt 10 mA If the DUT current falls below the LO Limit of AC Withstand Voltage test the display will show MXX LO limit XXX X s XX XX KV XX XX mA If the DUT current is within the metering range of the AC Withstand Voltage test and an Arcing current exceeds the Arc Sense limit and the Arc function is set to ON then an Arc failure has occurred and the display will show MXX Arc Fail XXX X s XX XX KV XX XX mA If a Ramp DOWN time has been set and the dwell portion of the test is complete the display will show MXX Ramp DOWN XXX X s XX XX KV XX XX mA If the DUT has passed the AC Withstand Voltage test and the test process is compl
14. the Key Lock function from LOCK to UNLOCK or UNLOCK to LOCK mode and advance the program to the Operation mode automatically Ifthe Key Lock function is in the Lock mode the LOCK indicator on the front panel will light If the Memory Lock function is selected to ON the Memory selection Menu will be disabled when in the Lock Mode Ifthe Memory Lock is selected to OFF the Memory selection Menu will be enabled when in the Lock Mode Different memories can be recalled but the test parameters or steps cannot be changed Please refer to section 4 1 7 Memory Lock for instructions on this feature 4 2 2 Local Function Use this key when you wish to go from the Remote operation of the instrument to the Local mode 4 3 Password Setting Press the 4 and 7 keys simultaneously and then turn the input power switch on The program will automatically enter to the Password Setting mode and the display screen will show Password 0 or Password XXXX Range 0 9999 Range 0 9999 The Password can be any four 4 digit number If the Password is set to 0 the keyboard lock out will be selected by the LOCK key on the front panel without a Password The Password default is preset to 0 at the factory 32 CXI ech 5 Test Parameters Setup Procedures 5 1 Test Parameters Description of Test Parameters Voltage The Voltage that is applied to the High Voltage and Return terminals or the Current and Return terminals during a test
15. to use the High Withstand Voltage Tester in an automated environment without writing their own software Manufacturers can capture store and analyze relevant test data High Withstand Voltage Tester powers up with the parameters that were used during the last test to avoid operator set up errors The easy to follow setup screens ensure that the operator correctly sets up all test parameters This makes it possible to limit user access to the setup screens so that only authorized personnel with a security code can change test parameters CX sc Electronic dwell settings PLC remote inputs and outputs Software calibration control User selectable output voltage frequencies of 50 or 60 hertz Output voltage fine adjustment Flashing high voltage indicator User selectable input voltage Low current sense Electronic ramping up amp down 14 The electronic dwell control helps keep test results consistent by ensuring that the test duration is the same for each product tested The standard 9 pin interfaces provide outputs for Pass Fail and Test in Process Inputs include Test Interlock and Reset Remote recall of memory program 1 2 and 3 This gives the user all the basic remotes required to configure the High Withstand Voltage Tester through simple PLC relay control High Withstand Voltage Tester is calibrated through the front panel keypad All calibration information is stored in non volatile memory This a
16. which has a volume resistivity of at least 1012 ohm cm and is used for the purpose of resisting current flow between conductors Insulation Resistance Tester An instrument or a function of an instrument capable of measuring resistance s in excess of 200 megohms Usually employs a higher voltage power supply than used in ohmmeters measuring up to 200 megohms Leakage AC or DC current flow through insulation and over its surfaces and AC current flow through a capacitance Current flow is directly proportional to voltage The insulation and or capacitance is thought of as a constant impedance unless breakdown occurs Resistance That property of a substance that impedes current and results in the dissipation of power in the form of heat The practical unit of resistance is the ohm Symbol R Trip Point A minimum or maximum parameter set point that will cause an indication of unacceptable performance during a run test Voltage Electrical pressure the force which causes current through an electrical conductor Symbol V CX sci 1 4 Safety This product and its related documentation must be reviewed for familiarization with safety markings and instructions before operation This product is a Safety Class I instrument provided with a protective earth terminal Before applying power verify that the instrument is set to the correct line voltage 115 or 230 and the correct fuse is installed A Hipot produces voltages and cur
17. writing of the parameter requires that the unit not be included with the value only the numeric value should be included with the command Also when the query commands are used the response will not include the unit s characters Many of the commands will function the same way for multiple test types however the input range may be different and therefore used a different possible set of values Types EA DCW EAD DCW ECC DCW ECG EDW lt value gt Edit Dwell ACW _ 0 0 3 999 9s 7470 7473 EDW DCW 0 0 4 999 9s 7472 7474 0 0 1 999 9m EF 1 0 Edit Frequency 1 60Hz 0 50Hz EF 0 0 999 9 uA 7472 7474 1000 9999uA 7472 1000 5000uA 7474 ERD DCW _ 0 1 0 999 9s 7472 7474 ERH ERU lt value gt Edit Ramp UP ACW 0 1 999 9s 7470 ERU DCW 0 3 999 95 7473 0 4 999 9s 7472 7474 EV lt value gt Edit Voltage ACW 0 10 00kV 7470 EV DCW 0 12 00kV 7472 0 20 00KV 7473 0 20 00KV 7474 9 8 4 System Parameter Editing Commands and Companion Queries EL lt value gt _ LO Limit EL EH lt value gt Edit HI Limit ACW 0 000 9 999mA 7473 7470 EH DCW 10 00 20 00mA 7470 56 cXI ech These commands are used to modify the system parameters for the instrument These commands require a parameter value to be included with the command The companion query command will read the parameter using the same value that is used for setting the para
18. 2 NO 1003 65 CX sci 11 Calibration Procedure This instrument has been fully calibrated at the factory in accordance to our published specifications It has been calibrated with standards traceable to CNLA You will find in this manual a copy of the Certificate of Calibration It is recommended that you have this instrument re calibrated and a safety check done at least once per year EXTECH recommends you use Calibration Standards that are CNLA traceable or traceable to agencies recognized by CNLA to keep this instrument within published specifications End user metrology standards or practices may vary These metrology standards determine the measurement uncertainty ratio of the calibration standards being used Calibration adjustments can only be made in the Calibration mode and calibration checks or verifications can only be made while operating in Test mode 11 1 Required Calibration Equipment e 0 10kV RMS AC and DC Voltage Divider Voltage divider must handle 14 14kV peak e 7470 20mA AC Ammeter e 7473 10mA AC Ammeter e 7472 10mA DC Ammeter e 7474 5mA DC Ammeter e 7470 7472 100KQ 20 watt resistor 1000 volt e 7472 7473 100KQ 10 watt resistor 1000 volt e 7474 100KQ 2 5 watt resistor 1000 volt e 7472 7474 IMQ 0 25 watt resistor 300 volt 11 2 Calibration Initialization Press and hold the calibration key on the rear panel with a pen pencil or small screwdriver while powering ON the High Withst
19. AC 3 500mA 100KQ OK lt TEST gt to Calibrate 11 3 3 Calibration of 7473 AC Hipot Current AC Hipot 10mA current range Press the v key the program will advance to the AC 10 00mA range calibration of the hipot test The display will show AC 10 00mA 100KQ lt TEST gt to Calibrate Connect a resistor about 100K Q 10W in series with a AC standard Ammeter which can measure up to 10 00mA to the output leads The Ammeter should be connected to the return lead then press the TEST button the program will automatically generate an output of about 1000V 10 00mA and the display will show Current mA Enter Standard I out Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of AC 10 00mA range for calibration and the display will show AC 10mA 100KQ OK lt TEST gt to Calibrate AC Hipot 3 500mA current range Press the v key the program will advance to the AC 3 500mA range calibration of the hipot test The display will show AC 3 500mA 100KQ lt TEST gt to Calibrate Connect a resistor about 100K Q 10W in series with a AC standard Ammeter which can measure up to 3 500mA to the output leads The Ammeter should be connected to the return 68 cXI ech lead then press the TEST button the program will automatically generate an output on the output connectors about 350V 3 00mA and the display will show Current mA Enter Standard I out Use the Nume
20. HI Limit A maximum current or resistance threshold that when exceeded triggers a failure LO Limit A minimum current or resistance threshold that when not exceeded triggers a failure Ramp UP A length of time that is allowed for the test voltage to climb from 0 to the voltage set point Dwell Unit Allows for the selection of seconds or minutes as the Dwell timers base unit Dwell A length of time that is allowed for the set point voltage to be applied Ramp DOWN A length of time that is allowed for the test voltage to decay from set point to zero Arc Detect This function when turned on activates the Arc Detection threshold controlled by the Arc Sense parameter Arc Sense The numbers corresponding to the different arc sensitivity levels are 1 through 9 1 meaning the maximum threshold of allowable arcing 9 meaning the minimum threshold of allowable arcing During Hipot testing some low current arcing may be allowable Arc sense is a maximum allowable threshold for arcing Frequency This parameter is available in AC tests only and is selectable using the settings menu between 50 and 60Hz Connect This function when turned ON will connect or link the current memory to the next memory This function allows all 50 memory locations to be connected together Ramp HI Ramp HI will allow current higher than the normal HI Limit current setting of the DC Withstand Voltage test during the Ramp Up time to avoid false failure due to char
21. High Withstand Voltage Tester MODEL 7470 10KV AC ONLY HIPOT MODEL 7472 12KV DC ONLY HIPOT MODEL 7473 20KV AC ONLY HIPOT MODEL 7474 20KV DC ONLY HIPOT Operation Manual EXTECH Electronics Co Ltd PHONE 886 26943030 FAX 886 26947575 4F NO 252 Nan Yang Street Shih Chih City Taipei Hsien 221 Taiwan Website http www extech electronics com Printed in Jan 2006 EV 1 01 CONTENT 1 INTRODUCTION a o 1 1 1 Warranty Policies a A E uk ena aieci ahold 1 1 2 Safety Symbols rides 2 1 3 Glossary of Terms As used in this manual 0 00 0 cccecceeseceseeeecceeseecaeceeceeeeeeseecaeceeeeeeeeeneees 3 LA SE A A AS A a E 4 1 5 Introduction to Product Safety Testing o ooonoocnnoconococonccconcconnnononooncccnonono nono ncon nono no cnn ncnnnncanncins T 1 6 The Ditferent Types of Safety Ted das 8 1 7 Rey Features ABS AA A ed da 13 22 GETTING STARTED get e ol o 15 21 Unpacking atid Inpec rs iia bios 15 22 s A un tenseahia ev Ned ot aap OR AG aE ALE a de MA 16 3 SPECIFICATIONS AND CONTROLS 0 ccccssssssesssesesesssessesesesesesececeeseseseuesseseseeeeeeeees 18 3 1 Funcional Special e A A asa 18 3 2 Instrument Controls sisia a aa aaa iaaa iaaa 23 A A E T 26 4 SYSTEM SETTINGS e es Eos 28 4 A OS 28 AMOR LOA E TENE 31 4 3 Password Setting ses Siecle atd an va aS a ae ase a ahaa aad an Recta rat 32 5 TEST PARAMETERS SETUP PROCEDURES c ccccccccsssesssseseseseseseseseeseseseeeeeeeees 33 SL Pest PAra
22. RESET key will return you to the Settings screen 5 4 Default Test Parameters The following table is a listing of the Default Parameters for the ACW tests available in the 7470 and 7473 High Withstand Voltage Tester and the DCW tests available in the 7472 and 7474 High Withstand Voltage Tester When you receive your High Withstand Voltage Tester all 50 memory locations will be loaded with these parameters The Default Parameters are as follows Test Type ACW units DCW units Parameter Voltage HI Limit current LO Limit current Ramp UP Dwell Unit Dwell Time Ramp DOWN Frequency Arc Detect Arc Sense Connect Voltage HI Limit LO Limit Ramp UP Dwell Unit Dwell Time Ramp DOWN Arc Detect Arc Sense Ramp HI Charge LO Connect 1 24kVAC 5 000mA 0 000mA 0 3s Second 1 0s 0 0s 60Hz OFF 5 OFF 1 50k VDC 5000HA 0 0UA 0 4s Second 1 0s 0 0s OFF 5 OFF 0 0UA OFF 39 CXI sc 6 Operating Instructions 6 1 Preparation and Instrument Connections Before the operation of this instrument make sure that all Test Parameters have been set properly according to the Test Parameters Setup Procedures Also check the system setting of Remote Control LCD Contrast the Alarm Volume and Fail Stop Be sure to connect the appropriate test leads to the device under test DUT or test fixture Be sure to connect the safety ground on the rear panel to a suitable known good ground before energizing this instrument Th
23. RQ functions All commands can be found in section 9 Bus Remote Interface GPIB RS 232 of this manual Printer Port Option This option allows the instrument to generate hardcopy printout of the test results The printout can be configured to print automatically with each test or manually by pressing a front panel key There is also capability to enter a serial number identifier to each test that increments automatically after each test is performed The test can be further configured to print only results from tests that have failed or to print all test results from every test performed The Printer Port is a parallel interface and should be compatible with most parallel printers The printer port output uses simple ASCII characters and control codes Simply connect the printer to the instrument and configure the printer output using the Setup menu The following sections describe the setup procedures for configuring the printer output Auto Print Please press the SETUP key to enter the Setup menu Press the SETUP key four more times to scroll to the Auto Print selection the screen will show AUTO Print ON AUTO Print OFF lt ENTER gt to Select lt ENTER gt to Select To configure Autoprinting press the ENTER key to change the selection When Auto Print ON the printer output will generate data every time the test has completed and will also enable two other menus to configure the Print Mode and the Print Number When Auto Print OFF
24. Status Byte ESE Queries the Standard Event enable register Returns the decimal value of the binary weighted sum of bits STB Read the Status Byte Returns the decimal value of the binary weighted sum of bits SRE lt value gt Service Request enable register controls which bits from the Status Byte should be use to generate a service request when the bit value 1 SRE Queries the Service Request enable register Returns the decimal value of binary weighted sum of bits 9 8 7 Status Reporting 60 CcXI sc H Status reporting system is configured using two types of registers An Event Register and a Summary register The summary register is known as the Status Byte register and records high level summary information acquired by the event registers An Event register reports defined conditions or messages at each bit The bits are latched and remain at an active state until the register is either Read or Cleared Reading the event register automatically clears the register and sets all bits to inactive state or 0 When querying an event register the information is returned as a decimal number representing the binary weighted sum of all bits within the register The Enable registers bits represent the selection of bits that will be logically ORed together to form the summary bit in the status byte The CLS command will not clear the enable registers and if you wish to clear the register you must set it to a value of0 Like the e
25. Volume setting Press the EXIT key to return to the operation mode The program will store the Contrast setting automatically 4 1 4 Alarm Volume Press the SETUP key to advance the menu to the Volume parameter The display will show Alarm X 0 9 0 0OFF 9 High The Audible Alarm Volume range is from 0 9 Level 0 is used to disable the Audible Alarm Level 1 is the lowest volume and level 9 is the loudest Use the Numeric keys to enter the Audible Alarm level then press the ENTER key The program will provide a sample sound for checking immediately when the ENTER key is pressed Change the Volume again or press the SETUP key to forward to the Smart GFI selection 29 CX sc Press the EXIT key to return to the operation mode The program will store the Volume setting automatically 4 1 5 Smart GFI Press the SETUP key to advance the menu to the Smart GFI parameter The display will show Smart GFI ON or Smart GFI OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to toggle the Smart GFI ON and OFF The High Voltage power supply of the instrument is internally referenced to earth ground The leakage current measuring circuits monitor only currents that flow through the Return lead Therefore the possibility exists for current to flow directly from the High Voltage output to earth ground that typically would not be monitored GFI is a circuit that monitors the current between the High Voltage output a
26. a variable high voltage power supply with the return circuit directly connected to earth ground therefore current from the high voltage output will flow through any available ground path Rules Operators should be thoroughly trained to follow all of the aforementioned rules in addition to any other applicable safety rules and procedures Defeating any safety system should be considered a serious offense with severe penalties such as removal from the Hipot testing job Allowing unauthorized personnel in the area during a test should also be dealt with as a serious offense Dress Operators should not wear jewelry that could accidentally complete a circuit Medical Restrictions Personnel with heart ailments or devices such as pacemakers should be informed that the voltages and currents generated by the instrument are very dangerous If contacted it may cause heart related problems that a person of good health may not experience Please have the test operator consult their physician for recommendations 1 4 4 Instrument Connections WARNING Never perform a hipot test on energized circuitry or equipment l The instrument is equipped with a safety ground connection be sure that this is connected to a good earth ground Always connect the return lead first regardless of whether the item under test is a sample of insulating material a component tested with the high voltage test lead or a cord connected device with a two or three prong plu
27. adjust the output voltage Pressing the A up key will increase the output voltage pressing the v down key will decrease the output voltage Manual voltage adjustment temporarily overrides the voltage setting and only remains in effect until the test is terminated by Pass Fail or Abort When the Lock parameter is selected ON in the system menu manual voltage adjustment is disabled 43 CX sc 7 Displayed Messages 7 1 Running Test Messages all units If the test in process is Aborted with the RESET button or remote control the display will show MXX Abort XXX X s XX XX KV XX XX mA If the test in process is Aborted with the RESET button or remote control before the meter readings are taken the display will show MXX Abort XXX X s or MXX Abort XXX X s KV mA XX XX KV mA At the beginning of AC Withstand Voltage test when the voltage begins to ramp but before the meter readings are taken the display will show MXX Ramp UP XXX X s KV mA During the AC Withstand Voltage test when the values are being updated in real time during the ramp cycle the display will show MXX Ramp UP XXX Xs XX XX KV XX XX mA During the AC Withstand Voltage test when the values are being updated in real time during the dwell cycle the display will show MXX Dwell XXX X s XX XX KV XX XX mA If the ramp time is very short and the program has not read the meter readings the display will show MXX Dwell XXXX
28. and Voltage Tester The High Withstand Voltage Tester enters calibration mode after the power on sequence is complete The program will automatically enter to the calibration mode and the display screen will show Calibration Mode v Forward lt A Backward Use the v Forward and a Backward keys to move through the calibration menu The following instructions follow the sequence scrolling forward through the menu 11 3 Calibration Procedure 11 3 1 Calibration of Hipot Voltage The first screen to appear in the Calibration mode is the Voltage calibration display The display will show ACW Voltage 10KV or DCW Voltage 1 OKV lt TEST gt to Calibrate lt TEST gt to Calibrate cXI ech Connect an AC standard voltage meter for 7470 and 7473 or a DC standard voltage meter for 7472 and 7474 which can measure up to 10KV to the output connectors and then press the TEST button the program will automatically generate an output of about 10KV and the display will show HI Voltage V Enter Standard V out Use the Numeric keys to enter the standard value of voltage unit V and then press the ENTER key to store the standard value of AC or DC hipot voltage for calibration and display will show ACW Voltage 10KV OK or DCW Voltage 10KV OK lt T E S T gt to Calibrate lt T E S T gt to Calibrate 11 3 2 Calibration of 7470 AC Hipot Current AC Hipot 20mA current range Press the v key the program will advance to the AC 20 00mA r
29. ange calibration of the hipot test The display will show AC 20 00mA 100KQ lt T E S T gt to Calibrate Connect a resistor about 100KQ 40W in series with a AC standard Ammeter which can measure up to 20 00mA to the output leads The Ammeter should be connected to the return lead then press the TEST button the program will automatically generate an output of about 2000V 20mA and the display will show Current mA Enter Standard IJ out Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of AC 20 00mA range for calibration and the display will show AC 20mA 100KQ OK lt T E S T gt to Calibrate AC Hipot 3 500mA current range Press the v key the program will advance to the AC 3 500mA range calibration of the hipot test The display will show AC 3 500mA 100KQ lt T E S T gt to Calibrate Connect a resistor about 100KQ 40W in series with a AC standard Ammeter which can measure up to 3 500mA to the output leads The Ammeter should be connected to the return 67 CX sc lead then press the TEST button the program will automatically generate an output on the output connectors about 300V 3 00mA and the display will show Current mA Enter Standard I out Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of AC 3 500mA range of the hipot test and the display will show
30. ate data being sent from the instrument including the ACK and NAK response strings until it has been read by the controller 9 8 GPIB RS 232 Interface Command List A GPIB read command must be sent after the command strings to retrieve any data from a query command The High Withstand Voltage Tester GPIB bus will not send any data to the controller without being queried The RS 232 bus will automatically send any response back to the controller s input buffer Each command string should be terminated by the ASCII control code New Line lt NL gt OAh or the end of line EOL message for GPIB The following conventions are used to describe the commands syntax for High Withstand Voltage Tester Braces enclose each parameter for a command string Triangle brackets lt gt indicate that you must substitute a value for the enclosed parameter The Pipe 1s used to separate different parameter options for a command select one of these as the data for the command When sending the command none of the previous mentioned characters should be included they are only for reference purposes in this manual Nor should quotation marks be include when sending the commands Also the command and the parameter data must be separated with a space All commands that end with a question mark are query commands and required an IEEE 488 read command to retrieve the data from the device s output buffer 9 8 1 Test Execution Commands
31. ck contacts are opened during a test the pop up message will be displayed and the test will abort The hardware has been configured to provide the interlock connections on pins 4 and 5 of the Remote Interface Signal Input port The instrument can still be used without the external interlock device as long as the Interlock Connector is plugged into the Remote Interface Signal Input port If there is nothing connected to the Remote Interface Signal Input port to provide a connection to the interlock the instrument will not perform tests Please check your connections to be sure they are making good contact Clear the area of any debris that may create a hazardous situation and ask any unnecessary personnel to leave the area To initiate the test press the GREEN test button on the front panel This is a momentary button and does not need to be held in the pressed position during the test The instrument will then initiate the test presently loaded in this case Memory 1 If the DUT passes the test you will hear a short audible beep If a failure occurs you will hear a long audible alarm and the red failure indicator will light up Ifa failure occurs during the test a continuous alarm will sound and the red indicator light in the RESET button will illuminate To stop the alarm you must press the illuminated RED button marked RESET This will silence the alarm clear the red fail light and reset the instrument for the next test The RESET bu
32. complish this Three internal memory programs can be accessed by connecting terminals 7 8 and 9 in different combinations The memory select lines should be set simultaneously and remain set for a minimum of 20ms to guarantee that the correct memory will be selected However the memory select bits may be set in sequential manner provided that the time delay between each bit is less than 4ms When the desired bit pattern has been established it should remain set for a minimum of 20ms to guarantee that the correct memory will be selected It may be necessary to OR the momentary switches relay contacts to prevent incorrect program selection due to timing errors ACTIVATING MEMORY PROGRAM FUNCTIONS THROUGH THE WARNING REMOTE CONNECTOR SELECTS THE PROGRAM AND STARTS THE TEST WHICH IS PREPROGRAMMED INTO THAT MEMORY DO NOT CONNECT VOLTAGE OR CURRENT TO THE SIGNAL CAUTION INPUTS THIS COULD RESULT IN DAMAGE TO THE CONTROL CIRCUITRY MEMORY ONE Momentarily connecting terminal 7 to 8 signals the instrument to immediately begin the test program that is stored in memory one 49 CX sci MEMORY TWO Momentarily connecting terminal 7 to 9 signals the instrument to immediately begin the test program that is stored in memory two MEMORY THREE Momentarily connecting terminal 7 to terminals 8 and 9 signals the instrument to immediately begin the test program that is stored in memory three Remote Interlock High Withstand Voltage Test
33. continuous j 0 0 1 999 9 hr 0 1 O continuous Cycle Test 0 9999 Times 0 continuous Arc Detection 1 9 ranges 9 is the most sensitivity DC Current Offset pA 0 0 200 0 or Auto Set Option Ramp High Current ON OFF User Selection Charge Low Current HA 0 0 350 0 or Auto Set Discharge Time lt 200 msec 1 5uF lt 2KV 0 12uF lt 12KV 0 28uF lt 4KV 0 12uF lt 14KV Maximum Capacitive Load 0 18uF lt 6KV 0 10uF lt 16KV 0 15uF lt 8KV 0 08uF lt I18KV 0 15uF lt 10KV 0 08uF lt 20KV MEASUREMENT DC Voltage KV 0 20 00 0 01 1 5 of reading 2counts 0 350 0 0 1 DC Current Range pA 300 3500 1 2 of reading 3counts 3000 5000 1 21 CX sci 3 1 5 General Specifications MODEL 7470 7472 7473 7474 GENERAL Input Voltage AC 115 230VAC 15 50 60Hz 5 Fuse 6 3A Slow Input Test Reset Memory1 2 3 Interlock Output Pass Fail Processing Safety Smart GFI Function lt 1mA Memory 50 memories Display 20 2 LCD with back light Key Lock To prevent unauthorized alteration of the test Parameters Calibration Build in software and external calibrated meters Interface RS232 GPIB Printer Card Option Alarm Volume Setting 10 ranges set by the numeric keys on the front panel Environment Dimension mm WxHxD Net Weight STANDARD ACCESSORIES Power Cord 10A Interlock Disable Key 1505 Hipot R
34. device The Earth Leakage Current is the leakage current that flows through the ground conductor in the line cord back to earth The Enclosure Leakage Current is the current that flows from any enclosure part through a person back to ground if it were contacted by a person The Applied Part Leakage Current or Patient Lead Leakage Current is any leakage that flows from an applied part between applied parts or into an applied part The Applied Part Leakage Current test is required only for medical equipment All of these tests are used to determine if products can be safely operated or handled without posing a shock hazard to the user Line Leakage Testers provide the capability of meeting the line leakage test specified in the following standards UL 544 IEC 950 UL 1950 IEC 601 1 UL 2601 UL 1563 UL 3101 IEC 1010 and others The Line Leakage test is a test which measures the leakage current of a product through a circuit that is designed to simulate the impedance of the human body The simulation circuit is called the Measuring Device MD The instrument has five different MD circuits selectable through the menu which are representative circuits designed to simulate the impedance of the human body under different conditions The impedance of the human body will vary depending upon point of contact the surface area of the contact and the path the current flows For these reasons the specifications of the Measuring Devices are different dependin
35. e Elimination of any connections in the earth grounding system or bypassing any safety systems Use of non authorized parts in the repair of this instrument Parts used must be parts that are recommended by EXTECH as an acceptable specified part This warranty does not cover accessories not of EXTECH manufacture Except as provided herein EXTECH makes no warranties to the purchaser of this instrument and all other warranties express or implied including without limitation merchantability or fitness for a particular purpose are hereby excluded disclaimed and waived EXTECH recommends that your instrument be calibrated on a twelve month cycle C Tegl mm 1 2 Safety Symbols 1 2 1 Product Marking Symbols Product will be marked with this symbol when it is necessary to refer to the operation and service manual in order to prevent injury or equipment damage Product will be marked with this symbol when hazardous voltages may be present tS gt Product will be marked with this symbol at connections that require earth grounding 1 2 2 Caution and Warning Symbols WARNING Calls attention to a procedure practice or condition that could possibly cause bodily injury or death Calls attention to a procedure practice or condition that could possibly cause damage to equipment or permanent loss of data CAUTION N CXI sci Alternating Current AC Current that reverses direction on a regular basis commonly in the
36. e Spacing of Components e Pinched Insulation Dielectric Withstand Test AC verses DC Please check with the Compliance Agency you are working with to see which of the two types of voltages you are authorized to use In some cases a Compliance Agency will allow either AC or DC testing to be done However in other cases the Compliance Agency only allows for an AC test Many safety agency specifications allow either AC or DC voltages to be used during the hipot test When this is the case the manufacturer must make the decision on which type of voltage to utilize In order to do this it is important to understand the advantages and the disadvantages of both AC and DC testing AC testing characteristics Most items that are hipot tested have some amount of distributed capacitance An AC voltage cannot charge this capacitance so it continually reads the reactive current that flows when AC is applied to a capacitive load AC testing advantages AC testing is generally much more accepted by safety agencies than DC testing The main reason for this is that most items being hipot tested will operate on AC voltages AC hipot testing offers the advantage of stressing the insulation alternately in both polarities which more closely simulates stresses the product will see in real use Since AC testing cannot charge a capacitive load the current reading remains consistent from initial application of the voltage to the end of the test Therefore there is n
37. e message The REM indicator will be displayed when the instrument is in the Remote Control mode When the BUS Remote is on the instrument is able to send and receive signals across the GPIB TEEE 488 or RS 232 bus MXX Set XXX X s XX XX KV REM X XXX mA 46 CALES 7 4 Fatal Error The only active button or key in this situation is the RESET button The only reason the RESET button is active is to allow you to silence the alarm and open the fail relay This type of failure permanently locks the instrument in the Fatal Error mode and requires that the instrument be serviced by Extech The customer should contact Extech Electronics Ltd Co to receive further instruction An example of the Fatal Error screen appears as follows FATAL ERROR 9002 Call 1 800 858 8378 FATAL ERROR 9003 Call 1 800 858 8378 The following Fatal Error identification numbers will represent type of the failure that has occurred Error Code 9002 will appear on the display if the instrument s System data or the Model Option Serial Number data are corrupted and do not match the settings Error Code 9003 will appear on the display if the instrument s Calibration data is corrupted 7 5 Output Error If the instrument has an internal problem and the TEST button is pressed the Output Error screen will appear as follows OUTPUT ERROR Press EXIT Continue The RESET button is not active while this screen is displayed To clear this screen and return
38. ecific to any memory location 4 1 1 PLC Remote Press the SETUP key to advance to the PLC Remote parameter The display will show PLC Remote ON or PLC Remote OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to select the mode PLC Remote Control If the Remote Control is set to ON the test function will be controlled by the Remote Control via the remote connectors located on the rear panel The TEST button on the front panel is disabled but the RESET button is still enabled The remote Memory Program recall functions can be performed only when the PLC Remote is set ON In addition when the PLC remote is set to ON the remote TEST signal input is active while in the Bus Remote Mode If the Remote Control is set to OFF the operation of the instrument will be controlled by the local TEST and RESET buttons on the front panel After selecting PLC Remote mode press the SETUP key to advance to the Fail Stop setting Press the EXIT key to exit from the PLC Remote selection to the operation mode The instrument will store the PLC Remote selection automatically 4 1 2 Fail Stop Press the SETUP key to advance the menu to the Fail Stop parameter The display will show Fail Stop ON or Fail Stop OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to toggle the Fail Stop ON and OFF This mode allows the instrument to be setup to continue testing after detecting a failure Fail Stop OFF
39. en connect the return lead first to the test fixture or the DUT followed by the high voltage lead Please check your connections to be sure they are making good contact Clear the area of any debris that may create a hazardous situation and ask any unnecessary personnel to leave the area WARNING DO NOT TOUCH THE DEVICE UNDER TEST HIGH VOLTAGE TEST LEAD ALLIGATOR CLIP OR CLIP INSULATOR ONCE THE TEST HAS BEEN STARTED This instrument is supplied with a high voltage test lead terminated with an alligator clip This clip is designed to allow firm connection to the DUT without the need for an operator to hold a probe or lead in place during the test This clip and insulator will carry the voltage and current of this tester but they are not intended to be held by the operator during the test while the high voltage is energized Please insure that you do not make contact with the alligator clip or the clip insulator while high voltage is energized 6 2 Power Up Turn on the Input Power Switch The display will show the Trade Mark Model Number and Version Number first as follows EXTECH HIGH WITHSTAND VOLTAGE TESTER Note X Numeric 7471X VER X XX The program will then recall the Memory which was last executed 6 3 Settings Screen The settings screen will show parameter settings of the test that will be performed and the memory location that they are stored in This screen can be accessed after a test is Aborted or Passed by
40. er is equipped with a featured referred to as Remote Interlock Remote Interlock is a feature that utilizes a set of closed contacts to enable the instruments output In other words if the Interlock contacts open the output of the instrument will be disabled Remote Interlock could also be referred to as a remote system lockout utilizing Fail When Open logic Ifthe Interlock contacts are open and the Test button is pushed a pop up message will be displayed on the screen for two seconds The message will appear as follows Interlock Is Open If the Interlock contacts are opened during a test the pop up message will be displayed and the test will abort The hardware and has been configured to provide the interlock connections on pins 4 and 5 of the Remote Interface Signal Input port The instrument can still be used without the external interlock device as long as the Interlock Connector is plugged into the Remote Interface Signal Input port If there is nothing connected to the Remote Interface Signal Input port to provide a connection to the interlock the instrument will not perform tests PLC Remote Pop up message If you attempt to start a test from the front panel Test button and the PLC remote function is turned ON a pop up message will be displayed The pop up message will appear as follows PLC Remote ON 50 CXT cc ELECTRONICS 9 Bus Remote Interface GPIB RS 232 Option This section provides information on the
41. er uses it to tell devices to identify their response in a parallel poll 9 4 GPIB Connector Connection is usually accomplished with a 24 conductor cable with a plug on one end and a connector at the other end Devices may be connected in a linear star or a combination configuration The standard connector is the Amphenol or Cinch Series 57 Microribbon or AMP CHAMP type The GPIB uses negative logic with standard transistor transistor logic TTL levels When DAV is true for example it is a TTL low level lt 0 8 V and when DAV is false it is a TTL high level 2 0 V Restrictions and Limitations on the GPIB A maximum separation of 4 m between any two devices and an average separation of 2 m over the entire bus A maximum total cable length of 20 m No more than 15 device loads connected to each bus with no less than two thirds powered on For example GPIB controller and a maximum of 14 GPIB instruments Note A bus extender which is available from numerous manufacturers is available to overcome these limitations 9 5 GPIB Address This interface is optional on the High Withstand Voltage Tester Each device on the GPIB IEEE 488 interface must have a unique address You can set the address of the High Withstand Voltage Tester to any value between 0 and 30 The address is set to 8 when the instrument is shipped from the factory The address can only be set from the front panel The address is stored in non volatile memory a
42. ers expense 1 4 2 Test Station Location Select an area away from the main stream of activity which employees do not walk through in performing their normal duties If this is not practical because of production line flow then the area should be roped off and marked for HIGH VOLTAGE TESTING No employees other than the test operators should be allowed inside CXLESIT If benches are placed back to back be especially careful about the use of the bench opposite the test station Signs should be posted DANGER HIGH VOLTAGE TEST IN PROGRESS UNAUTHORIZED PERSONNEL KEEP AWAY Work Area Perform the tests on a non conducting table or workbench if possible If you cannot avoid using a conductive surface be certain that it is connected to a good earth ground and the high voltage connection is insulated from the grounded surface There should not be any metal in the work area between the operator and the location where products being tested will be positioned Any other metal in the work area should be connected to a good ground never left floating Position the tester so the operator does not have to reach over the product under test to activate or adjust the tester Ifthe product or component being tested is small it may be possible to construct guards or an enclosure around the device to be tested Construct the guards of a non conducting material such as clear acrylic so that the item being tested is within the guards
43. ess the MEMORY key and select the memory you wish to perform using the numeric keypad then press the ENTER key to return you to the Perform Test screen 2 Attach the appropriate load or DUT to the instrument refer to section 6 1 for instrument connections DO NOT TOUCH THE DEVICE UNDER TEST HIGH WARNING VOLTAGE TEST LEAD ALLIGATOR CLIP OR CLIP INSULATOR ONCE THE TEST HAS BEEN STARTED 41 CX sci 3 Press the TEST button 4 The instrument will now perform the test or connected sequence of tests 6 5 2 Discharge Function in DC units The 7472 and 7474 units are equipped with a Discharge function that is designed to discharge the voltage of a capacitive DUT so that it may be safely disconnected from the test leads of the instrument The discharge function monitors the voltage of the DUT and remains active until the voltage of the DUT falls below 40 volts The instrument will also not allow another test to be executed until the voltage of the DUT falls below 40 volts The discharge period will occur either directly after the Dwell time if Ramp DOWN is set to 0 or after the designating Ramp DOWN time DO NOT TOUCH THE DEVICE UNDER TEST HIGH VOLTAGE TEST LEAD ALLIGATOR CLIP OR CLIP INSULATOR DURING THEDISCHARGE CYCLE The Discharge cycle is a means by which the instrument drains any WARNING remaining charge from a DUT after the completion of a test The Discharge cycle is active when the word Discharge appears
44. ete the display will show MXX Pass XXX X os XX XX KV XX XX mA 45 CX sc 7 2 Additional Displayed messages for DC units If the Ramp HI function is enabled and the leakage current during the Ramp cycle exceeds 5mA then the display will show MXX Ramp HI XXX X s XX XX KV gt 5000 uA If the leakage current during the Ramp cycle falls below the Charge LO setting then the display will show MXX Charge LO XXX X s XX XX KV XXX X WA When running capacitive DUTS the instrument will discharge the DUT at the end of the Dwell or Ramp DOWN cycle depending on the test settings The display will show the following screen during the discharge cycle MXX Discharge XXX X s XX XX KV If the capacitance of the DUT is very small it is possible that you will not see this display due to the short amount of time required to discharge the DUT DO NOT TOUCH THE DEVICE UNDER TEST HIGH VOLTAGE TEST LEAD ALLIGATOR CLIP OR CLIP INSULATOR DURING THE DISCHARGE CYCLE The Discharge cycle is a means by which the instrument drains any WARNING remaining charge from a DUT after the completion of a test The Discharge cycle is active when the word Discharge appears on the screen and is also indicated by the flashing high voltage lamp active voltmeter and timer Never attempt to remove a DUT from the instrument during the Discharge cycle Always allow the Discharge cycle to complete before powering down the instrument 7 3 BUS Remot
45. eter which can measure up to 5 00mA to the output leads The Ammeter should be connected to the return 70 cXI sc H lead then press the TEST button the program will automatically generate an output of about 500V 5 00mA and the display will show Current mA Enter Standard IJ out Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of DC 5 00mA range for calibration and the display will show DC 5 00mA 100KQ OK lt TEST gt to Calibrate DC Hipot 35004A current range Press the v key the program will advance to the DC 3500uA range calibration of hipot test The display will show DC 35001A 100KQ lt TEST gt to Calibrate Connect a resistor about 100KQ 2 5W in series with a DC standard Ammeter which can measure up to 3000UA to the output leads The Ammeter should be connected to the return lead then press the TEST button the program will automatically generate an output of about 300V 30001A and the display will show Current uA Enter Standard I out Use the Numeric keys to enter the standard value of current unit uA and then press the ENTER key to store the standard value of DC 3500uA range of hipot test and the display will show DC 35001A 100KQ OK lt TEST gt to Calibrate DC Hipot 3504A current range Press the v key the program will advance to the setting and reading of DC 350uA range calibration of the hipot test The display wil
46. eturn Lead 1 8m 1144 Hipot Test Lead 1 5m 1142 Hipot Test Lead 1 5m 1143 22 0 40 C 20 80 RH 430x133x400 24Kg 22 5Kg 23Kg 24Kg x x2 Include a spare contained in the fuse holder AAA E A CX sci 3 2 Instrument Controls 3 2 1 Front Panel Controls 10 747X AC WITHSTAND VOLTAGE TESTER 123 456 78 9 10 11 12 13 14 POWER SWITCH Rocker style power switch with international ON and OFF 0 markings RESET BUTTON Momentary contact switch used to reset the instrument Ifa failure condition occurs during a test you will need to reset the system to shut off the alarm and signal the system that you are aware of a failure condition The reset button must be pressed before you can proceed to the next test or change any of the set up parameters This switch also serves as an abort signal to stop any test in progress controlled by the High Withstand Voltage Tester TEST BUTTON Momentary contact switch used to start tests Press the green button to activate the test that is set up in the test buffer shown on the display MEMORY Use this key to select one of the 50 memories to modify or run stored test parameters LOCK LOCAL Use this key to select key lockout mode A password may be used when setup in the calibration mode Use this key when you wish to go from the Remote operation of the instrument to the Local mode UP DOWN ARROW KEYS Use these keys to enter and move through the function paramete
47. g The return lead should be connected first for any type of hipot testing Plug in the high voltage test lead only when it is being used Handle its clip only by the insulator never touch the clip directly Be certain that the operator has control over any remote test switches connected to the Hipot Double check the return and high voltage connections from the Hipot and the Line Neutral Ground and Case connections from the Line Leakage tester to be certain that they are proper and secure CXI sc H Never touch the Device Under Test DUT or anything connected to it while high voltage is being applied by the hipot 1 4 5 Device Under Test WARNING When testing with DC always discharge the capacitance of the item under test and anything the high voltage may have contacted such as test fixtures before handling it or disconnecting the test leads HOT STICK probes can be used to discharge any capacitance in the device under test as a further safety precaution A hot stick is a non conducting rod about two feet long with a metal probe at the end that is connected to a wire To discharge the device under test two hot sticks are required First connect both probe wires to a good earth ground Then touch one probe tip to the same place that the return lead was connected While holding the first probe in place touch the second probe tip to the same place where the high voltage lead was connected 1 4 6 Key Safety Points to Remember e
48. g upon the type of test being performed as well as the maximum allowable leakage current Leakage current measurements are performed on products under normal conditions and single fault conditions as well as reversed polarity This simulates possible problems which could occur if the product under test is faulted or misused while the product is operating under high line conditions 110 of the highest input voltage rating of the product Line Leakage tests are normally specified as Type Tests or Design Tests which are performed during the development of the product This helps verify that the design is safe but it does not guarantee the safety of the products being produced on the production line The only way to be sure you are shipping safe products is to test each product at the end of the production line The user may perform a Leakage Current test along with other common safety test such as Dielectric Withstand Insulation Resistance and Ground Bond on the production line with a single connection to the device under test 12 CXLESIT 1 7 Key Features and Benefits Patented SmartGFI Storage of up to 50 setups RS 232 or GPIB interfaces Line and Load regulation The SmartGFI provides maximum operator protection If the circuit detects excessive leakage to ground it shuts down the high voltage in less than 1 millisecond SmartGFI is automatically activated if the DUT is not grounded The operator does not need to make t
49. ging current Ramp HI may be selected ON or OFF using a softkey A description of how to set up this parameter is given in the 5 2 11 Ramp Hi selection section of this manual Charge LO The Charge LO function is used to check if the cables are connected properly at the beginning of a test This function is only available in DC Withstand and Insulation resistance testing A description of how to set up this parameter is given in the 5 2 10 Charge Lo setting section of this manual 33 CX sci 5 2 Setting Up Tests Before going to setup the Test Parameters make sure that the Keyboard is in the Unlock mode and then follow this procedure to setup the Test Parameters Press the Memory key and using the numeric keypad enter the Memory number you would like to edit and then press the ENTER key Use the or v arrow keys to progress through the test parameters menu The v key will advance forward and key will advance backward The sequential forward menu items are Voltage HI Limit LO Limit Ramp UP Dwell Unit Dwell Time Ramp DOWN Frequency Arc Detect Arc Sense and Connect Withstand Display MXX Set XXX Xs Note X Numeric XX XX KV X XXX xA Note x milli or micro M XX Memory Program number Set Withstand Voltage test setting screen XXX Xs Dwell Time setting X XX KV Output Voltage setting X XXX mA High Limit current setting AC withstand instruments XXXX uA High Limit current setting DC withstand instrument
50. he decision whether to activate the SmartGFI A real benefit for manufacturers that test different products The instrument can store 50 individual memories that may be performed individually or connected for a 50 step test All the functions of the instruments can be programmed over a RS 232 GPIB or printer interface which makes them adaptable to any automated production environment Maintains the output voltage to within 1 of setting even if the load or the line voltage varies This ensures that the test results remain consistent and within safety agency requirements Digitally controlled arc detection Allows the operator to select whether low level arcs system should be detected and provides the operator with the ability to digitally select and program multiple sensitivity levels No load setup of trip current and This provides the operator with an easy and safe way to output voltage TUV amp UL listing Autoware software control Automatic storage of test program All parameters for the setups can be adjusted through a simple menu driven program Tamper proof front panel controls set trip currents and output voltages since parameters are set without the high voltage activated This assures you that this instrument meets or exceeds safety requirements to ensure operator safety High Withstand Voltage Tester may also be controlled through Extech s stand alone automation software This allows manufacturers
51. he British Standards Institution BSD the Association of German Electrical Engineers VDE and TUV the Japanese Standards Association JSI These same agencies may also require that an insulation resistance test and high current ground bond test be performed CX sci 1 6 The Different Types of Safety Tests 1 6 1 Dielectric Withstand Test The principle behind a dielectric voltage withstand test is simple Ifa product will function when exposed to extremely adverse conditions it can be assumed that the product will function in normal operating circumstances Common Applications of the Dielectric Withstand Test e Design performance testing Determining design adequacy to meet service conditions e Production Line testing Detecting defects in material or workmanship during processing e Acceptance testing Proving minimum insulation requirements of purchased parts e Repair Service testing Determine reliability and safety of equipment repairs The specific technique used to apply the dielectric voltage withstand test to each product is different During a dielectric voltage withstand test an electrical device is exposed to a voltage significantly higher than it normally encounters for a specified duration of time During the test all current flow from the high voltage output to the return is measured If during the time the component is tested the current flow remains within specified limits the device is assumed
52. he memory number is the actual memory number that has been saved within the file not the order of which the memories were executed For example if the test was executed starting from memory 3 and ending with memory 5 then the first test results will be found in location 3 not in location 1 Each parameter is separated by commas and includes memory number test type test status and metering The syntax for this command response is memory test type status kV meter mA meter dwell time Each meter will contain only the value and not the units In the case of DCW current where both uA and mA are used on the display the command response will always indicate the current in uA for example 2 0mA will respond with 2000 for 2000uA RR Read the remote Reset input signal When the remote reset has be activated by closing the contacts the query will return a value of 1 to indicate the instrument is being Reset RI Read the remote Interlock input signal When the remote Interlock has be activated by opening the contacts the query will return a value of 0 to indicate the instrument is in the Interlock state and will not be able to generate output voltage or current LS Lists all the Parameters for the individual memory that is currently selected See the ADD command for the list of parameters A comma will separate each parameter and will be preceded with the memory number LS lt memory number gt Lists all the Parameters for the individual
53. ight data lines DIO1 through DI08 carry data and command messages The 7 bit ASCII or ISO code set is used and the eighth bit DIOS is unused Handshake Lines The transfer of message bytes between devices is done via three asynchronous control lines Referred to as three wire interlocked handshake This guarantees that message bytes on the data lines are sent and received without transmission error NRFD not ready for data indicates when a device is ready or not ready to receive a message byte NDAC not data accepted indicates when a device has or has not accepted a message byte DAV data valid tells when the signals on the data lines are stable valid and can be accepted safely by devices Interface Management Lines Five lines are used to manage the flow of information across the interface ATN attention ATN is driven true by the controller when it uses the data lines to send 51 CX sc commands and drivers ATN false when a Talker can send data messages IFC interface clear IFC is driven by the system controller to initialize the bus and become CIC REN remote enable The REN line is driven by the controller that is used to place devices in remote or local program mode SRQ service request The SRQ line can be driven by any device to asynchronously request service from the Controller EOI end or identify This line has two purposes the Talker uses this line to mark the end of a message string and the Controll
54. ill automatically generate an output of about 69 CX sc 300V 30001A and the display will show Current uA Enter Standard I out Use the Numeric keys to enter the standard value of current unit uA and then press the ENTER key to store the standard value of DC 3500uA range of hipot test and the display will show DC 35001A 100KQ OK lt TEST gt to Calibrate DC Hipot 3501A current range Press the v key the program will advance to the setting and reading of DC 350uA range calibration of the hipot test The display will show DC 350nA IMQ lt TEST gt to Calibrate Connect a resistor about 1MQ 0 25W in series with a DC standard Ammeter which can measure up to 300A to the output leads Connect the Ammeter to the return leads then press the TEST button the program will automatically generate an output of about 300V 300UA and the display will show Current uA Enter Standard I out Use the Numeric keys to enter the standard value of current unit uA and then press the ENTER key to store the standard value of DC 350uA range of the hipot test and the display will show DC 350nA IMQ OK lt TEST gt to Calibrate 11 3 5 Calibration of 7474 DC Hipot Current DC Hipot 5 00mA current range Press the v key the program will advance to the DC 5 00mA range calibration of the hipot test The display will show DC 5 00mA 100KQ lt TEST gt to Calibrate Connect a resistor about 100K Q 2 5W in series with a DC standard Amm
55. l show DC 3501A IMQ lt T E S T gt to Calibrate Connect a resistor about 1MQ 0 25W in series with a DC standard Ammeter which can measure up to 300uA to the output leads Connect the Ammeter to the return leads then press the TEST button the program will automatically generate an output of about 300V 300uA and 71 CX sci the display will show Current uA Enter Standard I out Use the Numeric keys to enter the standard value of current unit LA and then press the ENTER key to store the standard value of DC 3501A range of the hipot test and the display will show DC 3501A IMQ OK lt T E S T gt to Calibrate 11 3 6 Calibration Complete Message When a complete calibration of Hipot voltage and current has been performed a message will appear on the screen to confirm the calibration is finished The message will appear as follows Calibration complete 72
56. llows High Withstand Voltage Tester to be completely calibrated without removing any covers and exposing the technician to hazardous voltages High Withstand Voltage Tester was designed for the global market This feature makes it simple for the user to select the output frequency in the AC hipot mode so that products can be tested at the same frequency they will be used at To make High Withstand Voltage Tester usable in all types of applications the operator can manually bring the voltage up or down in 10 volt increments by simply pressing the up and down arrow keys This makes it very easy to adjust the output voltage even while High Withstand Voltage Tester is in the dwell mode so you can analyze test results at different voltages A flashing LED located directly over the high voltage terminal clearly indicates when high voltage is active to provide maximum operator safety High Withstand Voltage Tester can be switched for either 115 or 230 volt input operation through an easy access rear panel mounted switch to allow it to be used in any country Monitors the minimum level of current flow thus ensuring that the DUT is properly connected and that the hipot test is being performed Provides a gradual and timed method to increase or decrease output voltage to the DUT minimizing any damage from quick high voltage changes to sensitive DUTs a IE CXT cc ELECTRONICS 2 Getting Started Introduction This section contains inf
57. main plug shall only be inserted in a socket outlet receptacle provided with a protective ground earth contact This protective ground earth must not be defeated by the use of an extension cord without a protective conductor grounding The instrument is shipped with a three wire power cable When the cable is connected to an appropriate AC power source the cable will connect the chassis to earth ground The type of power cable shipped with each instrument depends on the country of destination The output power supplies of this instrument are referenced directly to earth CAUTION ground Any conductor that completes a path between the high voltage and earth ground will form a completed circuit Return Connection When the instrument Return is grounded any internal and external stray leakage will be monitored due to currents that flow from High Voltage to earth ground such as from HV to the chassis of the instrument This current is inherent and will cause errors when trying to monitor very low leakage currents in the micoamp range 2 2 4 Environmental Conditions This equipment is intended for indoor use only This instrument may be operated in environments with the following limits Temperature eeeee 32 104 F 0 40 C 16 CcXI sci Relative humidity 20 80 AMIA ee csecssnntscrsianteacesonss 6560 feet 2 000 meters Storage and Shipping Environment This instrument may be stored or shipped
58. meter SPR SF sil sain eo SAL SC SL 1 0 Lock 1 On 0 Off oo Lio ARM SML SSG SD1 lt value gt Device ID 0 9999999 spo pve ee SD2 SPM SPRE SPS SFF 9 8 5 Query Commands These query commands will retrieve data from the instrument The GPIB bus application requires an IEEE 488 read command to be sent after the query command These commands include functions for retrieving test data test results and remote hardware status as well as setup file information TD List Testing Data List Results Data memory number 1 50 Read Remote Reset 1 Open 0 Closed Read Remote Interlock 1 Open 0 Closed LS List Memory Parameters Po 57 CX sc LS lt memory number gt List Memory Parameters by memory number 1 50 memory number TD Read the active data being displayed on the LCD display while the test is in process It will also read the last data taken when the test sequence has completed Each parameter is separated by commas and includes memory number test type test status and metering The syntax for this command response is memory test type status kV meter mA meter dwell time Each meter will contain only the value and not the units In the case of DCW current where both uA and mA are used on the display the command response will always indicate the current in uA for example 2 0mA will respond with 2000 for 2000uA RD lt memory number gt Read the results for an individual memory T
59. n the normal HI Limit current setting of the DC Withstand Voltage test to avoid false failure due to charging current 5 2 11 Charge LO setting DC units only Advance the menu to the Charge LO parameter The display will show Charge LO XXX XUA lt TEST gt to Auto Set The Charge LO function is used to check if the test cables are connected properly at the 37 CX sci beginning of atest A capacitive DUT will draw charging current on the DC Withstand Voltage test when the Output is activated Ifthe charging current was lower then the setting the test cables may not be connected properly This instrument can set the Charge LO value manually or automatically To set the Charge LO value manually use the numeric keys to enter the Charge LO current setting and then press the ENTER key The program will store the Charge LO setting and advance to the Ramp HI parameter The setting range of Charge LO is from 0 0 to 350 0 uA The unit is uA and 0 luA per step To use Auto Set be sure that the test parameter of Output Voltage and Ramp Time have been set to the values that will be used for the Final test and connect the test cables and or test fixture between the instrument and DUT Ifthe scanner is to be used then the scanner channel must also be set and then press the TEST button The instrument will apply the voltage that has been entered for this memory step selection WARNING Please be aware that the program will activate high voltage
60. nd does not change when the power has been off or after a remote reset 9 6 Interface Functions The capability of a device connected to the bus is specified by its interface functions These functions provide the means for a device to receive process and send messages over the bus The interface functions are listed in the chart below 52 cXI ech GPIB 488 1 INTERFACE FUNCTIONS Interface Function Source Handshake SH1 Complete Source handshake capability Acceptor Handshake AHI Complete Acceptor handshake capability Talker T6 Talker functions unaddress if MLA Listener L4 Listener functions unaddress if MTA Service Request SRI Complete Service request capability Remote Local RLO No remote local capability Parallel Poll PPO No parallel poll capability Device Clear DC1 Complete Device clear capability Device Trigger DTO No device trigger capability Controller CO No controller capability Electrical Interface E2 Three state drivers Controllable Items Test and Reset control Setting of test parameters for tests Reading of instrument status and test results Data Codes ASCII Delimiter NE EOI 9 7 RS 232 Interface This interface is standard on High Withstand Voltage Tester This interface provides all of the control commands and parameter setting commands of the GPIB interface with the exception of some of the 488 2 Common Commands and SRQ capability All commands can be found in the command list section 9
61. nd earth ground The GFP s main purpose is to protect the operator from prolonged exposure to High Voltage in the case of an accidental contact with the High Voltage lead and earth ground If the operator accidentally touches the High Voltage lead and earth ground the High Voltage will be shut off immediately and the test will be aborted Ifthe GFI threshold is exceeded the display will indicate a GFI Fail Smart GFI allows the user to automatically configure the instruments return configuration When the Return lead is earth grounded the GFI circuit is disabled and the instrument operates in a grounded return mode of operation Grounded Return allows the user to perform tests on devices that have their chassis earth grounded by the test fixture or test environment The standard configuration of High Withstand Voltage Tester is a floating return connection that is not directly connected to Earth ground The standard configuration allows monitoring of very low level leakage current without internal or external stray earth ground leakage currents being measured and thereby causing errors in the reading Grounding the return will create some amount of leakage current that is proportional to the High Voltage output and can cause small amounts of error depending on the test voltage and physical environment Toggle the Smart GFI function or press the SETUP key to forward to the GPIB address selection Press the EXIT key to return to the operation mode The p
62. nd of this instrument is connected to a known good ground Refer to section 4 1 5 Smart GFI for an explanation of DUT grounding configurations DO NOT TOUCH THE DEVICE UNDER TEST HIGH WARNING VOLTAGE TEST LEAD ALLIGATOR CLIP OR CLIP INSULATOR ONCE THE TEST HAS BEEN STARTED This instrument is supplied with a high voltage test lead terminated with an alligator clip This clip is designed to allow firm connection to the DUT without the need for an operator to hold a probe or lead in place during the test This clip and insulator will carry the voltage and current of this tester but they are not intended to be held by the operator during the test while 26 cXI sc H the high voltage is energized Please insure that you do not make contact with the alligator clip or the clip insulator while high voltage is energized 3 3 1 1 Remote Interlock High Withstand Voltage Tester is equipped with a featured referred to as Remote Interlock Remote Interlock is a feature that utilizes a set of closed contacts to enable the instruments output In other words if the Interlock contacts open the output of the instrument will be disabled Remote Interlock could also be referred to as a remote system lockout utilizing Fail When Open logic If the Interlock contacts are open and the Test button is pushed a pop up message will be displayed on the screen for two seconds The message will appear as follows Interlock Is Open If the Interlo
63. nd will not provide any voltage or current The ratings of the contacts are 1 AAC 125 VAC 0 5 ADC 30 VDC The signal outputs are provided on the 9 pin female D connector Below is a listing that indicates what conditions activate each pin Whena terminal becomes active the relay closes thereby allowing the external voltage to operate an external device Pins and 2 provide the PASS signal Pins 3 and 4 provide the FAIL signal Pins 5 and 6 provide the PROCESSING signal Pins 7 and 8 provide the RESET OUT signal The following describes how the relays operate for each test condition PROCESSING The relay contact closes the connection between pin 5 and pin 6 while the instrument is performing a test The connection is opened at the end of the test The process contact is closed all the way through to the end of the discharge cycle in DC units PASS The relay contact closes the connection between pin 1 and pin 2 after detecting that the item under test passed all tests The connection is opened when the next test is initiated or 48 cXI sc H FAIL The relay contact closes the connection between pin 3 and pin 4 after detecting that the item under test failed The connection will open when the next test is initiated or the reset function activated the reset function is activated RESET OUT The relay contact closes the connection between pin 7 and pin 8 while the reset function is activated This is only
64. ngs for each test All parameters must be included with the command and should appear in the same order that is shown in the table below Also like the individual parameter editing commands the unit should not be included with the value Only the numeric value should be included in the command string The list of parameters can also be found in the default parameters section of the manual or refer to the Test Parameter Editing commands section for the proper values The parameter values should use complete text and not use the coded values that are associated with the individual parameter setting commands such as ON and OFF The LS companion command will also list all parameters in complete text in the order as they appear in the following table preceded by the memory number ACW DCW 1 Voltage Voltage 2 HI Limit HI Limit 3 LO Limit LO Limit 4 Ramp Up Ramp Up 5 Dwell Unit Dwell Unit 6 Dwell Time Dwell Time 7 Ramp Down Ramp Down 8 Frequency 50 60 Arc Detect ON OFF 9 Arc Detect ON OFF Arc Sense 1 Arc Sense Ramp HI ON OFF 55 CX sci 11 Connect ON OFF Charge LO 12 Connect ON OFF 9 8 3 Test Parameter Editing Commands and Companion Queries These commands are used to modify the test parameter within each memory These commands require a parameter value to be included with the command The companion query command will read the parameter The
65. o need to gradually bring up the voltage since there is no stabilization required to monitor the current reading This means that unless the product is sensitive to a sudden application of voltage the operator can immediately apply full voltage and read current without any wait time Another advantage of AC testing is that since AC voltage cannot charge a load there is no need to discharge the item under test after the test AC testing disadvantages One disadvantage of AC testing surfaces when testing capacitive products Again since AC cannot charge the item under test reactive current is constantly flowing In many cases the reactive component of the current can be much greater than the real component due to actual leakage This can make it very difficult to detect products that have excessively high leakage 9 CX sc current Another disadvantage of AC testing is that the hipot has to have the capability of supplying reactive and leakage current continuously This may require a current output that is actually much higher than is really required to monitor leakage current and in most cases is usually much higher than would be needed with DC testing This can present increased safety risks as operators are exposed to higher currents DC testing characteristics During DC hipot testing the item under test is charged The same test item capacitance that causes reactive current in AC testing results in initial charging current which exponen
66. oc as ae e e OTE EE E EE a E E T 52 OTR S22 3 2 MINOT ACG PA o T a S 52 9 8 GPIB RS 232 Interface Command Listin 53 9 9 Example of Communicating Over the GPIB Bus ss ssssesssessssssesseessesessseesseseesstessessessresseseess 54 9 10 Nor Volatile Menor NR EST 62 911 BUS R mote message a E anatase Blade S 62 LO OPLTTONS ns tes de seed os Ds a de 63 11 CALIBRATION PROCEDURE 6000 ds 66 11 1 Required Calibration Equip MEM aa 66 Mae AAA I 66 Ale S Calibration Procedure tt aaa 66 ii CXI ech 1 Introduction 1 1 Warranty Policies EXTECH ELECTRONICS CO LTD certifies that the instrument listed in this manual meets or exceeds published manufacturing specifications This instrument was calibrated using standards that are traceable to the National Institute of Standards Taiwan Your new instrument is warranted to be free from defects in workmanship and material for a period of 1 year from date of shipment During the warranty period you must return the instrument to Extech Electronics Co or its branches or its authorized distributor for repair Extech Electronics Co reserves the right to use its discretion on replacing the faulty parts or replacing the assembly or the whole unit Follow below states EXTECH will void your warranty Operate under non normal contrived omission or accidental calamity including temblor floods rebellion and fire etc Any non authorized modifications tampering or physical damag
67. oes not display This is not the case with DC testing since a sinewave is not generated when testing with direct current In order to compensate for this most safety agencies require that the equivalent DC test be performed at higher voltages than the AC test The multiplying factor is somewhat inconsistent between agencies which can cause confusion concerning exactly what equivalent DC test voltage is appropriate 10 O C X Tec ELECTRONICS 1 6 2 Insulation Resistance Test Some dielectric analyzers today come with a built in insulation resistance tester Typically the IR function provides test voltages from 500 to 1 000 volts DC and resistance ranges from kilohms to gigaohms This function allows manufacturers to comply with special compliance regulations ABT T V and VDE are agencies that may under certain conditions require an IR test on the product before a Hipot test is performed This typically is not a production line test but a performance design test The insulation resistance test is very similar to the hipot test Instead of the go no go indication that you get with a hipot test the IR test gives you an insulation value usually in Megohms Typically the higher the insulation resistance value the better the condition of the insulation The connections to perform the IR test are the same as the hipot test The measured value represents the equivalent resistance of all the insulation which exists between the two points and any com
68. on the screen and is also indicated by the flashing high voltage lamp active voltmeter and timer Never attempt to remove a DUT from the instrument during the Discharge cycle Always allow the Discharge cycle to complete before powering down the instrument During the Discharge time the display will show MXX Discharge XXX X s XX XX KV If the capacitance of the DUT is very small it is possible that you will not see this display due to the short amount of time required to discharge the DUT discharge the DUT The voltage and time of the discharging DUT will be displayed during the discharge period but this information is only intended for reference and cannot be reviewed after the end of the discharge period The process signal of the remote I O remains active during the discharge period and the high voltage lightning bolt indicator on the front panel of the instrument is also active during the discharge period As a safety precaution if the RESET button is pressed during the discharge period the instrument will log the RESET but will not discontinue the discharge function Pressing the RESET during the discharge will only prevent a connected memory from executing after the discharge time 42 CXLESIT The capacitance of the DUT should never exceed the maximum specification listed in this manual 6 5 3 Manual Voltage Adjustment When HIGH WITHSTAND VOLTAGE TESTER is performing a test the v down and A up keys may be used to
69. on the output connector while the Test button is pressed The program will read the charging current of DUT and set the Charge LO current at approximately one half 1 2 of the reading The display will show Charge LO XXX X uA lt TEST gt to Auto Set The value showing on the display is the Charge LO setting and is not the reading of the charging current of the DUT Then press the or v key to advance the program to another test parameter or press the EXIT key to exit from the setting mode to the operation mode 5 2 12 Connect Advance the menu to the Connect selection The display will show Connect ON or Connect OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to toggle the Connect Mode ON and OFF This function when turned ON will connect or link the current memory to the next memory This Allows High Withstand Voltage Tester to Run 50 consecutive tests in a sequence if desired CXT ecli ELECTRONICS 5 3 Reviewing Test Results The method for reviewing test results is to press the ENTER key at the end of the test sequence Results can be reviewed at any time before the next test is executed by pressing the ENTER key and then scrolling with the up and down arrow keys or repeatedly pressing the ENTER key The results of the last test in the process will be followed by the first test when scrolling through the results All buffers are cleared at the start of the next test cycle Pressing the EXIT or
70. or enclosure during the test If possible the guards or enclosure should also contain safety switches that will not allow the tester to operate unless the guards are in place or the enclosure closed Keep the area clean and uncluttered All test equipment and test leads not necessary for the test should be removed from the test bench and put away It should be apparent to both the operator and to any observers the product that is being tested and the product that is waiting to be tested or has already been tested Do not perform Hipot tests in a combustible atmosphere or in any area where combustible materials are present Power Dielectric Voltage Withstand Test Equipment must be connected to a good ground Be certain that the power wiring to the test bench is properly polarized and that the proper low resistance bonding to ground is in place Power to the test station should be arranged so that it can be shut off by one prominently marked switch located at the entrance to the test area In case of an emergency anyone can cut off the power before entering the test area to offer assistance 1 4 3 Test Operator Qualifications This instrument generates voltages and currents that can cause harmful or fatal electric shock and must only be operated by a skilled worker trained in its use CX sci The operator should understand the electrical fundamentals of voltage current and resistance They should recognize that the test instrument is
71. ormation for the unpacking inspection preparation for use and storage of your Extech Electronics Ltd Co product 2 1 Unpacking and Inspection 2 1 1 Packaging Your instrument was shipped in a custom foam insulated container that complies with ASTM D4169 92a Assurance Level II Distribution Cycle 13 Performance Test Sequence If the shipping carton is damaged inspect the contents for visible damage such as dents scratches or broken display If the instrument is damaged notify the carrier and Extech s customer support department Please save the shipping carton and packing material for the carrier s inspection Our customer support department will assist you in the repair or replacement of your instrument Please do not return your product without first notifying us e Please retain all of the original packaging materials 2 1 2 Returning the Instrument When it is necessary to return the instrument for servicing or calibration repackage the instrument in its original container please include all accessories and test leads Indicate the nature of the problem or type of service needed Also please mark the container FRAGILE to insure proper handling If you do not have the original packaging materials please follow these guidelines e Wrap the instrument in a bubble pack or similar foam Enclose the same information as above e Use a strong double wall container that is made for shipping instrumentation 350 Ib test mate
72. pany Extech Electronics Ltd CO RST Reset the instrument to original power on configuration Does not clear Enable register for Standard Summary Status or Standard Event Registers Does not clear the output queue Does not clear the power on status clear flag TST Performs a self test of the instrument data memory Returns 0 if it is successful or 1 if the test fails CLS Clears the Status Byte summary register and event registers Does not clear the Enable registers 59 CX sc OPC Sets the operation complete bit bit 0 in the Standard Event register after a command is completed successfully OPC Returns an ASCII 1 after the command is executed WAI After the command is executed it prevents the instrument from executing any further query or commands until the no operation pending flag is TRUE PSC 1 03 Sets the power on status clear bit When set to 1 the Standard Event Enable register and Status Byte Enable registers will be cleared when power is turned ON O setting indicates the Enable registers will be loaded with Enable register masks from non volatile memory at power ON PSC Queries the power on status clear setting Returns 0 or 1 ESR Queries the Standard Event register Returns the decimal value of the binary weighted sum of bits ESE lt value gt Standard Event enable register controls which bits will be logically OR d together to generate the Event Summary bit 5 ESB within the
73. ponent resistance which might also be connected between the two points Although the IR test can be a predictor of insulation condition it does not replace the need to perform a dielectric withstand test 1 6 3 Ground Bond Test The Ground Bonding test determines whether the safety ground circuit of the product under test can adequately handle fault current if the product should ever become defective A low impedance ground system is critical in ensuring that in case of a product failure a circuit breaker on the input line will act quickly to protect the user from any serious electrical shock International compliance agencies such as CSA IEC TUV VDE BABT and others have requirements calling out this test This test should not be confused with low current continuity tests that are also commonly called out in some safety agency specifications A low current test merely indicates that there is a safety ground connection It does not completely test the integrity of that connection Compliance agency requirements vary on how different products are to be tested Most specifications call for test currents of between 10 and 30 amps Test voltages at these currents are typically required to be less than 12 volts Maximum allowable resistance readings of the safety ground circuit are normally between 100 and 200 milliohms If you are testing a product that is terminated in a three prong plug you are required to perform a continuity or ground bond
74. pressing the RESET button or after a test failure by pressing the RESET button twice The following is an example of a Settings Screen for the 7473 before any test has been executed MXX Set Note X Numeric XXX X s Note x milli or micro 40 a CXT cc ELECTRONICS XX XX KV X XXX xA M XX Memory Program number Set Withstand Voltage test setting screen XXX Xs Dwell Time setting X XX KV Output Voltage setting X XXX mA High Limit current setting AC withstand instruments XXXX uA High Limit current setting DC withstand instruments The Settings screen is the main operational screen of instrument From this screen test parameters are monitored while the test is being performed 6 3 1 Connected Memory indicator The connected memory indicator is an under score symbol located directly next to the Memory number and only will be displayed when the connect function has been turned ON in the Test parameters Note X Numeric A AAA Connected Memory Indicator 6 4 Metering The same parameters described in section 6 3 Settings Screen are monitored live while performing tests The following table describes what meters will be displayed Model Test Type Current Voltage Time 7470 7473 AC Withstand X X X 7472 7474 DC Withstand X X X The memory location will also be indicated on the display as well as the connect function 6 5 Performing a Test 1 From the Settings screen pr
75. proper use and configuration of bus remote interface The RS 232 interface also uses the same command set as the GPIB interface for setting of test parameters However many functions of the GPIB 488 2 interface are not available through RS 232 The IEEE 488 interface included with High Withstand Voltage Tester conforms to the requirements of the IEEE 488 2 standard 9 1 GPIB Messages There are typically two types of messages that GPIB devices use to communicate with other interconnected GPIB devices Interface messages Often called commands or command messages and Device dependent messages often called data or data messages Data Messages Contain information such as programming instructions or measurement results Command Messages perform functions such as initializing the bus and addressing and unaddressing devices 9 2 Functions A GPIB device can be a Listener Talker and or Controller A Talker sends data messages to one or more Listeners which receive data A Controller manages the information flow on the GPIB by sending commands to all devices The GPIB bus is much like a computer bus except a computer has circuit cards connected via a backplane and the GPIB has stand alone devices connected via a cable 9 3 Signals and Lines The GPIB consists of 16 signal lines and 8 ground return or shield drain lines The 16 signal lines are grouped into 8 data lines 3 handshake lines and 5 interface management lines Data Lines The e
76. r menu for test parameter setup SETUP Use this key to enter the setup menu and view or change the display contrast alarm volume and PLC remote settings EXIT Use this key to exit any menu or to clear an unwanted entry in a parameter field LCD DISPLAY The 2x20 character display indicates test function memory location test parameter and failure type as well as test measurements during a test DATA ENTRY KEYS Use these keys to input numeric parameters followed by the ENTER key 23 CXLS51 747X AC WITHSTAND VOLTAGE TESTER 12 3 456 78 9 10 11 12 13 14 11 ENTER Use this key as an ENTER key to accept numeric data for parameter settings 12 HIGH VOLTAGE OUTPUT JACK Connector used to attach the High Voltage test lead or test fixture high voltage lead to the instrument The connector is recessed for safety when not being used 13 RETURN OUTPUT JACK Connector used to attach the Return test lead or test fixture return lead to the instrument This connection provides the return current path for the high voltage 14 HIGH VOLTAGE ON INDICATOR This indicator flashes to warn the operator that high voltage is present at the high voltage terminal 24 CXI ech 3 2 2 Rear Panel Controls cyo 6 7 8 9 1 CHASSIS GROUND EARTH TERMINAL This terminal should be connected to a good earth ground before operation 2 CALIBRATION BUTTON To put the instrument into the calibration mode push this button and turn on
77. rents that can cause harmful or fatal electric shock To prevent accidental injury or death these safety procedures must be strictly observed when handling and using the test instrument WARNING 1 4 1 Service and Maintenance User Service To prevent electric shock do not remove the instrument cover There are no user serviceable parts inside Routine maintenance or cleaning of internal parts is not necessary Avoid the use of cleaning agents or chemicals on the instrument some chemicals may damage plastic parts or lettering Any external cleaning should be done with a clean dry or slightly damp cloth Schematics when provided are for reference only Any replacement cables and high voltage components should be acquired directly from Extech Electronics Co Ltd Service Interval The instrument its power cord test leads and accessories must be returned at least once a year to an Extech authorized service center for calibration and inspection of safety related components Extech will not be held liable for injuries suffered if the instrument is not properly maintained and safety checked annually User Modifications Unauthorized user modifications will void your warranty Extech will not be responsible for any injuries sustained due to unauthorized equipment modifications or use of parts not specified by Extech Instruments returned to Extech with unsafe modifications will be returned to their original operating condition at the custom
78. requency 50Hz 60Hz 100ppm User Selection Output Waveform Sine Wave THD lt 2 Resistive Load Crest Factor 1 3 1 5 Output Regulation 1 of output 10V From no load to full load SETTINGS Hi Lo Limit AC Current mA gt y 90 7473 ONLY 0 9 999 0 001 12 of setting 2counts Ramp Up Time second 0 1 999 9 0 1 Ramp Down Time second 0 0 999 9 0 1 0 0 3 999 9 sec 0 1 0 continuous 0 1 0 05sec Dwell Time Us ma 0 1 O continuous 0 0 1 999 9 hr 0 1 0 continuous i Cycle Test 0 9999 Times 0 continuous Arc Detection lt 15KV 1 9 ranges 9 is the most sensitivity gt 15KV 1 7 ranges 7 is the most sensitivity AC Current Offset mA 0 2 000 or Auto Set Option MEASUREMENT AC Voltage KV 0 20 00 0 01 2 of reading 2counts 0 3 500 0 001 AC Current Range mA 2 of reading 3counts 3 00 10 00 0 01 20 3 1 4 7474 Functional Specifications CXI sc H Output Rating 20KVDC SmA DC WITHSTAND VOLTAGE Output Voltage DCV 0 20000 10 1 2 of setting 20V Output Ripple lt 5 20KV 50001A at Resistive Load SETTINGS Hi Lo Limit DC Current uA 0 0 999 9 1000 5000 0 1 1 2 of setting 2counts Ramp Up Time second 0 4 999 9 0 1 Ramp Down Time second 0 0 1 0 999 9 0 1 Dwell Time 00A ala ca 0 1 O continuous 0 1 0 05sec 0 0 1 999 9 min 01 O
79. response will be sent automatically to the controller The instrument will send a string of parameters separated by commas for each meter on the display for example the data for an ACW test might be as follows 01 ACW Dwell 3 00 1 25 2 5 this represents an ACW test at memory number 1 3 00kV output voltage 1 25mA total current and the elapsed time for the Dwell cycle is 2 5 seconds 9 10 Non Volatile Memory The instrument saves each parameter in non volatile memory when the parameters are sent to the instrument The non volatile memory has a limited write cycle life therefore for programmers who wish to send all parameters before executing each test should use Memory 50 The parameters will be stored in the CPU s Random Access Memory RAM until another memory location is selected However settings written to RAM from GPIB RS 232 mode will be lost when power is shut down Parameter changes to RAM are unlimited and will not affect the life of the internal non volatile memory chip 9 11 BUS Remote message The REM indicator will be displayed when the instrument is in the Remote Control mode When the BUS Remote is on the instrument is able to send and receive signals across the GPIB TEEE 488 or RS 232 bus MXX Set XXX X s XX XX KV REM X XXXmA 62 CXI ech 10 Options GPIB Interface This option may be substituted for the RS232 interface This option provides all of the function control of the RS232 interface with the addition of S
80. rial is adequate e Use a layer of shock absorbing material 70 to 100 mm 3 to 4 inch thick around all sides of the instrument Protect the control panel with cardboard e Seal the container securely e Mark the container FRAGILE to insure proper handling CX sc 2 2 Installation 2 2 1 Work Area Locate a suitable testing area and be sure you have read all safety instructions for the operation of the instrument and suggestions on the test area set up in the Safety section Make sure the work area you choose has a three prong grounded outlet Be sure the outlet has been tested for proper wiring before connecting the instrument to it 2 2 2 Power Requirements This instrument requires a power source of either 115 volts AC 15 50 60 Hz single phase or 230 volts AC 15 50 60 Hz single phase Please check the rear panel to be sure the proper switch setting is selected for your line voltage requirements before turning your instrument on For operation at 115 and 230 Volts AC use a 6 3 Amp Slo Blo 250VAC Do not switch the line voltage selector switch located on the rear panel while CAUTION the instrument is on or operating This may cause internal damage and represents a safety risk to the operator 2 2 3 Basic Connections Power Cable Before connecting power to this instrument the protective ground Earth terminals of this instrument must be connected to the protective conductor of the line mains power cord The
81. ric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of AC 3 500mA range of the hipot test and the display will show AC 3 500mA 100KQ OK lt T E S T gt to Calibrate 11 3 4 Calibration of 7472 DC Hipot Current DC Hipot 10mA current range Press the v key the program will advance to the DC 10 00mA range calibration of the hipot test The display will show DC 10 00mA 100KQ lt TEST gt to Calibrate Connect a resistor about 100KQ 10W in series with a DC standard Ammeter which can measure up to 10 00mA to the output leads The Ammeter should be connected to the return lead then press the TEST button the program will automatically generate an output of about 1000V 10mA and the display will show Current mA Enter Standard J out Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of DC 10 00mA range for calibration and the display will show DC 10 00mA 100KQ OK lt TEST gt to Calibrate DC Hipot 35004A current range Press the v key the program will advance to the DC 3500uA range calibration of hipot test The display will show DC 35001A 100KQ lt TEST gt to Calibrate Connect a resistor about 100KQ 10W in series with a DC standard Ammeter which can measure up to 3500UA to the output leads The Ammeter should be connected to the return lead then press the TEST button the program w
82. rogram will store the Smart GFI setting automatically 4 1 6 GPIB Address Only appears if the GPIB option 01 is installed Press the SETUP key to advance the menu to the GPIB address parameter The display will show GPIB addr XX Range 0 31 30 CXI sc H Use the Numeric keys to enter the GPIB Address then press the ENTER key Change the GPIB address again or press the SETUP key to advance to the Memory Lock parameter Press the EXIT key to return to the operation mode The program will store the GPIB address automatically 4 1 7 BUS Remote Command Set Will not appear if the Printer Card option 02 is installed Press the SETUP key to advance the menu to the Command Set Format parameter The display will show Command Set 488 1 or Command Set 488 2 lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to toggle the remote command set between 488 1 and 488 2 Please refer to section 9 Bus Remote Interface GPIB RS232 for additional information about this selection Change the BUS Remote Command Set again or press the SETUP key to advance to the Memory Lock parameter Press the EXIT key to return to the operation mode The program will store the BUS Remote Command Set automatically 4 1 8 Memory Lock Press the SETUP key to advance the menu to the Memory Lock parameter The display will show Memory Lock ON or Memory Lock OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to toggle
83. s 5 2 1 Output Voltage setting Advance the menu to the Voltage parameter The display will show Voltage XX XX kv Range 0 00 XX 00kV Use the Numeric keys to enter the voltage setting and then press the ENTER key The program will store the voltage setting and advance to the High Limit parameter automatically Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set 5 2 2 HI Limit Current setting Advance the menu to the HI Limit parameter The display will show HI Limit XXXX HI Limit XXXX uA mA Range 0 5000UA Range 0 000 9 999mA Use the Numeric keys to enter the HI Limit setting and then press the ENTER key The program will store the HI Limit setting and advance to the LO Limit parameter automatically 34 cXI ec Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set 5 2 3 LO Limit Current setting Advance the menu to the LO Limit parameter The display will show LO Limit XXXXmA or LO Limit XXX X uA Range 0 000 9 999mA Range 0 0 999 9uA Use the Numeric keys to enter the LO Limit setting then press the ENTER key The program will store the LO Limit setting and advance to the Ramp UP parameter automatically Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set If the LO Limit is set to 0 the LO Limit is disabled 5 2 4
84. safe under normal conditions The basic product design and use of the insulating material will protect the user against electrical shock The equipment used for this test a dielectric withstand tester is often called a hipot for high potential tester The rule of thumb for testing is to subject the product to twice its normal operating voltage plus 1 000 volts However specific products may be tested at much higher voltages than 2X operating voltages 1 000 volts For example a product designed to operate in the range between 100 to 240 volts can be tested between 1 000 to 4 000 volts or higher Most double insulated products are tested at voltages much higher than the rule of thumb Testing during development and prototype stages is more stringent than production run tests because the basic design of the product is being evaluated Design tests usually are performed on only a few samples of the product Production tests are performed on every item as it comes off the production line The hipot tester must also maintain an output voltage between 100 and 120 of specification The output voltage of the hipot must have a sinusoidal waveform with a frequency between 40 to 70 Hz and has a peak waveform value that is not less than 1 3 and not more than 1 5 times the root mean square value CXI ech Types of Failures only detectable with a Hipot test e Weak Insulating Materials e Pinholes in Insulation e Inadequat
85. t to match the exact serial number or some portion of actual serial number of the item under test or just used as an identifier or tracking number Type in the desired starting number in the range from 0 9999 This number will increment as each test is performed The next number that will be used can be viewed from this menu at any time after a test has been completed This number is not save as part of the non volatile memory setup parameters Therefore each time the power to the instrument is turned off the number will be reset to 0 Form Feed Please press the SETUP key The Form Feed screen appears as follows Form Feed ON Print Mode OFF lt ENTER gt to Select lt ENTER gt to Select This command forces a form feed after each complete test sequence When the form feed is turned off the pages will break whenever the page is determined to be full by the printer Sample Printer Outputs Sample printer output with the following setup Auto Print ON and Print Mode All and Print No 1000 NO 1000 M1 Pass 1 0s 5 00KV 0 000mA NO 1001 M 1 Hi Limit 0 5s 5 00KV 10 21mA NO 1002 M1 Pass 1 0s 5 00KV 0 000mA NO 1003 M1 Pass 1 0s 64 cXI ech 5 00KV 0 000mA Sample printer output of the same test results but the Print Mode Fail In this case the test number of every test is printed but fail result details are printed only when a failure occurs NO 1000 NO 1001 M 1 Hi Limit 0 5s 5 00KV 10 21mA NO 100
86. ted the RQS bit will be cleared to 0 and the remaining bits will remain unchanged The status byte ESB bit will not change value until the event register is read and cleared for the corresponding status byte bit 61 CX sci For example after the All Pass SRQ has been enabled when the test s have finished with pass indications the instrument will set the hardware SRQ line and output the status byte of 41 hex This means that bit 6 and bit 0 are set to a value of 1 After reading the status byte the status byte value will change to 01 hex 9 9 Example of Communicating Over the GPIB Bus To write commands over the IEEE bus you must enter the code that is specific to the software language you are using Then follow the example below To set the output voltage across the IEEE bus at 8000 volts do the following First select a memory by sending for example the string for memory one FL 1 then send the string EV 8 0 This tells the instrument to set the voltage at 8 0kV A string is a list of ASCII characters octal or hex bytes or special symbols However do not include the quotation marks when sending the command string If you wish to set the Ramp UP time of the test across the IEEE bus at 10 seconds do the following send the string ERU 10 00 This tells the instrument to set the Ramp UP time at 10 00 seconds To read the live testing data first send the string TD then send the GPIB command to read For RS 232 the
87. test on the ground conductor to the chassis or dead metal of the product 1 6 4 Run Test All manufacturers of a product that runs on line power normally need to run the DUT Device Under Test after final safety testing so that they can verify the functionality of their products 11 CX sci In addition to running the DUT to test its basic functionality many customers also require some basic test data to be recorded while the DUT is powered up A Run Test System allows the product to be powered up immediately after the safety tests are completed with a single connection to the DUT Measurements that are commonly made while the DUT is running can include Amperage Voltage Watts and Power Factor 1 6 5 Line Leakage Test The Line Leakage test is one of many product safety tests that are normally specified for electrical products by safety testing agencies such as Underwriters Laboratories UL and the International Electrotechnical Committee IEC The line leakage specifications vary as well as the method in which the measurements are taken depending upon the application or function of a product and the standard to which the product is being tested Current Leakage or Line Leakage tests are general terms that actually describe three different types of tests These tests are Earth Leakage Current Enclosure Leakage Current and Applied Part Leakage Current The main differences in these tests are in the placement of the probe for the measuring
88. the EXIT key to exit from the setting mode to the operation mode Advance the menu to the Arc Sense parameter The display will show Arc Sense X Range 1 9 9 High For model 7470 7472 and 7473 the range of ARC sense is from 1 to 9 For model 7473 if the voltage is lower than 15KV the range of Arc sense is from 1 to 9 If the voltage is higher than 15KV the range is from 1 to 7 Use the Numeric keys to enter the Arc Sense setting and then press the ENTER key The numeric value is proportional to the amount of sensitivity i e 9 is the highest sensitivity The program will store the Arc Sense setting and advance to the Connect mode selection automatically If the Arc Detect mode is set to ON the program will indicate an arc failure when the arc current is over the setting and the program will shut down the test immediately If the Arc Detect mode is set to OFF the program will not indicate an arc failure when the arc current is over the setting 5 2 10 Ramp HI selection DC units only Advance the menu to the Ramp High parameter The display will show Ramp HI ON or Ramp HI OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to select the Ramp HI mode then press the A or v key to advance the program to another test parameter or press the EXIT key to exit from the setting mode to the operation mode The Ramp HI function is active during the Ramp period only Ramp HI will allow current higher tha
89. the Memory Lock ON and OFF Memory Lock is a sub function of the Lock setting In order for the Memory Lock function to work the Lock must first be turned ON Selecting the Memory Lock OFF will allow the user to access all available Memory locations but restricts access to memory editing capabilities Selecting the Memory Lock ON will allow the user to only run the currently loaded memory Toggle the Memory Lock function or press the SETUP key to forward to the PLC Remote selection Press the EXIT key to return to the operation mode The program will store the Memory Lock setting automatically 4 2 LOCK LOCAL Key 4 2 1 Lock Function Press the LOCK LOCAL key Ifthe Password is enabled the display will show Password 31 CX sci Range 0 9999 Use the Numeric Key to enter the password and then press the ENTER key The program will switch the Key Lock function from LOCK to UNLOCK or UNLOCK to LOCK mode and advance the program to Operation mode automatically If the wrong password is entered the program will give a warning sound and the display will show Password ERROR Range 0 9999 And then the program will return to the original screen and wait to enter the new password If the Password is disabled Password is set 0 the display will show Key Lock ON or KeyLock OFF lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to select the Key Lock mode and then press the EXIT key The program will switch
90. the power switch simultaneously 3 REMOTE SIGNAL INPUT 9 Pin D subminiature male connector for remote control of test reset and interlock functions as well as remote program memory selection 4 REMOTE SIGNAL OUTPUT 9 Pin D sub miniature female connector for monitoring PASS FAIL and PROCESSING output relay signals 5 BUS INTERFACE RS 232 Bus interface gt 1 IEEE 488 interface and PRINTER interface may be selected 6 FUSE RECEPTACLE To change the fuse unplug the power mains cord and turn the fuse receptacle counter clockwise The fuse compartment will be exposed Please replace the fuse with one of the proper rating 7 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord 8 INPUT POWER SWITCH Line voltage selection is set by the position of the switch The left position is set for 115 volt operation the right position is set for 230 volt operation 9 THERMAL COOLING FAN Runs continuously to cool the instrument 25 CX sc 3 3 Quickstart This quick start guide assumes the operator has some familiarity with automated Electrical Safety testing WARNING Locate a suitable testing area and be sure you have read all safety instructions for the operation of the instrument and suggestions on the test area set up in the Safety section Locate a three prong grounded outlet Be sure the outlet has been tested for proper wiring before connecting the instrument to
91. the user must press the LOCAL PRN key on the lower left section of the keypad to generate printer output When the EXIT PRINT key is pressed after the test is completed the printer output will be a duplicate of the front panel LCD test results This key should only be used to retrieve test results after the test has been completed Although the output will print the LCD screen during a test the actual elapsed test time may be effected when printing while the test is active Print Mode Please press the SETUP key This menu selection works in conjunction with Auto Print The Print Mode screen appears as follows Print Mode All Print Mode Fail lt ENTER gt to Select lt ENTER gt to Select The printer output will generate the 40 character LCD display test results when the test is complete This selection will determine when the 40 character output will print When Print Mode All the printer output will print the test results from every test performed When Print 63 CX sc Mode Fail only the test that have failed will be printed The Print Number or Serial number will print for every test followed by the appropriate test results depending on the Print Mode that has been selected Print Number Please press the SETUP key This menu selection works in conjunction with Auto Print The Print Number screen appears as follows Print NO 0 Range 0 9999 The print number is used to identify each test result The number can be se
92. tially drops to zero in DC testing DC testing advantages Once the item under test is fully charged the only current flowing is true leakage current This allows a DC hipot tester to clearly display only the true leakage of the product under test Another advantage to DC testing is that the charging current only needs to be applied momentarily This means that the output power requirements of the DC hipot tester can typically be much less than what would be required in an AC tester to test the same product DC testing disadvantages Unless the item being tested has virtually no capacitance it is necessary to raise the voltage gradually from zero to the full test voltage The more capacitive the item the more slowly the voltage must be raised This is important since most DC hipots have failure shut off circuitry which will indicate failure almost immediately if the total current reaches the leakage threshold during the initial charging of the product under test Since a DC hipot does charge the item under test it becomes necessary to discharge the item after the test DC testing unlike AC testing only charges the insulation in one polarity This becomes a concern when testing products that will actually be used at AC voltages This is an important reason that some safety agencies do not accept DC testing as an alternative to AC When performing AC hipot tests the product under test is actually tested with peak voltages that the hipot meter d
93. to test mode the EXIT key must be pressed When the EXIT key is pressed the instrument will continue with its normal failure indication process The failure light and Alarm can then be cleared by pressing the RESET button This message appears on the display after exiting from the Output Error screen MXX Out Error XXX Xs XX XX KV XX XX mA 47 CX sc 8 Connection of Remote I O Two 9 pin D type connectors are mounted on the rear panel that provide REMOTE INPUT OUTPUT control and information These connectors mate with standard 9 pin D sub miniature connector provided by the user The output mates to a male plug connector while the input mates to a female receptacle connector For best performance a shielded cable should be used To avoid ground loops the shield should not be grounded at both ends of the cable Suggested AMP part numbers for interconnecting to the Remote I O are shown below Remote Interface Rear Panel SIGNAL OUTPUT SIGNAL INPUT FAIL PASS eF RESET El TEST INTERLOCK 5 1 1 5 NI a ee J O RESET ouT MEMORY 1 PROCESSING ys MEMORY 2 e ee MEMORY 3 8 1 Signal Outputs on Remote I O The rear panel connector provides three output signals to remotely monitor PASS FAIL and PROCESSING conditions The monitoring signals are provided by three normally open internal relays that toggle on and off to indicate the condition of the tester These are normally open free contacts a
94. tton may also be used to quickly ABORT a test and cut off the power to the DUT When a test is being performed a red lightning bolt indicator located in the lower right side of the front panel will illuminate and flash until the test is finished If the DUT passed the test you will hear a brief beep indicating the DUT passed and that the tests are complete 3 3 1 2 Reviewing Results The method for reviewing test results is to press the ENTER key at the end of the test sequence Results can be reviewed at any time before the next test is executed by pressing the ENTER key and then scrolling with the up and down arrow keys or repeatedly pressing the ENTER key The results of the last test in the process will be followed by the first test when scrolling through the results All buffers are cleared at the start of the next test cycle Pressing the EXIT key will return you to the Settings screen 27 CX sci 4 System Settings 4 1 SETUP Key Parameters At the Setting Pass or Fail screen press the SETUP key Use the SETUP key to progress through the menu of System Parameters Successive key presses will advance the menu forward The sequential forward menu items are PLC Remote Fail Stop Contrast Alarm Smart GFI GPIB address BUS Remote Command Set Memory Lock The setting of system parameters affect the operating conditions of the instrument and are separate from the functional settings The system settings are also global and are not sp
95. vent register the enable register is represented as a decimal number that equals the binary weighted sum of all bits The enable register will clear to value of 0 at power up unless the PSC 0 command had been executed before power off The PSC command tells the device whether or not it should clear the enable registers at power on Using this command will allow SRQs to function immediately after power on Standard Event Register Status Byte Register Event Register Enable Summary Register Enable Register Register Operation Complete hotused QueryError _ Device Error TEST IN PROCESS Execution Error Message Available MAV Command Error ___ Event Summary Bit SB not used Request Service RQS or not used Master Summary Status MSS PowerO0n_______ ___ motused___________ ESR ESE STB SPOLL SRE ESE SRE 9 8 8 GPIB Service Request The service request capability is not available with the RS 232 interface The SRQ line will be activated only after one or more of the service request functions have been enabled using the Status Byte Enable Register command SRE The status byte bit assignments are as described in the previous section for status reporting When the instrument has requested service the enabled bit or bits and the RQS bit 6 will be active or 1 Bit 4 5 and 7 are not used and will be set to false or 0 for all status byte reads After the serial poll SPOLL is execu
96. well Time is set to 0 the timer will continue to count to the maximum test time then reset to 0 and start over automatically The test will continue until a reset is executed or a failure occurs 5 2 7 Ramp DOWN Time setting Advance the menu to the Ramp DOWN time parameter The display will show ACW Units DCW Units Ramp DOWN XXX X s or Ramp DOWN XXX X s Range 0 1 999 9s Range 0 1 0 999 9s Use the Numeric keys to enter the Ramp DOWN time setting then press the ENTER key The program will store the Ramp DOWN time setting and advance to the Frequency Selection automatically Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set 5 2 8 Frequency Selection AC units only Advance the menu to the Frequency parameter and the display will show Frequency 60 Hz or Frequency 50 Hz lt ENTER gt to Select lt ENTER gt to Select Use the ENTER key to select the Output Frequency then press the A or v key to advance to another test parameter or press the EXIT key to exit from the setting mode to the operation mode 5 2 9 Arc Detect and Arc Sensitivity Selection Advance the menu to the Arc Detection selection The display will show Arc Detect ON or Arc Detect OFF lt ENTER gt to Select lt ENTER gt to Select 36 CcXI sc H Use the ENTER key to toggle the Arc Detect mode then press the or v key to advance the program to the Arc Sense parameter or press

High Withstand Voltage Tester Operation Manual

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